TECHNICAL

MANUAL

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04 SY
Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
Text for back of binder:

Highlander
HLD-A2 VDR Technical Manual
Beijing Highlander Digital Record Technology Co., Ltd.

• First page of this document shall be used as front page on Binder. The frame on top of this page shall be cut out and used on back of the binder.
• Table of content (page 3) of this document shall be put in front of index leafs
• Add the documents under the leafs according to description below:
Index Contents Doc ID Comment
1 How to use this manual HLD04 SY
2 Warnings
3 Handling
4 Technical Specification HLD04 JS
5 System description HLD04 ST
6 User Guide HLD04 SS2
7 Player Guide HLD04 PB
8 Main Unit(MU)installation HLD-04.1 AZ
9 Final recording medium(FRM/Capsule)installation CH01 SS PDU100 INSTALLATION MANUAL
10 Data Acquisition Unit(DAU)Installation HLD12.8 AZ
11 Alternative Power Supply Unit (PSU 3) HLD12.7 AZ/WC
12 Alternative Power Supply Unit (PSU 24) HLD04.7 AZ/WC
13 Drawings Actual drawing file 7 drawings
14 Type Approval Documents, Delivery Test Certificate
15 Acceptance Record Certificate At installation
16 Service Reports, Annual Performance Test Reports To be added on board

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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Tel:+86-10-82678888 Fax:+86-10-82150083

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Table of Contents
Section
Description Doc ID
A Introduction HLD04 SY
Binder text and binding instruction. Notes and Updates
1 How to use this manual
2 Warnings
3 Handling
B Technical Information
4 Technical specifications HLD04 JS
5 System description HLD04 ST
C User Manual
6 User Guide HLD04 SS2
7 Player Guide HLD04 PB
D Installation Manual
8 Main Unit (MU) Installation incl. Microphones and SCU HLD04.1 AZ
9 Power Supply Unit24 (PSU24) Installation HLD04.7 AZ
10 Final Recording Medium (PDU100)
E Accessories Manual
11 Data Acquisition Unit (DAU) Installation HLD12.8 AZ
12 Alternative Power Supply Unit (PSU 3) HLD12.7 AZ
F Appendix
13 Drawings
14 Type Approval Documents, Delivery Test Certificate
15 Acceptance Record Certificate
16 Service Reports,
17 Annual Performance Test Reports

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn
Tel:+86-10-82678888 Fax:+86-10-82150083

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Notes and Updates

Revisions:
Date Ver Issue by Description
2005-10-01 A0 NE Created
2005-10-10 A1.0 LCW Modified as Highlander requirement

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn
Tel:+86-10-82678888 Fax:+86-10-82150083

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1. How to use this manual

This manual contains all on-board relevant documents related to the Simplified Voyage Data
Recorder (S-VDR) application and to the “full” Voyage Data Recorder (VDR) application of
Highlander VDR HLD-A2. In this manual the equipment is called VDR HLD-A2 or just
VDR and will be named S-VDR and “full VDR” only where necessary to separate the two
types of application.

The purpose of this manual is to give written instructions for every-day use, accident /incident
procedures as well as for mechanical / electrical installation. It shall also incude ship-related
documentation, drawings and reports.

Before installing the VDR HLD-A2, please read section A2 (Warnings), A3 (Handling) and
B5 (System Description).
Before using the VDR HLD-A2, please read section B5 (System Description).
For looking up technical facts, please use B4 (Technical specifications) and F16 (Drawings)

Note: The setting up procedure, which shall be performed by specially trained tecnicians, is
described in a separate Commissioning Manual.

The sections in the Technical Manual are grouped as follows:

Section Content
(A) 2 and 3 Introduction – contains the manual spanner front and backpage and
instructions for how to use the manual, how to compose the manual at
printing, how to avoid accidents (warnings) and finally how to transport
and store the equipment (handling)
(B) 4 and 5 Technical information – contains table of Technical Specification for each
VDR HLD-A2 unit and a general System Description explaining the
function of the VDR HLD-A2 units and how they are connected to each
other.
(C) 6 User Guide – contains the instruction for the daily on board use of the
VDR HLD-A2, i.e. Incident back up, Data down load by routine, Alarms
etc.
(C) 7 Player Guide – contains instruction for how to use the replay program after
downloading data from the VDR HLD-A2.
(C) 8 Investigative Authority Guide – contains special instructions for
investigating authorities to download data after an incident or accident
(D) 9, 10 and 11 Installation Manual – contains instruction for mechanical and electrical
installation, i.e. mounting, cabling and cable termination of the VDR
HLD-A2 standard units MU, PSU and FRM.
(E) 12, 13, 14 Accessories Manual – contains instruction for mechanical and electrical
and 14 installation, i.e. mounting, cabling and cable termination of the VDR
HLD-A2 optional units, e.g. alternative PSU and alternative FRM/Capsule.
(F) Contains - Annex with Ship Specific Documents, such as:

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E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn
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(F) 16 Drawings, mechanical and electrical drawings for installation

(F) 17 Copy of VDR HLD-A2 type approval document and Factory Delivery Test
Certificate
(F) 18 Acceptance Record Certificate from installation
(F) 19 Copy of service reports and Annual Performance Test Reports

We would appreciate all comments from readers and users that would help us to improve this
manual.

Beijing Highlander Digital Record Technology Co., Ltd.

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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2. Lethal Warning!

Voltages within this equipment are sufficiently high to endanger life.

Covers are not to be removed, except by persons qualified and authorized to do so, and these persons should
always take extreme care once the covers have been removed.

First Aid in Case of Electric Shock

1. Lay victim on his back.
2. Clear victim’s mouth and throat
3. Tilt victim’s head back as far as
possible and raise his head

4. Pinch victim’s nostrils

5. Take a deep breath
6. Cover the victim’s mouth with yours
and blow, watching his chest rise.
Note: Blow forcefully into adults, but
gently into children.
7. Move your face away to allow victim
to breathe out, watching his chest
fall.
8. Repeat first five to ten breaths at
rapid rate; thereafter, take one breath
every three to five seconds.
9. Keep victim’s head back as far as
possible at all times.

Have someone else send for a doctor, keep patient warm and loosen his clothing

Do not give liquids until the patient is conscious.

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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3. Handling
Shipping
Following general rules apply:
• Inspection for damage during transport
• When the unit(s) arrives at destination, inspection should be performed immediately to
register any damage that may have occurred during transfer
• The customer is normally responsible for insurance during the transportation. If any
damage is found, both the insurance company and the shipping agent must be informed
immediately
• The content of the goods shall also be compared with the Packing List. Complain
regarding the shipped content must be sent to Beijing Highlander Corporation within
seven days from goods arrival to the addressee.

Storage
After the material, contained in the boxes, has been inspected in the presence of customer and
it has been verified that no damage has occurred, the unit shall be stored in its original
packing until the time of installation. The storage premises must be dry and well protected.
If the electronic units must be kept in storage for more than one month, it is advisable to insert
hygroscope substances, such as silicon gel salts, in the crates.

Handling
The electrical part should be kept in their packing as long as possible and shall be unpacked at
the place of installation.

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 TECHNICAL
SPECIFICATION

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04 JS
Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
 海兰信数据科技
Beijing Highlander Digital Record Technology Co., Ltd.

Notes and Updates

Revisions:
Date Ver Issue by Description
2005-9-27 A0 NE Created
2005-09-29 A1 LNY Added and changed data
2005-10-10 A1.0 LCW Modified it as Highlander requirement

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn
Tel:+86-10-82678888 Fax:+86-10-82150083

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TECHNICAL SPECIFICATIONS
VDR M4 System performance data

VDR (Full VDR) According to IMO Resolution A.861 and IEC

61996

S-VDR According to IMO MSC.163(78) and IEC PAS

61996-2

Main Unit (MU)

Mechanical specification
Height: 600 mm
Width: 500 mm
Depth: 250 mm
Weight: 32 kg

Electrical specification:
Input voltage: 24 VDC (19 – 28VDC)
Power consumption: < 200VA
Indicator power output: 24VDC (19VDC- 28VDC)
Serial input: 14 channels according to IEC 61162-1
2 channels according to IEC 61162-2
Jumper for termination resistor of 120Ω
(default)
Serial input/ output 1 channel RS485
Serial output: 4 channel according to IEC 61162-1
Pulse inputs 2 channel isolated pulse inputs
(200- 20000p/NM (12V- 48V)
Resolution: 0.1 Knot at 50 Knots
Updating frequency 1.1 Hz
Digital inputs 4 channels isolated digital inputs (12V- 48V)
Relay outputs: 2 Switching relays
Rating: Maximum current 1A,
Maximum voltage 125VAC, 60VDC
Maximum switching capacity: 30W
Minimum permissible load: 1mA, 5VDC
Service connection: Ethernet, RJ45

Environmental specification
Enclosure material: Steel

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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Enclosure protection: IP22

EMC: IEC 60945
Radiated Noise: According to IEC 60945
Heat dissipation (max) = Power consumption
Color: RAL 7035
Operating temperature: －15°C to +55° C
Operating Humidity: 40 to 90 % RH (non condensing)

Power Supply Unit (PSU3)

Mechanical specification
Height: 500 mm
Width: 380 mm
Depth: 210 mm
Weight: 36 kg

Electrical specification
Input voltage: 85-265 VAC
Frequency: 47-63 Hz
Max current at lowest input voltage 5A RMS
Max power output load: 12A, 7A continuous
Serial inputs: RS-232
Serial outputs: RS-232

Environmental specification
Enclosure material: Steel
Enclosure protection: IP44
EMC: IEC 60945
Heat dissipation (max) = Power consumption
Color: RAL 7032
Operating temperature: -15°C to +55° C
Operating Humidity: 40 to 90 % RH (non condensing)

Power Supply Unit (PSU24)

Mechanical specification
Height: 385 mm
Width: 260mm
Depth: 226.5 mm
Weight: 19 kg

Electrical specification

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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Input voltage: 18 – 36 VDC

Max current at lowest input voltage 10A
Max inrush current: 10A
Output voltage: 22-27.5 VDC when charging
Max power output load: 10A, 8A continuous
Serial inputs: RS-232
Serial outputs: RS-232

Environmental specification
Enclosure material: Steel
Enclosure protection: IP44
EMC: IEC 60945
Radiated Noise: According to IEC 60945
Color: RAL 7035
Heat dissipation (max) = Power consumption
Operating temperature: -15°C to +55° C
Operating Humidity: 40 to 90 % RH (non condensing)

System indicator SD4-6

Mechanical specification
Height: 144 mm
Width: 144mm
Depth: 15 mm
Weight: 0,5kg

Electrical specification
Input voltage: 10-32 VDC (12 or 24 VDC nominal)
Current: 400 mA maximum, max light level & lamp test
Serial input: Isolated IEC 61162-1 (NMEA)
Remote inputs: 3 inputs with internal pull-up to +5V, activated
by grounding to 0 V
Serial output: Standard IEC 61162-1 (NMEA) based on RS
485 driver
DC output +5 V with 35 mA current capacity

Environmental specification
Enclosure material: Aluminum (frame)
Enclosure protection: IP66 in SD4 BMB box. IEC 60945 ”exposed”
in watertight cabinet. Otherwise ”protected”
EMC: IEC 60945
Radiated Noise: According to IEC60945
Color: Black
Operating temperature: -15°C to +55° C

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn
Tel:+86-10-82678888 Fax:+86-10-82150083

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Data Acquisition Unit DAU

See DAU Installation Manual, 709233, Chapter E12 in this manual.

Final Recording Medium type A / 709231 PDU (Protective Data Unit)

Color Fluorescent International Orange

Weight – Protected Data Unit 33 kg
Dimensions – Protected Data Unit 220 D x 316 H mm
Dimensions – Mounting Base 320 D x 63 H mm
Dimensions – PDU & Mounting 360 W x 320 D x 359 H mm
Base Assy
Input Power 24 VDC +/-20%
Power Consumption 10W nominal
Memory Type Solid State
Capacity 12-hour minimum (1.5GB~4GB)
Computer Interface 10Base-T(IEEE802.3) /
100Base-TX(IEEE802.3u)
Release mechanism 50 lb pull on release clamp
Underwater Acoustic Beacon SA 8405 compliant
Regulatory Specifications IEC-61996, 60945, IMO A.861(20)
Compass safety distance:
Standard compass 98 cm
Steering, standby and emergency
compass 80cm

Electrical specification
Power Variation: 19.2-28.8 VDC
Excessive Conditions: 16-36 VDC, Fuse cutoff >36VDC, reverse
polarity
Dangerous Voltage: IP22

Environmental specification
Material Steel
Shock: 50 g, 11 ms, 1/2 sine, 3 orthogonal directions, 3
shocks each
Penetration: 250 kg weight with 100mm pin dropped from 3
meters height
Low Temp Fire: 10 hours @ 260 degrees C
High Temp Fire: 1 hour @ 1100 degrees C

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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Deep-Sea Immersion: 6000 Mpa (6000 meters) for 24 hours

Seawater Immersion: 3 Mpa (3 meters) for 30 days
Dry Heat: 70 degrees C storage test, 55 degrees C
functional test
Damp Heat: 40 degrees C and 93% humidity functional test
Low Temperature: -25 degrees C functional test
Rain: 30 Minutes @ 100 liters/min from2.5 meters
Vibrations: 2-5 to 13.2 Hz +/-1mm, 13.2-100Hz @7m/s/s

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 SYSTEM
DESCRIPTION

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04 ST
Version V1.0
Date 2006.2

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
 海兰信数据科技
Beijing Highlander Digital Record Technology Co., Ltd.

Notes and Updates

Revisions:
Date Ver Issue by Description
2005-10-01 A0 NE Created
2005-12-06 A1 NE Editorial corrections
2006-3-6 A1.0 Li ChW Modified as HLD-A2 system

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

Tel:+86-10-82678888 Fax:+86-10-82150083
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General
The VDR HLD-A2 is designed to meet the performance requirements and technical
characteristics for simplified shipborne voyage data recorders (S-VDRs) as required by IMO
MSC.163(78) and IEC PAS 61996-2. However the HLD-A2 VDR can easily be expanded to
a “full VDR”, e.g. meeting performance requirements and technical characteristics for ship
borne voyage data recorders (VDRs) as required by the earlier published IMO Resolution
A.861 and IEC 61996.

In this manual the equipment is called VDR HLD-A2 where the description is the same and
will be named S-VDR or “full VDR” only where necessary for separating the two different
applications.

Units
The VDR HLD-A2 consists of following units:

Main Unit (MU) composed of Data Collecting Unit (DCU) Board

Audio Mixer Unit (AMU) Board
Radar Grabber Unit (RGU) Board
System Integration (SIU) Unit Board
Ethernet switch / Firewall Unit (ETU)
DC/DC Converter
Power Supply Unit (PSU) There are 2 different types of PSU:
PSU24 (24V DC) and PSU3 (115/220 AC)

System Control Unit (SCU) Remote Control and Alarm Panel SD4-6

Final Recording medium (FRM) Placed in a capsule e.g. Protective Data Unit (PDU) or
Hardened Voyage Recorder (HVR), or Simplified
Hardened Voyage Recorder (S-HVR)

Optional for S-VDR and for full VDR version there is also a Data Acquisition Unit (DAU) for
analogue and digital signals. There is also a Video Mixer Unit Board, to be placed in the Main
Unit, if more than one radar/video source is recorded.

The MU, the PSU and the DAU are separate steel cabinets. They can be placed anywhere on
the bridge or in the vicinity of the bridge. The SCU is a SD4-6 instrument to be placed at the
conning navigation work station on the bridge.

The daily user communication with the VDR HLD-A2 is via SCU. There is no display or
other buttons on any unit. For service and closer communication with the VDR a portable
PC/laptop can be connected to the MU. An external ship’s computer can also be connected
via a local network.

The main memory of the VDR HLD-A2 is that in the FRM (Capsule). A copy of the capsule
data can be stored on a (USB) memory stick in the MU. It can be used as a transfer memory
of data to and from the VDR. There is no other ship data memory built in the VDR. When the

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VDR HLD-A2 is network connected to an external ships computer, data can be stored there
continuously. Replaying of data can be performed on any external PC with Highlander Player
software installed and with data input via Ethernet or USB.
MU
The main unit is a steel cabinet of approximately h600 x w500 x d230 mm for wall mounting.
It has one door and cable glands are in the bottom. The units are mounted in the cabinet as
shown on figure below.

HLD-A2 VDR Main Unit

DC/DC conv
SIU board
RGU boards USB
Memory
Covered by a
plate stick
Fan

AMU
DCU board
In/out for board
IEC 61162/NMEA Microphones
Fuses
ETU

RS 485, USB VHF

Puls inputs Mic. control
On/off inputs

Video
Cable glands
input

Sockets for cable connections are shown in the MU Installation Manual.

DCU
The Data Collecting board can receive signals from 14 IEC 61162-1/NMEA sources but it can
also communicate over two IEC 61162-2 / high speed NMEA and one channel RS485. It has
two opto isolated inputs for pulses (100-20000 / Nm) with 24 V power feed facility and four
opto isolated digital (on/off) inputs. Two switching relays can be controlled.

AMU
The Audio Mixer board can connect up to eight controlled microphones plus two VHF
separated, on together four audio channels. There is also room for another four, not
supervised, audio inputs.

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RGU
The Radar Grabber board can directly handle one radar input, which is sufficient according to
both S-VDR and “full-VDR” regulations. However if more radars or other video signals shall
be recorded (ECDIS, Conning display etc) a special Video Mixer Unit, VMU, must be
installed in the MU.

SIU
The System integration unit includes the processor and internal memory for supervising of the
VDR HLD-A2 System

ETU
The Ethernet switch Unit is for all external and internal Ethernet communication.

DC/DC converter
A separate DC/DC converter supplies the MU boards with needed DC power.
PSU
The Power Supply Unit is placed in a separate wall mounted steel cabinet of about the same
size as MU. It can be fed with 230 VAC and with 115VAC as well as 24 VDC over optional
converter. The PSU supplies the VDR HLD-A2 with 24 VDC. It also includes necessary
batteries to power the VDR for the 2hours audio recording if ship’s emergency power is lost.
That process is controlled by the SIU in MU.
SCU
The System Control Unit is a Highlander SD4 instrument type 6. It is an alarm and remote
instrument for the VDR which must be placed at the conning navigation work station on the
bridge. It has an incident button which will save data for longer time and 12 hours on a
separate USB memory stick placed in the MU. Number and length of saved data sequences
can be changed. The alarm function tells what type of alarm/alert or warning the VDR
HLD-A2 is generating. Relay and serial outputs are available for external alarms or central
alarm table.
FRM
The Final Recording Medium is a capsule which is designed for “full VDR” or S-VDR
demands. It saves data during 12 hours and then starts to erase the oldest information minute
by minute. Data can be downloaded from the capsule to the USB-memory stick, an external
laptop computer or other permanently network connected external PC on board the ship.
DAU
The Data Acquisition Unit is mounted in a separate steel cabinet of about the same size as
MU. It can receive and transform to MU all type of analogue, digital(on/off) or synchro
signals, occurring on instruments which must be recorded by a “full VDR”. The DAU is an
optional unit. As the S-VDR has data available in IEC61162/NMEA format (except rarely
from speed and heading), the DAU will normally not be needed at S-VDR installations.

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VDR HLD-A2 System Process

FRM
Final Recording Medium
Date & Time Main Unit (Capsule)
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
Heading (Data Collecting Unit)
SCU
AIS System Control &
Alarm Unit
(SD4-6)
Ship Audio AMU OUTPUT OF
Audio Mixer Unit
(Microphones) Ship’s Ethernet Interface
VHF SIU Service/Investigator’s
System Integration Unit
Ethernet Interface
RECORDED DATA
VMU RGU
Radar Video Mixer Unit Radar Grabber Unit
Ship’s (Investigator’s)
(Optional/Full VDR) USB Interface
ETU (Memory Stick)
Ethernet & Firewall Unit

IEC 61162/
Other items to
be recorded NMEA
PSU
Analogue/Dig DAU Power Supply Unit
signals Data Aquision Unit (incl. batteries)
(Optional / Full VDR)

115/230 VAC
24 VDC

Input Data:
Date & Time and Ship position is normally received from the GPS in IEC61162/NMEA
format. The signal goes to the DCU board in MU.

Normally this also holds for Speed, Heading and AIS information. Older Heading Gyros and
Speed Logs may have the output in other format but due to the regulations for AIS
installations there are most often IEC61162/NMEA signals available. However the DCU also
has input for pulse signals (100-20000 / Nm) with a 24V power feed facility.

Ships Audio can be received from up to eight supervised microphones plus 2 VHF separated
on together four audio channels and connected to the AMU board. There is also room for
another four, not supervised, audio inputs. The microphones are of Highlander’s own, high
performing design and are available for indoor and outdoor mounting. Normally 3-4
microphones and one VHF will cover the VDR regulation demands.

The Radar is connected via a special video input and is then prepared by the RGU. One
picture every 15 second from the radar master display is sufficient for a normal VDR
installation. Only when the radar has no video output and no video interface is available on
the market (i.e. special manufacturing is needed) is it possible to omit the radar recording
and instead use the AIS information.

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If more than one video display is desired to record (i.e. more radar, ECDIS and/or Conning)
the optional VMU must be installed in MU.

Any other data items listed for the “full VDR” (IMO Resolution A.861 and IEC 61162) must
be recorded if they are available in IEC61162 format. Note that NMEA-like serial signals (so
called proprietary formats) may, but does not need be recorded.

Analogue, digital(on/off) and synchro signals etc. from “other items to be recorded” can be
necessary to treat at a “full VDR installation. Main alarms, Rudder order/response, Engine
order/response, Hull openings, Water tight doors and Fire doors are still very rarely available
in serial format and needs the optional DAU. However a few(4) digital signals can be
connected directly to the DCU.
Stored Data
All data received through the DCU, AMU, RGU boards is prepared by the SIU and sent to the
FRM (Capsule). The ETU (Ethernet switch/Firewall Unit) is sending the Ethernet data do
correct addresses. Data is only stored on the FRM if no other directives are given.
Alarm
The SCU unit communicates with the MU by serial connection. If there is an alarm or a
warning condition in the VDR the SCU start alarming. A short description of the alarm is
shown on the SCU display, but is also further explained in the User Guide.
Data outputs
Data from the capsule can be downloaded from the FRM by pressing the “Incident” button on
the SCU.

Such “Incident recorded data”, and other on the SCU selected data from the FRM, can be sent
by the local network to any connected PC or Laptop computer. It can also be stored on the
USB Memory stick.
Due to data safety reasons there is a data firewall in the ETU. Data can only be received to an
external network connected ship’s PC. All VDR data is protected by passwords.
Service
For service purpose it is possible to connect a service Laptop computer and work in the VDR
program by using a special password.

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 USER GUIDE

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04 SS2

Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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Notes and Updates

Revisions:
Date Ver Issue by Description
2005-10-01 A0 NE Created
2005-10-10 A1 NE Annex completed with MSC circ 1024
2005-10-10 A1.0 Li Chw Modified as HLD-A2 system

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CONTENTS

1 VDR HLD-A2 – Quick Guide 4

1.1 System Control&Alarm Unit (SCU) type SD4-6 4
1.1.1 Incidents/Accidents 5
1.1.2 Alarms/Warnings 5
1.1.3 Annual performance test (APT) 6
2 Regulations 6
2.1 Purpose of VDR 6
2.2 Carriage requirements and data items to be recorded 6
2.3 Resistance to tempering and Continuity of operation 7
2.4 Ownership of VDR information 7
2.5 Annual performance test (APT) 7
3 Incidents and Accidents 8
3.1 Download to an USB stick 8
3.1.1 Capsule type A 8
3.1.2 Capsule type B 10
3.2 Download to a temporarily LAN connected external laptop 10
3.3 Download to a permanently LAN connected external ship computer or ship network 11
3.4 Download by a direct connection from the FRM/Capsule to an investigator computer 11
4 Alarms and warnings 11
4.1 Actions following Alarms and Warnings 11
5 Annex 16

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1 VDR HLD-A2 – Quick Guide

The VDR HLD-A2 is designed to work automatically without any break or supervision at all.
The only reasons to care about the VDR HLD-A2 are
• at incidents to remember to save (back up) and transfer data another memory
• at alarms or warnings, if any, to find out what reason(s) have caused the alarm or the
warning
• at the annual performance test which also is a service of the VDR that assures that the
VDR functions correctly and will do so for at least another year

We recommend to read the chapter VDR HLD-A2 System Description and the detailed guide
below, particularly the Accident and Incident paragraph, which is necessary to know by heart
at a stressed incident or accident situation.

1.1 System Control & Alarm Unit (SCU) type SD4-6

Messages, total number

VD R
S D 4 -6

Message id.
Warning

Alarm

Test
Message Scrolling

Back-up Setting DIM

U/N 704046

The SCU shall be placed at that position on the bridge from which the vessel is normally
navigated. The displays and buttons (except the warning/alarm and back-up LEDs) can be
dimmed with the two dimmer buttons down to the right.

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1.1.1 Incidents/Accidents
The procedure to back-up and save information for more than 12 hours at incident and
accidents is depending on type of Final Recording Medium FRM/Capsule that is installed.
Therefore carefully find out and memorize relevant Accident/Incident procedure (see below)
for own vessel. Normally the information is backed up to an USB Memory Stick
automatically, or by using the SCU Back-up button. The USB Memory Stick is placed inside
the locked door of the VDR HLD-A2 Main Unit (MU).

Do not forget to transfer data as soon as possible from the USB memory stick to another
computer memory, to prevent the data to be erased by mistake and to make the USB
memory stick available for new incident/accident recording.

VDR M4.0 Main Unit USB Memory Stick

DC/DC conv

SIU board
RGU boards USB
Memory
Covered by a
plate stick
Fan

AMU
DCU board
In/out for
board
Fuses

Microphones
ETU

IEC 61162/NMEA
VHF
RS232, RS 485
Mic. control
Puls, USB

Video
Cable glands
input

The on-board standing orders at incident and accident shall include the relevant back-up
procedure, including instructions for how to get access to the USB memory stick in the
locked VDR HLD-A2 Main Unit.

Regarding procedure at investigation on board from authorities after accidents, see paragraph
2.4 below, and Chapter C8 Investigative Authorities Guide.

1.1.2 Alarms/Warnings
At an alarm there is a sound which can be muted with the button down left at the SCU. The
Alarm LED will light and the displays will show information about the alarm. At Warnings
there is no sound but the Warning LED will light.
• The top display tells the number of contemporary warning and alarm messages.
• Next display tells the identification number of the warning or alarm. At more than
one message the numbers can be scrolled by using the + and – buttons. The Alarm list

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(placed at the end of this chapter) tells details and recommended action at each
alarm/warning.
• The third (larger) text display gives short information of what kind of alarm or
warning that is running.

Note 1: When a unit which also is an item to be recorded, is turned off intentionally, e.g. the
radar or the speed log, there is automatically a warning. This is a normal procedure telling that
the VDR is not recording according to its configured set-up.

Note 2: Once every 12 hour there is a short beep heard from each microphone. This also a
normal procedure, to assure a normal operation of the audio recordings on the bridge.

1.1.3 Annual performance test (APT)

A certificate affirming that the VDR has passed the APT must be kept on board to certify to
inspecting authorities that the VDR is working properly. The test is normally performed
together with other annual classification works of the vessel. See further paragraph 2.5 below.

2 Regulations
2.1 Purpose of VDR
According to IMO, the purpose of a Voyage Data Recorder (VDR) is to maintain a store, in a
secure and retrievable form, of information concerning the position, movement physical status,
command and control of a vessel over the period leading up to, and following, an incident
having an impact thereon. This information is for use during any subsequent investigation to
identify the cause(s) of the incident.

2.2 Carriage requirements and data items to be recorded

Further IMO [SOLAS] has regulated that all ships (fishing ships excluded) over 500 gross
tonnage engaged on international voyages shall be fitted with a VDR.
• Older cargo ships built before 1 July 2002 can have a Simplified VDR (S-VDR),
meaning that at least Date and Time, Ship position, Speed, Heading, Bridge Audio,
Communication Audio, Radar main display and AIS, shall be recorded by the VDR
and stored in Final Recording Memory (FRM) and protected by a Capsule. (If more
bridge information is available as IEC 61162 [NMEA] data signals, it must also be
recorded.)
• Modern cargo Ships (built after 1 July 2002), all passenger ships and all ro-ro
passenger ships must have “full” VDR, meaning that more information available on
the bridge must be recorded and stored in the FRM/Capsule. Such additional
information is Echo Sounder, IMO mandatory bridge alarms, Rudder order/response,
Main engine and Thruster order/response. If these ships are enjoined to have
indicators on bridge for Status of Hull- Watertight- and Fire- doors, Acceleration and
hull stresses, Wind speed and direction, that information must also be recorded and
stored.

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2.3 Resistance to tempering and Continuity of operation

The equipment is designed, as far as practicable, so it is not possible to tamper with the data.
Any attempt to interfere with the integrity of the data or the recording is recorded by the VDR.
The recording progress must not be interrupted. If the ship’s emergency power is lost the
VDR proceeds recording the bridge audio for two hours. The VDR automatically starts full
recording again if power comes back.

