VDR Instruction Manual

Consilium S-VDR/VDR
M4
Technical Manual
Article No. 709502
Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Phone +46-(0)8-563 051 00 Fax +46-(0)8-563 051 99 E-mail: navigation@consilium.se
Text for back of binder:
Consilium
S-VDR/VDR Technical Manual, U/N 709502
Consilium Navigation AB
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 bibder.
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 709540
2 Warnings
3 Handling
4 Technical information 709541
5 System description 709542
6 User Guide 709543
7 Player Guide 707203
8 Investigative Authority Guide 709545
9 Main Unit(MU)installation 709546
10 Power Supply Unit(PSU 2)Installation 707402
11 Final recording medium(FRM/Capsule)installation 709242
12 Data Acquisition Unit(DAU)Installation 709233
13 Alternative Power Supply Unit (PSU 3) 709241
14 Alternative Power Supply Unit (PSU 24)
15 Alternative Final Recording Medium (FRM Type B/Caps) 707262
16 Drawings Actual drawing file 7 drawings
17 Type Approval Documents, Delivery Test Certificate
18 Acceptance Record Certificate At installation
19 Service Reports, Annual Performance Test Reports To be added on board

Table of Contents
Section
Description Doc ID
A Introduction 709540
Binder text and binding instruction. Notes and Updates
1 How to use this manual
2 Warnings
3 Handling
B Technical Information
4 Technical specifications 709541
5 System description 709542
C User Manual
6 User Guide 709543
7 Player Guide 707203
8 Investigative Authority Guide 709545
D Installation Manual
9 Main Unit (MU) Installation incl. Microphones and SCU 709546
10 Power Supply Unit (PSU 2) Installation 707402
11 Final Recording Medium (FRM Type A/Capsule) 709242
E Accessories Manual
12 Data Acquisition Unit (DAU) Installation 709233
13 Alternative Power Supply Unit (PSU 3) 709241
14 Alternative Power Supply Unit (PSU 24)
15 Alternative Final Recording Medium (FRM Type B/Caps) 707262
F Appendix
16 Drawings
17 Type Approval Documents, Delivery Test Certificate
18 Acceptance Record Certificate
19 Service Reports, Annual Performance Test Reports

Consilium VDR M4 Technical Manual Art No. 709540 A0
Notes and Updates
Revisions:
Date Ver Issue by Description
2005-10-01 A0 NE Created
_________________________________________________________________________________
4 (8)
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
Consilium VDR M4. In this manual the equipment is called VDR M4 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 M4, please read section A2 (Warnings), A3 (Handling) and B5
(System Description).
Before using the VDR M4, 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 M4 unit and a general System Description explaining the function of
the VDR M4 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 M4, 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 M.4.
(C) 8 Investigative Authority Guide contains special instructions for
investigating autorities 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 M4
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 M4
optional units, e.g. alternative PSU and alternative FRM/Capsule.
(F) Contains - Annex with Ship Specific Documents, such as:

(F) 16 Drawings, mechanical and electrical drawings for installation
_________________________________________________________________________________
5 (8)
(F) 17 Copy of VDR M4 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.
Consilium Navigation AB
_________________________________________________________________________________
6 (8)
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 victims mouth and throat
3. Tilt victims head back as far as possible and
raise his head
4. Pinch victims nostrils

5. Take a deep breath
6. Cover the victims 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 victims 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.
_________________________________________________________________________________
7 (8)
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 Consilium Navigation AB 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.
_________________________________________________________________________________
8 (8)
Consilium VDR M4
Technical
Specifications
Article No. 709541

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navigation@consilium.se
Consilium VDR M4 Technical Specification Art No. 709541 A1
Notes and Updates
Revisions:
2005-11-29 A1 LNY Added and changed data
______________________________________________________________
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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 120
(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
Enclosure protection: IP22
EMC: IEC 60945
______________________________________________________________
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Radiated Noise: According to IEC 60945

Heat dissipation (max) = Power consumption
Color: RAL 7032
Operating temperature: 0 to +55 C
Operating Humidity: 40 to 90 % RH (non condensing)
Power Supply Unit (PSU2)
Height: 500 mm
Width: 500 mm
Depth: 200 mm
Weight: 44 kg
Electrical specification
Input voltage: 85-265 VAC
Frequency: 47-63 Hz
Max current at lowest input 5 A RMS
voltage
Max power output load: 10A, 7A continuous
Serial inputs: RS-232
Serial outputs: RS-232
EMC: IEC 60945
Color: RAL 7032
Height: 500 mm
Width: 380 mm
Depth: 210 mm
Weight: 36 kg
Input voltage: 85-265 VAC
Frequency: 47-63 Hz
______________________________________________________________
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Max current at lowest input 5A RMS

voltage
EMC: IEC 60945
Color: RAL 7032
Height: 385 mm
Width: 260mm
Depth: 226.5 mm
Weight: 19 kg
Input voltage: 18 36 VDC
Max current at lowest input 10A
voltage
Max inrush current: 10A
Output voltage: 22-27.5 VDC when charging
EMC: IEC 60945
Radiated Noise: According to IEC 60945
______________________________________________________________
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System indicator SD4-6
Height: 144 mm
Width: 144mm
Depth: 15 mm
Weight: 0,5kg
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
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
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
______________________________________________________________
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Regulatory Specifications IEC-61996, 60945, IMO A.861(20)

Compass safety distance:
Standard compass 98 cm
Steering, standby and emergency
compass 80cm
Power Variation: 19.2-28.8 VDC
Excessive Conditions: 16-36 VDC, Fuse cutoff >36VDC, reverse
polarity
Dangerous Voltage: IP22
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
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
Final Recording Medium Type B / 707150, L3 HVR01-xxx-xx
See L3 capsule installation and operation manual, 707262, Chapter D 15 in this

manual.
______________________________________________________________
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Consilium VDR M4
System Description
Article No. 709542
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) Ships Ethernet Interface
VHF SIU Service/Investigators
System Integration Unit
Ethernet Interface
RECORDED DATA
VMU RGU
Radar Video Mixer Unit Radar Grabber Unit
Ships (Investigators)
(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

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Consilium VDR M4 System Description Art No. 709542 A1
________________________________________________________________________
Notes and Updates
Revisions:
2005-12-06 A1 NE Editorial corrections
2 (8) 2
________________________________________________________________________
General
The VDR M4 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 M4 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 M4 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 M4 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:
24V DC and 115/220 AC
System Control Unit (SCU) Remote Control and Alarm Panel
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 M4 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 ships computer can also be
connected via a local network.
The main memory of the VDR M4 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
3 (8) 3
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memory of data to and from the VDR. There is no other ship data memory built in the
VDR. When the VDR M4 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 Consilium 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.
VDR M4.0 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.
4 (8) 4
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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.
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 M4 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 M4 with 24 VDC. It also includes
necessary batteries to power the VDR for the 2hours audio recording if ships emergency
power is lost. That process is controlled by the SIU in MU.
SCU
The System Control Unit is a Consilium 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 M4 is generating. Relay and serial outputs are available for external alarms or
central alarm table.
5 (8) 5
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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.
VDR M4 System Process
FRM
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
SCU
Alarm Unit
(SD4-6)
Audio Mixer Unit
Ethernet Interface
RECORDED DATA
VMU RGU
ETU (Memory Stick)
IEC 61162/
Other items to
be recorded NMEA
PSU
115/230 VAC
24 VDC
6 (8) 6
________________________________________________________________________
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 Consiliums
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.
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.
7 (8) 7
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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 ships 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.
8 (8) 8
Consilium VDR M4
User Guide
Article No. 709543
Messages, total number
VDR
SD4-6
Message id.
Warning
Alarm
Test
Message Scrolling
Back-up Setting DIM

U/N 704046

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Consilium VDR M4 System Description Art No. 709543A1
________________________________________________________________________
Notes and Updates
Revisions:
2005-11-28 A1 NE Annex completed with MSC circ 1024
2
________________________________________________________________________
Table of contents
1 VDR M4 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 11
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 15
3
________________________________________________________________________
1 VDR M4 Quick Guide

The VDR M4 is designed to work automatically without any break or supervision at all.
The only reasons to care about the VDR M4 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 M4 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
VDR
SD4-6
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.
4
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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 M4 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 M4 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.
5
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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.
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
6
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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.
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 ships 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 M4 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.
7
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For Consilium VDRs, the APT is performed in practice by Consilium technicians
approved by the classification society and/or national maritime organization of the
vessels flag state. APT can be ordered directly to Consilium Navigation in Nacka
Sweden or via local Consilium service agent.
All APT performed on Consilium VDRs are managed from and registered in Consilium
Navigation Service Center in Nacka, Sweden. A unique numbered certificate is issued for
each APT and is only valid if signed by a technician approved by and listed at Consilium
Navigation.
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=Consilium 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 Consilium)
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 Consilium 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.
8
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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
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
9
________________________________________________________________________
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
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.
10
________________________________________________________________________
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
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 Consilium. If any risk
that the FRM has been exposed to any damage, contact Consilium Navigation AB,
Nacka, Sweden.
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.
11
________________________________________________________________________
Message Alarm / Message description Explanation Required action
id
General faults
001 Alarm. System Failure VDR not operating / Check on Main unit to verify
communication to remote if VDR is working. Check
display not working. other alarms
002 Alarm. Lost main power No power to VDR. VDR will Find cause of power loss,
work on UPS for 2 hrs. check fuses
004 Alarm. Data lost Recorded data lost. Consult Consilium
005 Alarm. Flash failure Internal memory error Contact Consilium
Audio
100 Alarm. Audio general failure Consult Consilium
101 Alarm. Audio failure Consult Consilium