The VDR Main unit must be locked and the key shall be kept by a dedicated officer e.g. the
Master or Safety Officer of the ship. The recording must be terminated only
• during essential maintenance purposes whilst the vessel is in port
• when the vessel is laid-up

All breaks and other interruptions in the normal VDR HLD-A2 operation are recorded in
special log and event files, which are not erased after 12 hours.

2.4 Ownership of VDR information

IMO has regulated that the ship owner will, in all circumstances and at all times, own the
VDR and its information. However, in the event of an accident special guidelines would apply
(see IMO MSC/Circ1024 in paragraph 5 Annex). The owner is responsible, through its
on-board standing orders, for ensuring the timely preservation of relevant recorded evidence.
Further the owner of the ship shall make available and maintain instructions necessary to
recover the recorded information. During the course of an investigation, the investigator shall
have custody of the original VDR information in the same way that the investigator will have
custody of other records and evidence under the Code for Investigation of Marine Causalities
and Incidents.

The procedure how to save and download data is described below in paragraph 2 Incidents
and Accidents. How to replay data is described in chapter C7 Player Guide. A special
instruction for investigation officials is described in chapter C 8 Investigative Authority
Guide.

2.5 Annual performance test (APT)

IMO has also regulated in SOLAS that the VDR system, included all sensors, shall be subject
to an annual performance test. The test shall be conducted by an approved testing or
servicing facility to verify the accuracy, duration and recoverability of the recorded data. In
addition, tests and inspections shall be conducted to determine serviceability of all protective
enclosures and devices fitted to aid location. A copy of the certificate of compliance issued by
the testing facility, stating the date compliance and applicable performance standards, shall
be retained on board the ship.

For Highlander VDRs, the APT is performed in practice by Highlander technicians approved
by the classification society and/or national maritime organization of the vessel’s flag state.
APT can be ordered directly to Highlander or via local Highlander service agent.

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All APT performed on Highlander VDR’s are managed from and registered in Highlander
Service Center in Beijing. A unique numbered certificate is issued for each APT and is only
valid if signed by a technician approved by and listed at Highlander.

3 Incidents and Accidents

If an incident or accident occurs the FRM/Capsule data shall be copied to another memory to
prevent automatic erasing after 12 hours (“last minute in-oldest minute out”). The procedure
is different depending on what type of capsule (A=Highlander HL or B=L3) is installed in the
system.

Data stored on the FRM/Capsule (IEC 61996 4.5.1.Operation) can be copied to other memory
with different methods:
1. Download to an USB stick. Action initiated from SCU (SD4-6).
2. Download to a temporarily LAN connected external laptop. Action initiated from the
external laptop computer.
3. Download to a permanently LAN connected external ship computer or ship network.
Action initiated from the external computer.
4. Download by a direct connection from the FRM/Capsule to an investigator computer.
(If risk for damaged capsule, contact Highlander)

3.1 Download to an USB stick

3.1.1 Capsule type A

An USB stick shall always be connected to the USB socket in the VDR MU. If no memory
stick is connected there is an alarm (174) “USB memory not connected”.
Note: The USB stick must be of size 2 GB or more and must be formatted and delivered by
Highlander to assure a safe function.
Note: After the memory stick has been removed from the socket, ALL DATA ON THE USB
STICK WILL BE AUTOMATICALLY ERASED AT NEXT BACK UP, AFTER
REPLACED AGAIN IN THE VDR MU.

There are two ways to make a memory download of the capsule memory to the USB-stick
memory, initiated from the SCU (SD4-6):
Full Back-up, which means that the last 12 hrs, counted from starting of the back-up, are
downloaded to the USB-stick memory.
Incident Back-up (not IMO mandatory), which means that a certain time around the starting
of the back-up is downloaded to the USB-stick memory. The time can be selected from
default 2hrs (minus one to plus one hrs) to 11 hrs (minus 10 to plus one hrs).

Full Back-up

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Press Back-up button for more than 2 seconds. Before 2 seconds (and if only a short depress
of the button) the display will show: PRESS 2 SEC FOR FULL BACKUP.

1234567890123456
PRESS 2 SEC FOR
FULL BACKUP

After 2 seconds depressing of the Back-up button the download will start and the display
shows: FULL BACKUP IN PROGRESS.

1234567890123456
FULL BACKUP
IN PROGRESS

The red LED placed over the back-up button will be on during the backup procedure.
NOTE: This back-up can take up to 30 minutes.
When the back-up is ready the red LED is off and there is a warning saying: BACKUP
COMPLETED. TRANSFER DATA.

1234567890123456
BACKUP COMPLETED
TRANSFER DATA

Incident Back-up (not IMO mandatory)

Press the minus(-) and the plus(+) buttons simultaneously for 2 seconds. Before 2 seconds
(and if only a short depress of the button) the display will show: PRESS 2 SEC FOR
INCIDENT BACKUP.

1234567890123456
PRESS 2 SEC FOR
INCIDENT BACKUP

After 2 seconds depressing of both buttons simultaneously the display will show:
-1 TO + 1 HRS INCIDENT BACKUP.

1234567890123456
-1 TO +1 HRS
INCIDENT BACKUP

The length of the downloaded recorded time can now be extended backwards by depressing
the minus button. The time is extended backwards one hour for each depress of the minus
button.
Start the Incident Back-up by depressing the Back-up button. The display will then show:
INCIDENT BACKUP IN PROGRESS.

1234567890123456
INCIDENT BACKUP

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IN PROGRESS

The red LED placed over the back-up button will be on during the backup procedure.
When the back-up is ready the red LED is off and there is a warning saying: BACKUP
COMPLETED. TRANSFER DATA

1234567890123456
BACKUP COMPLETED
TRANSFER DATA

NOTE: The Incident Back-up will always record and download one hour forward from the
moment the process is started by the Back-up button.

After completing a Full Back-up or an Incident Back-up, the USB-stick must be removed
from and plugged in again in its socket/holder before making another back-up. The data will
the be erased from the USB-stick. When trying to start a Full Back-up or an Incident Back-up
with earlier downloaded data on the USB-stick, there will be a message on the display saying:
MEMORY FULL. TRANSFER DATA.

1234567890123456
MEMORY FULL
TRANSFER DATA

NOTE: Therefore always make as a routine to transfer the USB-stick data to another
computer immediately after the back-up is completed. While the memory stick is
removed from the VDR MU there is an alarm: USB memory not connected

3.1.2 Capsule type B

The type B capsule stores the data on the Capsule FRM in such a way that only parts of the
memory can not be copied to the USB memory stick. Therefore the capsule memory is
continuously backed up on the stick and can be removed any time including the last 12 hours
data., Installations with capsule type B gives an immediately access to the currently stored
memory, accordingly.

Note: The USB memory stick is erased in the same way as the capsule, “last minute in / oldest
minute out”. Therefore it is very important to take out the USB memory stick immediately
after an incident or accident and copy it to another computer memory.

3.2 Download to a temporarily LAN connected external laptop

See Investigative Authorities Guide

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3.3 Download to a permanently LAN connected external ship computer or

ship network
Special instruction in manual following such installation

3.4 Download by a direct connection from the FRM/Capsule to an

investigator computer
This should be performed only by a person specially trained by Highlander. If any risk that
the FRM has been exposed to any damage, contact Highlander.

4 Alarms and warnings

At an alarm there is a sound which can be muted with the button down left at the SCU. The
Alarm LED will light and the displays will show information about the alarm. At Warnings
there is no sound but the Warning LED will light.
• The top display tells the number of contemporary warning and alarm messages.
• Next display tells the identification number of the warning or alarm. At more than
one message the numbers can be scrolled by using the + and – buttons. The Alarm list
(placed at the end of this chapter) tells details and recommended action at each
alarm/warning.
• The third (larger) text display gives short information of what kind of alarm or
warning that is running.

4.1 Actions following Alarms and Warnings

Any alarm status indicates some specific VDR malfunction, which should always be
investigated to provide guidance to relevant action.
Any Warning indicates an abnormal status of the VDR, which the Officer on Watch must
be informed about.
The identity numbers along with an explanation and troubleshooting help are listed in the
table below.

Message Alarm / Message description Explanation Required action

id
General faults
001 Alarm. System Failure VDR not operating / Check on Main unit to
communication to remote verify if VDR is
display not working. working. Check other
alarms
002 Alarm. Lost main power No power to VDR. VDR Find cause of power

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Message Alarm / Message description Explanation Required action

id
will work on UPS for 2 hrs. loss, check fuses
004 Alarm. Data lost Recorded data lost. Consult Highlander
005 Alarm. Flash failure Internal memory error Contact Highlander
Audio
100 Alarm. Audio general failure Consult Highlander
101 Alarm. Audio failure Consult Highlander
103 Alarm. Audio failure Consult Highlander
104 Alarm. Audio failure Consult Highlander
Radar
120 Warning. Video input -1 signal Missing input from Check radar is on.
missing recorded Radar Contact radar service

130 Warning. Video input -2 Check video item is on.

140 Warning. Video input -3 Analyze missing video
Warning. Video input -4 Missing input from other
150 recorded video item, e.g. source. Contact
radar 2, Ecdis appropriate service

159 Alarm. Video failure General Video failure Consult Highlander

CCTV
160 Warning. CCTV camera 1 sign Missing input from Analyze missing video
161 missing camera #1 Missing input source. Contact
162 Warning. CCTV camera 2 sign from camera #2 Missing appropriate service
163 missing input from camera #3
164 Warning. CCTV camera 3 sign Missing input from
missing camera #4 Missing input
Warning. CCTV camera 4 sign from camera #5
missing Warning. CCTV camera
5 sign missing
169 Warning. CCTV failure. Consult General cctv video Consult Highlander
manual failure
Backup
170 Warning. Backup failed Current back-up Repeat back-up
interrupted procedure.
177 Warning. Backup failed Current on-line back-up Check connection to the

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Message Alarm / Message description Explanation Required action

id
failed back-up computer

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Watchdog
190 Alarm. Watchdog error
consult man Configuration error. Contact Highlander
191 Alarm. Watchdog error Watchdog drive missing
consult man
192 Alarm. Watchdog error
consult man
Sixnet analogue/digital interface
200 Alarm. Sixnet digital signal Missing digital input signal Check Sixnet power
missing supply
201 Alarm. Sixnet analogue input Missing analogue input Check Sixnet
missing signal connections
Contact Highlander
202 Alarm. Sixnet failure. General Sixnet failure
NMEA serial input
220 Warnings. “NNN” Signal The signal specified on Check if specified unit is
to missing. display is missing on.
263 Check output and
connections
Consult drawings
Contact appropriate
service.
301 Warnings. NMEA Com #. The IEC 61162/NMEA Find actual unit
to Signal missing signal to specified com # is connected to com#.
missing. Consult drawings. Check
325 outputs and connections.
Contact appropriate
service.
VDR
400 Alarm. VDR failure General VDR Failure Contact Highlander
VUB
409 Alarm. No DCU signal Software failure Contact Highlander
410 Alarms. NNN voltage error The power is missing to Consult technical manual
to displayed unit or sub unit. to find position of fuse
419

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Microphone Test
460 Alarm. Microphone 1 self test The microphone(s) in Is the alarm recurrent?
461 failed question has stopped Single self tests can fail
462 Alarm. Microphone 2 self test working or have weak due to simultaneous high
463 failed reception. noice e.g. other alarms.
464 Alarm. Microphone 3 self test Check connections to the
465 failed microphone. Change
466 Alarm. Microphone 4 self test the microphone(s).
467 failed
Alarm. Microphone 5 self test
failed
Alarm. Microphone 6 self test
failed
Alarm. Microphone 7 self test
failed
Alarm. Microphone 8 self test
failed
Power Supply
500 Alarm. UPS general failure No contact with PSU Check connections
PSU-MU
Contact Highlander
Capsule type B (L3)
800 Alarm. Capsule, no connection Capsule, connection Check connections to
failure. capsule
801 Alarm Capsule, overrun Data missing in Capsule Contact Highlander
802 Alarm. Capsule, Space Possible error. Capsule Contact Highlander
insufficient memory not enough if Se note below.
current recording size
continues for 12 hrs.
803 Warning. Capsule, lost data Data sequence interrupted If remaining after 12 hrs
or repeated, contact
Highlander
804 Capsule, internal loop error Capsule memory error. Contact Highlander
Capsule type A (HL)
900 Alarm. Capsule, no connection Capsule, connection Check connections to
failure. capsule
901 Alarm Capsule, overrun Data missing in Capsule Contact Highlander

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902 Alarm. Capsule, Space Possible error. Capsule Contact Highlander

insufficient memory not enough if Se note below.
current recording size
continues for 12 hrs.
903 Warning. Capsule, lost data Data sequence interrupted If remaining after 12 hrs
or repeated, contact
Highlander
904 Capsule, internal loop error Capsule memory error. Contact Highlander
905 Alarm. Capsule, no connection Capsule, connection Check connections to
failure. capsule

Note: Alarm No 802 /902 can occur occasionally when radar screen is filled with echoes

e.g. sea/rain clutter or when the ship is in harbor or in narrow archipelago. If so the alarm

will disappear on open sea or when radar range is increased.

5 Annex
INTERNATlONAL MARITlME ORGANlZATlON
4 ALBERT EMBANKMENT
LONDON SE1 7SR
Telephone: 020 7735 7611
Fax: 020 75873210
Telex: 23588 lMOLDN G
IMO
MSC/Circ.1024
29 May 2002

GUIDELINES ON VOYAGE DATA RECORDER (VDR)

OWNERSHIP AND RECOVERY

I The Maritime Safety Committee, at its seventy-fifth session (IS to 24 May 2002), approved
the annexed Guidelines on voyage data recorder (VDR) ownership and recovery which have
been developed to support provisions of the revised SOLAS regulation VIIS, as amended by
resolution MSC.99(73), and, in particular, to support the carriage requirements for voyage

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data recorders contained in the revised SOLAS regulation V 120, which are expected to enter
into force on I July 2002.

2 These Guidelines reflect the five basic issues relevant to VDR ownership and recovery ,
which are ownership, custody , recovery , read-out and access to the VDR information, as
envisaged by the revised SOLAS chapter V.

3 In view of the complexity of the matter, close co-ordination and co-operation among
interested parties, as appropriate, in any recovery operation of a VDR is encouraged.

4 Member Governments are invited to bring the annexed Guidelines to the attention of all
parties concerned.

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MSC/Circ.1024

GUIDELINES ON VOYAGE DATA RECORDER (VDR)

OWNERSHIP AND RECOVERY

Ownership of VDR information

1 The ship owner will, in all circumstances and at all times, own the VDR and its
information. However, in the event of an accident the following guidelines would apply. The
owner of the ship should make available and maintain all decoding instructions necessary to
recover the recorded information.

Recovery of VDR and relevant information

2 Recovery of the VDR is conditional on the accessibility of the VDR or the information
contained therein.

1. Recovery of the VDR information should be undertaken as soon as possible after an

accident to best preserve the relevant evidence for use by both the investigator} and
the ship owner. As the investigator is very unlikely to be in a position to instigate this
action soon enough after the accident, the owner must be responsible, through its
on-board standing orders, for ensuring the timely preservation of this evidence.

2. In the case of abandonment of a vessel during an emergency , masters should, where

time and other responsibilities permit, take the necessary steps to preserve the VDR
information until it can be passed to the investigator.

3. Where the VDR is inaccessible and the information has not been retrieved prior to
abandonment, a decision will need to be taken by the flag State in co-operation with
any other substantially interested States2 on the viability and cost of recovering the
VDR balanced against the potential use of the information. Ifit is decided to recover
the VDR the investigator should be responsible for co-ordinating its recovery . The
possibility of the capsule having sustained damage must be considered and specialist
expertise will be required to ensure the best chance of recovering and preserving the
evidence. In addition, the assistance and co-operation of the owners, insurers and the
manufacturers of the VDR and those of the protective capsule may be required.

Custody of VDR information:

3 In all circumstances, during the course of an investigation, the investigator should have
custody of the original VDR information in the same way that the investigator would have
custody of other records or evidence under the Code for the Investigation of Marine
Casualties and Incidents.
1. The term investigator refers to the Marine Casualty Investigator as per the term of the
Code for Investigation of Marine Casualties and Incidents.
2. Refer to paragraph 4.11 of the CO<k: for the Investigation of Marine Casualties and
Incidents, as adopted by resolution A.849(20).
I:\CIRC\MSC\1024.doc

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MSC/Circ.1024
ANNEX
Page 2

Read-out of VDR information:

4 In all circumstances the investigator is responsible to arrange down loading and read-out of
the information and should keep the ship owner fully informed. In some cases, the assistance
of specialist expertise may be required.

Access to the VDR information:

5 A copy of the VDR information must be provided to the ship owner at an early stage in all
circumstances.

6 Further access to the information will be governed by the applicable domestic legislation of
the flag State, coastal State and other substantially interested States as appropriate and the
guidelines given in the Code for the Investigation of Marine Casualties and Incidents.

7 Any disclosure of VDR information should be in accordance with section 10 of the Code
for the Investigation of Marine Casualties and Incidents.

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 PLAYER
MANUAL

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04 PB
Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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1 Notes and Updates

Revisions:
Date Ver Issue by Description
01-07-06 A0 Stoft Created from previous documents
02-10-01 A1 JXA Updates
05-10-10 A1.0 Li Chw Update the contact information

2 Where to call in case of problems or faults

Highlander Corporation maintains a call centre service at:

Call: +86 10 821 501 82 Email: service@highlander.com.cn

Fax: +86 10 821 500 83

The Call Centre is open during office hours, 09.00 – 17.30, UTC+8.

Please note: Email is the preferred method of communication. Please state the fault or problem
as fully as possible, mentioning all details that could be relevant for solving the problem.

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CONTENTS

1. NOTES AND UPDATES ...................................................................................................................... 0

2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS ........................................................ 0

3. OVERVIEW OF THIS MANUAL ...................................................................................................... 0

4. INTRODUCTION................................................................................................................................. 0

4.1. What does the Program ....................................................................................................0

4.2. What this Program Does Not ................................................................................................... 0

5. TERMINOLOGY.................................................................................................................................. 0

6. INSTALLATION AND FIRST RUN .................................................................................................. 0

7. GETTING STARTED .......................................................................................................................... 0

8. THE COMPLETE WALKTHROUGH .............................................................................................. 0

8.1. Data flow ............................................................................................................................0

8.2. Windows and their Use .....................................................................................................0

8.3. Toolbars and icons ............................................................................................................0

8.4. Customising a Window .....................................................................................................0

8.5. Playing in Step Mode ........................................................................................................0

8.6. Play to Text File Mode......................................................................................................0

8.7. Graphing in the Multi-graph Window............................................................................0

8.8. Graphing in Normal Mode ...............................................................................................0

8.9. Searching and Finding......................................................................................................0

8.10. File Operations Summary ................................................................................................0

8.11. View Operations Summary ...................................................................................................... 0

9. FILE SYSTEM AND FILE NAME DETAILS .................................................................................. 0

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9.1. File Types ...........................................................................................................................0

9.2. File Structure ............................................................................................................................... 0

10. TROUBLESHOOTING.................................................................................................................... 0

11. SYSTEM REQUIREMENTS........................................................................................................... 0

11.1. Dual Screen Mode ...................................................................................................................... 0

12. ORDERING INFORMATION ........................................................................................................ 0

12.1. Activation ..................................................................................................................................... 0

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3 Overview of this Manual

This manual is intended for investigative authorities, ship owners, legal advisors or others
wanting to replay a voyage recorded by a Highlander HLD-A2 Voyage Data Recorder for
investigation of accidents, dangerous situations or claims of responsibility. It is also an excellent
way to check that all the ship’s sensors are working as intended, and for periodic checking of
backups for maintenance reasons.

Using this manual you will get all the skills needed to install, understand and use all the features
of the Voyage Data Player program. You will also gain some insight into the file system of the
source (backup) data set. At the end there also are some troubleshooting tips and tricks.

4 Introduction

The Voyage Data Player is a Windows application that displays the contents of a backed up
data portion from HLD-A2 Voyage Data Recorder unit, copied from the VDR in the form of a
backup data set, usually on a USB memory stick. The player can be used for replaying whole or
part of the backup, at normal or high speed, forwards or backwards.

Replaying a backup data set is like travelling the recorded voyage in virtual reality, viewing all
the ship’s controls and seeing all the events of the trip. The Player is an invaluable tool for incident
reporting, investigating instrument malfunctions or voyage archiving work.

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4.1 What does the Program

• Let you run the data playback with easy-to-use, intuitive controls

• Displays information from the indicators in several, resizable, movable windows

• Let you select indictors to be displayed, and arrange the screen layout according to your needs

• Interprets the NMEA codes into useful, human-readable indicators

• Displays indicators, radar images, ECDIS display, CCTV images and captured audio
synchronously for a full voyage experience

• Let you search for certain events, such as “heading north, or nearly north” to find specific points
of the voyage, or potentially dangerous conditions, such as “bow port open” or “fire door
changing status”

• Plots numerical values graphically, such as depth, for trend analysis. Plotted graphs can be
manipulated in several ways

• Displays system errors, as reported by the VDR, such as malfunctioning sensors

4.2 What this Program Does Not

Presently it is not possible to use the Voyage Data Player to download data directly from the
protective capsule. Should you need to perform this; special software is needed, used only by the
investigative group at Highlander.

There are some types of NMEA data that the Player cannot interpret. This data is displayed in
the “Unsupported data window” or the “Unsupported proprietary data window” in text form.
Should you need to decode such data, a special interpreter is needed. Highlander could furnish such
an interpreter upon request.

Please contact Highlander for further information.

5 Terminology
Throughout this manual, some application-specific terms are used.

• Channel: A logical grouping and naming of input signals from the ship’s sensors. All input data
to the VDR is assigned channel and sub-channel numbers and names, for easier reference.

• Database: a collection of status data maintained and used internally by the Player in relation to
the Source data set being imported. Imported source data sets are referred to as voyage
databases (VDB).

• Indicator: The display of the output from a sensor on the ship, displayed in an Indicator
Window in the desktop.

• Inspection pointer: The point in time being displayed at present. The inspection pointer is
displayed as a grey arrow on the Timeline toolbar.

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• Inspection range: The range of time being displayed on the Timeline toolbar. This may or may
not be the full time range of the imported data set. It may be a zoomed-in, smaller portion. Note
that some functions, such as graphing in Static mode, use the inspection range as their default
operation range.

• Source data: The voyage data to be displayed or imported. This data was obtained from the
VDR unit, as result of a backup operation.

• Timeline: The time ruler containing the full time range of the displayed source data set. Note
that it is possible to display only a portion of the Time line.

6 Installation and First Run

The Voyage Data Player is supplied on a CD-ROM disk and should be installed directly from
the CD-ROM.

1. Begin by closing all other open programs.

2. After the CD has been inserted into the drive, the installer will auto-start. Follow the instructions
in the installer wizard.

Should the installer not start automatically, click Start / Run... and enter the following
command in the Open box:

d:\install.exe

where d: should be substituted for your CD drive where the CD-ROM is inserted.

Press Enter for the installation to begin.

3. After the installation is finished, there will be a Player icon on your desktop and a Highlander
item on the Start menu.

4. Start the Player by clicking the Player icon or selecting Highlander / Voyage Data Player on
the Start menu.

The VDR Player is password protected. Two levels of access are provided:

• Normal access, excluding audio data. The audio indicator will not be shown.

• Full access, including audio data.

When the VDR Player is initially started, the user will have to supply a user name, an activation
code and a password. The password is used to define the access level for the current session. If all
the information entered is correct, the Player will start. At all subsequent start-ups only the
password will be required.

Activation information will be supplied to registered users.

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The first time the program is started it asks for a VDR Player Data directory. This is the
program working directory, where the databases and status information will be stored. Either enter a
directory manually, or browse for it, using the arrow button.

Once this value is entered you should not change it unless you want to utilise a second data
directory. It is possible to view or change the value by selecting File / Options and changing the
value in the text box.

• Exit the program by selecting File / Exit.

7 Getting Started
The easiest way to get started is to walk through a typical playback situation. Here is a step-by-
step guide to the typical use of Voyage Data Player.

What you need:

• An USB memory stick with backup data from Voyage Data Recorder Main Unit.

or

• The same source data available on your had disk or on a network.

• The source data should not be imported (yet).

A computer with the Voyage Data Player installed, fulfilling the system requirements (see the
System Requirements chapter).

The procedure for creating a backup USB Memory Stick in the VDR HLD-A2 unit is covered
in the VDR User’s Guide.

1. Insert the USB Memory Stick with the source data to computer USB slot (or make a note of the
source data directory on your hard disk or on the network).

2. Start the Voyage Data Player by clicking the icon on the desktop or selecting Highlander /
Voyage Data Player on the Start menu.

3. Enter a password to get the proper access level.

4. Should you see the Select VDR Player Data directory dialog box, go back to the Installation
section and complete the settings for this dialog box.

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5. The Player starts up with an empty desktop. Select the Import VDB alternative on the File
menu to start importing the new source data. The Import Source dialog box opens.

6. Enter the appropriate information into the dialog box to start the import process.

The Source directory is the directory where the source files should be fetched from, typically
the backup directory on the USB memory stick (or some similar directory on your hard disk or on
the network). Browse to this directory by clicking the arrow button. Be sure to select the data set
top-level directory (“\Leo” in this case) and not one of the subdirectories (such as a “00” directory).

You may enter a Source name to identify this voyage in various lists in the program and in the
Player title bar.

Tick the Copy source files box if you intend to copy the source files into your working
directory (for faster access), or leave it un-ticked if you will be reading the source directly off the
USB memory stick (or network) to conserve disk space.

The Database directory is the working directory of the program, and the directory where the
imported source files will be stored if you ticked the Copy Source files tick box. Normally you
should not change this.

You can enter any relevant information or notes into the Info field.

Click OK to continue. The Player will start scanning the source data and build a database of
status information. In case you want to import the source files too, they will now be copied to the
hard disk. This may take some time if you have a backup covering many voyage hours. The
Indicators dialog box opens.

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7. Select which indicators (indicator windows) to display, by double-clicking the red Show dot in
the Show column. The dot changes from red to green and the View status changes from
HIDDEN to the proper indicator type. For starters, we will just click the Show All button to
display all windows. The windows start appearing on the desktop.

8. Click the Close button to exit the Indicators dialog box.

9. The windows are all in a mess. Straighten out everything by selecting the Window / Tile
command. The windows will all line up nicely. This may not be the optimal configuration, but
you can now move them around by simply dragging and dropping.

Note that all the title bars disappeared. This is done to reduce the space needed on the desktop.
You can put the title bars back later. All the colours and sizes of windows and characters are default
settings that can also be changed later.

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Also notice that the inspection window on the Timeline toolbar displays the full-recorded time
of the source data set (04:24:35 - 06:30 in this case), with the inspection pointer set at the beginning
(04:24:35). This is where the Player will start playback. The inspection window can be zoomed and
panned along the timeline for greater resolution, and the pointer can be freely moved to any time
along the line.

10. There is no information in the windows. The information will appear as you start playing. Do
this by clicking the Play Forward arrow on the playback toolbar (much resembling the buttons
on an audio CD player). This arrow is red, indicating that it is available. The Play Backwards
arrow is not available, and will not be, in Normal play mode.

11. Information will start appearing in the windows. If there is audio available, it will play through
the speakers. Select the desired channel(s) in the Audio window. Sit back and enjoy the trip.

12. During playback you may want to rearrange or resize the windows for easier viewing. You
might, for example, want to enlarge the window displaying the conning station, or group the
windows in a logical configuration. Note this:

• Drag and drop the windows as desired.

• The windows with scrollbars are freely resizable.

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• The windows without scrollbars (including the image windows) are resizable with the
up/down arrows on the View toolbar. The audio window is not resizable.

13. Right-click the selected window to get more customisation alternatives. Try for example
selecting the Title bar item to show the title bar for this window.

14. If the Error indicator/counter in the lower right corner turns red, it means a VDR system error
has been encountered. Open the Errors window by selecting the View / System channels /
Errors command.

15. Halt playback by clicking the Stop button (a black square) on the Playback toolbar. Move to
any desired time in the data set by simply pulling the inspection pointer on the Timeline toolbar.

Exit the program by selecting the File / Exit command.

As your source data set is now imported, there is no need to import it again, the next time you want
to view it, whether you actually copied the data files or not. Instead you simply open it with the File /
Open VDB command. You will have all your settings, customisations and window positions restored.
If you import it, you will have to start over again, from Step 4 in this description.

8 The complete walkthrough

Before you start getting into program details, please acquaint yourself with the software by
going through the Getting Started chapter.

8.1 Data flow

A voyage is represented by one or more continuous streams of time stamped snippets of data
(NMEA, images, and audio files) flowing through the player application.

The player can display the data streams as they flow by moving the inspection pointer in normal
or accelerated speed, backwards or forwards, or in steps, by single-stepping one event stream, and
displaying the other streams in synchronism. The events appearing in the data streams are put on
screen as they appear, synchronously.

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In static mode, on the contrary, nothing is moving. Instead, one or several data streams can be
analysed in their entirety (or in part) and graphed against time.

The Player has controls much resembling those on an audio CD player, although it is able to
play backwards too, in single step mode.

With the Find function you may search for a specific event, or an event within a value range.
You may for example ask the system: “Go to the time when the ship was heading south, or
thereabouts” by entering a query on the compass data stream, looking like this:

Heading > 175 and < 185 [degrees]

When you click Find, the player will jump to the first time when the course heading lies
somewhere between 175 and 185 degrees. You may opt to start playing from there or jump to the
next (or previous) time the ship is heading south, by continuing to search forwards or backwards.

The inspection pointer may be manually set at any time along the timeline, and the inspection
window, the visible portion of the timeline, may be zoomed in for greater resolution in the time
domain.

8.2 Windows and their Use

Data from the VDR system flows into the Player, where it is displayed and manipulated. There
are four main data sources that feed data into the Player:

NMEA data originating from the event files in each minute directory. NMEA data is broken
down according to Player support. Unsupported data is displayed as raw text, whereas supported
data is interpreted and displayed in human-readable form. Interpreted data may also be graphed.

Picture data originating from the jpeg image files. Radar frames grabbed by the VDR frame
grabber, and CCTV images grabbed by the external camera gateway are treated the same.

VDR System errors originating from the event files.

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Audio data originating from the audio files in each minute directory. Up to four audio channels
are available and can be selected for playback in any combination.

The Player can display several different types of windows, depending on the type of data to be
displayed. Most windows are resizable and can be customised according to needs by changing
colours, fonts, title bars etc. In some cases it is possible to switch a window between types. Most
windows can, for example be changed into text windows for displaying the raw data that that “lies
behind” the interpreted display.

Before you will see any windows, you must enable them with the View / Indicators command
and select the windows to display in the dialog box that opens.

8.2.1 Text Window

The basic form of window, displaying the raw text as stored in the event file, used for example
for NMEA data. If there is no interpreter available, this is the only way to view unsupported or
unsupported proprietary NMEA data

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The window may be customised. See below. This window type is freely resizable by just
dragging its borders.

8.2.2 Indicator Window

This is a window for displaying interpreted NMEA data such as speed log, ship’s position,
interpreted alarms etc. This window type is resizable by clicking the up/down buttons on the View
toolbar.

The window may be customised. See below. The window data may be graphed. See the
graphing section.

8.2.3 Multiple Source Indicator Window

This is a window for displaying simple digital inputs from on/off-type sources such as hull
openings, fire doors etc. It contains a list of signals, displaying on or off as green or red indicators.

The window may be customised. See below. The window data may be graphed. See the
graphing section.

8.2.4 Graph Window

This is a window for displaying graph data from Indicator or Multiple Source Indicator
Windows. In fact, you change the Indicator window into a Graph window. The X- and Y-scales of
the graph are automatically set. The window is typically used for plotting values that change over
time such as speed, course, depth etc. Only one value per indicator can be plotted at a time (for
multiple values plotting – see Static mode).

Note that only the time period of data that has been played back will be graphed. If you view
only a small time window, such as a few minutes, you may not be able to see the graph. In static
mode though, the whole data set will be graphed (depending on the selected inspection range).

This window type is freely resizable by just dragging its borders. The window may be
customised. See below.

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8.2.5 Errors Window

This is a window for displaying system errors, as recorded by the VDR in the event files. It is a
standard text window. The alarms encountered are not interpreted.

This window type is freely resizable by just dragging its borders. The window may be
customised. See below.

8.2.6 Image Window

This is a window for displaying all kinds of images, grabbed by the frame grabber or by the
external video interface, such as radar, conning display, ECDIS or other electronic chart systems,
CCTV etc. This window type is resizable by clicking the up/down buttons on the View toolbar. The
window may be customised. See below.

8.2.7 Audio Channel Selector Window

This window displays all the audio channels available and allows you to select one or more of
them for listening. This window type is not resizable. The window may be customised. See below.

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8.3 Toolbars and icons

The command interface has four toolbars controlling various functions of the Player. The
toolbars may be docked below the menu bar or can be ripped off and used as free-floating objects.

• Ripping off: Pull with the mouse pointer at the handle bar to the extreme left in the toolbar, and
drop the toolbar window anywhere on the screen.

• Docking: Move the toolbar window close to the menu bar, and it will snap in below the menu
bar.

• Rearranging: Docked toolbars can be rearranged by simply pulling them, and dropping them
somewhere else among the other docked toolbars.

Most of the toolbar tools are available as menu commands as well. The tables below list all the
tools and their menu command equivalents.

THE VDB TOOLBAR

For importing, opening and closing a voyage database (source data).

Tool Name Menu Command Comment

1 Handle bar For ripping off or moving the docked tool bar
2 Import VDB File / Import VDB Importing a new backup set into the Player
3 Open VDB File / Open VDB Opening an imported backup set
4 Close VDB File / Close VDB Closing the active data set, emptying the screen

THE VIEW TOOLBAR

For controlling the viewing style of the selected window, and for opening more toolbars and
indicator windows.

Tool Name Menu Command Comment

1 Handle bar For ripping off or moving the docked tool bar
2 Shrink window View / Shrink window Sizing for windows that are not freely sizable
3 Grow window View / Grow window Sizing for windows that are not freely sizable
4 Show/hide title bar View / Title bar Title bar on of, saves space on screen
5 Full screen mode View / Full screen Selected window takes up all the screen
6 Dual screen mode View / Dual screen Dual monitors if supported by Windows
7 Toggle Timeline toolbar View / Toolbars /
Ruler

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Tool Name Menu Command Comment

8 Toggle Playback View / Toolbars /
toolbar Playback
9 Toggle Static control View / Toolbars /
toolbar Static control
10 Navigate indicators View / Data Open or close more indicator windows
channels...

THE PLAYBACK TOOLBAR

For controlling playback and stepping, speeding, stopping and searching for specific data or
events.

Tool Name Menu Command Comment

1 Handle bar For ripping off or moving the docked tool bar
2 Rewind Playback / Rewind Pan the inspection window one window range to
the left
3 Backward play Playback / Back Step backwards, only in step mode
4 Forward play Playback / Start Standard play
5 Pause/stop Playback / Stop Temporarily halt playing
6 Forward Playback / Forward Pan the inspection window one window range to
the right
7 Normal playback Playback / Normal mode Play back at normal speed
8 Fast playback Playback / Fast mode Play back at higher or lower speed, selectable
9 Step mode Playback / Step mode Step, event by event
10 Play to text file Playback / Play to file Records time-stamped selected values to a semi-
mode colon separated text file (text report)
11 Set current Playback / Set position Enter position of inspection pointer
position
12 Find Playback / Find Search for event or value
13 Playback mode Step mode initialisation
options

THE TIMELINE TOOLBAR

For viewing and controlling the inspection pointer along the timeline.

Tool Name Menu Command Comment

1 Handle bar For ripping off or moving the docked tool bar
2 Reset Show full time range
3 Zoom out Zoom the inspection window out, show more time
4 Zoom in Zoom the inspection window in, show less time
5 Inspection pointer. Pull the pointer left – right

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6 Inspection window. Pull the timeline left – right

7 Active time, time and date at inspection pointer

THE STATIC CONTROL TOOLBAR

For controlling the multi-graph window.

Tool Name Menu Command Comment

1 Handle bar For ripping off or moving the docked tool bar
2 Static graph Playback / Static mode Show / hide the static multi-graph window
window
3 Mode: normal Selects Normal mode for the multi-graph window
4 Mode: Selects Measuring mode for the multi-graph window
measuring
5 Mode: Selects Zooming mode for the multi-graph window
zooming
6 Mode: layers Selects Layer managing mode
7 Legend Opens the Legend window with information about
graphs displayed in the multi-graph window
8 Zoom reset Resets zooming to view the full time range and Y-
range
9 Y-Zoom reset Resets Y-axis zooming to view the whole Y range.
10 Data selection Opens Static mode initialisation dialog for selecting
data to be viewed in the multi-graph window

8.3.1 The status bar

The status bar is located at the bottom of the screen. It shows program running status, progress
bars, error messages and more.

Tool Name Comment

1 Message pane Shows running status, directory being loaded, progress bars etc.
2 Mode indicator Shows playback mode, or the event being stepped in step mode
3 Error indicator Shows the number of system errors encountered. Turns red after the first
error was encountered, after the error window was manually cleared
or closed.
4 Resizing tab Pull for resizing the main window

8.3.2 Full Screen View

Any freely resizable window as well as the image window can be viewed in full screen mode
by selecting it and clicking the Full screen mode icon on the View Toolbar, or selecting the View /
Full screen command. The image will be shown in 1:1 proportions, that is, one pixel in the original
picture will be mapped on one display pixel, for maximum detail resolution. Of course, no toolbars
or menus are visible.

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A mini-version of the View toolbar is displayed on the screen. With the mini-toolbar you can
choose to go back to normal display mode, or to display further toolbars as floating objects.

Tool Name Comment

1 Full screen For getting out of full screen mode
2 Display Timeline toolbar Open the Timeline toolbar as a floating object
3 Display Playback toolbar Open the Playback toolbar as a floating object
4 Display Static control Open the Static control toolbar as a floating object
toolbar
8.3.3 The Desktop Popup
Right-clicking on an empty area of the desktop brings up a popup menu with three items, for
displaying more toolbars and indicators. The same alternatives are available on the View menu.

Popup item Corresponding Menu Command Comment

Toolbars View / Toolbars Select which toolbars to view or hide
Status bar View / Status bar View or hide the status bar
Channels... View / Data channels Open or close more indicator windows
8.3.4 Dual Screen Mode
During investigations it is sometimes helpful to display an image of interest in its entirety on
another monitor, always having it available in full size, for spotting small details, etc. The image
may be zoomed to any desired zoom factor, up to full screen size.

The Player may be run in dual screen mode, if your Windows installation supports it. Presently
dual screen mode is only reliable on some graphics boards, and only under Windows 2000.

Move any window to the second screen by selecting it and clicking the Second screen button
on the View toolbar or selecting the View / Second screen command.

8.4 Customising a Window

A window can be customised in many ways, normally to make the window stand out among the
others, or to save space on screen. To customise, right-click the active window, and select options in
the popup menu. Each window type has its own set of options, where some options are common for
all window types. Some customisations are not possible for certain window types or in certain
situations. These options may not exist, or are greyed out. The table below shows most of the
options.

Popup menu item Comment

Full screen Expands the active window to cover the full screen, with no menu or toolbars.
Same as the View / Full screen command.
Title bar Displays or hides the title bar for the active window, a space saver. Same as the
View / Title bar command.
Properties... Opens the Indicator properties dialog box, for customising the window
Text Shows the window as text (images will be file names, NMEA will be raw text,
audio will show as file names)
Picture Shows an image window as a picture (and not text)
Audio Shows the audio channel sector buttons instead of audio file names

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Subject Shows the interpreted window in a short-form interpretation

Subject extended Shows the interpreted window in a long-form interpretation
Subject graph Shows the interpreted window as a curve graph
Clear Empties a text window, for example the error window, waiting for more input
Buffer size Sets the available buffer size for buffering data, in text lines or number of
consecutive source data values. The buffer size controls how much data can be
graphed or shown at any time.
8.4.1 Properties Dialog Box
Right-clicking a window and then selecting the Properties... alternative, opens up the
Indicator Properties dialog box, with which you can customise the look and feel of the window.

The dialog box has tree main sections, which lets you change three main aspects of the window.

NAME SECTION

The Default text box contains the default title bar name for the window. In the Name box you
can enter a suitable name to display in the title bar. The Restore default name button puts the
default name back.

CHANNEL SECTION

The channel list displays the VDR channel and sub channel used to display this window. The
values cannot be changed.

EDIT TABS – TEXT VIEW

On the Text view tab you can change the properties for the window in text mode. Using the
Colors fields you can set the window background and text colours used in text view. Using the
Font selector and size selector you can set the font and size of the characters displayed in text view.
The Buffer value sets the number of text lines that can be displayed simultaneously in text view.

EDIT TABS – GRAPH VIEW

The Buffer value sets the amount of buffer space reserved for graphing. The value is expressed
in text lines or number of consecutive source data values. The buffer size controls how much data

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can be graphed or shown at any time. The Y-axis range boxes let you set the minimum and
maximum values for the graph Y-axis. The axis has a default setting, but you can override it using
these boxes. Using the Font selector you can set the font of the characters displayed in graph view.
Using the various Colors fields you can set the window background and text colours used in
graph view.

EDIT TABS – DIGIT VIEW (INTERPRETED MODE)

Using the Colors fields you can set the window background and text colours used in
interpreted view. Using the Font selector and arbitrary size selector you can set the font and size of
the characters, as well as bolding displayed in interpreted view.

EDIT TABS – COMMON BUTTONS

The Set as default button will save the current settings as defaults for later use, in this window
only, and for this view type only. All windows and view types have individual defaults. The Use
default button will take back the default values set earlier. The dialog box shown above is for an
interpreted window. Other window types have slightly different dialogs.

8.4.2 Additional Properties for Graph Windows

Y-axis range: Allows you to set your own maximum (High box) and minimum (Low box)
values to be displayed, overriding the preset default values selected by the system.

Legend: Displays the graph legends (colours, hatching etc.), along with some basic graph data
such as time, date etc.

Data mode: When presenting a graph (especially for greater time ranges) in a situation where
the data resolution is much higher than the resolution displayed, i.e. one pixel along the X-axis
(time domain) corresponds to a number of consecutive source values. Then you must use the Data
mode. Suppose there are n consecutive values (V1, V2 ... Vn), for which it is only possible to show
one value in the graph. The data modes will then display as indicated below.

Mode Value displayed in graph

Last data Vn
Minimal Min (V1, V2 ... Vn)
Maximal Max (V1, V2 ... Vn)
Average (V1 + V2 + ... Vn) / n
First data V1

To use a data mode, you must first select the mode, and then plot, or re-plot the graph.

8.5 Playing in Step Mode

Before you start getting into program details, please go through the Getting Started chapter.
Step Mode allows you to examine the behaviour of one indicator, while the other voyage data is
played back in steps along with the indicator chosen.

1. Open a source data set by selecting File / Open VDB and select one of the currently imported
data sets from the list box that opens. The screen configuration from the previous session with
this data set should be restored.

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2. Select the desired source indicator by clicking on its window, to make it active. In this example
we choose the Depth window. Depth soundings occur fairly regularly. Note that there will be no
audio during stepping.

3. If the playback is running in Normal mode, you must stop it first, before you can select step
mode. Initialise step mode by clicking the Step Mode icon on the Playback toolbar. The Step
Mode Initialisation dialog box opens.

4. Select the source indicator to step. The Depth indicator is already selected for you, and this
should normally be the case, but you are able to change your selection in this dialog box. Click
OK to exit the dialog.

5. Step mode is now ready. Notice that you now have a Play forward and a Play backward arrow
on the Playback toolbar. Step in any desired direction. As you step forward, you will see the
depth gauge changing with each click on the Play arrow. All the other indicators follow.

6. Step mode is primarily used for analysing incoming data in detail. For this you may change the
view mode to text, to see the details of each incoming NMEA message. Change the Depth
window to text mode by selecting View / View class / Text or by right-clicking in the window
and selecting Text from the popup menu.

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7. Slightly enlarge the Depth window, to see the full length of the text strings.

8. Continue stepping forwards or backwards, and you will see new NMEA strings being added in
the Depth window.

9. Go back to Normal playback mode by clicking on the Normal Playback tool on the Playback
toolbar. Notice that the Backwards play button is greyed out.

10. Restore the Depth window to interpreted mode by right-clicking it and selecting the Depth item
on the popup menu.

8.6 Play to Text File Mode

Play to Text file mode allows you to generate a semi-colon separated text file containing time-
stamped data from a currently loaded VDB that could be used for offline analysis or report
generation using standard software tools working with tabular data (e.g. Microsoft Excel)

1. Open a source data set by selecting File / Open VDB and select one of the currently imported
data sets from the list box that opens. The screen configuration from the previous session with
this data set should be restored.

2. Select the Play to Text File mode by clicking on the Play to text tile mode button on the
Playback toolbar (the button is available only when playback is stopped). The Writing text
report dialog box opens.

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3. Select time range for which the data shall be played (the range currently selected on the timeline
is used as the default). Select time step (time interval between two subsequent time-stamped
lines) if you need to reduce the resulting file size. Select whether to use your Windows locale
settings (for dates and numbers presentation). Select a filename and a location for the report file
to be generated. Select one or more values in the tree control to be included in the resulting text
file. Click OK to exit the dialog. The Report formatting dialog box opens (see above).

4. Select the data presentation mode – either Machine parsed or Human readable. For example, a
geographical position in the Human readable form will be presented as degrees, minutes (with
fractional part) and the hemisphere-letter.
Then arrange the order of the selected values in which they will be written to a text line. To
do this, select a line in the list. Click on Up button to move it upwards in the list, click on Down
button to move it downwards, or click on Remove button to exclude the value. Click on OK to
start playing (writing) to text file. The cursor turns to hourglass while the operation is in
progress.

The first line of the generated text file will contain semi-colon separated column headers as
“<Channel name> -> <Sub-channel name> - <Value name>”.

8.7 Graphing in the Multi-graph Window

Before you start getting into program details, please go through the Getting Started chapter. In
the Multi-graph window you will see graphical presentation of selected values for a selected time
interval. Up to 10 values can be presented simultaneously. Different layers can be used for
presenting values with different ranges. You will be able to arrange graphs in the window, to
perform measurements on graphs and to use the advanced zooming functionality. The window can
also be displayed during a playback session showing a current position of the inspection pointer.

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1. Open a source data set by selecting File / Open VDB and select one of the currently imported
data sets from the list box that opens. The screen configuration from the previous session with
this data set should be restored.

2. To open the Multi-graph window click on the Static graph window button on the Static
control toolbar. First the Static mode initialisation dialog box will appear.

3. Select time range for which the data shall be graphed (the range currently selected on the
timeline is used as the default). Select one or more values (up to 10) to be shown in the graph
window. Click OK for the window to open.

4. The system will now start scanning the data set for all the selected values. The scanning time
depends on the time range you have selected. When scanning is finished, the graphs will be
displayed. You can freely resize the window. How to operate the window is described below.

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Note: the time range of the timeline and of the multi-graph window are linked to each other.
Thus if you change the time range in one of them it will change in the other one automatically. The
same applies to the inspection pointers.

8.7.1 Measuring in the Multi-graph Window

Click on the Mode: measuring button on the Static Control toolbar. When you move the
cursor into the multi-graph window it will turn to a crosshair stretching across the window. The
information is displayed in the upper left corner of the multi-graph window.
Press and hold the left mouse button to see the time and the value under cursor (the value is
displayed for the active layer):

Drag with the button pressed to see the time and value offset:

To leave the measuring mode select any other mode.

8.7.2 Zooming the Multi-graph Window

Click on the Mode: zooming button on the Static Control toolbar. When you move the cursor into
the multi-graph window it will turn to a magnifying glass with a crosshair inside.

• Click on the left mouse button to zoom in (200% at a time) with the centre at the
cursor position.
• Hold the left mouse button pressed and drag to select a rectangular area that will
define new ranges for both axes.

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• Click on the left mouse button to zoom out (50% at a time) with the centre at the
cursor position.
To reset zooming for both axes click on the Zoom reset button on the Static Control toolbar.
To reset zooming only for Y-axis (values axis) click on the Y-Zoom reset button on the Static
Control toolbar.
To leave the zooming mode select any other mode.

8.7.3 Viewing the Legend window

Click on the Legend button on the Static control toolbar. The Legend window shall pop-up. The
window is non-modal, so it may stay open while other operations are available.

The information/controls presented in the window includes the currently active layer and, for each
graph, the following:

• line sample used for the graph

• data source name
• current value (for the current inspection pointer position)
• measuring units
• visibility switch
• layer the graph belongs to (selectable) – see Working with layers section.

Click “X” button in the window’s upper right corner to close it.

8.7.4 Working with layers

Layer in the multi-graph window is a rectangular area moveable and sizeable in the vertical direction.
A layer has its own independent range for Y-axis. Layers can overlap. The use of layers could be
simultaneous examining of the graphs with much different value ranges.

You can assign the selected values to different layers using the Legend dialog window. By default
all values are displayed in the layer “A“. All logical data belong to the layer “B”.

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You can move layers by dragging the layer’s name tab and resize them by dragging their top and
bottom borders.

Right-click on the layer’s name tab to get access to the Layer properties dialog allowing setting the
layer’s display properties (axis labels, grid and border).

8.8 Graphing in Normal Mode

Before you start getting into program details, please go through the Getting Started chapter.
When playing in Normal mode, you can change any window, which contains data that is possible to
graph, into a graphic window, and the source data of the selected indicator will be graphed on the
fly.

From the beginning, the interval graphed is very small, in fact you may not be able to see it.
Wait for a few minutes, and you will see the curve emerging in the graph window.

1. Go to Normal mode by clicking on the Normal Playback tool on the Playback toolbar. The
player will be in Stop mode.

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2. Start playing the data set by clicking the Play button on the Playback toolbar.

3. Select the desired source indicator by clicking on its window. In this example we choose the
Depth window. Should the indicator still be in graph mode, right-click it and select the Depth
item on the popup menu, to restore the window to interpreted view. Note that the view
classes (Depth Graph, Depth and Text) are not available during Static mode. The depth is
constantly changing as the data set is being played back.

4. Right-click the Depth window and select the Depth Graph item.

5. The portion of the data set played so far will be graphed. The graph will be constantly
growing towards the right. Notice the hatched areas, indicating no data was plotted there.

6. Buffer size note: If the buffer size is too small to cover the current inspection range (the
amount of values possible to buffer), the graph will be continuously cleared from the left side
after the buffer size limit is reached.

7. Again, you may select the Properties item on the popup menu and change the graph to your
liking. You may also set the Y-axis scale to any desired range with the Y-axis Range item.
The changes will occur on the fly.

8. If you decide to play from some other point in time, stop the player by clicking the Stop tool
on the Playback toolbar, move the inspection pointer to the desired time and click Play again.
Be aware, however, that the graph window will be cleared and the graph started anew.

8.9 Searching and Finding

By searching the data set, you are able to find critical information in any of the indicators
displaying a value that can be searchable. A critical value may be, for example, the depth going too
shallow.

Image indicators or audio channels are not searchable, neither is unsupported NMEA data.

The search will start where the inspection pointer is right now, and go forwards or backwards as
selected. If you do not want to search from the current position, change the current position to the
beginning of the timeline, before opening the Find dialog box.

8.9.1 Values
The values that can be searched are either numerical, if the indicator is of the numerical type
(such as depth or heading), or digital (with the possible values of Switch ON or OFF or Change of

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state, to find a time when a change occurred, i.e. someone opened or closed a door) if the indicator
is an on/off-type (such as the bow port or fire door status).

8.9.2 Procedure
In this case we choose to search the Depth indicator for depths of less than 12 metres.

1. If the playback is running in Normal mode, you must stop it first before you can start searching.

2. Be sure to set the inspection pointer to a useful point in time, by dragging it along the inspection
window.

3. Click the Search icon on the Playback toolbar, or select the Playback / Search command. The
Search dialog box opens.

4. Select the Type for search by finding the indicator you want to search, typically the one you
are graphing already. In this case, select the Depth indicator.

5. Select to search Forward.

6. Enter the search condition: Click Less Than (<) and enter the value of 12. this will mean:
“Search until you find a point in time where the depth is 12 metres or less”.

7. If you were searching for a range of values, you could click the Use condition 2 box and then
enter another condition in the Condition 2 area.

8. Click the Search button to start searching.

9. The data set is scanned and the first occurrence of the condition is found and displayed on
screen. There is nothing in the windows, as the Player is not currently playing. The only
window showing some data is the one being searched. It shows a bar graph containing one very
thin slice of data only, in this case the first depth sounding fulfilling our criteria, a depth of 11.7
metres at 06:02:06 o’clock (as viewed in the Active time indicator on the Timeline toolbar).

Note that the inspection pointer is set to this new time point.

If there are no matching values in the data set, you will get an error message presenting this
fact. You probably entered some criteria wrong. Go back and re-search and enter the criteria
again.

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10. Switch the graph window to interpreted view by right-clicking it and selecting the Depth item.
You see the Depth value (11.7 metres) expressed numerically.

11. You can choose to start playing from this new point in time or to search again.

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8.10 File Operations Summary

File / Import VDB
Command for importing a new source data set, recently created as a backup in a Voyage Data
Recorder. The data set could reside on a DVD disk, on the hard disk or on a network. Opens the
Import Database dialog box. If you tick the Copy Source Files tick box, the entire data set will be
copied to your working directory (up to a few gigabytes). If not, the data set will be registered and
scanned only.

8.10.1 File / Export VDB

Command for writing all or part of a data set on another media or in another directory. A good
method if you want to distribute only part of a backup.

1. The dialog box Export Database opens.

2. Enter a file name for the new source data set in the VDB Name field.

3. Find a location for the data set by browsing with the arrow button to the right of the Location
field.

4. Specify a time range to export in the Time Range for Export Database fields.

5. Click the Export button. You will get a confirmation dialog box, asking you to verify the
exported time range. After you click OK you will get another conformation dialog box showing
the final file size of the exported data set, asking you for a go-ahead. After you click OK the
export process will begin.

The new source data set will be imported automatically.

8.10.2 File / Open VDB

Command for opening an imported database. The database will be opened and the settings
made at exit time (window sizes, colours and positions etc) will be restored.

1. The Select Database dialog box opens.

2. Select the database to open in the list.

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3. Click the OK button to start loading the data set.

8.10.3 File / Close VDB

Closes the data set on display and asks if you want to save the settings made so far. After the
close operation, the Player is ready for opening another data set.

8.10.4 File / Delete VDB

Command for deleting one or more registered, imported data sets from the working directory.
The Delete Database dialog box opens.

1. Select the database you want to delete.

2. Click the Delete button.

3. You will get a conformation dialog box, asking if you really want to delete the database.
Confirm by clicking Yes or cancel by clicking No.

Be careful! Deleted databases cannot be restored. The status database, as well as the
imported source data set will be deleted.

8.10.5 File / Options

Opens up the Select VDR Player data directory dialog box, in which you can enter the VDR
Player Data directory. This is the program working directory, where the databases and status
information will be stored. Either enter a directory manually, or browse for it, using the arrow
button. Once this value is entered you should not change it unless you want to utilise a second data
directory. It is possible to have several data directories, but only one at a time. If the earlier existing
path is restored, access to the earlier information is restored.

8.10.6 File / Exit

Ends the Voyage Data Player program.

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8.11 View Operations Summary

Command Comment
View ÆToolbars Viewing or hiding toolbars on screen.
View ÆStatus bar Viewing or hiding the status bar at the bottom of the screen.
View ÆTitle bar Viewing or hiding the title bar of the active window.
View ÆFull screen Expanding the active window to full screen, hiding the title bar, menu
bar and toolbars.
View ÆSecond screen Transferring the active window to the second screen, if such a screen
has been configured in Windows.
View ÆShrink
window
Shrinks / Grows an image window, having the same effect as the
View ÆGrow up/down arrows on the View toolbar.
window

View ÆView class Changes the view mode of a window, for switching between for example
text and graphics modes, interpreted mode etc. Only those modes allowed
for the active window are available for selection.
View ÆY Axis Range Changes the Y axis scale of a graph window, to view the graph in
greater detail.
View ÆClear Empties the active text window, to give a new, fresh, empty list. Also
empties the active graph window. Has no function for interpreted
or image windows.
View ÆData buffer Sets the buffer size for display data for the active window. The buffer
size size determines how much data that may be presented in the
window at one time.
View ÆData mode Various methods for averaging and smoothing a graph.
ViewÆIndicators Selects which indicators to view on screen.
View ÆSystem Viewing or hiding the Errors window, displaying the system errors
channels encountered by the VDR. This is just another indicator, it is not handled by
the Indicators menu alternative since it contains data produced by the
recorder itself.
View ÆSources Shows the data sources tree. The first (top) level corresponds to
channel names, the second level to sub-channel names. The
channel and sub-channel names (i.e. text on level 1 and 2) can be
changed. The third level describes data types and cannot be
changed.
View ÆVdrexport.txt Shows the first five lines of the vdrexport.txt file (containing the
format and VDR configuration version information).
View ÆShrink to fit These alternatives apply only to images in full screen mode, and in

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View ÆEnlarge to fit second screen mode.

Shrink to fit works when true image size is larger than current screen
(desktop) size. If the option is selected, the image will be squeezed
in order to fit the screen. Otherwise the image will not be fully
visible without scrolling.
Enlarge to fit works when true image size is smaller than current
screen (desktop) size. If the option is selected, the image will be
enlarged (proportionally) in order to cover the whole screen.
Otherwise the image will be shown in true scale, centred on the
screen.