Radar
120 Warning. Video input -1 signal Missing input from recorded Check radar is on. Contact
missing Radar 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. radar 2, source. Contact appropriate
Ecdis service
159 Alarm. Video failure General Video failure Consult Consilium
CCTV
160 Warning. CCTV camera 1 sign missing Missing input from camera #1 Analyze missing video
161 Warning. CCTV camera 2 sign missing Missing input from camera #2 source. Contact appropriate
162 Warning. CCTV camera 3 sign missing Missing input from camera #3 service
163 Warning. CCTV camera 4 sign missing Missing input from camera #4
164 Warning. CCTV camera 5 sign missing Missing input from camera #5
169 Warning. CCTV failure. Consult manual General cctv video failure Consult Consilium
Backup
170 Warning. Backup failed Current back-up interrupted Repeat back-up procedure.
177 Warning. Backup failed Current on-line back-up failed Check connection to the
back-up computer
12
________________________________________________________________________
Watchdog
190 Alarm. Watchdog error consult man
191 Alarm. Watchdog error consult man Configuration error. Watchdog Contact Consilium
drive missing
192 Alarm. Watchdog error consult man
Sixnet analogue/digital interface

200 Alarm. Sixnet digital signal missing Missing digital input signal Check Sixnet power supply
201 Alarm. Sixnet analogue input Missing analogue input signal Check Sixnet connections
missing Contact Consilium
202 Alarm. Sixnet failure. General Sixnet failure
NMEA serial input

220 Warnings. NNN Signal missing. The signal specified on display is Check if specified unit is on.
to missing Check output and connections
263 Consult drawings
Contact appropriate service.
301 Warnings. NMEA Com #. Signal The IEC 61162/NMEA signal to Find actual unit connected to
to missing specified com # is missing. com#. Consult drawings.
Check outputs and
325 connections. Contact
appropriate service.
VDR
400 Alarm. VDR failure General VDR Failure Contact Consilium
VUB
409 Alarm. No DCU signal Software failure Contact Consilium
410 Alarms. NNN voltage error The power is missing to displayed Consult technical manual to
to unit or sub unit. find position of fuse
419
13
________________________________________________________________________
Microphone Test
460 Alarm. Microphone 1 self test failed The microphone(s) in question Is the alarm recurrent? Single
461 Alarm. Microphone 2 self test failed has stopped working or have self tests can fail due to
462 Alarm. Microphone 3 self test failed weak reception. simultaneous high noice e.g.
463 Alarm. Microphone 4 self test failed other alarms.
464 Alarm. Microphone 5 self test failed Check connections to the
465 Alarm. Microphone 6 self test failed microphone. Change the
466 Alarm. Microphone 7 self test failed microphone(s).
467 Alarm. Microphone 8 self test failed
Power Supply
500 Alarm. UPS general failure No contact with PSU Check connections PSU-MU
Contact Consilium
Capsule type B (L3)

800 Alarm. Capsule, no connection Capsule, connection failure. Check connections to capsule
801 Alarm Capsule, overrun Data missing in Capsule Contact Consilium

802 Alarm. Capsule, Space insufficient Possible error. Capsule memory Contact Consilium
not enough if current recording Se note below.
size continues for 12 hrs.
803 Warning. Capsule, lost data Data sequence interrupted If remaining after 12 hrs or
repeated, contact Consilium
804 Capsule, internal loop error Capsule memory error. Contact Consilium
Capsule type A (HL)

901 Alarm Capsule, overrun Data missing in Capsule Contact Consilium

902 Alarm. Capsule, Space insufficient Possible error. Capsule memory Contact Consilium
not enough if current recording Se note below.
size continues for 12 hrs.
903 Warning. Capsule, lost data Data sequence interrupted If remaining after 12 hrs or
repeated, contact Consilium
904 Capsule, internal loop error Capsule memory error. Contact Consilium
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.
14
________________________________________________________________________
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 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.
15
________________________________________________________________________
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
16
________________________________________________________________________
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.
17
Consilium VDR M4
Investigative
Authority Guide
Article No. 709545
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
VDR M4.0 Main Unit

CONSILIUM VDR M4 Investigative Authority Guide Art No. 709545A0
Notes and Updates

Revisions:
Where to call in case of problems or faults

Consilium Navigation maintains a call center service at:
Call: +46 8 563 051 00 Email: VDR-Service@consilium.se
Fax: +46 8 563 051 99
The Call Center is open during office hours, 08.00 16.30, UTC+1.
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.
ii (11)
CONSILIUM VDR M4 Investigative Authority Guide Art No. 709545 A0
Table of Contents
1 OVERVIEW OF THIS MANUAL.............................................................................................. 3
1.1 VDR M4 Function ............................................................................................................................. 3
1.2 An Undamaged Unit.......................................................................................................................... 3
1.3 A Damaged Unit ................................................................................................................................ 3
2 HOW TO DOWNLOAD DATA FROM THE EQUIPMENT ...................................................... 4
2.1 FRM/Capsule type A: ....................................................................................................................... 4
2.2 FRM/Capsule type B:........................................................................................................................ 5
3 DATA STRUCTURE................................................................................................................ 6
3.1 File Types ........................................................................................................................................... 6
3.2 File Structure ..................................................................................................................................... 7
4 SOFTWARE FOR PLAYBACK OF RECORDED DATA ........................................................ 9
4.1 System Requirements...................................................................................................................... 10
2 (11)
1 Overview of this Manual

The VDR M4 Information for Use by an Investigation Authority Manual is intended for use by an
investigative body after an incident.
It contains information on how to download data from the VDR M4 and information about the
downloaded data. It also gives information about Consilium software for interpreting and playback of
the data.
1.1 VDR M4 Function

The VDR M4 automatically records and stores data according to IMO resolution A.861 for the
full VDR and according to IMO MSC.163(78) for the S-VDR. Other connected input sources can
also be recorded i.e. other radar-, ECDIS-, conning-displays, ITV, etc. Data is stored for 12 hours
(optionally longer), and is then automatically over-written with new data.
The backup can be performed from a incident back-up memory, e.g. performed by the crew at or
directly after the incident. (see User Manual). It can also be directly downloaded from the capsule or via
an intermediate memory. This may need a special download program, depending on type of capsule.
All directly downloaded data from the capsule must be performed within 12 hours from the start of the
incident. All data recorded more than 12 hrs back will be automatically overwritten and erased from the
capsule. Downloading and saving capsule data will not interrupt the VDR M4 saving of data on the
capsule.
1.2 Undamaged VDR and FRM/Capsule

For retrieving data from an undamaged VDR, with an undamaged FRM/Capsule, only a portable
PC / laptop with an USB port or an Ethernet port and cable is needed.
The procedure is explained below in under par.2: How to Download Data from the Equipment.
1.3 Damaged FRM/Capsule

In the event of a serious accident, data can be downloaded and restored directly from the protective
capsule to a computer, without connecting to a VDR main unit. Special connecting device, software
and password is needed.
NOTE! If data must be downloaded from a damaged capsule, or from a capsule that might have
been exposed to damage, we highly recommend to contact Consilium Navigation AB
before trying to restore the data.
3 (11)
2 How to download Data from the Equipment

Downloading data can be preformed in different ways depending on type of FRM/Capsule and
data transfer methods.
NOTE: A full 12 hrs download of data can take up to 30 minutes.
2.1 FRM/Capsule type A:

2.1.1 Saved data from the USB memory device:
The VDR M4 has a remote incident function which can save and protect 2-11 hrs data related to an
accident or incident. The data is saved on an USB memory stick by an active action of the crew on the SCU
(System Control & Alarm Unit) and will not be automatically erased after 12 hours. The USB memory stick
is placed behind the locked door in the Main Unit cabinet.
Remove the USB memory stick from the VDR M4. An alarm will appear on the VDR M4
saying that the USB memory stick is removed.
Place the memory stick in the USB port of a portable PC (laptop).
Copy the data from the USB memory stick to the PC. Check that the files have been copied
properly.
Replace the USB memory stick in the VDR M4 Main Unit. The Alarm will disappear.
NOTE: After replacing the USB memory stick in the VDR M4, the data will be overwritten and
erased immediately at next saving of incident data.
2.1.2 Capsule data via the USB memory device:

The current capsule data can be saved on the USB memory stick and then copied to a portable PC
(Laptop). The VDR M4 saving process will not be interrupted. The USB memory stick is placed behind the
locked door in the Main Unit cabinet. (See front page picture).
Make sure that the USB memory stick does not include useful data.
Act according to Full Back Up explained in the User Guide
Remove the USB memory stick from the VDR M4 and place it in the USB port of a portable
PC (laptop). An alarm will appear on the VDR M4 saying that the USB memory stick is
removed.
Copy the data from the USB memory stick to the PC. Check that the files have been copied
properly.
2.1.3 Capsule data via the Ethernet port:

By using the Ethernet port, the current capsule data can be downloaded directly from the capsule
memory to a portable PC (Laptop). The VDR M4 saving process will not be interrupted. The Ethernet port
is placed on the ETU behind the locked door of the Main Unit cabinet. (See front page picture).
Change the IP address of you computer to the same subnet as 192.168.5.120 255.255.255.0
for example 192.168.5.121
4 (11)
Connect the Ethernet cable to a free socket on the VDR M4 switch (ETU).
Open Windows Explorer and choose Map Network Drive in the tools menu.
Select a drive and folder \\192.168.5.250\data.
Use user backup and password backup
Copy data.
2.1.4 Saved data via the Ethernet port: (NOT YET implemented in VDR M4)
The VDR M4 has a remote incident function which can save and protect 2-11 hrs data related to an
accident or incident. The data is saved by an active action of the crew on the SCU (System Control &
Alarm Unit) and will not be automatically erased after 12 hours. By using the Ethernet port, this saved data
can be downloaded from the capsule memory to a portable PC (Laptop). The Ethernet port is placed on
the ETU behind the locked door of the Main Unit cabinet. (See front page picture)
Open Windows Explorer and choose Map Network Drive in the tools menu.
Select a drive and folder \\192.168.5.250\data.
Use separately received user name and password
Copy data from xxx.
2.2 FRM/Capsule type B:

2.2.1 Saved data from the USB memory device:
The VDR M4 equipped with capsule B continuously saves a copy of capsule data on an USB memory
stick. Like the Capsule memory it will be automatically erased after 12 hours. At an accident or incident it
can manually be disconnected from the VDR M4 and copied to a portable PC (Laptop). The USB memory
stick is placed behind the locked door in the Main Unit cabinet.
Remove the USB memory stick from the VDR M4, if not already removed by the crew. An
alarm will appear on the VDR M4 saying that the USB memory stick is removed.
Place the memory stick in the USB port of a portable PC (laptop).
Copy the data from the USB memory stick to the PC by using a special downloading program
(HV read). Check that the files have been copied properly.
NOTE: After replacing the USB memory stick in the VDR M4, the data will be overwritten and
erased immediately.
2.2.2 Capsule data via the Ethernet port:

By using the Ethernet port, the current capsule data can be downloaded directly from the capsule
memory to a portable PC (Laptop). The VDR M4 saving process will not be interrupted. The Ethernet port
is placed on the ETU behind the locked door of the Main Unit cabinet. (See front page picture).
5 (11)
Start the software program HV read
Chose the length of the download and press start.
3 Data structure
3.1 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. It takes the following form:
Navigational data, depth, speed, IEC 61162/NMEA-compatible data, etc., is stored as
text files once per minute. The VDR M4 makes no attempt to decode the NMEA data, it just
stores it. At viewing time, it is up to the player application to decode the NMEA protocol data
and display it.
Sound information from microphones, VHF communications, etc., is stored in the form
of compressed MPEG1 layer 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.
Ship specific data and configuration of the data needed for replaying are saved as
configuration text files (VDR config).
On the capsule type A the data is stored with a file structure in the FRM as explained below.
On the capsule type B the data is converted and stored in another format in the FRM. When
downloading the data from the FRM, using the software (HV read), the data is reverted to the
file structure explained below.
On the USB memory stick the data is stored with a file structure in the FRM as explained
below.
6 (11)
3.2 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 VDR event.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 VDR event.log file of each minute directory. The interpretation of the data
should be left to the Voyage Data Player. After 12 hours of data has been stored, the oldest data is
removed as the next minute is recorded.
3.2.1 File Names
The VDR event.log file containing time stamped NMEA data, system events, fault messages and
other text data has this name format:
VDR event.log
Example:
D:\VDR\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.
7 (11)
Example:
D:\VDR\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.
HiRes[c]_[nnnnnnnnnn].jpg
where [c] is the channel number (0-3) and [n...n] is a system-generated ten-digit serial number.
Example:
D:\VDR\00\00\12\92\HiRes3_9087654321.jpg
Low-Res Video files containing close-circuit TV images are named after the video channel whose
data they contain, and ending in a .jpg extension.
cctv[c]_[nnnnnnnnnn].jpg
where [c] is the channel number (arbitrary number) and [n...n] is a system-generated ten-digit serial
number.
Example:
D:\VDR\00\00\09\72\cctv4_9087654321.jpg
8 (11)
4 Software for playback of recorded data

The Voyage Data Player (VDP) program provides an easy to use, interactive way of playing back voyage
data from the VDR M4 or a protective capsule on an IBM PC Compatible computer.
The information is presented in a user-friendly Windows interface, where different sensors are
displayed in different windows. All information, including audio playback, is synchronized in time and
simultaneously replayed.
With the VDP it is possible to locate an event or a time sequence of interest using various search
methods. It is possible to run the playback in normal, reverse, fast or step mode. It is easy to access data
by date and time.
The Voyage Data Player can be ordered from Consilium Navigation AB.
Part number 707015.
9 (11)
4.1 System Requirements

The computer used should be equipped, at a minimum, according to the specifications in the
Voyage Data Player Specifications.
DVD-R player.
Operating systems Windows NT, 2000 and XP
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.
For detailed information of the Voyage Data Player (VDP) see VDP User Guide.
10 (11)
Consilium VDR M4 Installation Manual Art No. 709546 A1
Consilium VDR M4
Installation Manual
Article No. 709546
FRM
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
SCU
Alarm Unit
(SD4-6)
Audio Mixer Unit
Ethernet Interface
RECORDED DATA
VMU RGU
ETU (Memory Stick)
IEC 61162/
Other items to
be recorded NMEA
PSU
115/230 VAC
24 VDC
Consilium VDR M4 Installation Manual Art No. 709546 A1
1. Notes and Updates

Revisions:
Date Version Issued by Description
2005-10-01 A0 NE Document created
2005-01-17 A1 PL Corrections
2. Where to call in case of problems or faults

Call: +46 8 563 051 00 Email: VDR-service@consilium.se

Fax: +46 8 563 051 99
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
Consilium VDR Installation Manual Art No. 707596A1
Table of Contents
1. NOTES AND UPDATES ......................................................................................................... 2
2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS .................................................. 2
3. 3. OVERVIEW OF THIS MANUAL ...................................................................................... 4
4. COMPASS SAFE DISTANCE................................................................................................. 4
5. PLACING OF MICROPHONES .............................................................................................. 4
5.1. Unit Front Panel ................................................................................................................................ 5
5.2. Unit Back............................................................................................................................................ 5
5.3. General Information ......................................................................................................................... 5
5.4. Selecting Locations ............................................................................................................................ 5
5.5. Mechanical Mounting ....................................................................................................................... 6
6. PLACING OF ALL OTHER COMPONENTS OF THE VDR M4 CONFIGURATION .............. 7
6.1. Main Unit 707000B............................................................................................................................ 7
6.2. Power Supply Unit .......................................................................................................................... 11
7. CABLING OF THE VDR M4 SYSTEM.................................................................................. 12
7.1. Cabling Between VDR M4 Units ................................................................................................... 13
7.2. Cabling from Bridge Systems to VDR M4 Main Unit ................................................................. 18
8. GENERAL NOTES ON CABLES AND CONNECTIONS ..................................................... 23
8.1. On Cable Dimensions and Standards............................................................................................ 23
8.2. On Cable Types .............................................................................................................................. 24
9. GENERAL NOTES ON EMI .................................................................................................. 25
9.1. EMI....................................................................................................................................................... 25
9.2. Termination of Signal Cables........................................................................................................ 25
9.3. On Shields ....................................................................................................................................... 26
(29) 2
9.4. On Cable Placement....................................................................................................................... 26
10. MECHANICAL DRAWINGS .............................................................................................. 28
11. ELECTRICAL DRAWINGS ............................................................................................... 28
(29) 3
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 M4 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.
(29) 4
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.
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.
(29) 5
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 its not practical to have a panel mounted microphone.
(29) 6
6. Placing of All Other Components of the VDR M4

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 Input/output Comments

of
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)
(29) 7
RS-485 1 I/O
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 to 8 O
AMU
Digital output to 4 O
VMU
Switching relay 2 O
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
(29) 8
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
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
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.
(29) 9
6.1.4. Connection Points in the Main Unit

Power and signal cables connect to various points inside the VDR M4 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 M4
Main Unit chapter.
6.1.5. General Information

A drawing of the Main Unit can be found in the Mechanical Drawings chapter.
(29) 10
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 M4 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.
(29) 11
7. Cabling of the VDR M4 System

All cabling necessary to interconnect the VDR M4 system units is described in this section.
FRM
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
SCU
Alarm Unit
(SD4-6)
Audio Mixer Unit
Ethernet Interface
RECORDED DATA
VMU RGU
ETU (Memory Stick)
IEC 61162/
Other items to
be recorded NMEA
PSU
115/230 VAC
24 VDC
Full VDR
FRM
IEC 61162/ ETHERNET
Position
NMEA
Speed DCU
SCU
Alarm Unit
(SD4-6)
Audio Mixer Unit
Ethernet Interface
RECORDED DATA
Radar RGU Ships (Investigators)
Radar Grabber Unit
USB Interface
ETU (Memory Stick)
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 M4 System is closer described in B 4 the System Description Chapter of this Technical
Manual.
(29) 12
7.1. Cabling Between VDR M4 Units

7.1.1. Main Unit to Power Supply Unit 2
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-mm wires for powering the VDR M4.
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 mm for the power cable.
CONNECTIONS
Cabling between Main Unit (right) and Power Supply Unit (left) and
ships 230(115) VAC emergency power supply
(29) 13
PSU terminal DCU terminal # Cable Type: Two twisted pairs with common screen
#
5 RXPSU (4) Control PSU -> VDR
6 TXPSU (5) Control VDR -> PSU
7 GND PSU (6) Control GND