9 File System and File Name Details

The VDR unit records ship data and stores it on the hard disk in the form described below. This
is also the form the data will have on the backup media, and therefore, the form the data will have
when read by the Player.

The description below will help you understand the finer details of the file system and the data
formats, and aid you, should troubleshooting be necessary.

9.1 File Types

All data is recorded when received or at preset intervals, and stored in folders for each minute of
the hour. All input data is written in the form of digital files onto the hard disk. It takes the
following form:

• Navigational data, depth, speed, NMEA-compatible data, etc., is stored as text files once per
minute. VDR stores the NMEA data, it does not decode it. At viewing time, it is up to the
viewer application to decode the NMEA protocol data and display it properly.

• Sound information from microphones, VHF communications, etc., is stored in the form of
compressed MPEG 2 sound files, once per minute, one for each of the four mixer output
channels.

• Video from radar and other high-resolution video sources is stored as JPEG files once every
15 seconds, in one file for each of the four input channels. This will typically result in four files
per channel per minute, i.e. 16 files per minute directory.

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9.2 File Structure

All files are stored in a common directory structure on the hard disk consisting of:

• One-minute directories for each stored minute of information, containing the audio channel
files, high-res video, low-res video files, and the VDRevent.log file containing text.

• 100 (00-99) one-minute directories put into hundred-minute directories.

• 100 (00-99) hundred-minute directories put into ten-thousand-minute directories

• 100 (00-99) ten-thousand-minute directories put into one-million-minute directories

• 100 (00-99) one-million-minute directories put into the \vdr main directory.

There is no way of telling the exact time that data was recorded by looking at the directory
names. The time stamps are in the VDRevent.log file of each minute directory. The interpretation of
the data should be left to the Voyage Data Player.

After 24 hours of data has been stored, the oldest data is removed as the next hour is recorded,
except for the VDRevent.log file of each minute directory. This file is comparatively small and can
be kept for longer time, preserving navigational data for, perhaps, several weeks. The old
VDRevent.log files are kept until a minimum level (100 MB) of hard disk space, set in the VDR
unit dialog box in the VDR Configuration Tool, is reached, and then deleted.

9.2.1 File Names

The VDRevent.log file containing time stamped NMEA data, system events, fault messages
and other text data has this name format:

VDRevent.log

Example:

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C:\00\00\01\47\VDRevent.log

Sound files containing mpeg 1 layer 2 encoded audio information are named after the mixer
channel whose data they contain, and ending in a .mp2 extension.

The file name format looks like this:

Audio[c]_[nnnnnnnnnn].mp2

where [c] is the channel number (1-4) and [n...n] is a system-generated ten-digit serial number.

Example:

C:\00\00\03\32\Audio2_1234567890.mp2

HiRes Video files containing radar images are named after the video channel whose data they
contain, and ending in a .jpg extension.

The file name format looks like this:

HiRes[c]_[nnnnnnnnnn].jpg

where [c] is the channel number (0-3) and [n...n] is a system-generated ten-digit serial number.

Example:

C:\00\00\12\92\HiRes3_9087654321.jpg

LowRes Video files containing close-circuit TV images are named after the video channel whose
data they contain, and ending in a .jpg extension.

The file name format looks like this:

cctv[c]_[nnnnnnnnnn].jpg

where [c] is the channel number (arbitrary number) and [n...n] is a system-generated ten-digit
serial number.

Example:

C:\00\00\09\72\cctv4_9087654321.jpg

10 Troubleshooting
Listed below are some error conditions you might encounter when using the Player.

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Directory contains no data

Error message: The directory doesn’t contain VDB data. Select again?

While importing a data set of source data, you are requested to select the directory to import
from. If you do not select the top-level directory, but instead select some lower level directory, such
as a “00” directory, you will receive this error message.

Try again, this time selecting the top-level directory.

Sound breaks off

The sound breaks off or the machine freezes dead at intervals, perhaps while continuously
accessing the disks.

Your machine is too slow for the amount of data you try to play. Try playing less data or get a
faster machine with more memory. See the System Requirements chapter.

11 System Requirements
The computer used should be equipped, at a minimum, according to the specifications in the
Voyage Data Player Specifications.

• DVD-RAM player capable of reading FAT16 5,2Gb type 1 DVD-RAM disks

• Operating systems Windows NT and 2000

• Minimum 600 MHz Pentium III Processor

• Minimum 128 MB RAM

• Minimum 20 GB hard disk

• SoundBlaster compatible Audio board

• Graphics board capable of true color 1280*1024 pixels and 75Hz refresh-rate

• 21-inch monitor recommended.

11.1 Dual Screen Mode

The Player can be run with two monitors, in dual screen mode. This has to be fully supported by
Microsoft Windows to work properly. Please see the Windows documentation. For this you will
need:

• Microsoft Windows 2000 in dual screen mode

• Dual graphics boards with the same display resolution

• Dual monitors

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12 Ordering Information
The software can be ordered directly from Beijing Highlander Corporation, in China or any of
its subsidiaries. For the latest address information, please view the Highlander web site at
www.highlander.com.cn, and select the Contact Us button.

The software is distributed on one CD-ROM along with this documentation.

12.1 Activation
When the VDR Player is initially started, the user will have to supply a user name, an activation
code and a password. The password is used to define the access level for the current session. If all
the information entered is correct, the Player will start. At all subsequent start-ups only the
password will be required.

Activation information will be supplied to registered users.

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MAINTENANCE
MANUAL
（MAIN UNIT）

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04.1 AZ
Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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CONTENTS
1. Notes and Updates......................................................................................................................3
2. Where to call in case of problems or faults ................................................................................3
3. 3. Overview of this Manual ............................................................................................................2
4. Compass safe distance................................................................................................................2
5. Placing of Microphones..............................................................................................................2
5.1. Unit Front Panel......................................................................................................................2
5.2. Unit Back ................................................................................................................................2
5.3. General Information................................................................................................................3
5.4. Selecting Locations.................................................................................................................3
5.5. Mechanical Mounting .............................................................................................................3
6. Placing of All Other Components of the VDR HLD-A2 Configuration....................................4
6.1. Main Unit 707000B ................................................................................................................4
6.2. Power Supply Unit..................................................................................................................8
7. Cabling of the VDR HLD-A2 System........................................................................................9
7.1. Cabling Between VDR HLD-A2 Units ................................................................................10
7.2. Cabling from Bridge Systems to VDR HLD-A2 Main Unit ................................................16
8. General Notes on Cables and Connections ..............................................................................21
8.1. On Cable Dimensions and Standards....................................................................................21
8.2. On Cable Types ..................................................................................................................22
9. General Notes on EMI..............................................................................................................22
9.1. EMI ........................................................................................................................................22
9.2. Termination of Signal Cables .............................................................................................22
9.3. On Shields...........................................................................................................................24
9.4. On Cable Placement............................................................................................................24
10. Mechanical Drawings ...............................................................................................................24
11. Electrical Drawings ..................................................................................................................24

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1 Notes and Updates

Revisions:
Date Version Issued by Description
2005-10-01 A0 NE Document created
2005-10-10 A1 PL Corrections
2005-10-10 A1.0 Li ChW Modified as HLD-A2 system

2 Where to call in case of problems or faults

Beijing Highlander Digital Record Technology Co., Ltd. maintains a call center service at:

Call: +86 10 821 501 82 Email: service@highlander.com.cn

Fax: +86 10 821 500 83
The Call Center is open during office hours, 08.00 – 16.30, UTC+8.
Please note: Email is the preferred method of communication. Please state the fault or problem
as fully as possible, mentioning all details that could be relevant for solving the problem

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3 Overview of this Manual

The Installation Manual is intended for use by an authorized installation company.
It contains general information for installation of hardware and wiring of the system
components, such as the main unit, the power supply unit, the remote display,
microphones, and the final recording medium (Protective Capsule)
It also contains notes on installation practice, and how to protect the equipment from
Electromagnetic Interference (which is an installation issue). Also, carefully read and
understand the “General Notes on Cables and Connections” before you select cable
material for the installation. Using the wrong cable may harm the long-term stability of
the installation, introduce noise on the data and sound channels, and in serious cases, void
the warranty.

4 Compass safe distance

The compass safe distance for all VDR HLD-A2 units are described in the table
below.
Unit Standard compass Steering, standby and
emergency compass
Main Unit 5.5 m 4.8 m
PSU3 3.4 m 3.2 m
DAU 3.4 m 3.6 m
SD4-6 49 cm 38 cm
FRM 28 cm 27 cm

5 Placing of Microphones
Microphones are used to record orders, sounds, and alarms on the bridge, aiding in any
later investigation of an accident or an accident situation.
5.1 Unit Front Panel

Front Panel of the microphone AM1

5.2 Unit Back
The microphone is a sealed unit with push-press terminals on the circuit board on the back.
It is also available with a protective back cover.

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Back Panel of the microphone AM1

5.3 General Information

A drawing of the microphone can be found in the “Mechanical Drawings” chapter.
5.4 Selecting Locations
Microphone locations should be carefully chosen to optimize recording of all vital voice
communication at the bridge workstations as well as any other communication from
VHF/PA/intercom systems or audible alarm systems.
In general microphones 0,5 -1,0 m in front of working place
The number of microphones needed depends on bridge layout, but most bridges can be
covered using four to six microphones:
• One or two microphones mounted in the overhead panel above the main conning
station covering the area by the main radar and the helmsman.

• One microphone mounted in the overhead panel above the chart table.

• One microphone at each bridge wing maneuvering station.

• One microphone mounted over the radio desk.

5.5 Mechanical Mounting

The unit is to be panel mounted, into the proper panel cut out. A mounting drawing can be
found in the “Mechanical Drawings” chapter. Optional bulkhead mounting is used when
mounted on outside bridge wings or where it’s not practical to have a panel mounted
microphone.

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6 Placing of All Other Components of the VDR HLD-A2

Configuration
6.1 Main Unit 709657A0
6.1.1 Internal Parts of the Main Unit
The Main Unit consists of a number of internal parts and subassemblies that it is
necessary that you familiarize yourself with, before beginning the installation and start-up.

VDR M4.0 Main Unit

DC/DC conv
SIU board
RGU boards Memory

Covered by a USB
plate sticks
Fan

AMU
DCU board
In/out for
board
Microphones
Fuses
ETU

IEC 61162/NMEA
VHF
RS 485, USB
Mic. control
Puls inputs
On/off inputs

Video
Cable glands
input

The parts of the Main Unit

6.1.2 Data collecting Unit (DCU) board

All termination except Audio and Video is made on the DCU board
DCU signals Number of Input/output Comments
channels
NMEA 0183 14+2+1 I 14 ch. of IEC61162-1
2 ch. of IEC61162-2.
Baud rate shall be configured
by SW.
1 ch. is dedicated to the
SD4-instr. (SCU)
NMEA 0183 4+1 O 4 ch. of IEC61162-1 and
1 ch. is dedicated to the
SD4-instr. (SCU)
RS-485 1 I/O
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RS-232 2 I/O Channel 2 dedicated for the

PSU.
Digital input 6 I Channel one and two are
dedicated for 200p/Nm to
20000p/Nm
Digital output 8 O
to AMU
Digital output 4 O
to VMU
Switching 2 O
relay
USB 1 upstream The interface to the SIU is
USB upstream line fulfilling
the USB 1.1 protocol with full
speed (12Mbit/s).
USB 1 downstream USB downstream line fulfilling
the USB 1.1 protocol with full
speed (12Mbit/s). Device
interface (“USB DEV”) is bus
powered from the SIU.
JTAG 1 I/O Optional connector for
programming the CPLD

6.1.3 Indicators and Indicator Lights in the Main Unit

Indicator lights display the status of most of the subassemblies in the Main Unit

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VDR M4.0 Main Unit

DC/DC conv
SIU board
RGU boards Memory

Covered by a USB
plate sticks

Fan
AMU
DCU board
In/out for
board
Fuses Microphones
ETU

IEC 61162/NMEA
VHF
RS 485, USB
Mic. control
Puls inputs
On/off inputs

Video
Cable glands
input

Indicator Lights in the Main Unit

The lights inside the Main Unit either indicate that the proper power is available to the
subassembly or that some input signal is coming or is being sampled.
• The computer storage devices have Access and Error lights whose functions do not
differ from the same lights on any desktop computer.

• The Ethernet Switch has activity lights that should light up stable when an Ethernet
device is attached. This is the way to troubleshoot Ethernet connections, such as the
one to the capsule.

See picture above for details.

6.1.4 Connection Points in the Main Unit

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Power and signal cables connect to various points inside the VDR HLD-A2 Unit.

Connections on the Data Collecting Unit (DCU) board in Main Unit

Lay out the cables neatly, avoiding snags and too long or too short cables. Replace the
cable duct covers after assembly.
Near the bottom of the cabinet is a grounding rail, for internal cabinet grounding only.
External grounding must be performed at the cable glands.
NOTE: The three vertical rails on the DCU board are for striping of cables and can NOT
be used as grounding rails.
At the bottom are cable ports with clamps for strain relief (and grounding) of incoming
cables.
The radar/video inputs are to the right on the outside bottom of the unit. Video is
connected as per the “Radar, Other High-Resolution Video” section in the “Cabling from
Bridge Systems to VDR HLD-A2 Main Unit” chapter.

6.1.5 General Information

A drawing of the Main Unit can be found in the “Mechanical Drawings” chapter.
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6.1.6 Notes on Connections and EMI

The door edges of the Main Unit are fitted with an EMI seal, protecting the unit from
external radiation, and protecting sensitive equipment like VHF receivers from high
frequency emissions from the unit. Always check the seal for dents or rips and replace a
faulty seal. Failure to do so may harm the long-term stability of the unit and add unwanted
noise to communications channels.

6.1.7 Location of Main Unit Cabinet

Recommended conditions for the chosen location of the cabinet are listed below:
• The cabinet shall be bolted to a bulkhead in a location where necessary cabling from
bridge equipment can be brought to the unit, preferably close to the bridge.

• The location shall be protected from weather and shall offer a stable temperature.

• The location shall not expose the unit to excessive vibration levels.

• The location shall be far from electrical installations giving excessive electric and/or
magnetic fields.

• The main unit bottom shall be placed approximately 1,2 m from the floor where
practical.

6.1.8 Mechanical Mounting

The cabinet shall be mounted to a flat surface on the bulkhead using 10-mm steel bolts. A
mounting drawing can be found in the “Mechanical Drawings” chapter.
6.2 Power Supply Unit
Refer to separate section of the Technical Manual for the "VDR HLD-A2 Power Supply
Manual" for further details about installation issues.

Short-Circuit Warning!
Be careful to avoid shorting the DC power output and remember that the Power
Supply Unit will feed power on the DCU terminals 19+ and 19- from the batteries,
even without AC input.

High Voltage Warning!

230 volts alternating current exists inside the Power Supply Unit on exposed
terminals. Do not open the unit if you are not properly qualified.

6.2.1 Mechanical Mounting

The unit is to be panel mounted, into the proper panel cutout. A mounting drawing can be
found in the “Mechanical Drawings” chapter.

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7 Cabling of the VDR HLD-A2 System

All cabling necessary to interconnect the VDR HLD-A2 system units is described in this
section.

FRM
Final Recording Medium
Date & Time Main Unit (Capsule)
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
Heading (Data Collecting Unit)
SCU
AIS System Control &
Alarm Unit
(SD4-6)
Ship Audio AMU OUTPUT OF
Audio Mixer Unit
(Microphones) Ship’s Ethernet Interface
VHF SIU Service/Investigator’s
System Integration Unit
Ethernet Interface
RECORDED DATA
VMU RGU
Radar Video Mixer Unit Radar Grabber Unit
Ship’s (Investigator’s)
(Optional/Full VDR) USB Interface
ETU (Memory Stick)
Ethernet & Firewall Unit

IEC 61162/
Other items to
be recorded NMEA
PSU
Analogue/Dig DAU Power Supply Unit
signals Data Aquision Unit (incl. batteries)
(Optional / Full VDR)

115/230 VAC
24 VDC

“Full” VDR

FRM
Final Recording Medium
Date & Time Main Unit (Capsule)
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
Heading (Data Collecting Unit)
SCU
AIS System Control &
Alarm Unit
(SD4-6)
Ship Audio AMU OUTPUT OF
Audio Mixer Unit
(Microphones) Ship’s Ethernet Interface
VHF SIU Service/Investigator’s
System Integration Unit
Ethernet Interface
RECORDED DATA
Radar RGU Ship’s (Investigator’s)
Radar Grabber Unit
USB Interface
ETU (Memory Stick)
Ethernet & Firewall Unit

IEC 61162/
Other items to
be recorded NMEA
PSU
Analogue/Dig Power Supply Unit
signls (incl. batteries)

115/230 VAC
24 VDC

SVDR
The VDR HLD-A2 System is closer described in B 4 the System Description Chapter of
this Technical Manual.

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7.1 Cabling Between VDR HLD-A2 Units

7.1.1 Main Unit to Power Supply Unit 3

General Information

• Two cables, with a maximum length of 10 m shall be used to interconnect these units.

• The power supply cable should consist of two stranded 2,5-mm² wires for powering
the VDR HLD-A2.

• The other cable serves as the data link between the two units.

• It is possible to use longer cables, up to 30 m, but in such situations the loop resistance
should be kept low by increasing the copper cross section to 4 mm² for the power
cable.

CONNECTIONS

Cabling between Main Unit (right) and Power Supply Unit3 (left) and ship’s
230(115) VAC emergency power supply

PSU 3 DCU Cable Type: Two twisted pairs with common screen
terminal # terminal #
5 RXPSU (4) Control PSU -> VDR

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PSU 3 DCU Cable Type: Two twisted pairs with common screen
terminal # terminal #
6 TXPSU (5) Control VDR -> PSU
7 GND PSU Control GND
(6)
8 +5V PSU(7) Control +5 V

PSU 3 DCU Cable Type: Two stranded 2,5 mm2 conductors

terminal # terminal #
11 19+ 24 V positive. If possible use red wire
12 19 - 24 V return. If possible use black wire

PSU 3 Ship’s Cable Type : Three stranded 1,5 mm2 conductors, brown,
terminal # Emergency blue and yellow/green
Power
Supply
Earth (PE) Earth PSU -> ship’s earth ground. Use yellow-green wire
1 230(115) PSU live -> Ship’s AC emergency power supply
(L) VAC (50 or 60 Hz)
2 230(115) PSU neutral -> Ship’s AC emergency power supply (50
(N) VAC or 60 Hz)

Identifying Wires

• The control wires (#5,6,7 and 8) will have to be identified by inspection.

• Powering up the Power Supply Unit and checking the polarity can identify the DC
wires.

• The 230/115 VAC wires must use the standardized colors to avoid any conflicts in
identification.

Short-Circuit Warning!

Be careful to avoid shorting the DC power output and remember that the Power
Supply Unit will feed power on the #11 and #12 terminals from the batteries, even
without AC input.

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High Voltage Warning!

230 volts alternating current exists inside the Power Supply Unit on exposed
terminals. Do not open the unit if you are not properly qualified.

Notes on connections and EMI

See also the “General Notes on EMI, Cables and Connections” chapter.

Remark:
And for the connection between PSU24 and Main Unit, please refer to the PSU24
installation manual.

7.1.2 Main Unit to System Control Unit SD4-6

General Information

A cable with three twisted, stranded pairs with a common screen shall be used to connect
the remote indicator to the Main Unit. The interface can accommodate any reasonable
wire length (300 m) on a ship. (A separate power cable with two stranded conductors can
be used to connect the power terminals of the remote indicator to the Main Unit.)

Connections

Termination of between MU/ DCU board (right) and System

Control Unit (left)
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SD4-6 terminal Main Unit, DCU Comment, Cable Type

# terminal
Two twisted pairs with common screen:
1 12 A Data VDR -> SD2-16 NMEA “A”
2 12 B Data VDR -> SD2-16 NMEA “B”
3 13 A Data SD2-16 -> VDR NMEA “A”
4 13 B Data SD2-16 -> VDR NMEA “B”
Two stranded conductors:
9 16 - 0 VDC
10 16 + + 12 V

Notes on connections and EMI

See also the “General Notes on EMI, Cables and Connections” chapter.

7.1.3 Main Unit to Microphones

General Information

The microphone unit consists of an electric microphone capsule, and a loudspeaker for
sounding the required test tone every 12 hours. The microphone requires external power,
which is phantom fed from the mixer. If you use Highlander AM1 microphones, phantom
feeding must be activated on the mixer board. This necessitates the screen of the microphone
pair to be connected in both ends.
The loudspeaker is fed the test chirp signal directly from the MU mixer.
A two twisted pair cable with common screen shall be used to connect each microphone to
the Main Unit. The interface can accommodate any reasonable wire length (300 m) on a
ship.

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Connections

Cabling between MU Mixer Board in Main Unit (left)

and microphone (right)
Microphone terminal # MU terminal # Comment, Cable Type
Two twisted pairs with common screen:
1 A1-1 to A8-1 Microphone output -> VDR, positive signal
2 A1-2 to A8-2 Microphone output -> VDR, negative signal

3 A1-3 to A8-3 GND, cable screen connected in both ends

4 A1-4 to A8-4 VDR acoustic monitor -> Microphone speaker, positive
5 A1-5 to A8-5 VDR acoustic monitor -> Microphone speaker, negative

Identifying Wires

A DMM (not a high voltage insulation tester!) can be used to identify the cable pairs with
a microphone connected in the remote end.
• The microphone pair (#1 and 2) will measure some 2 kOhms between the two wires
and some leakage to GND (#3). Microphones that should be routed to the same audio
channel should be connected with identical polarity, otherwise polarity is not
important.

• The speaker pair (#4 and 5) will measure some 10 ohms between the two wires and
isolation to GND (#3). Polarity is not important.

Notes on connections and EMI

IMPORTANT! To avoid interference, these cables must not be placed close to any cables
carrying high-powered currents, since noise may be induced in the microphone channels.
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See also the “General Notes on EMI, Cables and Connections” chapter.

7.1.4 Main Unit to Final Recording Medium/Capsule

General Information

A CAT-5 Ethernet cable, should be used to connect the capsule junction box to the switch
in the VDR HLD-A2 with a RJ45 connector. The capsule is delivered with 5 m
preterminated CAT-5 and power cabels. An Ethernet cable has a total maximum length of
100 meters.
The capsule is powered with 24 volts from the VDR HLD-A2 unit.
For power connections, please refer to the capsule handbook.

Precautions

The capsule has an “O” ring seal and an EMI seal braid. Avoid removing these from the
capsule base, and avoid nicking the braid seal.

The Ethernet cable is routed to the switch and pushed into one of the
free ports. The corresponding activity light should light up
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The CAT-5 cable could either be bought ready-made or terminated according to the
Ethernet standard. Terminating an Ethernet RJ-45 connector is outside the scope of this
handbook.

Notes on connections and EMI

See also the “General Notes on EMI, Cables and Connections” chapter.

7.1.5 Main Unit to Data Acquisition Unit

General Information

A cable with three twisted, stranded pairs with a common screen shall be used to connect
the Data Acquisition Unit to the Main Unit.

Connections

FOR CONNECTION OF DATA INPUT FROM SENSORS IN THE DATA

ACQUISITION UNIT, SEE SPECIAL INSTALLATION INSTRUCTION OF THAT UNIT.

7.2 Cabling from Bridge Systems to VDR HLD-A2 Main Unit

All cabling described here is based on the standard configuration, as described in the
“Technical Specifications” section in the “VDR HLD-A2 Technical Manual”.

7.2.1 Radar
A radar image is a raster-scanned image built up of one monochrome, or three video
channels, red, green and blue, and controlled by two synchronization signals, horizontal
and vertical. The VDR HLD-A2 grabs (samples) one screen from each video source (up to
four) and stores it.

General Information

Sampling of high bandwidth signals for radar display is technically complicated and
requires some extra care to be wired properly.
• Video connectors carry high bandwidth signals (up to 200 MHz), meaning that all
elements of radar output chain, cable and VDR HLD-A2 input, has to be matched to
the nominal system impedance. It is not allowed to connect the VDR HLD-A2 input in
parallel with a radar display, not even with short cables. Such a connection would ruin
the signal to the VDR HLD-A2, as well as to the radar!

• Each radar / high-resolution screen to be connected, must be equipped with a

proprietary video buffer unit. Any connected video buffer will actually be placed in
the signal chain to the VDR HLD-A2 but also to the radar display screen itself.
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• Use only BNC connectors and RG59/U coaxial cable, or other cable explicitly defined
as 75 Ohm cable.

• Use connector crimp tools to terminate coaxial cables only if you know exactly how to
use them!

Signal Format

The video format for a color raster scan CRT display consists of five signals or less.
See table below.
Name Comment
R Red Carries the red intensity amplitude for each line. The signal level shall
be between 0,5V pp to 1,0Vpp.
G Green Carries the green intensity amplitude for each line. The signal level shall
be between 0,5V pp to 1,0Vpp. In some video formats, synchronization
pulses are superimposed on the Green signal.
B Blue Carries the blue intensity amplitude for each line. The signal level shall
be between 0,5V pp to 1,0Vpp.
V Vertical Carries a short pulse (predominantly negative) for each new set of line
Sync scans (complete images). The image update frequency is normally in the
range of 50 to 85 Hz. The maximum signal level allowed is +2,0V to
-2,0V.
H Horizontal Carries a short pulse for each new line. The line frequency depends on
Sync the resolution and some other timing, and can be as high as 100 kHz.
The maximum signal level allowed is +2,0V to -2,0V.

Different signal combinations are possible, depending on the radar type. A monochrome
radar may have only one signal carrying intensity modulation (video) and horizontal and
vertical synchronization, but all combinations are possible, up to the complete set
described in the table above.
The VDR HLD-A2 is equipped with a four-input video multiplexer, giving the possibility
to connect four different sources.

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Connections

Connection of video sources to the VMU, at the bottom of the

enclosure

The connectors are located on the underside of the enclosure and there may be markings
on the metal plate itself to aid in connecting the cables.
Video sources number 1-4 are connected from left to right, when viewing from the
enclosure front. The red signal connector is closest to the edge, while the horizontal sync,
is closest to the bulkhead.

Configuration

The radar signal acquisition requires extensive configuration activities to adopt the VDR
HLD-A2 frame grabber software to the radar signal format. A software utility to analyze
signals in different formats is available and is described in the “Entering and Updating the
Static Configuration Data” chapter of this handbook. Make sure that cable connectors are
readily accessible, to be able to interchange cables depending on the results obtained from
these tests.

Identifying Wires

To make it easier to identify the coaxial cables they should be labeled, as in the picture
above. Preferably the cables should be labeled in both ends at the time they are connected
in the radar end. If there is more than one video source involved, also label the cable sets
with the source number.

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Notes on Connections and EMI

See also the “General Notes on EMI, Cables and Connections” chapter.

7.2.2 VHF/Communications Audio

Connecting VHF / communications audio to the VDR HLD-A2 is similar to connecting
microphones. These signals are also brought to the MU audio mixer.
Installation planning documents should tell you where to find the signal outputs. It should
be noted that connecting the VDR HLD-A2 directly to the VHF equipment loudspeaker
output is not sufficient, since it will only record received audio.
Any auxiliary device used to feed audio signals from the VHF set should be approved or
supplied by the VHF manufacturer to ensure that type approval is not violated.
IEC 61996 states that the output of a VHF unit should be a standard 0 dBm signal (which
corresponds to nominal level of 0.775 Vrms over 600 Ohms load).

General Information

Twisted pair cable with common screen shall be used to connect each VHF /
Communications output to the Main Unit. The interface can accommodate any reasonable
wire length (300 m) on a ship.

Connection Table balanced

Main Unit MU terminal # Cable Type

(input 2)
J41 (J44) VHF set lines output -> VDR, positive signal
J42 (J45) VHF set lines output -> VDR, negative signal
J43 (J46) VHF set signal GND -> VDR, GND.

Notes on connections and EMI

IMPORTANT! To avoid interference, these cables shall not be placed close to any cables
carrying high power supply currents, since noise can be induced in the audio channels.
See also the “General Notes on EMI, Cables and Connections” chapter.

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7.2.3 Navigation Sensors Using NMEA 0183/IEC 61162-1 Serial Output

General Information

The DCU carries the opto-isolated serial inputs for the main navigation sensor interface
to the VDR HLD-A2.
The NMEA interface format is generally very well suited for marine installations and the
isolated inputs make the system quite robust and insensitive to interference.
The installation planning documentation should tell you where the various sensor signals
are found.

DCU Inputs and Outputs Specification

All 16 VDR HLD-A2 NMEA inputs are identical and all channel assignments are
done via configuration in software. However, to ease implementation of non-standard
interfaces some channels are equipped with extra features, see table:
• “Normal” output only (standard) NMEA (IEC61162-1) devices should primarily be
connected to channels ranging from Rx3 to Rx16.

• Any “high-speed NMEA” (IEC61162-2) devices should be connected to channels Rx1

and Rx2.

• Any non-standard interface requiring two-way communication should be connected as

recommended by Highlander Corporation.