8 +5V PSU(7) Control +5 V
PSU terminal DCU terminal # Cable Type: Two stranded 2,5 mm2 conductors
#
11 19+ 24 V positive. If possible use red wire
12 19 - 24 V return. If possible use black wire
2
PSU terminal Ships Cable Type : Three stranded 1,5 mm conductors, brown, blue and
# Emergency yellow/green
Power Supply
Earth (PE) Earth PSU -> ships earth ground. Use yellow-green wire
1 (L) 230(115) VAC PSU live -> Ships AC emergency power supply (50 or 60 Hz)
2 (N) 230(115) VAC PSU neutral -> Ships AC emergency power supply (50 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!
Unit will feed power on the #11 and #12 terminals from the batteries, even without AC input.
HIGH VOLTAGE WARNING!
NOTES ON CONNECTIONS AND EMI
See also the General Notes on EMI, Cables and Connections chapter.
(29) 14
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)
SD4-6 terminal # Main Unit, DCU terminal Comment, Cable Type
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
(29) 15
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 Consilium 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.
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.
(29) 16
The speaker pair (#4 and 5) will measure some 10 ohms between the two wires and isolation to
GND (#3). Polarity is not important.
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.
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 M4 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 M4 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.
(29) 17
The Ethernet cable is routed to the switch and pushed into one of the free
ports. The corresponding activity light should light up
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.
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 M4 Main Unit

All cabling described here is based on the standard configuration, as described in the Technical
Specifications section in the VDR M4 Technical Manual.
(29) 18
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 M4
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 M4 input, has to be matched to the nominal system impedance. It is
not allowed to connect the VDR M4 input in parallel with a radar display, not even with short
cables. Such a connection would ruin the signal to the VDR M4, 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 M4
but also to the radar display screen itself.
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!
(29) 19
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 scans
Sync (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 the
Sync 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 M4 is equipped with a four-input video multiplexer, giving the possibility to connect four
different sources.
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.
(29) 20
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 M4 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.
(29) 21
7.2.2. VHF/Communications Audio

Connecting VHF / communications audio to the VDR M4 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 M4 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 # (input 2) Cable Type

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.
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.
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 M4.
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.
(29) 22
DCU INPUTS AND OUTPUTS SPECIFICATION
All 16 VDR M4 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 Consilium Navigation.
SERIAL PORT EQUIVALENCIES
The NMEA terminals on the DCU board are connected to the computers 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
NOTES ON EMI
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 M4 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.
(29) 23
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 M4 system shall have a cross section of at least
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 M4 system shall have a cross section of at least
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.
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.
(29) 24
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 Intermittent faults
Excessive noise on audio channels Entanglement
Short circuits Mix-ups
and to ease re-dressing of cabling and re-connections after service, all signal cables used for VDR
M4 connections should be terminated in the manner described here:
If the connection block terminals in the VDR M4 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.
(29) 25
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.
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 M4 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.
(29) 26
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.
(29) 27
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
11. Electrical Drawings

This section contains the following electrical drawings:
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
(29) 28
VDR
Consilium Power Supply
Manual
Article No. 707402
5 6 7 8
+24 VDC OUT

0 VDC OUT
OF
RS232 GND
RS232 DSR
RS232 RxD
RS232 TxD
C10
NC
NC
L N
PE 1 2 5 6 7 8 9 10 11 12
Input Fuse 2xT6.3A

1 2 5 6 7 8 9 10 11 12

Consilium VDR User Manual Art No. 707402A2

Revisions:
03-08-11 A0 Pbx KGS Created, Template added SFS

04-02-10 A1 SFS Connection Terminal corrected
04-02-10 A2 Pbx n Pictures updated, Auxiliary switch added

Call: +46 8 563 051 00 Email: navigation@consilium.se
Fax: +46 8 563 051 99

ii (16)
Consilium VDR Power Supply Manual Art No. 707402A2
Table of Contents
1. NOTES AND UPDATES ......................................................................................................... II
2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS .................................................. II
3. LETHAL WARNING!............................................................................................................... 4
4. FIRST AID IN CASE OF ELECTRIC SHOCK......................................................................... 4
5. OVERVIEW OF THIS MANUAL.............................................................................................. 5
5.1. General Information ..................................................................................................................... 5
5.2. Notes on Connections and EMI.................................................................................................... 5
6. POWER SUPPLY UNIT 707400 ............................................................................................. 6
6.1. Principle of operation.................................................................................................................... 6
6.2. Block diagram................................................................................................................................ 7
6.3. Technical Data ............................................................................................................................... 8
7. INSTALLATION .................................................................................................................... 12
7.1. Cabling Between Main Unit and Power Supply Unit............................................................... 12
7.2. Selecting Location........................................................................................................................ 14
7.3. Mechanical Mounting ................................................................................................................. 15
7.4. Start up......................................................................................................................................... 15
8. LIST OF SPARE PARTS ...................................................................................................... 16
3 (16)
3. Lethal Warning!
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

3. Tilt victims head back as far as possible
and raise his head

Note: Blow forcefully into adults, but gently
into children.
8. Repeat first five to ten breaths at rapid
rate; thereafter, take one breath every
three to five seconds.
9. Keep victims head back as far as possible
at all times.
4 (16)

general information for installation of hardware and wiring of the power supply unit. The PSU 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
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.

A drawing of the Power Supply Unit can be found in the Mechanical Drawings chapter.
5.2. 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.
5 (16)
6. Power Supply Unit 707400
Alarm & Filter

Board
Charger Unit 5 6 7 8
+24 VDC OUT

0 VDC OUT
OF
RS232 GND
RS232 DSR
RS232 RxD
RS232 TxD
C10
NC
NC
L N
PE 1 2 5 6 7 8 9 10 11 12
Input Fuse 2xT6.3A

1 2 5 6 7 8 9 10 11 12
Connection
Terminal
Batteries
6.1. Principle of operation

The PSU 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
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 PSU is shut down, during this
time the PSU is sending information to the VDR that the PSU will be shut down.
If battery voltage is below 19 V the PSU is also shut down.
The PSU 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 PSU.
6 (16)
RS232
TxD RxD GND DSR SCREW TERMINALS ALARM + - L N PE
5 6 7 8 9 10 11 12 2 1 PE
6.3AT
Consilium
X1 X5 X1 6.3AT X2
5 8 7 6 2 1 1,2 3,4
3
4
LOGIC AND SENSING CIRCUITS 5
Tx
Rx
6.2. Block diagram
GND
+12V
1
+OUT
-OUT
Alarm+
2 K3
Alarm-
+24V FILTER
+
-
Rxi Rx +BATT
MAINS FILTER
3
4
Txi Tx -BATT
Fuse 5
RS232 INTERFACE
2
3
4
5
Broken
K1
2
K2
7 (16)
INTERFACE UNIT
1,2 8 3,4 5,6 3 2 1

3,4 9
X6 X4 X5 X3
VDR Power Supply Manual
Circuit Signal
This block diagram shows the general layout of the system.

2x10A
I
breaker switch
L N PE
BATTERY 1
12 V
0V
BATTERY CHARGER
24Ah
+24V
2.2K
250 W
BATTERY 2
12 V
+TEMP
24Ah
Art No. 707402A2
6.3. Technical Data
6.3.1. Mechanical
The PSU is housed in an IP44, splash-proof cabinet with dimensions H=500 mm, W= 500 mm
and D=200 mm. All cabling is via cable glands in the bottom plate of the cabinet. Weight is 44 kg.
Mounting dimensions, etc are shown below:
200
GROUND STUD CABLE GLANDS

M20 (1x)
M25 (2x)
530
500
430
4x10
Case mounting
arrangement
20
Screw M8
430
500
Washer
8 (16)
6.3.2. Power input

Voltage 115/230 VAC, switch able in the Battery Charger.
The PSU is delivered with 230 V setting
Tolerance +/- 15%
Frequency 47-63 Hz
Max current at lowest voltage 5 A rms
Max inrush current <35 A <5 ms
Input fusing T6.3 AH in input screw terminals

Rectifier is also protected by internal T6.3A fuse
6.3.3. 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 2-pole 10 A circuit breaker, with signal switch
9 (16)
6.3.4. Alarms and indications
Communications interface unit
Interface RS232 speed 1200, N, 8.2
VDR requests status by sending 09h, 00h, 01h, 5Fh

PSU 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
PSU sends 00h,55h
Shut down command from VDR 09h,00h,11h,6Fh

Disconnects the Output Voltage from PSU after 2
minutes
Output Voltage returns when AC input is switched

OFF and ON again.
Battery low <20 VDC
Battery off <19 VDC
SMD LEDs on PCB Green LED:

Fixed Light Unit OK
Flashing Light Shut Down signal from VDR
Yellow LED:
Fixed Light Battery Voltage < 20 V
Flashing Light Battery Breaker Alarm
Red LED:
Fixed Light AC Failure
10 (16)
6.3.5. Battery specification

Type Valve regulated Lead-Acid
Manufacturer Yuasa NPL 24-12I or similar
Voltage 12 V per block
Expected life 7-10 years at 20oC
Capacity 24 Ah, dimensioned to provide min. 2 hours back-up
6.3.6. Environmental specifications

According to requirements in IEC 60945, class Protected IP44
6.3.7. EMC specifications

According to requirements in IEC 60945, class Protected
11 (16)
7. Installation
7.1. Cabling Between Main Unit and Power Supply Unit
General Information
The power supply cable should consist of two stranded 6-mm wires for powering the VDR.
All cabling to the Unit should be brought through the cable glands in the bottom of the cabinet.
Shields shall be grounded in the PSU (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 Ground
Terminal 1 AC in AC = 230/115 V
Terminal 2 AC in
Terminal 5 RS232 TxD
Terminal 6 RS232 RxD
Terminal 7 RS232 GND
Terminal 8 RS232 DSR
Terminal 9 Alarm Contact Not used in Consilium VDR System
Terminal 10 Alarm Contact Not used in Consilium VDR System
Terminal 11 +24 V DC out
Terminal 12 0 V DC out
12 (16)
Inter-connections
ships 115/230 VAC supply
PSU terminal VUB terminal # Cable Type: Two twisted pairs with common screen
#
5 TX3 (6) Control VDR -> PSU / Note: VUB TX3 should connect to PSU 6
6 RX3 (5) Control PSU -> VDR / Note: VUB RX3 should connect to PSU 5
7 0V (7) Control GND
8 +12V (8) Control +12 V
PSU terminal Main Unit Cable Type: Two stranded 6 mm2 conductors
# terminal #
11 + 24 V positive. If possible use red wire
12 0 24 V return. If possible use black wire
2
PSU terminal Ships Power Cable Type : Three stranded 1,5 mm conductors, brown, blue and
# yellow/green
Earth Earth PSU -> ships earth ground. Use yellow-green wire
1 115/230 VAC PSU live or neutral -> Ships 115/230 VAC supply
13 (16)
2
PSU terminal Ships Power Cable Type : Three stranded 1,5 mm conductors, brown, blue and
# yellow/green
2 115/230 VAC PSU neutral or live -> Ships 115/230 VAC supply
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 115/230 VAC wires must use the standardized colors to avoid any conflicts in
identification.
Unit will feed power on the #11 and #12 terminals from the batteries, even without AC input.

Notes on connections and EMI

See also the General Notes on EMI, Cables and Connections chapter of the "VDR Installation
Manual".
7.2. Selecting Location

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 PSU and Main Unit is 10 m.
14 (16)

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.
7.4. Start up
7.4.1. Power up
Connect 230 VAC to the system (115 VAC if the mains selector in the Battery Charger is set in
pos 115).
The green LED in the Battery Charger and the green LED on the PCB shall have fixed light.
Before start testing let the PSU run for at least 15 minutes.
To power down the PSU switch OFF the AC input and then press the switch marked Battey OFF
on the PCB for at least 3 seconds
7.4.2. Testing
There is no mains switch in the in the PSU so for switching the AC power ON and OFF use the
input fuses on terminals 1 and 2 which can easily be taken out.
Test 1. Switch OFF the AC power as described above, the green LED in the Battery Charge shall
remain with fixed light. The green LED on the PCB shall go out instead the red LED shall have fixed
light.
Test 2. Press the switch on the PCB marked Battery OFF see fig below for 3 seconds. Now all
LEDs shall go out and there should be no 24 DC out.
Test 3. Connect the AC power again and check that green LED have fixed light.
15 (16)
8. List of Spare Parts
Description Part number

Battery B43244012
Alarm and filter board PBSE0947001
Rectifier A26025024
Fuse kit c/o
2 pc T6,3 A 250 V 5*20 F93316301
Air vent M14094701
16 (16)
Consilium
VDR
Protected Data Unit
Manual
Article No. 709242

CONSILIUM VDR PSU MANUAL ART NO. 709242A2
Revisions:
05-03-10 A0 HL Created
05-04-14 A1 MC Updated drawings and minor corrections
05-08-01 A2 NE Corrections and adaptation to manual standard
Phone: +46 8 563 051 00 Email: vdr-service@consilium.se

Fax: +46 8 563 051 99
ii (24)
Table of Contents
1. NOTES AND UPDATES ...............................................................................................................II
2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS...................................................II
3. LETHAL WARNING! .....................................................................................................................4
4. FIRST AID IN CASE OF ELECTRIC SHOCK ...........................................................................4
5. PROTECTED DATA UNIT (PDU) DESCRIPTION.........................................................................5
5.1 GENERAL ...........................................................................................................................................5

5.2 HARDWARE ........................................................................................................................................6
5.2.1 Protected Data Unit...............................................................................................................6
5.2.2 Junction Box...........................................................................................................................7
5.3 SOFTWARE .........................................................................................................................................7
6. PDU SPECIFICATIONS.....................................................................................................................8
6.1 PDU SPECIFICATIONS ........................................................................................................................8

6.2 PDU JUNCTION BOX SPECIFICATIONS ................................................................................................8
7. PDU INSTALLATION INSTRUCTIONS ..........................................................................................9
7.1 GENERAL ...........................................................................................................................................9

7.2 REQUIRED TOOLS .............................................................................................................................10
7.2 REQUIRED TOOLS ............................................................................................................................. 11
7.3 MOUNTING PROCEDUR .................................................................................................................... 11
7.3.1 LOCATION SELECTION .................................................................................................................. 11
7.3.2 Mounting the PDU ............................................................................................................... 11
7.3.3 Mounting the Junction Box (JB) ........................................................................................14
7.4 CONNECTIONS..................................................................................................................................15
8. SOFTWARE INSTALLATION INSTRUCTIONS ..........................................................................18
8.1 GENERAL .........................................................................................................................................18

8.2 IP ADDRESS AND PASSWORD CONFIGURE ...........................................................................................18
8.3 REPLAY OF DATA .............................................................................................................................18
9. OPERATING PROCEDURE............................................................................................................19
9.1 OPERATION STEPS ............................................................................................................................19

9.2 DOWNLOADING AND CHECKING THE DATA FROM PDU. .....................................................................19
9.3 INFORMATION USED FOR INVESTIGATION ORGANIZATION ....................................................................20
10.1 WHEN TO RELEASE THE PDU?........................................................................................................21
10.2 HOW TO RELEASE PDU FOR SERVICE? ............................................................................................21
10.3 ROUTINE MAINTENANCE.................................................................................................................22
10.3.1 GENERAL ..........................................................................................................................22
10.3.2 Underwater Locator Device (Beacon) Cleaning ...........................................................22
10.3.3 Check and replacing of cables ........................................................................................22
CONSILIUM VDR PDU MANUAL ART NO. 709241A2
10.3.4 Check and replacing the O-ring ......................................................................................22

10.3.5 Checking of installing base fastening screws ...............................................................23
10.3.6 Corrosion-proof and rust-proof treatment of casing surface .......................................23
10.4 HOW TO REPLACE THE PDU? .........................................................................................................23
11. DATA RECOVERY AFTER AN ACCIDENT................................................................................23
3
3. Lethal Warning!
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.

and raise his head

into children.
9. Keep victims head back as far as
possible at all times.
4
5. PROTECTED DATA UNIT (PDU) DESCRIPTION
5.1 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 IEC-61996.
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
Deep-Sea Immersion: 6000 Mpa (6000 meters) for 24 hours
Seawater Immersion: 3 Mpa (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 IEC-60945, 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
Rain: 30 Minutes @ 100 liters/min from 2.5 meters
Vibrations: 2-5 to 13.2 Hz +/-1mm, 13.2-100Hz @7m/s/s
Power Variation: 19.2-28.8 VDC
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
5
5.2 Hardware
5.2.1 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 measures 360W x320D x 352H mm (Figure 3). It is designed to be deck-mounted. Two
5-meter shielded cables connects the PDU and the Junction Box (JB), which is designed for
under-deck installation. The exposed above-deck PDU assembly consists of two pieces. The
capsule can be separated from the base plate by simply pulling the release hooks. An acoustic
beacon is provided to aid locating the capsule underwater. Large pad handles are welded to the
PDU housing to facilitate easy lifting by divers or Remotely Operated underwater Vehicles (ROV).
360W x320D x 359H mm
Figure 3: PDU Dimension Drawing
6
5.2.2 Junction Box

The Junction Box (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 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/Switch is 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.
5.3 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 Gbytes of contiguous space for storing data, audio
and video files without the restrictive pre-determined partitions.
7
6. PDU SPECIFICATIONS
6.1 PDU Specifications
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 Base Assy 360 W x 320 D x 359 H mm
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:
Steering, standby and emergency compass
80cm
6.2 PDU Junction Box Specifications
Weight 2.0 kg excluding cables

Dimensions 188 W x 120 D x 79.5 H mm
Fuse 500mA
8
7. PDU INSTALLATION INSTRUCTIONS
7.1 General
Before installing the PDU, check all the parts against the component list as shown below.
Check the condition of all components.
Code Name No Remark

1 PDU capsule 1
2 Underwater location beacon 1 DK140
3 Quick release mechanism 1
4 Hex bolt 4 M1035
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 Shipyard Supply
10 Electric power cable 1 AWG28#
11 Data transmit cable 1 Shield net cable CAT 5
12 JB 1
13 Inner hex bolt 4 M420
14 Flat washer 4 M4
15 Spring washer 4 M4
16 Hex nut 4 M4
9
Figure 4: PDU
Protected Data Unit
Hex nut
Spring washer
Hex bolt
Underwater location beacon
Mounting base
Power Cable Quick release mechanism
(YMA18F3K/YM18T3Z)
Data Cable
(YMA18F4K/YM18T4Z)
Figure 5: Junction Box (JB)

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e
x
n
u
t
S
p
r
i
n
g
w
a
s
h
e
r
F
l
a
t
w
a
s
h
e
r
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10
7.2 Required Tools

Normal shipboard electricians tools are required. Welding equipment is necessary to weld the
stainless mounting base tubes to the deck or pedestal.
7.3 Mounting Procedur
7.3.1 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:
Separation from fuel or other potential fire sources

Separation from probable sources of mechanical damage
Operational environment for continued serviceability
Accessibility for copying of recorded data and for routine maintenance
Facilitation of underwater removal and retrieval by both divers and ROVs, there shall be a
clear unobstructed space in the vicinity of the capsule to allow an ROV or diver to work.
The location should be a minimum of 65 cm from the ships standard compass.
7.3.2 Mounting the PDU

Place the pedestal in the desired location on the ship deck.. Clean the weld surfaces from
corrosion, paint and any other obstructive material that would jeopardize the integrity of the
weld.
Figure 6: PDU mounting base
11
Place the PDU capsule on the mounting base.