Serial Port Equivalencies

The NMEA terminals on the DCU board are connected to the computer’s serial ports as
follows.
28 COM14 32 COM18 36 COM22 40 COM26
29 COM15 33 COM19 37 COM23 41 COM27
30 COM16 34 COM20 38 COM24
31 COM17 35 COM21 39 COM25

NMEA High Speed

22 25
23 COM12 26 COM13
24 27

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Notes on EMI

See also the “General Notes on EMI, Cables and Connections” chapter.

8 General Notes on Cables and Connections

8.1 On Cable Dimensions and Standards
8.1.1 Signal Cables
• All cables used for signal interconnection of the VDR HLD-A2 system units shall
have a cross section of 0.5 mm2 with a voltage rating of at least 60 volts.

• If the specifications state “twisted pair”, such cable should be used.

• If the specifications state a screen should be used, either an aluminum foil screen with
an inlaid, blank, stranded conductor, or tinned copper braid should be used.

Using any other cable type will void warranty.

For your own convenience, please use a cable with numbered conductors. This makes
identification much easier, and minimizes the risk of mis-connections. The directions in
this manual assume cables with numbered conductors.

8.1.2 DC Power Cables

• All cables used for supplying DC power in the VDR HLD-A2 system shall have a
cross section of at least 1.5 mm2 with a voltage rating of at least 120 volts.

• The installation directions may specify a heavier cross section.

Using any other cable type will void warranty.

To avoid problems with voltage drops across longer runs of cable, increase the cross
section as appropriate.
For your own safety, use cable with colored conductors, preferable one red part for the
positive voltage and one black part for negative return.

8.1.3 AC Power Cable

• All cables used for supplying AC power in the VDR HLD-A2 system shall have a
cross section of at least 1.5 mm2 with a voltage rating of at least 500 volts.

• The cable must be UL registered, for the environment in which it is used.

• The cable must have three conductors, colored blue, brown and yellow-green. The
yellow-green part is to be used for grounding only.

Failing to use UL registered cable will void warranty.

Follow established electrical safety regulations when selecting and using high voltage cabling.
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8.2 On Cable Types

8.2.1 On Twisted Pairs
• Twisted pair means two wires twisted together in a special noise-canceling
configuration.

• Two twisted pairs means two separate sets of two wires twisted together, not four
wires twisted together.

The twisted pair is a unit that by its twist protects itself from the environment, and
protects the environment (such as, the pair next to it) from itself. The pitch of the twist is
carefully calculated to maximize the noise-canceling properties, which is not the case with
ordinary multi-pole cable.

8.2.2 What is Not a Twisted Pair

All cables with two or more parts are twisted for manufacturing reasons. This does not
mean any two-conductor cable is a twisted pair.
If the specification says “two twisted pairs” this is for a good reason, i.e. noise reduction.
Do not use twisted quads or ordinary multi-pole cable, which also has somewhat twisted
parts.
In a twisted quad the signals in one pair will cross-couple to the other pair, because they
are so close, and because one pair has no means of protecting itself from the other pair.
In an ordinary multi-pole cable, the noise-canceling properties are random or unknown.
What one does know, is that cross-coupling between the individual wires is bound to
occur.

9 General Notes on EMI

9.1 EMI
Electromagnetic Interference is everywhere. It is the unwanted signal component that
disrupts your system, creates unwanted noise in the audio channels, or causes the system
to go down at irregular intervals. If EMI is not counter-acted at installation time, it will be
very costly to troubleshoot and change the system later. Intermittent faults with an EMI
background are almost impossible to find.
The main unit has been manufactured with EMI protection in mind, but
counter-productive wiring could very well spoil the whole construction.
9.2 Termination of Signal Cables
To reduce the risk of
• EMI induction • Entanglement

• Excessive noise on audio channels • Mix-ups

• Short circuits

• Intermittent faults

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and to ease re-dressing of cabling and re-connections after service, all signal cables used
for VDR HLD-A2 connections should be terminated in the manner described here:
• If the connection block terminals in the VDR HLD-A2 are of the press type, we
recommend you to use bare wires.

• If screw connectors - the blank, stranded ends of the wire should be terminated with
end caps, see picture below.

The free ends should be as short as possible, preferably around 10 – 15 millimeters. This
tends to make connecting more difficult, but greatly reduces the risk of EMI induction.

The end caps must be crimped with the proper tool. Never use pliers or
crimp-tools intended for anything else than end caps.

Examples of proper tools for crimping end caps, and a strip of end caps
Where there is a risk that the shield wire might make short circuit to anything, solder
traces, other wires, chassis, bulkhead, etc., it must be protected with a slip-on plastic tube
or shrink tubing. Remember that the screen is not to carry any current or signal, it is only a
screen.

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In the case of twisted pair wire, be sure to use the wires in the proper pairs, i.e. in the case
of the microphone, the microphone signals should use one pair, and the loudspeaker the
other pair. If you mix pairs, the noise-canceling properties of the twisted pair is lost.
9.3 On Shields
Shields should never be connected in both ends of the cable, unless expressly noted.
Grounding a screen “for safety” or “for good measure” could be devastating to noise
immunity, forming a ground loop the will let noise slip into the system.
The reason for this is that the chassis (bulkhead) potential is never the same in both ends
of the cable. Although the ship is made of steel, large currents flowing through the hull
may easily generate a potential difference of several volts across 100 meters of the ship.
The result is that noise current will start flowing from the “high” end of the screen to the
“low” end, maybe several amperes. On the way, it will induce into the signal leads,
causing signal degradation and improper operation of the VDR HLD-A2 unit.
9.4 On Cable Placement
Never strap high-current, noisy cables together with sensitive signal cables, shielded or
unshielded.
The reason is once again to avoid noise induction. Two cables lying tightly together work
like a transformer, the noise in one easily coupling to the other.
The cheapest measure of noise reduction in any design, is to keep sensitive cables away
from noisy cables. Doing this at the installation stage is much cheaper than fault-finding
and re-engineering it later, when all the paint has come on.
It should be noted that in some cases it will be necessary to allocate more than one input
for a recording channel, for instance rudder order and response, as the signals may be
output from different sources, requiring two VDR input channels.

10 Mechanical Drawings
This section contains the following mechanical drawings:

Drawing No: Unit Detail

707285A0 Main Unit Component Layout
707113A0 Main Unit Installations Dimensions
------------- Power Supply Component Layout
709114A0 Power Supply Installations Dimensions
707364A0 Protective Capsule Overview and Installations Dimensions
707182A0 Remote Display Installations Dimensions
707183A0 Microphone Installations Dimensions

11Electrical Drawings
This section contains the following electrical drawings:

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

Tel:+86-10-82678888 Fax:+86-10-82150083
E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn

24
 海兰信数据科技
Beijing Highlander Digital Record Technology Co., Ltd.

Drawing No: Unit Detail

707310A0 Audio Inputs MU Mixer Unit Cable Connections

707188A1 Serial Inputs ND16 Cable Connections

707186A0 Main Unit - PSU VUB 2 Cable Connections

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

Tel:+86-10-82678888 Fax:+86-10-82150083
E-mail: market@highlander.com.cn / service@highlander.com.cn Http:// www.highlander.com.cn

25
 INSTALLATION
AND OPERATION
MANUAL

NAME PROTECTED DATA UNIT

MODEL PDU100

Code CH01 SS
Version V2.03
Date March 2006

CONSILIUM-HIGHLANDER CO., LTD.

 PDU100 Installation and Operation Manual

Revisions:
Date Ver Issue by Description
2004-11-12
SH Created

V1.0 SH Modified according to CCS

2004-12-08
Modified according to new release mechanism
V2.0 James
2005-3-20 design
Modified PDU configuration parameter
2005-8-7 V2.01 Li Changwei
modification utility program operation procedure
2006-2-28 V2.02 SH Modified mounting bolts size from Φ12 to Φ10;
Modified the standard compass safe distance from
65cm to 98cm;
Modified how to release PDU;
Modified some pictures and contents about
PDU configclient software.
Update Consilium-Highlander service telephone
and fax.
The Version 2.0 series is used for VDR HLD-
A1/M3.5
2006-3-28 V2.03 SH Update PDU Junction Box (JB) as optional
component which has been approved by CCS.
Add PDU100 and JB outline and installation
drawings and connection drawing

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 PDU100 Installation and Operation Manual

Table of Contents
INSTALLATION AND OPERATION................................................................................................. 1

1. VOYAGE DATA RECORDER (VDR) SYSTEM OVERVIEW.................................................... 5

2.1 GENERAL ........................................................................................................................................7

2.2 HARDWARE ....................................................................................................................................8
2.2.1 Protected Data Unit ............................................................................................................... 8
2.2.2 Junction Box (optional).......................................................................................................... 9
2.3 SOFTWARE ......................................................................................................................................9

3. PDU SPECIFICATIONS ................................................................................................................. 10

3.1 PDU SPECIFICATIONS ...................................................................................................................10

3.2 PDU JUNCTION BOX(OPTIONAL) SPECIFICATIONS ........................................................................10

4. PDU INSTALLATION INSTRUCTIONS ..................................................................................... 10

4.1 GENERAL ......................................................................................................................................10

4.2 REQUIRED TOOLS .........................................................................................................................12
4.3 MOUNTING PROCEDURE ...............................................................................................................12
4.3.1 Mounting the PDU ............................................................................................................... 13
4.3.2 Mounting the Junction Box (optional) (JB).......................................................................... 15
4.4 CONNECTIONS ..............................................................................................................................16

5. SOFTWARE INSTALLATION INSTRUCTIONS....................................................................... 21

5.1 GENERAL ......................................................................................................................................21

5.2 INSTALL UTILITY SOFTWARE ----- PDU CONFIGCLIENT................................................................21
5.3 CHANGE THE CONFIGURATION PARAMETER ................................................................................23
5.4 CONFIGURE VDR SOFTWARE ........................................................................................................28
5.4 RECOVERY OF DATA .....................................................................................................................32

6. OPERATING PROCEDURE.......................................................................................................... 33

6.1 OPERATION STEPS .........................................................................................................................33

6.2 DOWNLOADING AND CHECKING THE DATA FROM PDU.................................................................33
6.3 INFORMATION USED FOR INVESTIGATION ORGANIZATION .............................................................33

7. MAINTENANCE ............................................................................................................................. 34

7.1 WHEN TO RELEASE PDU?.............................................................................................................34

7.2 HOW TO RELEASE PDU FROM THE PDU PEDESTAL?.....................................................................34

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 PDU100 Installation and Operation Manual

7.3 ROUTINE MAINTENANCE ..............................................................................................................35

7.3.1 GENERAL ............................................................................................................................ 35
7.3.2 Underwater Locator Device (Beacon) Cleaning.................................................................. 36
7.3.3 Check and replace of cable .................................................................................................. 36
7.3.4 Check and replace of O-ring................................................................................................ 36
7.3.5 Checking of fastening screws of installing base................................................................... 36
7.3.6 Corrosion-proof and rust-proof treatment of surface of casing........................................... 37
7.4 HOW TO REPLACE THE PDU?........................................................................................................37

8. DATA RECOVERY AFTER AN INCIDENT............................................................................... 37

APPENDIX1. PROTECTED DATA UNIT PDU100 OUTLINES DRAWING............................. 38

APPENDIX2. PROTECTED DATA UNIT PDU100 INSTALLATION DRAWINGS................. 39

APPENDIX3. PROTECTED DATA UNIT JUNCTION BOX (OPTIONAL) OUTLINE AND

INSTALLATION DRAWING................................................................................... 41

APPENDIX4. PROTECTED DATA UNIT CONNECTING DRAWING ...................................... 42

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 PDU100 Installation and Operation Manual

1. VOYAGE DATA RECORDER (VDR) SYSTEM OVERVIEW

“The purpose of a Voyage Data Recorder (VDR) is to maintain a store, in a secure and retrievable
form, of information concerning the movement, physical status, command and control of a vessel
over the period leading up to, and following, an incident having an impact thereon. This
information is for use during any subsequent investigation to identify the cause(s) of the incident.
The International Maritime Organization (IMO) passed resolution A.861 in November 1997,
requiring mandatory carriage of VDR for certain ship types and size according to a planned
schedule. The technical standard for the VDR was published in August of 2000 by IEC, document
number 61996. The IEC 61996 specifies the performance criteria and testing methods of
Shipborne Voyage Data Recorders. In particular, it refers that all the recordings shall be stored on
the final recording medium in a protective data Unit:

4.3 Final recording medium means the item of hardware on which the data is
recorded such that access to it would enable the data to be recovered and
played back by use of suitable equipment.

5.1.3 The final recording medium should be installed in a protective Unit which
should meet all of the following requirements:
.1 be capable of being accessed following an incident but secure against
tampering;

.2 maximize the probability of survival and recovery of the final recorded

data after any incident;

.3 be of a highly visible color and marked with retro-reflective materials;

.4 be fitted with an appropriate device to aid location.

A TYPICAL VDR CONSISTS OF A DATA ACQUISITION AND INTERFACE UNIT, WHICH PROCESSES DATA
FROM SHIP’S NAVIGATION/ENGINE/ALARM SYSTEM, AS WELL AS RECORDS BRIDGE AUDIO AND RADAR

IMAGES IN DIGITAL FORMAT. THE DATA ARE THEN SENT TO A PROTECTIVE UNIT, WHICH HOUSES THE
FINAL RECORDING MEDIUM. THE REMOTE BRIDGE ALARM UNIT REPORTS ANY FAULTS DEVELOPED

ON VDR. THE DATA STORED IN THE PROTECTIVE UNIT CAN BE DOWNLOADED FOR RE-PLAY DURING

AN INCIDENT INVESTIGATION.

Figure 1 below shows a system block diagram of a typical VDR design.

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 PDU100 Installation and Operation Manual

Radar Video Protected

RGB Data

HUB Unit
Serial data
IEC61162 VDR
VDR
Playback
Main Unit
Microphone W k t ti
VHF audio

Ship
Bridge Alarm
Emergency
Power Supply Unit (BAU)
(AC)

Figure 1 VDR block Diagram (Standard Configuration)

The Protected Data Unit (PDU) is a component of a Shipborne Voyage Data Recorder (VDR). It
contains the final storage medium, which is protected from shock, penetration, fire and deep-
seawater immersion. It is designed to be mounted on the external deck of the vessel. It is a highly
visible fluorescent orange color, and marked with retro-reflective material with the required
legend, “VOYAGE DATA RECODER DO NOT OPEN, REPORT TO AUTHORITIES”. An
acoustic underwater beacon is also mounted on the Unit to aid location. The PDU has a release
mechanism to facilitate recovery underwater by diver or Remotely Operated Vehicle (ROV).
Large pad eyes are welded to the outer shell to facilitate easy lifting. Figure 2 shows a fully
assembled PDU together with a Junction Box (optional) (JB). This document contains detailed
PDU specifications, installation instructions, and commissioning and maintenance procedures

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 PDU100 Installation and Operation Manual

Figure 2 – PDU and Junction Box (optional)

2. PROTECTED DATA UNIT (PDU) DESCRIPTION

2.1 General
The Protected Data Unit (PDU) has passed all survivability tests on shock, penetration,
lower temperature fire, high temperature fire and deep-sea immersion as specified in IEC61996.

Shock: 50 g, 11 ms, 1/2 sine, 3 orthogonal directions, 3 shocks each

Penetration: 250 kg weight with 100mm pin drop from 3 meters height
Low Temp Fire: 10 hours @ 260 degrees C
High Temp Fire: 1 hour @ 1100 degrees C
Deep-Sea Immersion: 60 Mpa (6000 meters) for 24 hours
Seawater Immersion: 30 kPa (3 meters) for 30 days

In addition to the survivability tests, the PDU also passed required operational tests in cold,
hot and damp environment, as well as vibration and electromagnetic conditions onboard ships.
All tests were conducted according to IEC60945, Maritime Navigation and Radio Communication
Equipment and Systems – General Requirements:

Dry Heat: 70 degrees C storage test, 55 degrees C functional test

Damp Heat: 40 degrees C and 93% humidity functional test
Low Temperature: -25 degrees C functional test, -30 degrees C storage test,
Rain: 30 Minutes @ 100 liters/min from 2.5-3meters
2
Vibrations: 2-5 to 13.2 Hz +/-1mm, 13.2-100Hz @ 7m/s
Power Variation: 19.2-28.8 VDC

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 PDU100 Installation and Operation Manual

Excessive Conditions: 16-36 VDC, Fuse cutoff >36VDC, reverse polarity

Dangerous Voltage: IP22
EMI/EMC: Conducted emissions/interferences,
Per IEC spec. Radiated emissions/interferences:
Electromagnetic radio frequency interference

2.2 Hardware

2.2.1 Protected Data Unit

The Protected Data Unit (PDU) contains the final recording medium in the form of a solid-
state memory disk protected from high temperature fire and deep-sea immersion. At least the last
12 hours of data, audio communication and radar video are stored. The PDU provides the means
to store the voyage data and ensure that it will survive the extreme environmental conditions
associated with a maritime disaster or incident.
The PDU is painted in fluorescent orange color with a reflective label that reads “VOYAGE
DATA RECODER DO NOT OPEN, REPORT TO AUTHORITIES”. Each PDU weighs
approximately 33kg and measures360W ×320D ×359H mm (Figure 3). It is designed to be
deck-mounted. Two shielded cables connect to the PDU and the Junction Box (optional) (JB),
which is designed for under-deck installation. When the Junction Box is not required by user, the
two shielded cables connect the PDU to the VDR main unit directly. The suggested the length of
cables is that 30 meters when JB is not required and 5-meters when JB is required together with
PDU.
The exposed above-deck PDU assembly has two pieces. The Unit can be separated from the
base plate by simply pulling the release hooks. An acoustic beacon is provided to aid locating the
Unit underwater. Large pad eyes are welded to the PDU housing to facilitate easy lifting by divers
or Remotely Operated underwater Vehicles (ROV).

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 PDU100 Installation and Operation Manual

360W ×320D × 359H mm

Figure 3 – PDU Dimensional Drawing
2.2.2 Junction Box (optional)
The Junction Box (optional) (JB) provides the interface between the VDR recording system
and the PDU. The JB contains replaceable fuse, protective circuitry and a terminal block used for
field wiring terminations between the Ethernet LAN and +24VDC power cables from the VDR
system, and the Special 5-meter long cables provided with the PDU. The PDU Junction Box
(optional) is not rated for exterior installation. It should be installed in an interior space close by
the weather deck location where the PDU is mounted.

A regulated 24 VDC power supply and an Ethernet Hub should be provided in the VDR
system to power the PDU and provide communication to the PDU. The power cable from the
VDR system to the JB should be shielded and marine grade. Shielded CAT5 cable of up to 100
meters can be used for the Ethernet connection. Cables from the VDR and the PDU are joined at
labeled terminal blocks in the Junction Box (optional).

2.3 Software

Once it is powered up, PDU will show up as a shared drive with password protected
read/write privileges on the dedicated VDR local area network (LAN). The Solid State Memory
has a data integrity period of 10 years. The built-in Reed-Solomon error detection and on-the-fly
correction (ECC) circuitry ensures extremely low bit error rate at < 1 in 1014, well below the
required 1 in 108. Available size of the Solid State Memory drive ranges from 1.5 to 4 Gigabytes

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 PDU100 Installation and Operation Manual

of contiguous space for storing data, audio and video files without the restrictive pre-determined
partitions.

3. PDU SPECIFICATIONS

3.1 PDU Specifications

Color Fluorescent International Orange

Weight – Protected Data Unit 33kg
Dimensions – Protected Data Unit 220D × 316H mm
Dimensions – Mounting Base 320D × 63H mm
Dimensions – PDU & Mounting Base 360W ×320D × 359H mm
Assy
Input Power 24 VDC （19～36V）
Power Consumption Max <10W , normal is about 5W at 25 ℃
Memory Type Solid State
Capacity 12-hour minimum (1.5GB~4GB)
Computer Interface 10Base-T(IEEE802.3) 100Base-TX(IEEE802.3u)
Release mechanism 50 lb pull on release clamp
Underwater Acoustic Beacon SA 8405 compliant
Regulatory Specifications IEC 61996, 60945, IMO A.861(20)
Compass safety distance
From standard compass 98 cm
From the steering, standby and emergency
compass 80cm

3.2 PDU Junction Box(optional) Specifications

Weight 2.0 kg excluding cables

Dimensions 208mm W × 160mm D × 85.5cm H
Fuse 500mA
Compass safety distance
From standard compass 95 cm
From the steering, standby and 60cm
emergency compass

4. PDU INSTALLATION INSTRUCTIONS

4.1 General

Before installing the PDU, check all the parts against the component list as shown below.
Check condition of all components.

Code Name No Remark

1 PDU Unit 1
2 Underwater location beacon 1 DK140
3 Quickly releasing mechanism 2

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 PDU100 Installation and Operation Manual

4 Hex bolt 4 M10×35

5 Spring washer 12 M10
6 Hex nut 4 M10
7 Waterproof connector 1 YMA18F4K/YM18T4Z
8 Waterproof connector 1 YMA18F3K/YM18T3Z
9 Mounting base 1 Supply by shipyard
10 Electric power cable 1 AWG28#
11 Data transmit cable 1 Shield CAT 5 cable
12 Junction box (optional) 1
13 Inner hex bolt 4 M6×15-20
14 Flat washer 4 M6
15 Spring washer 4 M6
16 Hex nut 4 M6

PDU capsule

Hex nut
Spring washer
Hex bolt
Underwater location beacon

Mounting base
Quickly releasing mechanism
Power Cable(YMA18F3K/YM18T3Z)
Data Cable(YMA18F4K/YM18T4Z)

Figure 4 PDU

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 PDU100 Installation and Operation Manual

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Figure 5 Junction Box (optional)

4.2 Required Tools

Normal shipboard electrician’s tools are required. Welding equipment is necessary to weld the
stainless mounting base tubes to the deck or pedestal.

4.3 Mounting Procedure

Place the pedestal in the desired location on the ship deck. Then weld pedestal by cleaning the
weld surfaces from corrosion, paint and any other obstructive material that would jeopardize the
integrity of the weld.

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 PDU100 Installation and Operation Manual

Figure 6 PDU mounting base

4.3.1 Mounting the PDU

1) Location Selection
The PDU shall be sited in the vicinity of the bridge on the external deck area of the vessel so
as to maximize the probability of its survival and recovery following an incident. The PDU shall
be positioned clear of rigging and other potential obstructions and as near to the centerline of the
ship as practically possible.
Criteria to be considered when assessing the optimum position shall include but not be limited
to the following:
A. Separation from fuel or other potential fire sources
B. Separation from probable sources of mechanical damage
C. Operational environment for continued serviceability
D. Accessibility for copying of recorded data and for routine maintenance
E. Facilitation of underwater removal and retrieval by both divers and ROVs, there shall be a
clear unobstructed space in the vicinity of the Unit to allow an ROV or diver to work.
F. The PDU should be mounted on an exterior deck e.g. compass deck at an easily accessible
location so that a diver or remotely operated vehicle (ROV) can retrieve the PDU with the
ship resting upright on the sea bottom. For reasonable ROV or diver access, it may be
necessary to elevate the PDU above the deck on a pedestal.
G. The location should be a minimum of 98 cm from the ship’s standard compass.

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 PDU100 Installation and Operation Manual

H. Due to its bright color and reflective tape, it should not be in direct view of the bridge.
I. Ensure that the reliable connection between the PDU and vessel neck via the mounting base.
J. Place the PDU on the mounting base.
K. The PDU should be mounted to the mounting base in the steps below. For the outline
dimensions of mounting base refer to Figure 7, Figure8 and Figure 9.
L. Clean the bottom surface of PDU pedestal and the top surface of mounting base, then move
the PDU and make the mounting holes on capsule pedestal aim at the screw holes on the
mounting base;
M. Assembly and fasten the M10 screws to keep the Protected data unit mounted on the
mounting base firmly;

Figure 7 Installing Dimension Drawing for Base of Protected Data Unit

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 PDU100 Installation and Operation Manual

Figure 8 Connection Drawing for Base Installation and Fixation (part)

Input Port of power supply Input Port of Ethernet signal

Figure 9 Outline drawing for Protected Data Unit

4.3.2 Mounting the Junction Box (optional) (JB)

The Junction Box (optional) (JB) encloses a terminal block used for field wiring terminations
between the Ethernet LAN and power cables from the VDR system, and the interconnecting
cables provided with the PDU. The JB is not rated for exterior installation. It should be installed in
an interior space close by the weather deck location where the PDU is mounted. The cables
supplied with the JB are 5 meters in length. Pull the JB cables through a deck or bulkhead gland
into the space where the Junction Box (optional) is located. Junction Box (optional) dimensions
and mounting holes locations are shown in Figure 10. The cover must be removed to access the
mounting holes.

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 PDU100 Installation and Operation Manual

Figure 10
1) Location selection
When selected mounting location of the JB, the following conditions should be considered:
A. The JB should be installed in an interior space, and, in general, the bridge room is
recommended.
B. The JB should be mounted in bulkhead close to the weather deck location where the PDU is
mounted, and note that the interconnecting cables ( The Ethernet LAN and power cables)
supplied with the JB to the PDU are 5 meters in length.
2) The chosen location, drill four mounting holes sized to “the JB outline and installing
drawing”
3) The cover must be removed to access the mounting holes.
4) After finished connecting, screw the four mounting screws into the JB and the bulkhead, and
tighten the screws.

4.4 Connections

Warning: it should be ensured that, before connecting the power supply line, the power
supply of Protected Data Unit should be switched off.

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 PDU100 Installation and Operation Manual

The data communication cables (Ethernet cables) and power supply cables are protected in
waterproof PVC pipe, they are routed and fixed between VDR main unit and PDU the JB
(optional);
CAUTION: The bending diameter of Ethernet wire should not exceed 12 times
the diameter of Ethernet.
1) Data cable connection
When PDU junction box is used:
Together with junction box, there are two shielded data and power supply cable provided by
PDU manufacturer, the cables are used for connecting PDU and JB, one terminal of the data
cable is connected to PDU via connectors and the Other terminal is connected to the terminal
blocks located in the JB PCB by conductors which terminals definition is as the table below.
Another two cables included data and power supply cable need to prepare to connect JB and
VDR main unit. The length of the cables is up to the distance between JB and VDR main unit.
For data cable, one terminal is connected to Ethernet switch through RJ45 plug, and the other
terminal is connected to terminal blocks located on JB PCB, the conductor definition is as the
table below.
The details of connection are shown in table below:

Connection The wire

Define YMA18F4K YM18T4Z pin of LAN color
TX+ 1 1 2 orange
TX- 2 2 1 Orange/white
RX+ 3 3 6 Green
RX- 4 4 3 Green/white
shield shell shell

When PDU junction box is not used:

When PDU Junction box is not used, two cable including data cable and power supply cable
is provided by manufacturer together with PDU, no other cable need to prepare. The data cable
is connected an electricity connector YMA18F4K on one terminal and RJ45 plug on the other
terminal. Only 5 conductors of the cable are used in connection as table above, It is necessary to
use shield cable CAT5 to transmit data between the VDR sever and the PDU. The armor shield
layer of any terminal of the cable should be connected to the VDR cabinet which is connected
to ship’s deck via ground terminal. The RJ45 plug of the data cable should be connected to one
port of the Ethernet switch located inside the VDR main unit, the other terminal with the
electricity connector YMA18F4K will be plugged into the connector socket YM18T4Z of
PDU.

Caution:

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 PDU100 Installation and Operation Manual

A. The data cable shall adopt shield Ethernet CAT5, ordinary Ethernet cable shall not be
proposed, so as to avoid communication data being interfered by radio RF signals. For the
same reason, the terminal connector shall adopt shield RJ45, ordinary RJ45 is not proposed.
B. The bend diameter of the Ethernet cable cannot exceed 12 times of outer-diameter of the
Ethernet cable.
C. Connect the data cable to Ethernet HUB inside the VDR main unit; the details of connection
refer to Figure 11 connecting with JB and figure 12 connecting without JB

JunctionBox
Pr ot e c t e d Dat a Uni t
Connecter 1 CEF80/SA 3×0.75 Shield Shield CEF80/SA 3×0.75 Shield

RED RED
1 +24V +24V +24V
CONNECT
BLUE BLUE TO VDR
2 GND GND GND
MainUnit
GREEN GREEN
3 Shield Shield Shield
1 Connect to
Ethernet Switch
Shield Shield Shield inside VDRMU
Connecter 2 CAT-5 CAT-5
RJ45
Green/White Green/White RX- 3
4 RX- RX-
Green
Green RX+ 6
3 Orange/White
RX＋ RX＋
Orange/White TX- 1
2 TX- TX-
Orange
Orange TX+ 2
1 TX＋ TX＋

Figure 11 connecting diagram with JB

Prot ect ed Dat a Uni t

Connector1 CEF80/ SA 3X0.75 Shield

RED +24V
1 Connect to
BLUE
GND VDRMain
2 Unit
GREEN
3 Shield

Shield
Connector2 CAT- 5
RJ45
Green/White RX- 3
4 Green RX+ 6 Connect to
3 Orange/White TX- Ethernet Switch
1
2 Orange
insideVDR Main
TX+ 2
1 unit

Figure12 the connecting diagram without JB

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2）Power supply cable

When PDU junction box is used:
Together with junction box, there are two shielded data and power supply cable provided by
PDU manufacturer, the cables are used for connecting PDU and JB, one terminal of the power
supply cable is connected to PDU via connector and the Other terminal is connected to the
terminal blocks located in the JB PCB through conductors, which terminal definition is as the
table below.
Another two cables included data and power supply cable need to produce to connect JB and
VDR main unit. The length of the cables is up to the distance between JB and VDR main unit.
For power supply cable, the conductors on one terminal should be connected to power supply
(+24V) terminals especially for PDU inside main unit, and the conductors on other terminal is
connected to terminal blocks located on JB PCB, the conductor definition is as the table below.
The PDU is powered up by DC24V from VDR, so connect the power supply cable of the
PDU to the JB, which terminals definition and connected position refer to the following table.