The Protected Data Unit should be connected to the mounting base in the steps below. For the
profile dimensions of installing base refer to Figure 7, Figure 8 and Figure 9.
A. Remove the paint from the installing holes in the Protected Data Unit, the faces of base
and the installing faces of the mounting base, and process the installing holes in the
installing support against the screw hole in installing base;
B. Connect the M12 screws for installing base of Protected Data Unit to the mounting base;
Figure 7: Installing Dimension Drawing for the base of the Protected Data Unit
12
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13
Power input
CONSILIUM
Figure 9: Profile drawing for PDU Protected Data Unit
7.3.3 Mounting the Junction Box (JB)

The Junction Box (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 to 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 is located. Junction box dimensions and mounting hole locations are shown in Figure
10. The cover must be removed to access the mounting holes.
188.0
120.0
150.9
4-Mounting Hole
218.9
.0
12
4.
2
Figure 10: Junction Box Mounting Dimension
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 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) 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.
14
7.4 Connections
Warning: it should be ensured that, before connecting the power supply line, the power
supply for the Protected Data Unit should be switched off.
1) The data communication cable (Ethernet cable) and power supply cable are sleeved in
waterproof PVC pipe, and laid and fixed in the transmission distance between VDR main unit
and PDU and the JB;
2) Data cable connection
It is necessary to use shielded cable CAT5 to transmit data between the VDR server and the PDU
through the JB. Only 5 pins of the cable are used in for the connection, the armor shield layer of
any end of the cable should be connected to the VDR shell which is connected to ships deck. One
end with the RJ45 terminal of the data cable will be connected to the Ethernet Switch located inside
the Main Unit, the other end with the connector will be plugged into the data socket of PDU.
The details of connection are shown in table below:
Name of Connection
YMA18F4K YM18T4Z The cable color
signal pin of LAN
TX+ 1 1 2 orange
TX- 2 2 1 Orange/white
RX+ 3 3 3 Green
RX- 4 4 6 Green/white
shield shell shell
Caution:
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 bending diameter of the Ethernet cable shall not be less than 12 times of its own cable
diameter.
C. Connect the data cable to Ethernet HUB inside the Power Unit; the details of connection refer
to Figure 11 below:
Junction Box
D.
Connecter 1 Shield Shield Shield
CEF80/SA 30.75 CEF80/SA 30.75
RED RED
1 +24V +24V +24V
CONNECT
BLUE BLUE TO VDR
2 GND GND GND
GREEN GREEN
3 Shield Shield Shield
1
Shield Shield Shield

Connecter 2 CAT-5 CAT-5 RJ45
Green/White Green/White RX- 6
4 RX- RX-
Green
Green RX+ 3 CONNECT
3 RX RX
Orange/White TO HUB
Orange/White TX- 1
2 Orange
TX- TX- Orange TX+ 2
1 TX TX
Fig. 11
15
3) Power supply cable
The PDU is powered by DC24V from the 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 12: Terminal definition of JB
16
4) Final Inspection
A. Secure the cables between the PDU and the JB to the deck.
B. Visually inspect all connectors to ensure they are fully seated.
C. Visually inspect all glands for tightness.
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 is correct.
G. Close the JB and check JB lid screws for tightness.
5) Applying Power for the First Time

A. Open the JB cover.
B. Apply power to the 24 Volt power supply from the VDR system.
C. Watch for the LED to illuminate on the JB over-voltage protection circuit board. If the LED
does not light up, the fuse may be blown, or the wiring or power supply is incorrect. In this
case, turn off the power and recheck the wiring. The power supply to the PDU should also be
checked with a voltmeter.
D. Check the PDU for proper operation by using a Notebook computer with Ethernet adaptor.
(See Software installation section below)
E. When the PDU is confirmed to be operating properly, replace the JB cover and secure the lid
screws.
17
8. SOFTWARE INSTALLATION INSTRUCTIONS
8.1 General
PDU Protected Data Unit works in the Linux operation system and makes data transmission with
the VDR main unit through standard 10M/100M self-adaptive Ethernet adapter. The Protected Data
Unit and the VDR main unit identifies each other through different IP addresses.
8.2 IP address and password configure

Prepare:
Before configuring, make sure that your PC or notebook is in the same subnet as the PDU. The
default IP address of the PDU is 192.168.5.250, net mask is 255.255.255.0. You can change IP
address of your PC to 192.168.5.121, for example.
Make sure your PC and PDU is connected via a hub or switch.
Login and Configure
The configuration of PDU is processed via telnet login. Users must use a telnet client software to
access the configuration program. There is a telnet client intergrated in Microsoft Windows 2000 or
XP. To use it, you should select "Start" menu and click "Run..." and type "telnet 192.168.5.250" and
press the "Enter" key.
You will see a prompt as "pdc login: " if the connection is okay.
There are two accounts in PDU, one is "vdradmin" and the other is "backup".
The privileges settings for vdradmin and backup are shown in the following table:
Previledge vdradmin backupp
Wtite data Yes No
Read data Yes Yes
Remove files Yes No
Change backups password Yes Yes
Change vdradmins password Yes No
Change ip address Yes No
The default password of vdradmin account is restricted for service engineers.

The default password of backup account is backup.
Log on to the PDU system using the account name and password and type the following command
after the shell prompt ``$``:
$ pdcconf
A menu will be shown and you can select the function you want.
8.3 Replay of data
The recorded data can be replayed by using a playback software - Voyage Data Player (VDP)
(optional) via the VDR Main Unit. See that part of the manual.
18
9. Operating Procedure
9.1 Operation steps

The PDU can be connected to the configured and tested VDR main.
1) Connection of data cable and power supply cable

Connect the power supply cable and data cable of the PDU to the VDR main unit through the JB
and switch on, and the Protected Data Unit will start to operate.
2) Recording data
After being switched on, the Protected Data Unit will be in a waiting state until the VDR main unit
transmits data. When the VDR sends data, the Protected Data Unit will receive data via Ethernet
and store the received data in the data folder of the final memory medium. Such a data storage
process is completed by the operating system software of the PDU, without the need of manual
intervention.
9.2 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 10/100M Ethernet adapter can be used to download the data from PDU
by authorized personnel and by setting correct Ethernet parameters. The data can be replied by
playback software (Voyage Data Player.
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.
19
9.3 Information used for investigation organization

1) Downloading and replaying the recorded data from the Protected Data Unit requires special
software, this software should be provided by the VDR manufacturer.
2) If you want to restore data from an undamaged Protected Data Unit (only protective casing
damaged), you may read the data from the Ethernet connection through normal operation
procedure.
Note:
If data must be restored from a damaged Protected Data Unit contact:
Consilium Navigation AB in Nacka Sweden
Tfn:+46(8) 563 051 00,
Fax:+46(8) 563 051 99,
E-mail: vdr-service@consilium.
20
10. MAINTENANCE
10.1 When to release the PDU?

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

1) Disconnect the two water-proof connectors from PDU.
2) Pull the release handle out completely (200N)
3) Lift up the top half of the PDU (>250N)
4) Unplug the data and power cables.
Caution: While the release mechanism is unconnected, dont lift the PDU too high
(length<150mm), in order to avoid the damaging or breaking of the data cable.
See below for the release process:
Figure 13: Release procedure
21
10.3 Routine Maintenance

10.3.1 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 a 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 PDUs 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 Consilium Highlander s factory for
repair 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 PLACED INTO
STATIC SHIELDING CONDUCTIVE BAGS WHEN HANDLING OR STORING.
10.3.2 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.
10.3.3 Check and replacing of cables
Periodically check 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 cables are
needed. It is recommended to make the checking according to the same as the checking cycle of the
VDR system.
10.3.4 Check and replacing the O-ring
Periodically check the O-ring to see whether it is aged. The checking and replacing of the O-ring
should be made after releasing the release mechanism and by the special technical personnel, to
ensure the water-tightness of casing after replacing. It is recommended to make the checking
according to the same as the checking cycle of the VDR system.
22
10.3.5 Checking of installing base fastening screws

Periodically check the fastening screws of installing base to see whether they are loose, and make
strengthening treatment. It is recommended to make the checking semi-annually.
10.3.6 Corrosion-proof and rust-proof treatment of casing surface

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 spread 3#calcium grease on
the release mechanism, screws and other places where may be rested.
PDU is solid-state equipment without detachable mechanical or electronic components. If it is

verified that there is a problem with the PDU, it is necessary to send it to the appointed
maintenance point to be changed or repaired.
10.4 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 separeted from the mounting base.
11. DATA RECOVERY AFTER AN ACCIDENT

If an accident has damaged the capsule or the VDR data collecting system, the capsule must be
returned to the manufacturer for repair and download assistance.
Phone: +46 8 563 051 00
Fax: +46 8 563 051 99
Email: vdr-service@consilium.se
23
Consilium VDR
Data Acquisition Unit
Manual
Article No. 709233

Revisions:
05-04-08 A0 HL Created
05-08-01 A1 NE Corrections and adaptation to manual standard

Call: +46 8 563 051 00 Email: vdr-service@consilium.
Fax: +46 8 563 051 99

CONSILIUM VDR DAU MANUAL ART NO.
709233A1
TABLE OF CONTENTS
1. NOTES AND UPDATES ........................................................................................................................... I
2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS ........................................................ I
3 LETHAL WARNING! .........................................................................................................................2
4 FIRST AID IN CASE OF ELECTRIC SHOCK................................................................................3
5 DATA ACQUISITION UNIT (DAU) INSTALLATION .........................................................................4
5.1 SELECTION LOCATION ............................................................................................................................4

5.2 INSTALLATION MATERIALS .....................................................................................................................5
5.2.1 The DAU Components Diagram ....................................................................................................5
5.2.2 Installation materials .....................................................................................................................6
5.3 MOUNTING PROCEDURE .........................................................................................................................6
5.3.1 Installation Preparation.................................................................................................................6
5.3.2 Installation method ........................................................................................................................6
5.4 CONNECTION ..........................................................................................................................................8
5.4.1 Connection Preparation.................................................................................................................8
5.4.2 Cable entry.....................................................................................................................................9
5.4.3 Wiring ..........................................................................................................................................10
5.4.4 Grounding ....................................................................................................................................10
5.4.5 Connect the cable.........................................................................................................................11
5.4.6 Fixing ...........................................................................................................................................11
6 ACQUISITION MODULES.....................................................................................................................12
6.1 LOCATION AND CONNECTION................................................................................................................17

6.2 REMOVE AN ACQUISITION MODULE FROM THE DAU ............................................................................17
6.3 SETTINGS ..............................................................................................................................................18
6.4 HOW TO REPLACE AN ACQUISITION MODULE ........................................................................................19
APPENDIX 1 DAU WIRING DIAGRAM .............................................................................................21
APPENDIX 2 DAU OUTLINE AND INSTALLATION DRAWING (HLD12.8 AZ ........................21
3 Lethal Warning!
2 (22)
709233A1
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

3. Tilt victims head back as far as
possible and raise his head

6. Cover the victims 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 victims head back as far as
possible at all times.
3 (22)
709233A1
5 Data Acquisition Unit (DAU) Installation

5.1 Selection Location
The mounting location shall fulfill the following conditions:
Refer to DAU installation diagram, for the mechanical dimension drawing.
The location needs to provide adequate space for cabling.
Cables between the DAU and the VDR should be kept as short as possible.
The location shall not expose the unit to excessive vibration.
The location must be far from electrical equipment, e.g. radar transceiver and radio
communication equipment, etc., emitting excessive electric and/or magnetic field.
The location must be easily accessible even with the front door opened, for operation,
maintenance and installation work, etc.
The grounding cable shall be kept as short as possible.
The location shall be protected from weather and offer a stable temperature.
4 (22)
709233A1
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
5 (22)
709233A1
5.2.2 Installation materials

Component Fix Power Supply Box
Index Name Picture Description Qty Remarks
1)
Inner hexagon M840 4 Mounting bracket
head bolt
2)
Flat washer 8 4 Mounting bracket
3)
Locking 8 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 H1.0H1.5
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.
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
Fig 1-2
6 (22)
709233A1
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/yard supply) 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
7 (22)
709233A1
5.4 Connection
5.4.1 Connection Preparation

Before connecting, please refer to the VDR drawings issued by Consilium 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, external power supply
must be turned off.
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.
HEX NUT
HEX NUT
HERMETIC RUB
HERMETIC RUBBER
GLAND BODY GLAND BODY
LOCKSHEATH LOCKSHEATH
LOCKNUT LOCKNUT
CABLE
Fig 1-5 Structure of the gland
8 (22)
709233A1
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 14-16 4
TJM22 20-22 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:
GLAND
CABLE
Fig1-6 Run the cable through the gland
9 (22)
709233A1
5.4.3 Wiring
Cable termination:
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 NSIU framework.
Fig1-8
NSIU FRAMEWORK
GROUNDING BOARD
Fig 1-8
10 (22)
709233A1
5.4.5 Connect the cable
Connect the phoenix terminals with the phoenix socket of the acquiring module Fig1-9
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
11 (22)
709233A1
6 Acquisition modules
There are several different acquisition input modules available, for example: Analog
Current Module, Analog Voltage Module and Dry Contact Digital 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.
Analog Voltage Module:
Fig 2-1 Analog Voltage Module

Input range: -10V~+10V
Input signal number: 4
Input Impedance: >100K
Resolution : 12 bit
Bipolar Offset @ +25 : <5 bit
Isolation voltage:
Input-Output: 500V DC
Channel-Channel: 500V DC
Output precision: 0.5%
Power Consumption: 330mA +5V
50mA +12V/+15V
50mA -12V/-15V
Working Temperature: -20 ~ +70
Storage Temperature: -40 +85
12 (22)
709233A1
Note: Output Value (X) and Input Voltage (Y, unit: V ) formula:
Y = (X-2048) / 204810When Y=0V, X=2048.
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.
13 (22)
709233A1
Analog Current Module
Fig 2-2 Analog Current Module

Input range: 4 ~ +20mA
Input signal number: 4
Input Impedance: 100
Resolution : 12 bit
Bipolar Offset @ +25 : <5 bit
Isolation voltage:
Channel-Channel: 500V DC
Output precision: 0.5%
Power: 330mA +5V
50mA +12V/+15V
50mA -12V/-15V
Working Temperature: -20 ~ +70
Storage Temperature: -40 +85
Note: (1) Output Value (X) and Input Voltage (Y, unit: mA) formula:
Y = (X-2048) / 204810 When Y=0mA, X=2048.
(2) The terminals definition same as for Analog Voltage Module.
14 (22)
709233A1
Dry Contact Module
Fig 2-3 Dry Contact Module
Channels: 16
Input Impedance: 150K
Isolation voltage:
Output precision: No Error
Power: +5V 15mA
+24V 30mA (16 channels are 0)
+24V 90mA (16 channels are 1)
Working Temperature: -20 ~ 70
Storage Temperature: -40 85
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 D2 D0 GND
Note:
(1) GND is input signal common reference.
(2) Dx: Digital input number.
15 (22)
709233A1
Central Module
Fig 2-4 Central Module
Power Supply: +24V (18~36V)

Output Power: +5V/4A, +12V/+15V/0.6A, -12V/-15V/0.6A
Input data protocol: RS-485, baud rate is 57,600bps
Output data protocol: RS-485, baud rate is 19,200bps
The output is a standard IEC 61162-1 sentence.

$VRXDR,type,data,unit,id,....*hh<CR><LF>
Type filed: S = switch open/closed
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,2046,,0601,G,2054,,0602,G,2049,,0603,G,2049,,0704*4D
1 2 3 4 5 6 7 8
24V+ 24V- +15/12V -15/-12V VCC GND B A
Note:
(1) Only one Central Modules can be connected.
(2) All module addresses must be individual otherwise the internal communication
will fail because more then one module will transmit data at the same time.
(3) All acquiring modules can be configured by the onboard DIP switch.
16 (22)
709233A1
(4) The DIP switch in the Central Module is for configuring the number of acquiring
modules the controller manages.
If you need another kind of acquiring modules to be replaced, please contact us.
When you change the position or replace an acquiring module, you should set its address
correctly and plug-in the DAU box, nothing else is not needed.
6.1 Location and connection

Acquiring Modules connect their input signals with phoenix plugs to sockets on the
PCB board.
ACQUIRING MODULES
INSTALLATION LOCATION
Fig 2-3 Acquiring modules installation location
6.2 Remove an acquisition module from the DAU

Procedure:
Turn off the DAU power source.
Please refer to the installation drawings in order to confirm the mounting location of
the acquiring module(s) (to be replaced) in the NSIU framework
Loosen the fixed cable.
Disconnect the phoenix plug from the acquiring module.
Loosen and the two mounting bolts of the acquiring module
Refer to (Fig 2-5) Remove the acquiring module
17 (22)
709233A1
NSIU FRAMEWORK
SIGNAL ACQUIRING MODULE
MOUNTING BOLTS
Fig 2-5
6.3 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 must most likely 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.
Fig 2-6 Address Setting SwitchAnalog Voltage Module

Note: Same procedure for Analog Current Module.
18 (22)
709233A1
Fig 2-7 Address Setting SwitchDry Contact Module
6.4 How to replace an acquisition module

After the address has been configured, it may be mounted. Following procedure should be
followed:
Push the acquiring module into the socket on the motherboard along the rails. Note
the direction of the modules components side, and ensure that the connection
between the plug on the module and the socket on the motherboard is reliable and
tight.
Fix the acquiring module to the NSIU by screwing the two mounting bolts into the
modules bracket and the framework.
Insert the disconnected Phoenix plug into the socket on the acquiring module. Ensure
they are connected tight and reliable.
Fix the front cover to the NSIU frame
Power on the DAU and verify the functionality from the VDR or other means.
19 (22)
709233A1
20 (22)
CONSILIUM VDR DAU MANUAL ART NO. 709233A1
Appendix 1 DAU WIRING DIAGRAM

Appendix 2 DAU OUTLINE AND INSTALLATION DRAWING (HLD12.8 AZ
21 (22)
VDR
Consilium Power Supply
Manual
Article No. 709241

Consilium VDR PSU Manual Art No. 709241A1

Revisions:
05-03-10 A HL Created
05-03-23 A0 MC Minor corrections
05-05-18 A1 MC Minor correction + adding compass safe dist.

Call: +46 8 563 051 00 Email: VDR-Service@consilium.se
Fax: +46 8 563 051 99

ii (17)
Table of Contents
1. NOTES AND UPDATES ......................................................................................................... II
2. WHERE TO CALL IN CASE OF PROBLEMS OR FAULTS .................................................. II
3. LETHAL WARNING!............................................................................................................... 4
4. FIRST AID IN CASE OF ELECTRIC SHOCK......................................................................... 4
5. OVERVIEW OF THIS MANUAL.............................................................................................. 5
5.1. General Information ......................................................................................................................... 5
5.2. Notes on Connections and EMI........................................................................................................ 5
6. POWER SUPPLY UNIT 709241 ............................................................................................. 6
6.1. Principle of operation........................................................................................................................ 6
6.2. Block diagram.................................................................................................................................... 8
6.3. Technical Data ................................................................................................................................... 9
7. INSTALLATION .................................................................................................................... 13
7.1. Cabling Between Main Unit and Power Supply Unit................................................................... 13
7.2. Selecting Location ........................................................................................................................... 15
7.3. Mechanical Mounting ..................................................................................................................... 16
7.4. Start up............................................................................................................................................. 16
8. SPARE PARTS LIST ............................................................................................................ 17
3 (17)
3. Lethal Warning!
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.

and raise his head

into children.
9. Keep victims head back as far as possible
at all times.
4 (17)

general information for installation of hardware and wiring of the power supply unit. The PSU 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
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.