Define YMA18F3K YM18T3Z terminal define in JB

+24V 1 1 OUT24V
GND 2 2 GND
Shield 3 3 Shell

Figure 13 the terminals definition of the JB

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 PDU100 Installation and Operation Manual

When PDU junction box is not used:

When PDU Junction box is not used, two cable including data cable and power supply cable
is provided by manufacturer together with PDU, no other cable need to prepare. The power
supply cable is connected an electricity connector YMA18F3K on one terminal and conductors
on the other terminal. Only 3 conductors of the cable are used in connection as table above, The
electricity connector YMA18F3K with the power supply cable should be plugged into the
power supply connector socket YMA18F3Z of PDU, while the conductors on other terminal
should be connect to power supply (+24V) terminals especially for PDU inside VDR main unit
directly. The shield conductor shall be connecting to the main unit cabinet which is in ground
connection with ship deck.
2) Final Inspection
A. Secure the cables between the PDU and the JB (optional) to the deck.

B. Visually inspect all connectors to ensure they are fully seated.

C. Visually inspect all glands for tightness if necessary.

D. Visually inspect welds and mounting bolts.

E. Visually inspect for integrity of wire seals and safety wire.

F. Visually confirm all of the wiring in the JB (optional) and relative wiring inside VDR main
unit is correct.

G. Measure if the power supplies terminals are in short-circuit between plus and minus and
between terminals and capsule or cabinet shell and if they are in good connection with VDR
main unit.

3) Applying Power for the First Time

A. Open the JB cover (if JB is used).

B. Apply power to the 24 Volt power supply from the VDR system.

C. If JB is used, watch for the LED to illuminate on the JB PCB. If the LED does not light, the
fuse may be blown, or the wiring or power supply is incorrect. In this case, turn off the power
and recheck the wiring.

D. Measure the PDU input voltage should be within correct voltage range by a voltmeter both
cases of using and no using JB.

E. Check the PDU for proper operation by using a Notebook computer with Ethernet adaptor.
(See Software installation section below)

F. When the PDU is confirmed to be operating properly, Close the JB and check JB lid screws

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 PDU100 Installation and Operation Manual

for tightness when JB is used.

5. SOFTWARE INSTALLATION INSTRUCTIONS

5.1 General

Protected Data Unit (PDU) works in the Embedded Linux Operation System and makes data
transmission with VDR main unit through standard 10MB/100MB Ethernet LAN. The Protected
Data Unit and VDR main unit identify each other through setting different address.
Consilium-Highlander Corporation provides utility software in Windows to help user to
change its configuration parameter, including IP address and password for vdradmin and backup
user account. Its can be run in Windows 2000/XP operation system, and free space for hard drive
is at least about 100MB.

5.2 Install utility software ----- PDU ConfigClient

1. Please double click the software setup file---setup.exe

2. Please select the installing directory

Caution: please click the “Browse” button to change the installing directory if you want to
select a new position of the disk.
3. Please confirm the installing directory and finish the installing procedure

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Please click the “Finish” button to end of this setup procedure

5.3 Change the configuration parameter

Prepare:
Before changing the configuration, make sure that your PC or notebook is in the same subnet
with PDU. The default IP address of PDU is 192.168.5.250, net mask is 255.255.255.0. You can
change IP address of your PC to 192.168.5.150, for example.
Make sure your PC and PDU is connected via a hub.

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The default password of vdradmin account is “vdradmin”. The default password of backup
account is “backup”.
The default user account information for vdradmin and backup is shown as the below table.
Caution: the user name for vdradmin and backup can’t be changed.

Purview Vdradmin backup

Write data Yes No
Read data Yes Yes
Remove files Yes No
Change backup’s password Yes Yes
Change vdradmin’s password Yes No
Change IP address Yes No

1. To login PDU
Please click “Start” --> “Program”--> “PDUConfigClient”--> “PDUConfigClient” to run the
configuration software.

Type in IP address of PDU, User Name, Password in the corresponding edit boxes, and then
click enter or click Login Button. If Login successfully, a message box will be shown to notice the
message you input is correct, otherwise some login failed information will be shown.
Some information will be shown if the message you input is incorrect!
List as follow:

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2. Change the Configuration parameter

If you login successfully, menu-items will be enabled. (some of the menu-items is still
disable because you login with backup account ).

(1).Click the “Change password of vdradmin” item, then a dialog will be shown as below.

Next, enter new password twice, and click the OK button. If you want to cancel, click the
CANCEL button.
Note: length of the password should be between 5 and 9.
(2).Click the “Change password of backup” item, a dialog will be shown.

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And then type in new password and click enter or click OK button. If you want to cancel,
please click CANCEL button.
Note: length of password should be between 5 and 9.
(3). Click “Change IP Address” item, a dialog will be pop-up.

Then Type in new IP address and new Net mask in corresponding textbox. Default value
shown above figure.
Click OK button to confirm your modification, Click CANCEL button to abort.
Well, if IP address and Net mask you input is correct, broadcast address will be automatically
worked out and shown to you.
Notice that the process of change IP address should cost about 15 seconds, so please wait before
the program responds.

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 PDU100 Installation and Operation Manual

Well, if the IP address is changed successfully, an information box will be shown. Then
Click OK button, you will logout automatically.
And you should login with the new IP address.

(4) Click “Show Software Version” item

A message box will show version of the software to you.

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 PDU100 Installation and Operation Manual

3. Logout
If Operation has been finished, click Logout button, so you can login with new account
information.
Exit the Program
If you want to end the program, click the Exit item in the “Operation” Menu.
Show about Information
Click “About” item in “Help” Menu, so you can get some information about this program.

5.4 Configure VDR software

1) Connect VDR main unit to Protected Data Unit through Ethernet cable, and power on the
Protected Data Unit to make it start the work.
2) Power on VDR main unit to make it start the work, ping \\192.168.5.250 to check if the
capsule is connected with main unit successfully.

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3) Configure capsule by touching the “config” button on small client screen. On the configure
interface, click the “capsule ”, then select “JV”, open the JV capsule configuration windows,
input correct win User name and SAMBA user name and password, then select which files
stored into the capsule. Click “OK” to finish the capsule configuration.

4) Save the configuration file, stop VDR sever and restart it to make sure the configuration file is
effective.
5) The capsule path \\192.168.5.250\data should be mapped as one hard disk G of VDR main unit.
Disk G is the default disk letter. All the capsule data can be accessed via the path: G:\data\vdr

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Figure 14
Data structure stored at the capsule is shown in the figure 14. The data folder contents a VDR
folder which includes the recorded data whose length is up to 12 hours and zipped configuration
files as shown in figure 15. Every 100 minutes a new folder is created under the
\\192.168.5.250\Data\vdr\00 directory. The new folder includes up to 100 sub folders each of
which created every one minute and contents 1 minute zipped information.
The data stored at capsule is at the path of \\192.168.5.250\data , the data can also be
accessed via Ethernet by another computer whish shall be at the same subnet with the capsule, but
correct username and password is needed as shown in figure 15. The computer can change capsule
username and IP address etc. but the configuration of capsule shall be finished by VDR main unit.

Figure 15

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Figure 16

The zipped recorded data information under each folder includes the image of radar, sensor
and bridge room sound of the ship and other allocated information of ship. The form of unzipped
data is as shown in the chart below:

Figure 17

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After Protected Data Unit is powered on, it always keeps in the waiting state until VDR
main unit send data then the recording of data memory will auto begin, in the mean time, the
VDR main unit will also record VDR data as backup in the data folder under local hard disk. The
backup data at local hard disk is stored in original data type created by main unit processor, but
the data stored at capsule is in zip data type which is for saving capsule memory capacity. The
stored data at capsule is the same as the backup data after unzipped, refer to figure 18
The backup data at local hard disk is located in the path of “D:\data\vdr”, the data folder and
the structural form of data is as follows:

Figure 18
After finishing the above works, the VDR system starts to work normally. The ship VDR data is
collected and processed by VDR main unit, then transmitted and stored to capsule and local hard
disk.
Caution:
The folder structure, file name, to create and recovery file are completely controlled by
VDR main unit. The PDU only provide the final memory medium to store the data and to
verify the record function to insure the reliability of recording.

5.4 Recovery of data

The recorded data can be replayed by playback software according to the recorded data form
(The playback software is provided by VDR manufacturer)

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6. Operating Procedure

6.1 Operation steps

After installing and setting the software in accordance with steps 2, 3, and 4, through the VDR
main unit PDU can be operating normally.
Connection of data cable and power supply cable
1) Connect the power supply cable and data cable of PDU to the VDR main unit through the
JB(optional) and switch on, and the Protected Data Unit will start to work.

2) Recording data
After being switched on, Protected Data Unit will be the waiting state until VDR main unit
transmits data. When the VDR sends data, the Protected Data Unit will receive data via Ethernet
and store the received data to the data folder into final memory medium. Such a data storage
process is completed by the operating system software of PDU, without the need of manual
intervention.
3) The downloading and access to PDU must be authorized by the related department and
personnel.

6.2 Downloading and checking the data from PDU.

1) The data download and check is made when any sensor of VDR or VDR itself is maintained
or repaired. Otherwise, the download and check shall be made at least once a year.
2) A notebook PC with 10/100MB Ethernet adapter can be used to download the data from PDU
by authorized personnel and by setting correct Ethernet parameter. The data can be replied by
playback software provided by VDR manufacturer.
3) The downloaded data may be compared with the VDR data stored in the HDD of VDR main
unit by the special data comparison software provided by the VDR manufacturer to verify if
the PDU is in normal operating status.

6.3 Information used for investigation organization

1) The works of Download and replay the recorded data from Protected Data Unit will use
special playback software, and the software should be provided by VDR manufacturer.
2) If you want to restore the data from an uninjured Protected Data Unit (data port not injured
and only Protective casing injured), you may read the data from the interface of the Ethernet
through normal operation procedure.
3) If VDR is unexpectedly injured, and the data cable and data port of Protected Data Unit will
also be injured. If you want to restore the data from the injured Protected Data Unit, it is
necessary to open the Protected Data Unit casing and take out other thermal isolation

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 PDU100 Installation and Operation Manual

components from inside until perfect data cable appears. Lead the data line one by one
according to the serial numbers identified on the data cable, and then connect them to the
main board of a PC through an externally connected standard IDE data plug and read data
again. If the injury is serious, it is necessary to send it back to PDU manufacturer for
treatment and reading.

7. MAINTENANCE

7.1 When to release PDU?

PDU need be released when one of the following condition happen:
1) Ship encounters severe accident, for sink etc.
2) According to the requirement of Annual survey by administration authority, need to inspect
the function of PDU release.

7.2 How to release PDU from the PDU pedestal?

1) Disconnect the two water-proof connectors from PDU.
2) Under the action of a pilling force of less than 500N, pull the rod of release mechanism
manually.
3) Pulling the release mechanism rod out suddenly to cut the safety wired lead seal first and then
withdrawing the rod out.
4) Lift up and apart the capsule from the pedestal
5) Disconnect the data cable between the capsule and pedestal.
Caution: While the release mechanism is unconnected, don’t lift the PDU upward too high
(the length<150mm), to avoid the damage or breakage of the data cable between the PDU
and base.
For the release process see the scheme below:

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 PDU100 Installation and Operation Manual

Figure 18 release protected data capsule from the PDU base

If the release mechanism fails to release the PDU naturally, drop several drips of lubricating
oil into the hole at the joint of release pull rod and release mechanism.

7.3 Routine Maintenance

7.3.1 GENERAL
This section is intended to contain information required to restore a worn or damaged part to a
serviceable condition. However, the PDU is a completely solid-state device that does not contain
any electro-mechanical moving parts. The PDU has been designed as maintenance-free unit which
makes extensive use of surface mount technology (SMT). The repair of printed wiring assemblies
(PWAs) containing SMT components requires specialized factory equipment, training, and
techniques, therefore, such PWAs are not field-repairable.
As a result, the PDU’s maintenance philosophy is replacement of failed assemblies. In the case
of the PDU, the replaceable assemblies are the Power and Processor Module, and the Memory
Module (Bell). There are no special calibration or overhaul requirements for the PDU.
When it has been determined that the Power and Processor Module or the Memory Module is
faulty, the faulty assembly should be removed and returned to the manufacturer for repairing or
replacement. Extreme care should be used when handling these assemblies.
NOTE: Attempts to repair any of these assemblies will void the warranty.
CAUTION:
THE PDU CIRCUIT BOARDS ARE SUSCEPTIBLE TO ELECTRO STATIC
DESTRUCTION (ESD). PRIOR TO HANDLING PWAs, ENSURE PROPER
PERSONNEL GROUNDING TECHNIQUES ARE USED. ENSURE THAT CARDS ARE

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 PDU100 Installation and Operation Manual

PLACED INTO STATIC SHIELDING CONDUCTIVE BAGS WHEN HANDLING OR

STORING.

7.3.2 Underwater Locator Device (Beacon) Cleaning

The PDU beacon water switch should be kept clean by wiping with a soft lint-free cloth at
least once a year (more frequently under high humidity conditions). The beacon cradle is
positioned on the PDU Bell housing.
The beacon cleaning procedure requires no disassembly and consists only of cleaning the
center contact of the beacon water switches. Make sure the beacon case and water switches are
free of dirt and/or grease film. If necessary, take the beacon out of the mounting bracket assembly
and wipe clean with a cleaning agent. The water switch end insulators must be free of dirt, lint, or
moisture to prevent current from leaking across the switch.
NOTE: The beacon is only activated when both switches are activated, to prevent
inadvertent activations due to weather conditions.
As an added note, the beacon’s battery has an expected life of six year. Consilium-Highlander
keeps selected beacon parts in stock, contact Consilium-Highlander for more information. To
obtain new beacon batteries, contact Dukane Corporation.
The approved beacon is the Dukane beacon, P/N DK140.
As a general rule, the beacon should be removed from service on or before the expiration date
printed on the beacon. The batteries installed in the DK140 beacons are field replaceable. Refer to
service information provided by the Dukane Corporation for servicing and recertification.

7.3.3 Check and replace of cable

Checking periodically the data transmission cable and power supply cable see whether they are
aged. If they are aged, it is necessary to change the cables. Please contact the manufacture if need
the cable. It is recommended to make the checking according to the same as checking cycle of the
VDR system.

7.3.4 Check and replace of O-ring

Checking periodically the O-ring whether they are aged. The checking and replace of the O-
ring should be taken right after releasing the release mechanism and/or by the special technical
personnel, to ensure the water-tightness of casing after replace. It is recommended to have a
checking according to checking cycle same as of the VDR system.

7.3.5 Checking of fastening screws of installing base

Check periodically the fastening screws of installing base whether they are loose, and make
strengthening treatment. It is recommended to make the checking semi-annually.

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7.3.6 Corrosion-proof and rust-proof treatment of surface of casing

Check periodically the condition of corrosion resistance and rust resistance of the surface of
casing and make corresponding maintenance and treatment. It is possible to coat 3#calcium grease
on the exposed surface of release mechanism, screws and other places where may be exposed

PDU is solid-state equipment without detachable mechanical or electronic components.

If it is ascertained that troubles happen in the PDU, it is necessary to send it to the
appointed maintenance point to be changed or repaired.

7.4 How to replace the PDU?

If the PDU need to be replaced, first disconnect the two water-proof connectors from PDU.
Then loose and take out the four screws mounted to the PDU pedestal and PDU mounting base.
After that, PDU with pedestal is apart from the mounting base.

8. DATA RECOVERY AFTER AN INCIDENT

All damaged Units must be returned to the supplier for download services and assistance. For
Undamaged Units, recorded data can be achieved by downloading via Ethernet and replayed by
the VDR playback software application.

Consilium-Highlander Co., Ltd.

TEL: (＋86－10) 60774939
FAX: (＋86－10) 60773151

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 PDU100 Installation and Operation Manual

Appendix1. Protected Data Unit PDU100 Outlines Drawing

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 PDU100 Installation and Operation Manual

Appendix2. Protected Data Unit PDU100 Installation Drawings

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PDU100 Installation and Operation Manual

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 PDU100 Installation and Operation Manual

Appendix3. Protected Data Unit Junction Box (optional)

Outline and Installation Drawing

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 PDU100 Installation and Operation Manual

Appendix4. Protected Data Unit Connecting Drawing

Consilium-Highlander Co., Ltd. 42

 VDR DATA
ACQUISITION UNIT
MANUAL

VOYAGE DATA RECORDER

Model: HLD-A1

Code HLD12.8 SS
Version V1.0
Date 2005.4

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
 海兰信数据科技
Beijing Highlander Digital Record Technology Co., Ltd.

1. Notes and Updates

Revisions:

Date Version Issued by Description

05-04-08 A1.0 HL Created

2. Where to call in case of problems or faults

Beijing Highlander maintains a call center service at:
Call: （+86）010 60774480/60774481
Fax: （+86）010 60773751
Email: engineer@highlander.com.cn
The Call Center is open during office hours, 09.00 – 17.30, UTC+8.
Please note: Email is the preferred method of communication. Please state the fault or
problem as fully as possible, mentioning all details that could be relevant for solving
the problem.

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

E-mail:market@highlander.com.cn/service@highlander.com.cn www.highlander.com.cn
Tel:+86-10-82678888 Fax:+86-10-82150083
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CONTENTS

1. NOTES AND UPDATES ...................................................................................................................0

2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS ................................................0

3 LETHAL WARNING! .................................................................................................................0

4 FIRST AID IN CASE OF ELECTRIC SHOCK........................................................................0

5 DATA ACQUISITION UNIT (DAU) INSTALLATION .................................................................0

5.1 SELECTION LOCATION...........................................................................................0

5.2 INSTALLATION MATERIALS....................................................................................0
5.2.1 The DAU Components Diagram ................................................................. 0
5.2.2 Installation materials.................................................................................... 0
5.3 MOUNTING PROCEDURE ........................................................................................0
5.3.1 Installation Preparation ................................................................................ 0
5.3.2 Installation method....................................................................................... 0
5.4 CONNECTION .........................................................................................................0
5.4.1 Connection Preparation................................................................................ 0
5.4.2 Cable entry ................................................................................................... 0
5.4.3 Wiring .......................................................................................................... 0
5.4.4 Grounding .................................................................................................... 0
5.4.5 Connect the cable......................................................................................... 0
5.4.6 Fixing ........................................................................................................... 0

6 ACQUISITION MODULES...............................................................................................................0

6.1 ANALOG VOLTAGE MODULE: ...............................................................................0

6.2 ANALOG CURRENT MODULE:................................................................................0
6.3 DRY CONTACT MODULE: ......................................................................................0
6.4 CENTRAL MODULE: ..............................................................................................0
6.5 LOCATION AND CONNECTION ................................................................................0
6.6 REMOVE AN ACQUISITION MODULE FROM THE DAU.............................................0
6.7 SETTINGS ..............................................................................................................0
6.8 HOW TO REPLACE AN ACQUISITION MODULE .........................................................0

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7 ABBREVIATIONS..............................................................................................................................0

8．TECHNICAL SPECIFICATION ...................................................................................................0

APPENDIX 1 —VDR BLOCK DIAGRAM.........................................................................................0

APPENDLX 2—VDR INTERCONNECTION DIAGRAM………………………………………..35

APPENDLX 3 —DAU INSTALLATION DRAWING……………………………………………..36

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APPENDIX 3 —DAU INSTALLATION DRAWING ........................................................................0

APPENDIX 3 —DAU INSTALLATION DRAWING ........................................................................0

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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Tel:+86-10-82678888 Fax:+86-10-82150083
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Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

E-mail: market@highlander.com.cn / service@highlander.com.cn www.highlander.com.cn
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3 Lethal Warning!

Voltages within this equipment are sufficiently high to endanger life.

Covers are not to be removed, except by persons qualified and authorized to do so,
and these persons should always take extreme care once the covers have been
removed.

4 First Aid in Case of Electric Shock

1. Lay victim on his back.
2. Clear victim’s mouth and
throat
3. Tilt victim’s head back as far
as possible and raise his head

4. Pinch victim’s nostrils

5. Take a deep breath
6. Cover the victim’s mouth with
yours and blow, watching his
chest rise.
Note: Blow forcefully into adults,
but gently into children.
7. Move your face away to allow
victim to breathe out,
watching his chest fall.
8. Repeat first five to ten breaths
at rapid rate; thereafter, take
one breath every three to five
seconds.
9. Keep victim’s head back as far
as possible at all times.

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Have someone else send for a doctor, keep patient warm and loosen his clothing
Do not give liquids until the patient is conscious.

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5 Data Acquisition Unit (DAU) Installation

5.1 Selection Location

The mounting location shall fulfill the following conditions:
z Refer to “DAU installation diagram (HLD12.8 AZ), for the mechanical
dimension drawing.
z The location needs to provide adequate space for cabling.
z Cables between the DAU and the VDR should be kept as short as possible.
z The location should not to expose the unit to excessive vibration.
z The location should be far from electrical equipment, e.g. radar transceiver and
radio communication equipment, etc., emitting excessive electric and/or magnetic
field.
z The location should be easily accessible even with the front door opened, for

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operation, maintenance and installation work, etc.

z The grounding cable should be kept as short as possible.
z The location should be protected from weather and offer a stable temperature.

5.2 Installation materials

5.2.1 The DAU Components Diagram

1 3 4 5

Fig1-1 Remote Acquisition Unit Components Diagram

Components List:
Index Name Qty Remarks
1 Data Acquisition Unit 1
2 Lock 2
3 Inner hexagon head bolt 4
4 Anti-loosing washer 4
5 Flat washer 4

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5.2.2 Installation materials

Component Fix Power Supply Box
Index Name Picture Description Qty Remarks
1) Inner hexagon M8×40 4 Mounting bracket
head bolt
2) Flat washer Φ8 4 Mounting bracket

3) Locking Φ8 4 Mounting bracket

washer
4) Crimp-on-plug OT1.5-4 15 Ground

5) Crimp-on-plug H0.5-14 500 Terminals

For Crimp-on-plug, different types may be chosen according to the diameter size of the cable, for
example H1.0××、H1.5××

5.3 Mounting procedure

5.3.1 Installation Preparation

Before mounting the DAU, drill the appropriate mounting holes on the chosen
location. Then fix the mounting bracket to the bulkhead. Mechanical mounting
according to: “Data Acquisition Unit Installation Drawing HLD12.8 AZ”.

5.3.2 Installation method

Erect the DAU box, and the plane which contact ground like the below figure.
Please take care the device and prevent it from damage. Fig1-2

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Fig 1-2
Ensure that the back of the DAU is fixed on the mounting wall; and the mounting
holes align with the ones in the mounting bracket. Then attaches the hex bolts,
locking washers, flat washers to the mounting holes, and loosely screw the bolts
into the mounting bracket.
Tighten the screws.
Connect ground. Use a wire (ship provided dedicated ground wire) binding to the
install bolt and compact it using its nut.

After mounting, the DAU looks like the figure below:

Connect ground

Fig 1-3 DAU mounted

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5.4 Connection

5.4.1 Connection Preparation

Before connecting, please refer to the VDR drawings issued by Highlander or
shipyard containing the VDR system cable diagram. The following are the methods of
connection.
Check the cable gland distribution at the bottom before connecting.
Caution: Before system installation and power connection the engineer must
turn off the external power supply.

Z1 Z2 Z3 Z4

Z5 Z6 Z7 Z8

Fig 1-4 Data Acquisition Unit Gland Distribution

There two kinds of cable glands at the bottom of the DAU unit. They have the same
structure, but different diameter size.

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HEX NUT
HEX NUT

HERMETIC RUB
HERMETIC RUBBER

GLAND BODY GLAND BODY

LOCKSHEATH LOCKSHEATH

LOCKNUT LOCKNUT

CABLE

Fig 1-5 Structure of the gland

Gland Tutorial:
Remove the nut from the gland, and run the cable through locknut , pressurized lock sheath,
gland body, the motherboard of the box ,hermetic rubber, hex nut , one by one;
Put the locknut into the gland body, and screw the nut.
Warning: Unless specially requested, the DAU is supplied with two kinds of glands, see table
below.

Model Cable size applied Number supplied

(cable diameter）
TJM16 φ14-φ16 4
TJM22 Φ20-φ22 4
Cables go through the glands and then connected according to the terminal definition
in “VDR SYSTEM CABLE DIAGRAM”, insert the terminal in to the phoenix socket,
in order to connect with the acquiring module.

5.4.2 Cable entry

Run the cable through the gland into the DAU according to below picture:

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CABLE GLAND
CABLE

Fig1-6 Run the cable through the gland

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5.4.3 Wiring
Cable termination:

200.0
crimp−on plugs
50.0

screen
plastic sheath
Fig 1-7 Cable preparation

1 Firstly, remove about 20 cm of the plastic sheath, in order to expose the

screen layer.
2 Cut off the screen, leaving about 5 cm
3 Strip off 10mm of sheath on each core and fit crimp-on plugs to each
conductor
4 Insert the cable core into the phoenix socket.

5.4.4 Grounding
Use ring terminals for connection to the grounding board at the end of framework.
（Fig1-8）

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FRAMEWORK

GROUNDING BOARD

Fig 1-8

5.4.5 Connect the cable

Connect the phoenix terminals with the phoenix socket of the acquiring module Fig1-
9

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PHOENIX TERMINAL

Fig 1- 9

5.4.6 Fixing
Fix the cable using the provided locations; make sure that the terminal is properly
connected, after that you should adjust the location of the cable, fix the cable using the
clamp. Screw the gland head to fix the nut (Fig 1-10)

CABLE FIXING LOCATIONS

CLAMP

Fig 1-10

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6 Acquisition modules
There are several different acquisition modules available, for example: Analog

Current Input Module, Analog Voltage Input Module and Dry Contact Digital Input

Module, shown in fig 2-1, fig 2-2 and fig 2-3. One Central Module is required for

communication with the acquisition modules, power supply and NMEA output,

shown in fig 2-4.

6.1 Analog Voltage Module:

Fig 2-1 Analog Voltage Module

6.1.1 Technical Specifications

Input channels: -10V~+10V

Input signal number: 4

Input Impedance: >100KΩ

Resolution : 12 bit
Bipolar Offset @ +25℃: <5 bit

Isolation voltage:

Input-Output: 500V DC

Channel-Channel: 500V DC

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Output accuracy: 0.5% Full Scale

Power Consumption: 330mA +5V

50mA +12V/+15V

50mA -12V/-15V

Working Temperature: -20 ~ +70℃

Storage Temperature: -40 ～ +85℃

Note: Output Value (X) and Input Voltage (Y, unit: V ) formula:

Y = (X-2048) / 2048×10；When Y=0V, X=2048.

6.1.2 Terminals diagram

16bit 64 pins
phoenix Europea

6.1.3 Terminals definition:

1 2 3 4 5 6 7 8
CH1+ CH1- NC NC CH2+ CH2- NC NC
9 10 11 12 13 14 15 16
CH3+ CH3- NC NC CH4+ CH4- NC NC

Note:

CHx+: Positive signal input for channel x.

CHx-: Negative signal input for channel x.

NC: No connection.

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6.2 Analog Current Module:

Fig 2-2 Analog Current Module

6.2.1 Technical specification

Input range: 4 ~ +20mA

Input signal number: 4

Input Impedance: 100KΩ

Resolution : 12 bit
Bipolar Offset @ +25℃: <5 bit

Isolation voltage:

Input-Output: 500V DC

Channel-Channel: 500V DC

Output accuracy: 0.5% FS

Power supply: +5V 330mA

+12V/+15V 50mA

-12V/-15V 50mA

Working Temperature: -20℃~ +70℃

Storage Temperature: -40℃~ +85℃

Note: (1) Output Value (X) and Input Voltage (Y, unit: mA) formula:

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Y = (X-2048) / 2048×10 When Y=0mA, X=2048.

(2) The terminals definition same as for Analog Voltage Module.

6.3 Dry Contact Module:

Fig 2-3 Dry Contact Module

6.3.1 Technical specification:

Input Channels: 16

Input Impedance: 150KΩ

Isolation voltage:

Input-Output: 500V DC 1 Min

Output precision: No Error

Power Supply: +5V 15mA

+24V 30mA (16 channels open)

+24V 90mA (16 channels close)

Working Temperature: -20℃~ 70℃

Storage Temperature: -40℃~ 85℃

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6.3.2 Terminals Drawing:

16bit 64 pins
phoenix European

6.3.3 Terminals definition:

1 2 3 4 5 6 7 8 9
GND D15 D14 D13 D12 D11 D10 D9 D8
10 11 12 13 14 15 16 17 18
D7 D6 D5 D4 D3 D2 D1 D0 GND

Note:

(1) GND is input signal common reference of all channels.

(2) Dx: channel x input port..

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6.4 Central Module:

Fig 2-4 Central Board Module

6.4.1 Technical specification:
Power Supply:
DC input: +24V (18~36V)
DC output: +5V/4A, +12V/+15V/0.6A, -12V/-15V/0.6A
Communication protocol:
Input: RS-485, baud rate is 57,600bps (1 start, 2 stop bit, 8 data bits, no verity)
Output: RS-485, baud rate is 19,200bps (1 start, 2 stop bit, 8 data bits, no verity)

The output is a standard IEC 61162-1 sentence.

$VRXDR,type,data,unit,id,....*hh<CR><LF>
Type filed:
D=digital type sensor
G = generic
Unit field is null.
ID field is constructed by the module address and channel number in module
with 4 bytes.
Example sentence:
$VRXDR,G,2047,,0201,G,2054,,0202,G,2051,,0203,G,2050,,0204

$VRXDR,G,2947,,0401,G,2906,,0402,G,2089,,0403,G,3074,,0404

$VRXDR,D,0,,0501,D,0,,0502,D,0,,0503,D,0,,0504

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$VRXDR,D,0,,0505,D,0,,0506,D,0,,0507,D,0,,0508

6.4.2 Terminals definition:

1 2 3 4 5 6 7 8
24V+ 24V- +15/12V -15/-12V VCC GND B A

Note:

(1) Only one Central Board Module can be connected.

(2) All module addresses must be individual otherwise the internal

communication will fail because more than one module will transmit data at

the same time.

(3) All acquiring modules can be configured by the onboard DIP switch.

(4) The DIP switch in the Central Module is for configuring the number of

acquiring modules the controller manages.

When you need to replace an acquiring module, you should set its address correctly

and plug-in the DAU box, nothing else is needed. If you need another kind of

acquiring modules, please contact Beijing Highlander Digital

Recorder co., Ltd.

6.5 Location and connection

Acquiring Modules connect their input signals with phoenix plugs to sockets on

the PCB board.

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ACQUIRING MODULES
INSTALLATION LOCATION

Fig 2-3 Acquiring modules installation location

6.6 Remove an acquisition module from the DAU

Procedure:

z Turn off the DAU power source.

z Please refer to the installation drawings in order to confirm the mounting location

of the acquiring module(s) to be replaced in the framework

z Loosen the fixed cable.

z Disconnect the phoenix plug from the acquiring module.

z Loosen the two mounting bolts of the acquiring module

z Refer to (Fig 2-5) Remove the acquiring module

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FRAMEWORK

SIGNAL ACQUIRING MODULE

MOUNTING BOLTS

Fig 2-5

6.7 Settings

The following method is suitable for configuring the address of an acquiring module.

On the acquiring module, there is a six bit DIP switch, which is used for setting the

physical address of the acquiring module. The preset address of the spare acquiring

module is most likely incorrect. It must be changed before mounting. Set the address

by selecting location for every bit with hand or screwdriver, note that the address

must be the same as the module to be replaced, i.e. the status of two option switches

must be identical.

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Fig 2-6 Address Setting Switch（Analog Voltage Module）

Note: Same procedure for Analog Current Module.

Fig 2-7 Address Setting Switch（Dry Contact Module）

Module allocation inside the cabinet:

As shown in the above picture, the central module locates in the right and the

data acquisition modules are in the left. The address of the central module shall be

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equal or greater than the total number of data acquisition modules. and Normally the

address of each acquisition module shall be serial from 1 to 6 according to the

allocation from right to the left or from left to right inside the cabinet.

Address setting method:

There is one six bits DIP switch on each PCB board, which is used for setting

address of each PCB board. Each bit stands for a bit of a binary address. The highest

significant bit is 6, and the lowest significant bit is 1. when the bit is in on status , it

means data 0, otherwise it means data 1.

Setting address table:

SW1 Setting Board
Hex value
Bit 5 Bit 4 Bit 3 Bit2 Bit1 Bit0 address

off off off off off on 01h 1

off off off off on off 02h 2

off off off off on on 03h 3

off off off on off off 04h 4

off off off on off on 05h 5

off off off on on off 06h 6

off off off on on on 07h 7

off off on off off off 08h 8

6.8 How to replace an acquisition module

After the address has been configured, it may be mounted. Following procedure

should be followed:

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z Push the acquiring module into the socket on the motherboard along the rails.

Note the direction of the module’s components side, and ensure that the

connection between the plug on the module and the socket on the motherboard is

reliable and tight.

z Fix the acquiring module to the by screwing the two mounting bolts into the

module’s bracket and the framework.

z Insert the disconnected Phoenix plug into the socket on the acquiring module.

Ensure they are connected tightly and reliable.

z Fix the front cover to the frame

z Power on the DAU and verify the functionality from the VDR or other means.

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7 Abbreviations

AC Alternating Current
BAU Bridge Alarm Unit
DC Direct Current
EPFS Electronic Position Fixing System
GMDSS Global Maritime Distress and Safety System
IEC International Electro technical Commission
IMO International Maritime Organization
INS Integrated Navigation System
MEE Main Electronics Enclosure
MIC Microphone
NSIU Not-Standard Interface Unit
PDC Protected Data Capsule
DAU Remote Acquisition Unit
ROV Remotely Operated Vehicle
UTC Universal Time Constant
UPS Uninterruptible Power Supply
VDR Voyage Data Recorder

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8．TECHNICAL SPECIFICATION

Mechanical and Electrical Features

Material DIN S185
Weight 12kg excluding cables
Dimensions 260mm L×360 mm H×255mm W
Input Power 24 VDC +/- 10% volts
Power Consumption 30W nominal
Interface with MEE RS422
Format: IEC61162-1 NMEA0183 XDR sentence
Interval of reporting to MEE Whole data set per second
Non-standard signals capacity Available slot number: 2
Combination limitation: No
Max channel number: 8 current/voltage analog
inputs or 16 digital inputs or 32 dry contact
inputs with COM or 2 sync inputs or 6 stepper
inputs
Analog input Input channels: 4
Input interface: 0+/-10V; 4-20mA
A/D bits: 12
Isolation voltage: input ~ output and channel ~
channel 500VDC 1 minute
Channel isolation degree: 80dB
Input resistance: >100K
Sampling accuracy: 0.5%
Digital input Input channels: 16 per module with COM
Isolation voltage: input ~ output 500VDC 1
minute
Input resistance: >100K
Dry contact input Input channels: 16 per module with COM
Isolation voltage: input ~ output 500VDC 1
minute
Input resistance: >100K
Environmental Technical Data
Dry Heat 55°Cstorage and working
Damp Heat 40 °C and 93% humidity storage and working
Low Temperature -15 °C storage and working
Vibrations 2-5 to 13.2 Hz +/-1mm, 13.2-100Hz @7m/s/s
Enclosure Protection IP22
EMI/EMC Per IEC 60945 4.0 edition 2002-08:
Conducted emissions/interferences
Radiated emissions/interferences:
Electromagnetic radio frequency interference

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Compass Safe Distance 340 cm from the ship’s standard compass and
360 cm from the steering, standby and
emergency compass
Regulatory Specifications IEC 61996 first edition 2000-07, IEC 60945
ed4.0, IMO A.861(20)

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Appendix 1 —VDR BLOCK DIAGRAM

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Appendix 2—VDR INTERCONNECTION DIAGRAM

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Appendix 3 —DAU INSTALLATION DRAWING

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Beijing Highlander Digital Record Technology Co. Ltd. 37

INSTALLATION
MANUAL
（POWER SUPPLY UNIT 3）

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD12.7 AZ
Version V1.0
Date 2005.4

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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IMPORTANT!
注意!
SAFETY安INFORMATION
全 提 示
Be sure to read all the safety information
仔细阅读安装手册内容后方可对 which follows
HLD-F 型船载航行
before attempting to operate this equipment.
数据记录仪电源进行操作!

General Safety Information

“DANGER”, “WARNING”, and “CAUTION” notices appear inside the equipment. It

is the responsibility of the person who conducts the installation and commissioning
tasks to read, understand and follow the instructions contained in this manual. If you
have any questions regarding these safety instructions, please contact a
HIGHLANDER expert.

Hazardous Voltages

This equipment uses 220VAC (or 110VAC) voltage electricity that can SHOCK,
BURN or cause DEATH.
Always make sure the electrical power is turned off before attempting to change a
component or inspecting the inside of the equipment. A residual charge may exist in
capacitors, even with the equipment turned off. Always short all supply lines to the
chassis with an insulated screwdriver or a similar tool before touching the circuit.

Installation and Commissioning Precautions

The installation should be done strictly confirming to the instructions contained in this
manual. The system cannot be powered on until the cabling inspection has been done
by a Highlander certified engineer.

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CONTENTS

1. MOUNTING POWER SUPPLY UNIT .................................................................4

1.1 LOCATION SELECTION...........................................................................................4
1.2 INSTALLATION MATERIALS....................................................................................4
1.2.1 The Power Supply Unit decomposer diagram ..............................................4
1.2.2 Installation materials.....................................................................................5
1.3 MOUNTING PROCEDURE ........................................................................................5
1.3.1 Installation Preparation .................................................................................5
1.3.2 Installation method........................................................................................5
1.4. CONNECTION........................................................................................................6
1.4.1 Connection Preparation.................................................................................6
1.4.2 Power supply cable connections ...................................................................8
1.4.3 Power supply cable connections .................................................................11
1.5 CHECK ................................................................................................................12

2 HOW TO REPLACE BATTERIES......................................................................12

2.1 WHEN REPLACE THE BATTERIES? ........................................................................12
2.2 REPLACEMENT PROCEDURE.................................................................................13
2.3 CAUTION .............................................................................................................13
2.4 ROUTE MAINTENANCE ........................................................................................14

3. ACRONYMS AND ABBREVIATIONS..............................................................14

APPENDIX 1 – SYSTEM BLOCK DIAGRAM .....................................................15

APPENDIX 2 –HLD-A VDR POWER UNIT OUTLINE AND INSTALLATION

DRAWING (HLD02.7 AZ) .......................................................................................16

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1. Mounting Power Supply Unit

1.1 Location Selection
The mounting location shall be satisfied with the following conditions:
z Installation position chosen refer to “the Power Unit outline and installation
drawing”
z The location should be suitable for leading the cables necessary for connection in
the vicinity of Switchboard on the ship
z The location should not to expose the unit to excessive vibration.
z The location should be far from electrical equipment, e.g. radar transceiver and
radio communication equipment, etc., emitting excessive electric and/or magnetic
field.
z The location should be easily accessible with opening front door, for operations,
data backup, maintenance and installation work, and so on.
z The location should be given a grounding terminal as short as possible.
z The location should be protected from weather and offer a stable temperature.

1.2 Installation materials

1.2.1 The Power Supply Unit decomposer diagram shown below:

1
3 4 5

Fig 1-1 Power Supply Unit decomposer

Parts list:
Code Name Qty remark

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1 Power Supply Unit 1

2 Lock 2
3 Inner hexagon head bolt 4
4 Anti-loosing washer 4
5 Flat washer 4

1.2.2 Installation materials

Installing materials For the Power Unit

No. Name Outline Descriptions Qty Remarks
1
Inner hexagon M8×40 4 Mounting bracket
head bolt
2
Flat washer Φ8 4 Mounting bracket

3
Anti-loosing Φ8 4 Mounting bracket
washer
4
Crimp-on-lug OT1.5-4 15 Ground

5
Crimp-on-lug H0.5-14 50 Terminals

For Crimp-on-plug, different types may be chosen according to diameter size of cable,
for example H1.0－××、H1.5－××

1.3 Mounting procedure

1.3.1 Installation Preparation

Before mounting the Power Unit, drill the appropriate mounting holes on the chosen
location. Then fix the mounting bracket to the bulkhead. Mounting sized to “the
Power Unit outline and installation drawing”

1.3.2 Installation method

Erect the PSU3 box, and the plane which contact ground like below figure. Please
care the device, prevent it from damage. (Figure 1-2)

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Figure 1-2
Ensure that back of the Power Unit fixed on the mounting wall; and the mounting
holes aim at ones in the mounting bracket. Then attaches the hex bolts, spring
washers, flat washers to the mounting holes, and loosely screw the bolts into the
mounting bracket.
Tighten the screws.
Connect ground. Utilize a wire (ship provided dedicated ground wire) binding to
an install bolt and compact it using its nut.

After complete the mounting, the PSU3 like the below figure.

Ground wire

Fig 1-3.The finished Power Unit mounting drawing

1.4. Connection

1.4.1 Connection Preparation

Before connecting, please refer to VDR work drawings which are issued by shipyard
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and contain the VDR system cable diagram. The following are the methods of
connection.
It is necessary to make clear the collocation of cable glands at the bottoms before
connecting.
Caution: Before system install and electrical connecting, the engineer must cut
off the external power supply. (This action will make no any currents pass by the
VDR)

Z3 Z2 Z1
signal output Power output Power input

Fig 1-4 Cable glands collocation diagram

There are several kinds of cable glands at the bottom used for the PSU3 unit. They
have the same structure, but different diameter size.

HEX NUT
HEX NUT

HERMETIC RUB
HERMETIC RUBBER

GLAND BODY GLAND BODY

LOCKSHEATH LOCKSHEATH

LOCKNUT LOCKNUT

CABLE

Fig 1-5 Cable gland decomposer and lead cable through cable gland

Methods of leading the cable through cable glands

Remove the nut from the gland, and drill the cable through locknut , pressurized
locksheath ,gland body, the motherboard of the box ,hermetic rubber, hex nut , one
by one;

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Put the locknut into the gland body, and screw the nut.

Warning: Unless special request, mother board is designed to supply two kinds of gland, and
you can refer to the table below for what kind of cable they apply to .Outer diameter of the
cable should be in suitable range as connecting the cable.

Model Cable diameter QTY.

GLB-14A φ10-φ14 1
GLB-18A Φ13-φ18 2
The power supply cable and the signal output cable connects with terminals module
through the cable gland. The terminals definitions like below table description.
Terminal No. Sign Description Remark
1 ACG
2 N
3 L
4 24V- Output for VDR
5 24V+ Output for VDR
6 RXD TX3
7 TXD RX3
8 DSR 0V
9 CTS +12V

1.4.2 Power supply cable connections

z Refer to below figure, and using the 220V AC power supply cable drills through
the Z1 gland into inside of the PSU3 box body. And put 24V DC power supply
cable drills through the Z2 gland into inside of the PSU3 box body.

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220V AC
24V DC

Fig 1-6 Power cable gland and terminal board collocation diagram
• Wiring
Power cables interconnect with switchboard and Power Supply Unit (220VAC), Main

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Electronics Enclosure and Power Supply Unit (24VDC).

Fabricate the cable as shown below

200.0
crimp−on lugs
50.0

armor
anti−corrositive sheath
power cable from the switchboard

Fig1-7 AC Power cable

200.0

50.0 crimp−on lugs

armor
anti−corrositive sheath
power cable from the MEE

Fig1-8 DC Power cable

a) Remove the anti-corrective sheath by about 200mm
b) Cut off the armor, leaving 50mm
c) Strip off the sheath of each core by 10mm,and fit crimp-on lugs to each
conductor
d) Mark the cores for future identification.
Cautions: AC power supply cable wants to peel 3 conduct wires’ skin whereas
DC power supply cable save that 2 conduct wires to be proceeded.
Connections
Referring to the connect diagram shown below. Inner connection of power cable is
finished by manufacturer, so terminal definition of terminal board is decided by
Manufacturer, the definition of conductors of cable should consider cable connection
of other end at Power Unit. Ascertain that each conductor of cable should be
connected to which terminal clip on terminal board.
Finally connecting conductors of the cable to the relevant terminals clips
Procedure of cable connection to the terminal board:
1) Using a screwdriver to insert the socket, and push the“α”elastic part down.

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2) Putting the cable core into the socket.

3) Release the“α”elastic part, thus the cable core will be hold by it.

Flat screwdriver

Fig 1-9 Power cable inner connect and method

1.4.3 Power supply cable connections

The signal output cable is used for connecting the PSU3 with the MEE.
The signal output cable traverse the MEE bottom (Z3 cable gland), and directly
connect to the terminals module inside of the MEE.
• Wiring
The engineers should first measures a distance between the PSU3 install position with
the MEE install position, and determine the length of a connection cable.
Fabricate the cable as shown below
200.0
CRIMP-ON LUGS
50.0

ARMOR
ANTI-CORROSITIVE SHEATH
SIGNAL CABLE FROM THE MEE

Fig1-10 Signal cable

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e) Remove the anti-corrective sheath by about 200mm

f) Cut off the armor, leaving 50mm
g) Strip off the sheath of each core by 10mm,and fit crimp-on lugs to each
conductor
h) Mark the cores for future identification.
Connection
Before connecting, please refer to VDR work drawings which are issued by shipyard
and contain the VDR system cable diagram.

1.5 Check
After the installation of Power Unit, check against the following way:
Check if the mounting screws tighten.
According to system cable diagram and work drawing, check if the connection is
right and reliable.
Check if grand terminal of the enclosure is connected to ship’s deck

2 How to replace batteries

2.1 When replace the batteries?
The battery age is a maximum of 3 years from the date leaving factory. And this age
is based on ambient operating temperature 25°C, and 70% load.
When exceeding the maximum age, replacing the batteries is necessary.

Battery
Main body
Working-limit block

Flat washer M4
Anti-loosing washer M4
Inner hexagon head bolt M4X10

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Fig2-1 Remove batteries

2.2 Replacement procedure

Open the door of the Power Unit.
Shut off the power switch.； (Fig2-1)
Remove the mounting bolts, Anti-loosing washer and flat washers from the cover
board;
Remove the cover board, and take out the two batteries; (Fig2-2)
Remove the connection from the terminals of two batteries. Pay attention, do not
cause short circuit. (Fig2-2)

+
-
+
-

Fig2-2
Place the two new batteries and referring to connection diagram Fig 2-2, connect
the two batteries, and note the polarity of the terminals. Avoid causing short circuit
or anti-connection.
Attach the cover board to the batteries; screw the mounting bolts, Anti-loosing
washer and flat washers into the cover board.

2.3 Caution
Do not dispose of batteries in a fire. The batteries may explode.
Do not open or mutilate batteries. They contain an electrolyte which is toxic and
harmful to the skin and eyes.
To avoid personal injury due to energy hazard, remove wrist watch and jewelry
such as rings when replacing the batteries. Use tools with insulated handles.
Replace the batteries with the same number and same or similar type of batteries as

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originally installed in the equipment

Batteries must be recycled. Deliver the battery to an appropriate recycling facility
or ship it to the supplier.

2.4 Route Maintenance

The UPS battery’s capability and batteries’ change date must be checked yearly by a
service engineer. If lower battery is detected periodically prior to the expiration date,
it should be replaced at once. Otherwise the UPS battery should be replaced at least 3
month prior to the expiration date.

3. Acronyms and abbreviations

AC Alternating Current
BAU Bridge Alarm Unit
CJB Connecting Junction Box
DC Direct Current
EPFS Electronic Position Fixing System
GMDSS Global Maritime Distress and Safety System
IEC International Electrotechnical Commission
IMO International Maritime Organization
INS Integrated Navigation System
MEE Main Electronics Enclosure
MIC Microphone Assembly
NSIU Non-Standard Interface Unit
PDC Protected Data Capsule
RAU Remote Acquisition Unit
ROV Remotely Operated Vehicle
UTC Universal Time Constant
UPS Uninterruptible Power Supply
VDR Voyage Data Recorder
VESA DMTS Video Electronics Standards Association Display Monitor
Timing Specification

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Appendix 1 – System Block Diagram

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Appendix 2 –HLD-A VDR Power Unit Outline And

Installation drawing
(HLD02.7 AZ)

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MAINTENANCE
MANUAL
（POWER SUPPLY UNIT 3）

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD12.7 WC
Version V1.0
Date 2006.2

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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1 Notes and Updates
Revisions:
Date Versio Issued by Description
n
06-02-11 A1.0 LCW Created

1 Where to call in case of problems or faults

Beijing Highlander Corporation maintains a call center service at:

Call: +86 10 821 588 88 Email: market@highlander.com.cn

Fax: +86 10 821 500 83

The Call Center is open during office hours, 08.30 – 17.30, UTC+8.

Please note: Email is the preferred method of communication. Please state the fault or problem
as fully as possible, mentioning all details that could be relevant for solving the problem

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CONTENTS

1. NOTES AND UPDATES ...................................................................................................................... 0

2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS ........................................................ 0

3. LETHAL WARNING!.......................................................................................................................... 0

4. FIRST AID IN CASE OF ELECTRIC SHOCK ................................................................................ 0

5. OVERVIEW OF THIS MANUAL ...................................................................................................... 0

5.1. General Information .........................................................................................................0

5.2. Notes on Connections and EMI ............................................................................................... 0

6. POWER SUPPLY UNIT 707400 ......................................................................................................... 0

6.1. Principle of operation .......................................................................................................0

6.2. Block diagram....................................................................................................................0

6.3. Technical Data ............................................................................................................................. 0

7. INSTALLATION .................................................................................................................................. 0

7.1. Cabling Between Main Unit and Power Supply Unit ....................................................0

7.2. Selecting Location .............................................................................................................0

7.3. Mechanical Mounting .......................................................................................................0

7.4. Start up ......................................................................................................................................... 0

8. LIST OF SPARE PARTS ..................................................................................................................... 0

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2 Lethal Warning!

Voltages within this equipment are sufficiently high to endanger life.

Covers are not to be removed, except by persons qualified and authorized to do so, and these
persons should always take extreme care once the covers have been removed.

3 First Aid in Case of Electric Shock

1. Lay victim on his back.
2. Clear victim’s mouth and throat
3. Tilt victim’s head back as far as possible
and raise his head

4. Pinch victim’s nostrils

5. Take a deep breath
6. Cover the victim’s mouth with yours
and blow, watching his chest rise.
Note: Blow forcefully into adults, but gently
into children.
7. Move your face away to allow victim to
breathe out, watching his chest fall.
8. Repeat first five to ten breaths at rapid
rate; thereafter, take one breath every
three to five seconds.
9. Keep victim’s head back as far as
possible at all times.

Have someone else send for a doctor, keep patient warm and loosen his clothing

Do not give liquids until the patient is conscious.

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4 Overview of this Manual

The Installation Manual is intended for use by an authorized installation company. It contains
general information for installation of hardware and wiring of the power supply unit. The PSU3
has built-in battery back-up for operations during mains outages.

It also contains notes on installation specifics, and how to protect the equipment from
Electromagnetic Interference (which is an installation issue). Also, carefully read and understand
the “General Notes on Cables and Connections” chapter of the "VDR Installation Manual" before
you select cable material for the installation. Using the wrong cable may harm the long-term
stability of the installation, introduce noise on the data and sound channels, and in serious cases,
void the warranty.

4.1 General Information

A drawing of the Power Supply Unit can be found in the “Mechanical Drawings” chapter.

4.2 Notes on Connections and EMI

The door edges of the Power Supply Unit are fitted with an EMI seal, protecting the unit from
external radiation, and protecting sensitive equipment like VHF receivers from high frequency
emissions from the unit. Always check the seal for dents or rips and replace a faulty seal. Failure to
do so may harm the long-term stability of the unit and add unwanted noise to communications
channels.

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5 Power Supply Unit 707400

Batteries

Charger Unit

Connection
Terminal

Filter

5.1 Principle of operation

The PSU3 provides the function of providing continuous nominal 24 VDC power to the
VDR during normal operation and mains failure.

The system is a so called direct power system, i.e., the rectifiers provide power to the load
(VDR) while charging the batteries.

The unit is equipped with an alarm interface, RS232, which communicates with the VDR.
The back-up power is provided by valve-regulated batteries and is dimensioned to operate at
minimum 2 hours.

Alarms are sent to the VDR when and if:

− The AC mains fail

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− The battery breaker is tripped. The breaker is supervised via an auxiliary switch placed
together with the breaker. (NOTE! On early models the auxiliary switch is triggered only
when the breaker is tripped by over current)

− The battery voltage is to low, <20V.

Two minutes after shut down command from the VDR the PSU3 is shut down, during this
time the PSU3 is sending information to the VDR that the PSU3 will be shut down.

If battery voltage is below 19 V the PSU3 is also shut down.

The PSU3 is housed in an IP44, splash proof, cabinet, which is intended to be mounted on a
wall. Only front access is required to operate the PSU3.

5.2 Block diagram

+ - + -

BATTERY1 J3
BATTERY2
7 5

- + - +
9 11 1 2 3
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J1
PE

DC AC
FILTER FILTER

PSU 14 15 13 16
BOARD

CTS DSR TxD RxD J4

9 8 7 6 5 4 3 2 1

Z2 Z1 Z3
RS232 DC out AC in
PSU3
Block Diagram 7 6 4 + 19 -
5 L N ACG
DCU in MU
HLD-A2 VDR or Marine AC Emergency
HLD-S SVDR Switchboard

This block diagram shows the general layout of the system.

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5.3 Technical Data

5.3.1 Mechanical
The PSU3 is housed in an IP44, splash-proof cabinet with dimensions H=500 mm, W= 380mm
and D=210 mm. All cabling is via cable glands in the bottom plate of the cabinet. Weight is 36 kg.

Mounting dimensions, etc are shown below:

GROUND STUD CABLE GLANDS

M20 (1x)
M25 (2x)

Screw M8

Washer

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5.3.2 Power input
Voltage 85－265 VAC

Frequency 47-63 Hz

Max current at lowest voltage 5 A rms

Max inrush current <35 A <5 ms

Input fusing T10 AH in input screw terminals

Rectifier is also protected by internal T10A fuse
5.3.3 Power outputs
Output voltage 19 – 27.2 VDC
AC OFF (Battery operation) 19 – 24.5 VDC
AC ON (Battery charging) 24 – 27.2 VDC

Output current 10 A max

7 A max continuous

Battery fuse 10 A fuse, inrush current 35A.

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5.3.3.1 Alarms and indications

Communications interface unit

Interface RS232 speed 1200, N, 8.2

VDR requests status by sending 09h, 00h, 01h, 5Fh

PSU3 responds by sending status byte and a checksum

Bit representation
00 AC Failure
01 Shutdown pending
05 Battery Breaker Alarm
07 Battery low

The checksum is calculated as follows:

Status byte +55h
Example:
Status byte=00h
PSU3 sends 00h,55h

Shut down command from VDR 09h,00h,11h,6Fh

Disconnects the Output Voltage from PSU3 after 2
minutes

Output Voltage returns when AC input is switched

OFF and ON again.

Battery low <20 VDC

Battery off <19 VDC

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5.3.4 Battery specification
Type NP-12 24AH

Manufacturer China East Company in Yang Zhou, Jiangshu Province..

Voltage 12 V per block

Expected life 3-5 years at 20oC

Capacity 24 Ah, dimensioned to provide min. 2 hours back-up

5.3.5 Environmental specifications

According to requirements in IEC 60945, class Protected IP44

5.3.6 EMC specifications

According to requirements in IEC 60945, class Protected

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6 Installation
6.1 Cabling Between Main Unit and Power Supply Unit
General Information
• Two cables, with a maximum length of 10 m shall be used to interconnect these units.

• The power supply cable should consist of two stranded 6-mm² wires for powering the VDR.

• The other cable serves as the data link between the two units.

• It is possible to use longer cables, up to 30 m, but in such situations the loop resistance should
be kept low by increasing the copper cross section to 10 mm² for the power cable.

• All cabling to the Unit should be brought through the cable glands in the bottom of the cabinet.
Shields shall be grounded in the PSU3 (cable glands).

• All cables shall be connected to the screw terminal blocks inside the cabinet see fig below

• It is important to have a solid ground connection between the case of the unit (the grounding
bolt) and the hull structure

List of connections
Terminal PE Protective
Terminal 1 AC in Ground ――>Marine AC Emergency Switchboard
Terminal 2 AC in N ――> Marine AC Emergency Switchboard
Terminal 3 AC in L ――> Marine AC Emergency Switchboard
Terminal 4 DC out－ -- (Cathode) ―――>DCU 19 lower Column
Terminal 5 DC out + + (Anode) ―――>DCU 19 Upper Column
Terminal 6 RS232 RxD ----> VDR TXD ―――>DCU 5
Terminal 7 RS232 TxD ----> VDR RXD ―――>DCU 4
Terminal 8 RS232 DSR ----> VDR 0V ―――>DCU 6
Terminal 9 RS232 CTS ----> VDR +12V ―――>DCU 7

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Inter-connections

Cabling between Main Unit (right) and Power Supply Unit (left) and ship’s
115/230 VAC supply

PSU3 DCU
Cable Type: Two twisted pairs with common screen
terminal # terminal #
6 5 Control PSU3 -> VDR Note: DCU 5 (Rxd) should connect to PSU3 6
7 4 Control +5 V
8 6 Control GND
9 7 Control VDR -> PSU3 / Note: DCU 7 (Txd) should connect to PSU3 9

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PSU3 Main Unit terminal # Cable Type: Two stranded 6 mm2 conductors
terminal #
4 DCU 19 Lower Column (-) 24 V return. If possible use black wire
5 DCU 19 Lower Column (+) 24 V positive. If possible use red wire

PSU3 Ship’s Power Cable Type : Three stranded 1,5 mm2 conductors,
terminal # brown, blue and yellow/green
1 Earth PSU3 -> ship’s earth ground. Use yellow-green
wire
2 115/230 VAC PSU3 live or neutral -> Ship’s 115/230 VAC
supply
3 85－265 VAC PSU3 neutral or live -> Ship’s 85－265 VAC
supply

Identifying Wires
• The control wires (#6, 7, 8and 9) will have to be identified by inspection.

• Powering up the Power Supply Unit and checking the polarity can identify the DC wires.

• The 85－265 VAC wires must use the standardized colors to avoid any conflicts in
identification.

Short-Circuit Warning!
Be careful to avoid shorting the DC power output and remember that the Power Supply
Unit will feed power on the #4 and #5 terminals from the batteries, even without AC input.

High Voltage Warning!

265 volts alternating current exists inside the Power Supply Unit on exposed terminals. Do
not open the unit if you are not properly qualified.

Notes on connections and EMI

See also the “General Notes on EMI, Cables and Connections” chapter of the "VDR
Installation Manual".

6.2 Selecting Location

Recommended conditions for the chosen location of the cabinet are listed below:

• The cabinet shall be bolted to a bulkhead in a location where necessary cabling from bridge
equipment can be brought to the unit, preferably close to the bridge.

• The location shall be protected from weather and shall offer a stable temperature.

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• The location shall not expose the unit to excessive vibration levels.

• The location shall be far from electrical installations giving excessive electric and/or magnetic
fields.

• The cabinet shall be easily accessible and it should be mounted in such a way that the built-in
LCD touch-screen display can be easily operated, for making back-up copies, performing
configuration changes etc.

• The Power Supply Unit bottom shall be placed approximately 1,2 m from the floor where
practical.

• The standard cable length between PSU3 and Main Unit is 10 m.

6.3 Mechanical Mounting

The cabinet shall be mounted to a flat surface on the bulkhead using 8-mm steel bolts.
A dimensional drawing can be found in the “Technical Data” chapter.

6.4 Start up
6.4.1 Power up
Connect 85－265VAC to the system.

The red LED1 in the Battery Charger and the red LED3 on the PCB shall have fixed light.

Before start testing let the PSU3 run for at least 15 minutes.

To power down the PSU3 switch OFF the AC input and then press the switch marked Battey
OFF on the PCB for at least 3 seconds.

6.4.2 Testing
There is no mains switch in the PSU3 so for switching the AC power ON and OFF use the input
fuses on terminals 2 and 3 which can easily be taken out.

Test 1. Switch OFF the AC power as described above, the red LED1 in the Battery Charge shall
remain with fixed light. The red LED3 shall have fixed light all the way.

Test 2. Connect the AC power again and check that red LED1 have fixed light.

7 List of Spare Parts

Description Part number
Fuse
5 pc 10 A 250 V 5*20 F4, F5, F6, F7, F9

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INSTALLATION
MANUAL
(POWER SUPPLY UNIT 24)

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04.7 AZ
Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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IMPORTANT!
注意!
SAFETY安INFORMATION
全 提 示
Be sure to read all the safety information
仔细阅读安装手册内容后方可对 which follows
HLD-F 型船载航行
before attempting to operate this equipment.
数据记录仪电源进行操作!

General Safety Information

“DANGER”, “WARNING”, and “CAUTION” notices appear inside the equipment. It

is the responsibility of the person who conducts the installation and commissioning
tasks to read, understand and follow the instructions contained in this manual. If you
have any questions regarding these safety instructions, please contact a
HIGHLANDER expert.

Hazardous Voltages

This equipment uses 220VAC (or 110VAC) voltage electricity that can SHOCK,
BURN or cause DEATH.
Always make sure the electrical power is turned off before attempting to change a
component or inspecting the inside of the equipment. A residual charge may exist in
capacitors, even with the equipment turned off. Always short all supply lines to the
chassis with an insulated screwdriver or a similar tool before touching the circuit.

Installation and Commissioning Precautions

The installation should be done strictly confirming to the instructions contained in this
manual. The system cannot be powered on until the cabling inspection has been done
by a Highlander certified engineer.

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CONTENTS

1. MOUNTING POWER SUPPLY UNIT .........................................................4

1.1 LOCATION SELECTION ........................................................................4
1.2 INSTALLATION MATERIALS .................................................................4
1.2.1 THE POWER SUPPLY UNIT DECOMPOSER DIAGRAM .........................4
1.2.2 INSTALLATION MATERIALS ..............................................................5
1.3 MOUNTING PROCEDURE ......................................................................6
1.3.1 INSTALLATION PREPARATION ..........................................................6
1.3.2 INSTALLATION METHOD ...................................................................6
1.4. CONNECTION .....................................................................................7
1.4.1 CONNECTION PREPARATION ............................................................7
1.4.2 POWER SUPPLY CABLE CONNECTIONS ..............................................9
1.4.3 POWER SUPPLY CABLE CONNECTIONS ............................................12
1.5 CHECK ..............................................................................................13
2 HOW TO REPLACE BATTERIES...............................................................13
2.1 WHEN REPLACE THE BATTERIES?......................................................13
2.2 REPLACEMENT PROCEDURE ..............................................................14
2.3 CAUTION...........................................................................................15
2.4 ROUTE MAINTENANCE......................................................................16
3. ACRONYMS AND ABBREVIATIONS .......................................................16
APPENDIX 1 – SYSTEM BLOCK DIAGRAM ...............................................17
APPENDIX 2 –HLD-A VDR POWER UNIT OUTLINE AND INSTALLATION
DRAWING (HLD02.7 AZ) .......................................................................18

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1. Mounting Power Supply Unit 24

1.1 Location Selection
The mounting location shall be satisfied with the following conditions:
z Installation position chosen refer to “the Power Unit 24 outline and installation
drawing”
z The location should be suitable for leading the cables necessary for connection in
the vicinity of Switchboard on the ship
z The location should not to expose the unit to excessive vibration.
z The location should be far from electrical equipment, e.g. radar transceiver and
radio communication equipment, etc., emitting excessive electric and/or magnetic
field.
z The location should be easily accessible with opening front door, for operations,
data backup, maintenance and installation work, and so on.
z The location should be given a grounding terminal as short as possible.
z The location should be protected from weather and offer a stable temperature.

1.2 Installation materials

1.2.1 The Power Supply Unit decomposer diagram shown below:

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1
3 4 5

Fig 1-1 Power Supply Unit 24 decomposer

Parts list:
Code Name Qty remark
1 Power Supply Unit 24 1
2 Lock 2
3 Inner hexagon head bolt 4
4 Anti-loosing washer 4
5 Flat washer 4

1.2.2 Installation materials

Installing materials For the Power Unit

No. Name Outline Descriptions Qty Remarks
1
Inner hexagon M8×40 4 Mounting bracket
head bolt

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2
Flat washer Φ8 4 Mounting bracket

3
Anti-loosing Φ8 4 Mounting bracket
washer
4
Crimp-on-lug OT1.5-4 15 Ground

5
Crimp-on-lug H0.5-14 50 Terminals

For Crimp-on-plug, different types may be chosen according to diameter size of cable,
for example H1.0－××、H1.5－××

1.3 Mounting procedure

1.3.1 Installation Preparation

Before mounting the Power Unit, drill the appropriate mounting holes on the chosen
location. Then fix the mounting bracket to the bulkhead. Mounting sized to “the
Power Unit outline and installation drawing”

1.3.2 Installation method

Erect the PSU box, and the plane which contact ground like below figure. Please
care the device, prevent it from damage. (Figure 1-2)

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Figure 1-2
Ensure that back of the Power Unit fixed on the mounting wall; and the mounting
holes aim at ones in the mounting bracket. Then attaches the hex bolts, spring
washers, flat washers to the mounting holes, and loosely screw the bolts into the
mounting bracket.
Tighten the screws.
Connect ground. Utilize a wire (ship provided dedicated ground wire) binding to
an install bolt and compact it using its nut.

After complete the mounting, the PSU like the below figure.

Ground wire

Fig 1-3.The finished Power Unit mounting drawing

1.4. Connection

1.4.1 Connection Preparation

Before connecting, please refer to VDR work drawings which are issued by shipyard
and contain the VDR system cable diagram. The following are the methods of
connection.
It is necessary to make clear the collocation of cable glands at the bottoms before
connecting.
Caution: Before system install and electrical connecting, the engineer must cut
off the external power supply. (This action will make no any currents pass by the
VDR)

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Z3 Z2 Z1
signal output Power output Power input

Grounding

Fig 1-4 Cable glands collocation diagram

There are several kinds of cable glands at the bottom used for the PSU unit. They
have the same structure, but different diameter size.
HEX NUT
HEX NUT

HERMETIC RUBBER
HERMETIC RUBBER

GLAND BODY GLAND BODY

LOCKSHEATH LOCKSHEATH

LOCKNUT LOCKNUT

CABLE

Fig 1-5 Cable gland decomposer and lead cable through cable gland

Methods of leading the cable through cable glands

Remove the nut from the gland, and drill the cable through locknut , pressurized
locksheath ,gland body, the motherboard of the box ,hermetic rubber, hex nut , one
by one;
Put the locknut into the gland body, and screw the nut.

Warning: Unless special request, mother board is designed to supply two kinds of gland, and

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you can refer to the table below for what kind of cable they apply to .Outer diameter of the
cable should be in suitable range as connecting the cable.

Model Cable diameter QTY.

GLB-14A φ10-φ14 1
GLB-18A Φ13-φ18 2
The power supply cable and the signal output cable connects with terminals module
through the cable gland. The terminals definitions like below table description.
Terminal No. Sign Description Remark
G Shield Shield
8 24V In - Input cathode
9 24V In + Input anode
1 24V- DCU 19 Lower Column
2 24V+ DCU 19 Upper Column
4 RXD DCU 5 (TxPSU)
5 TXD DCU 4 (RxPSU)
6 DSR DCU 6 (GND PSU)
7 CTS DCU 7 (+5V PSU)

1.4.2 Power supply cable connections

z Refer to below figure, and using the 24V DC power supply cable drills through
the Z1 gland into inside of the PSU 24 box body. And put 24V DC power supply
cable drills through the Z2 gland into inside of the PSU24 box body.

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Control DC Output DC Input

Signals

Fig 1-6 Power cable gland and terminal board collocation diagram
• Wiring
Power cables interconnect with switchboard and Power Supply Unit 24 (24VDC),

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Main Electronics Enclosure and Power Supply Unit (24VDC).

Fabricate the cable as shown below

200.0
crimp−on lugs
50.0

armor
anti−corrositive sheath
power cable from the switchboard

Fig1-7 DC Power In cable

200.0

50.0 crimp−on lugs

armor
anti−corrositive sheath
power cable from the MEE

Fig1-8 DC Power Out cable

a) Remove the anti-corrective sheath by about 200mm
b) Cut off the armor, leaving 50mm
c) Strip off the sheath of each core by 10mm,and fit crimp-on lugs to each
conductor
d) Mark the cores for future identification.
Cautions: DC power supply cable wants to peel 3 conduct wires’ skin whereas
DC power supply cable save that 2 conduct wires to be proceeded.
Connections
Referring to the connect diagram shown below. Inner connection of power cable is
finished by manufacturer, so terminal definition of terminal board is decided by
Manufacturer, the definition of conductors of cable should consider cable connection
of other end at Power Unit. Ascertain that each conductor of cable should be
connected to which terminal clip on terminal board.
Finally connecting conductors of the cable to the relevant terminals clips

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Procedure of cable connection to the terminal board:

1) Using a screwdriver to insert the socket, and push the“α”elastic part down.
2) Putting the cable core into the socket.
3) Release the“α”elastic part, thus the cable core will be hold by it.

Fig 1-9 Power cable inner connect and method

1.4.3 Power supply cable connections

The signal output cable is used for connecting the PSU24 with the MEE.
The signal output cable traverse the MEE bottom (Z3 cable gland), and directly
connect to the terminals module inside of the MEE.
• Wiring
The engineers should first measures a distance between the PSU install position with
the MEE install position, and determine the length of a connection cable.
Fabricate the cable as shown below
200.0
CRIMP-ON LUGS
50.0

ARMOR
ANTI-CORROSITIVE SHEATH
SIGNAL CABLE FROM THE MEE

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Fig1-10 Signal cable

e) Remove the anti-corrective sheath by about 200mm
f) Cut off the armor, leaving 50mm
g) Strip off the sheath of each core by 10mm,and fit crimp-on lugs to each
conductor
h) Mark the cores for future identification.
Connection
Before connecting, please refer to VDR work drawings which are issued by shipyard
and contain the VDR system cable diagram.

1.5 Check
After the installation of Power Unit, check against the following way:
Check if the mounting screws tighten.
According to system cable diagram and work drawing, check if the connection is
right and reliable.
Check if grand terminal of the enclosure is connected to ship’s deck

2 How to replace batteries

2.1 When replace the batteries?
The battery age is a maximum of 3 years from the date leaving factory. And this age
is based on ambient operating temperature 25°C, and 70% load.
When exceeding the maximum age, replacing the batteries is necessary.

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Battery
Main body

Flat washer M4
Anti-loosing washer M4
Inner hexagon head bolt M4X10

Fig2-1 Remove batteries

2.2 Replacement procedure

Open the door of the Power Unit.
Shut off the power switch.； (Fig2-1)
Remove the mounting bolts, Anti-loosing washer and flat washers from the cover
board;
Remove the cover board, and take out the two batteries; (Fig2-2)
Remove the connection from the terminals of two batteries. Pay attention, do not
cause short circuit. (Fig2-2)

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BAT-
NC
BAT+
+
-
+
-

Fig2-2
Place the two new batteries and referring to connection diagram Fig 2-2, connect
the two batteries, and note the polarity of the terminals. Avoid causing short circuit
or anti-connection.
Attach the cover board to the batteries; screw the mounting bolts, Anti-loosing
washer and flat washers into the cover board.

2.3 Caution
Do not dispose of batteries in a fire. The batteries may explode.
Do not open or mutilate batteries. They contain an electrolyte which is toxic and
harmful to the skin and eyes.
To avoid personal injury due to energy hazard, remove wrist watch and jewelry
such as rings when replacing the batteries. Use tools with insulated handles.
Replace the batteries with the same number and same or similar type of batteries as
originally installed in the equipment
Batteries must be recycled. Deliver the battery to an appropriate recycling facility
or ship it to the supplier.

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2.4 Route Maintenance

The UPS battery’s capability and batteries’ change date must be checked yearly by a
service engineer. If lower battery is detected periodically prior to the expiration date,
it should be replaced at once. Otherwise the UPS battery should be replaced at least 3
month prior to the expiration date.

3. Acronyms and abbreviations

AC Alternating Current
BAU Bridge Alarm Unit
CJB Connecting Junction Box
DC Direct Current
EPFS Electronic Position Fixing System
GMDSS Global Maritime Distress and Safety System
IEC International Electrotechnical Commission
IMO International Maritime Organization
INS Integrated Navigation System
MEE Main Electronics Enclosure
MIC Microphone Assembly
NSIU Non-Standard Interface Unit
PDC Protected Data Capsule
RAU Remote Acquisition Unit
ROV Remotely Operated Vehicle
UTC Universal Time Constant
UPS Uninterruptible Power Supply
VDR Voyage Data Recorder
VESA DMTS Video Electronics Standards Association Display Monitor
Timing Specification

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Appendix 1 – System Block Diagram

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Appendix 2 –HLD-A2 VDR Power Unit 24 Outline and

Installation drawing

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MAINTENANCE
MANUAL
（POWER SUPPLY UNIT 24）

VOYAGE DATA RECORDER

Model: HLD-A2

Code HLD04.7 WC
Version V1.0
Date 2005.10

BEIJING HIGHLANDER DIGITAL RECORD

TECHNOLOGY CO., LTD.
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Notes and Updates

Revisions:
Date Version Issued by Description
05-10-10 A1.0 LCW Created

1 Where to call in case of problems or faults

Beijing Highlander Corporation maintains a call center service at:
Call: +86 10 821 501 82 Email: service@highlander.com.cn
Fax: +86 10 821 500 83
The Call Center is open during office hours, 08.30 – 17.30, UTC+8.
Please note: Email is the preferred method of communication. Please state the fault or problem
as fully as possible, mentioning all details that could be relevant for solving the problem

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CONTENTS

1. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS ........................................................ 2

2. LETHAL WARNING!.......................................................................................................................... 4

3. FIRST AID IN CASE OF ELECTRIC SHOCK ................................................................................ 4

4. OVERVIEW OF THIS MANUAL ...................................................................................................... 5

4.1. General Information ..................................................................................................................... 5

4.2. Notes on Connections and EMI.................................................................................................... 5

5. POWER SUPPLY UNIT 707400 ......................................................................................................... 6

5.1. Principle of operation.................................................................................................................... 6

5.2. Block diagram................................................................................................................................ 7

5.3. Technical Data ............................................................................................................................... 8

6. INSTALLATION ................................................................................................................................ 11

6.1. Cabling Between Main Unit and Power Supply Unit............................................................... 11

6.2. Selecting Location ....................................................................................................................... 13

6.3. Mechanical Mounting ................................................................................................................. 14

6.4. Start up......................................................................................................................................... 14

7. LIST OF SPARE PARTS ................................................................................................................... 14

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2 Lethal Warning!

Voltages within this equipment are sufficiently high to endanger life.

Covers are not to be removed, except by persons qualified and authorized to do so, and these
persons should always take extreme care once the covers have been removed.

3 First Aid in Case of Electric Shock

1. Lay victim on his back.
2. Clear victim’s mouth and throat
3. Tilt victim’s head back as far as
possible and raise his head

4. Pinch victim’s nostrils

5. Take a deep breath
6. Cover the victim’s mouth with yours
and blow, watching his chest rise.
Note: Blow forcefully into adults, but
gently into children.
7. Move your face away to allow victim
to breathe out, watching his chest
fall.
8. Repeat first five to ten breaths at
rapid rate; thereafter, take one breath
every three to five seconds.
9. Keep victim’s head back as far as
possible at all times.

Have someone else send for a doctor, keep patient warm and loosen his clothing
Do not give liquids until the patient is conscious.

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4 Overview of this Manual

The Installation Manual is intended for use by an authorized installation company. It contains
general information for installation of hardware and wiring of the power supply unit. The
PSU24 has built-in battery back-up for operations during mains outages.

It also contains notes on installation specifics, and how to protect the equipment from
Electromagnetic Interference (which is an installation issue). Also, carefully read and
understand the “General Notes on Cables and Connections” chapter of the "VDR Installation
Manual" before you select cable material for the installation. Using the wrong cable may
harm the long-term stability of the installation, introduce noise on the data and sound
channels, and in serious cases, void the warranty.
4.1 General Information
A drawing of the Power Supply Unit can be found in the “Mechanical Drawings” chapter.
4.2 Notes on Connections and EMI
The door edges of the Power Supply Unit are fitted with an EMI seal, protecting the unit from
external radiation, and protecting sensitive equipment like VHF receivers from high
frequency emissions from the unit. Always check the seal for dents or rips and replace a
faulty seal. Failure to do so may harm the long-term stability of the unit and add unwanted
noise to communications channels.

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5 Power Supply Unit 24 709602

Batteries

Filter
PSU 24 Board

5.1 Principle of operation

The PSU24 provides the function of providing continuous nominal 24 VDC power to the
VDR during normal operation and mains failure.
The system is a so called direct power system, i.e., the rectifiers provide power to the
load (VDR) while charging the batteries.
The unit is equipped with an alarm interface, RS232, which communicates with the VDR.
The back-up power is provided by valve-regulated batteries and is dimensioned to operate
at minimum 2 hours.
Alarms are sent to the VDR when and if:
− The DC mains fail. If the DC power lost or the voltage increase to more than 37V, it
will send out alarm information.

− The battery breaker is tripped. The breaker is supervised via an auxiliary circle.
(NOTE! the auxiliary circle is triggered only when the breaker is tripped by over
current)

− Batteries connection fail: an auxiliary circle to detect the batteries connection status. If
the batteries are removed, it will alarm.

− The battery voltage is to low, <20V.

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Two minutes after shut down command from the VDR the PSU24 is shut down, during
this time the PSU24 is sending information to the VDR that the PSU24 will be shut down.
If battery voltage is below 19 V the PSU24 is also shut down.
The PSU24 is housed in an IP44, splash proof, cabinet, which is intended to be mounted
on a wall. Only front access is required to operate the PSU24.
5.2 Block diagram

- Battery1 + - Battery2 +
CON3

CON2
Bat+
NC

Bat-

F2

F-Out+
F-Out-
Shield
PSU24 Board

Filter
DSR/0V 6 GND PSU

+24V PSU
CTS/+12V 7 +5V PSU

RXD/TXD 4 RxPSU
TXD/RXD 5 TxPSU
MU

Highlander
19

HLD04.7
F1
GND/-
PSU24

+24V/+

V1.01 2005.10.25
PSU24 Board
24V+

Shield
Shield

F-In+
24V-

F-In-

SW2 SW1 GND

CON4

CON1
CON5

+24 PSU

Ground
24+
24-
19
4
7
6
5

Main Unit Emergency Switchboard

This block diagram shows the general layout of the system.

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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5.3 Technical Data

5.3.1 Mechanical
The PSU24 is housed in an IP44, splash-proof cabinet with dimensions H=500 mm, W=
380mm and D=210 mm. All cabling is via cable glands in the bottom plate of the cabinet.
Weight is 36 kg.
Mounting dimensions, etc are shown below:

206.5
192.5
320.0 170.0
260.0 10.0
360.0
385.0

5.3.2 Power input

Voltage 18－36 VDC

Max current at lowest voltage 10 A

Max inrush current <35 A <5 ms

Input fusing T10 AH in input screw terminals

Rectifier is also protected by internal T10A fuse

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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5.3.3 Power outputs

Output voltage 19 – 27.2 VDC
DC OFF (Battery operation) 19 – 24.5 VDC
DC ON (Battery charging) 24 – 27.2 VDC

Output current 10 A max

8A max continuous

Battery fuse 15 A fuse, inrush current 35A.

5.3.3.1 Alarms and indications

Communications interface unit

Interface RS232 speed 1200, N, 8.2

VDR requests status by sending 09h, 00h, 01h, 5Fh

PSU24 responds by sending status byte and a checksum

Bit representation
00 DC Failure
01 Shutdown pending
05 Battery Breaker Alarm, and Batteries connection fault
07 Battery low

The checksum is calculated as follows:

Status byte +55h
Example:
Status byte=00h
PSU24 sends 00h,55h

Shut down command from VDR 09h,00h,11h,6Fh

Disconnects the Output Voltage from PSU24 after 2
minutes

Output Voltage returns when AC input is switched

OFF and ON again.

Battery low <20 VDC

Battery off <19 VDC

5.3.4 Battery specification

Type NPH-12 12AH

Manufacturer TAIWAN YUASA BATTERY CO., LTD

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Voltage 12 V per block

Expected life 3-5 years at 20oC

Capacity 12 Ah, dimensioned to provide min. 2 hours back-up

5.3.5 Environmental specifications

According to requirements in IEC 60945, class Protected IP44

5.3.6 EMC specifications

According to requirements in IEC 60945, class Protected

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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6 Installation
6.1 Cabling Between Main Unit and Power Supply Unit 24
General Information
• Two cables, with a maximum length of 10 m shall be used to interconnect these units.

• The power supply cable should consist of two stranded 6-mm² wires for powering the
VDR.

• The other cable serves as the data link between the two units.

• It is possible to use longer cables, up to 30 m, but in such situations the loop resistance
should be kept low by increasing the copper cross section to 10 mm² for the power cable.

• All cabling to the Unit should be brought through the cable glands in the bottom of the
cabinet. Shields shall be grounded in the PSU24 (cable glands).

• All cables shall be connected to the screw terminal blocks inside the cabinet see fig below

• It is important to have a solid ground connection between the case of the unit (the
grounding bolt) and the hull structure

List of connections
Terminal PE Protective
CON1：
Terminal G shielded Ground
Terminal 8 DC in － Cathode
Terminal 9 DC in ＋ Anode
CON4：
Terminal 1 DC out－ ----> VDR DCU 19 Lower Column
Terminal 2 DC out + ----> VDR DCU 19 Upper Column
Terminal 4 RS232 TxD ----> VDR DCU 5
Terminal 5 RS232 RxD ----> VDR DCU 4
Terminal 6 RS232 DSR ----> VDR DCU 6
Terminal 7 RS232 CTS ----> VDR DCU 7

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Inter-connections
PSU24 PCB Board

Main Unit
DCU
Control
Signals DC Power
Input

DC
Output

Cabling between Main Unit (left) and Power Supply Unit 24 (right) and
ship’s 24 VDC supply

PSU24 DCU terminal Cable Type: Two twisted pairs with common screen
terminal # #
4 RX3 (DCU 5) Control PSU24 -> VDR / Note: DCU terminal 5 should
connect to PSU24 4
7 +5V (DCU 7) Control +5 V ( DCU terminal 7)
6 0V (DCU 6) Control GND (DCU terminal 6)
5 TX3 (DCU 4) Control VDR -> PSU24 / Note: DCU TX3 should
connect to PSU24 5

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PSU24 Main Unit Cable Type: Two stranded 6 mm2 conductors

terminal # terminal #
1 DCU 19 － 24 V return. If possible use black wire,

2 DCU 19 + 24 V positive. If possible use red wire

PSU24 Ship’s Power Cable Type : Three stranded 1,5 mm2 conductors, brown,
terminal # blue and yellow/green
G Earth PSU24 -> ship’s earth ground. Use yellow-green wire
8 24 VDC－ PSU24 live or neutral -> Ship’s 24VDC supply －
9 24 VDC＋ PSU24 neutral or live -> Ship’s 24VDC supply ＋

Identifying Wires
• The control wires (#4, 5, 6 and 7) will have to be identified by inspection.

• Powering up the Power Supply Unit 24 and checking the polarity can identify the DC
wires.

• The 18~36 VDC wires must use the standardized colors to avoid any conflicts in
identification.

Short-Circuit Warning!
Be careful to avoid shorting the DC power output and remember that the Power Supply
Unit 24 will feed power on the #4 and #5 terminals from the batteries, even without DC
input.

Notes on connections and EMI

See also the “General Notes on EMI, Cables and Connections” chapter of the "VDR
Installation Manual".

6.2 Selecting Location

Recommended conditions for the chosen location of the cabinet are listed below:
• The cabinet shall be bolted to a bulkhead in a location where necessary cabling from
bridge equipment can be brought to the unit, preferably close to the bridge.

• The location shall be protected from weather and shall offer a stable temperature.

• The location shall not expose the unit to excessive vibration levels.

• The location shall be far from electrical installations giving excessive electric and/or
magnetic fields.

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• The cabinet shall be easily accessible and it should be mounted in such a way that the
built-in LCD touch-screen display can be easily operated, for making back-up copies,
performing configuration changes etc.

• The Power Supply Unit bottom shall be placed approximately 1,2 m from the floor where
practical.

• The standard cable length between PSU24 and Main Unit is 10 m.

6.3 Mechanical Mounting

The cabinet shall be mounted to a flat surface on the bulkhead using 8-mm steel bolts.
A dimensional drawing can be found in the “Technical Data” chapter.
6.4 Start up
6.4.1 Power up
Connect 24VDC to the system.
The green LED0 and LED1 on the PCB shall have fixed light to indicate the external DC
power status. The green LED3 will indicate control and communication circle power status.
Before start testing let the PSU24 run for at least 15 minutes.
To power down the PSU24 switch OFF the DC input by remove the fuse F1.

6.4.2 Testing
There is no mains switch in the PSU24 so for switching the DC power ON and OFF use the
input fuse F1 which can easily be taken out.
Test 1. Switch OFF the DC power as described above, the red LED5 in the Battery Charge
shall remain with fixed light. The red LED3 shall have fixed light all the way.
Test 2. Connect the DC power again and check that red LED0 and LED1 have fixed light.

7 List of Spare Parts

Description Part number
Fuse
4 pc 15 A 250 V 5*20 F9, F10, F11, F12

Address:A605-606, SPTower Tsinghua Science Park Building, Beijing, 100084, P.R.China

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Tel:+86-10-82678888 Fax:+86-10-82150083

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