A drawing of the Power Supply Unit can be found in the Mechanical Drawings chapter.
5.2. 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.
5 (17)
6. Power Supply Unit 709241

6.1. Principle of operation
B atteries
C ha rger U nit
C on nection
Term inal
F ilter
The PSU provides 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 backup power is provided by valve-regulated batteries and is dimensioned to operate for 2
hours.
Alarms are sent to the VDR for the following conditions:
AC mains failure
Battery failure
The battery voltage is to low, <20V.
Two minutes after that the shutdown command have been received from the VDR the PSU will
shutdown, during this time the PSU is sending information to the VDR that shutdown is
pending.
If battery voltage goes below 19 V the PSU will also shut down.
The PSU is housed in an IP44, splash proof, cabinet, which is intended for wall mounting.
6 (17)
Only front access is required to operate the PSU.
7 (17)
6.2. Block diagram
+ - + -
BATTERY1 J3
BATTERY2
- + - +
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
BOARD
J4
9 8 7 6 5 4 3 2 1
CTS DSR TxD RxD
PSU
Block Diagram +12 0V RX3 TX3 + - L N ACG VDR
Z2 Z1 Z1
RS232 DC out AC in
General layout of the system
8 (17)
6.3. Technical Data
6.3.1. Mechanical
The PSU is housed in an IP44, splash-proof cabinet with dimensions H=500 mm, W= 380mm and
D=210 mm. All cable entries 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)
470.0
430.0
380.0
4x
8
.5
M
ou
nt
ing
Ho
Screw M8 les
Washer
430.0
500.0
525.0
9 (17)
6.3.2. 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 terminals

Rectifier is also protected by internal T10A fuse
6.3.3. 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.
10 (17)
6.3.4. Alarms and indications
Communications interface unit
Interface RS232 speed 1200, N, 8.2
VDR requests status by sending 09h, 00h, 01h, 5Fh

PSU responds by sending status byte and a checksum
Bit representation
00 AC fail
01 Shutdown pending
05 Battery fail
07 Battery low
The checksum is calculated as follows:

Status byte +55h
Example:
Status byte=00h
PSU sends 00h,55h
Shutdown command from VDR 09h,00h,11h,6Fh

Disconnects the Output Voltage from PSU after 2 minutes
Output Voltage returns when AC input is switched

OFF and ON again.
Battery low <20 VDC
Battery off <19 VDC
11 (17)
6.3.5. Battery specification

Type: NP-12 24AH
Manufacturer: China East Company in Yang Zhou, Jiangshu Province, P.R. China.
Voltage : 12 V per block
Expected life: 3-5 years at 20 C
Capacity: 24 Ah, dimensioned to provide min. 2 hours backup
6.3.6. Environmental specifications

According to requirements in IEC 60945, class Protected IP44
6.3.7. EMC specifications

According to requirements in IEC 60945, class Protected
6.3.8. Compass safe distance

Steering, standby and emergency compass 33 cm
12 (17)
7. Installation
7.1. Cabling Between Main Unit and Power Supply Unit
General Information
The power supply cable should consist of two stranded 2.5 mm wires for powering the VDR.
All cabling to the Unit should be brought through the cable glands in the bottom of the cabinet.
Shields shall be grounded in the PSU (cable glands).
All cables shall be connected to the pressure 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 Ships Ground
Terminal 2 AC in Ships AC Supply N
Terminal 3 AC in Ships AC Supply L
Terminal 4 DC out - VDR 24 IN Return
Terminal 5 DC out + VDR 24 IN Positive
Terminal 6 RS232 RxD VDR VUB2 TX3 (J12)
Terminal 7 RS232 TxD VDR VUB2 RX3 (J13)
Terminal 8 RS232 DSR VDR VUB2 0V (J14)
Terminal 9 RS232 CTS VDR VUB2 +12V (J15)
13 (17)
Inter-connections
ships 85-265 VAC supply
PSU terminal VUB2 terminal Cable Type: Two twisted pairs with common screen
# #
6 TX3 (J12) Control VDR -> PSU / Note: VUB TX3 should connect to PSU 6
7 RX3 (J13) Control PSU -> VDR / Note: VUB RX3 should connect to PSU 7
8 0V (J14) Control GND
9 +12V (J15) Control +12 V
PSU terminal Main Unit Cable Type: Two stranded 2.5 mm2 conductors
# terminal #
4 0 24 V return. If possible use black wire
5 + 24 V positive. If possible use red wire
PSU terminal Ships Power Cable Type : Three stranded 1,5 mm2 conductors, brown, blue and
# yellow/green
1 Earth PSU -> ships earth ground. Use yellow-green wire
2 85 - 265 VAC PSU live or neutral -> Ships 85 265 VAC supply
3 85 265 VAC PSU live or neutral -> Ships 85 265 VAC supply
14 (17)
Identifying Wires
The control wires (#6, 7, 8 and 9) will have to be identified by inspection.
Powering up the Power Supply Unit and checking the polarity to identify the DC wires.
The 85 265 VAC wires must use the standardized colors to avoid any conflicts in
identification.
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.

Up to 265 volts alternating current exists inside the Power Supply Unit on exposed terminals. Do
Notes on connections and EMI

See also the General Notes on EMI, Cables and Connections chapter of the "VDR Installation
Manual".
7.2. Selecting Location

The location shall be far from electrical installations giving excessive electric and/or magnetic
fields.
The cabinet shall be easily accessible.
The Power Supply Unit bottom shall be placed approximately 0.5 m from the floor where
practical.
The standard cable length between PSU and Main Unit is 10 m.
15 (17)

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.
7.4. Start up
7.4.1. 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 PSU run for at least 15 minutes.
To power down the PSU switch OFF the AC input and then press the switch marked Battery
OFF on the PCB for at least 3 seconds.
7.4.2. Testing
There is no mains switch in the PSU 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.
16 (17)
8. Spare Parts List

Description Part number
Battery B43244012
Rectifier A26025024
Fuse kit c/o F93316301
2 pcs T6.3 A 250 V 5*20
Air vent M14094701
17 (17)
INSTALLATION AND OPERATION
INSTRUCTION MANUAL
HARDENED VOYAGE RECORDER (HVR)
HVR PART NUMBERS

HVR00XXX--00
HVR01XXX--00
Initial Issue
Jun. 01/02 P/N: 165E2790--00
HARDENED VOYAGE RECORDER
INSTALLATION AND OPERATION MANUAL
HVR Manual 165E2790--01

Initial Issue
Jun. 01/02
The recorder products/software are being exported

from the United States in accordance with the Export
Administration Regulations ECCN 4D994, No License
Required. Diversion contrary to U.S. law is prohibited.
In accordance with U.S. Law (31 CFR Part 746, and
Supplement No.1 to Part 774, and CFR Part 550) re-
sale/re--export or transfer to the countries identified
therein is prohibited without the prior written consent
of the U.S. Department of Commerce.
This manual contains date sensitive information.

To verify the latest revision level of this manual,
visit our document download site at
http://www.L-- 3ar.net.
ECopyright 2002 by L-3 Communications.

All rights reserved. No part of this manual may be re-
produced or utilized in any form or by any means, elec-
tronic or mechanical, including photocopying, record-
ing, or by information storage and retrieval system,
without permission in writing.
Inquiries should be addressed to:

L-3 Communications
Aviation Recorders Publications
Vendor Code: 06141
P. O. Box 3041
Sarasota, Florida 34230
Phone: (941) 3710811
FAX: (941) 3775591
Hardened Voyage Recorder

Initial Issue Page ii
Jun. 01/02
GENERAL
This product and related documentation must be reviewed for familiarization with safety
markings and instructions before operation.
This board was constructed in an ESD (electrostatic discharge) protected environment. This is
because most of the semiconductor devices used in this board are susceptible to damage by static
discharge.
Depending on the magnitude of the charge, device substrates can be punctured or destroyed by
contact or mere proximity of a static charge. The results can cause degradation of device perfor-
mance, early failure, or immediate destruction.
These charges are generated in numerous ways such as simple contact, separation of materials,
and normal motions of persons working with static sensitive devices.
When handling or servicing equipment containing static sensitive devices, adequate precautions
must be taken to prevent device damage or destruction.
Only those who are thoroughly familiar with industry accepted techniques for handling static sen-
sitive devices should attempt to service circuitry with these devices.
In all instances, measures must be taken to prevent static charge buildup on work surfaces and
persons handling the devices.

Initial Issue Page iii
Jun. 01/02
THIS PAGE IS INTENTIONALLY LEFT BLANK

Initial Issue Page iv
Jun. 01/02
TABLE OF CONTENTS
SUBJECT/DESCRIPTION PAGE
SECTION 1 - Hardened Voyage Recorder Introduction
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
1.1. Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
1.2. Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.3. Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.4. Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.4.1 Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.4.2 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
1.4.3 Interface Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
1.4.4 Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
1.4.5 HVR Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
SECTION 2 -- HARDWARE INSTALLATION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2. HVR Power Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
3. Ethernet Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
3.1. Ethernet Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
3.2. Ethernet Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--5
4. Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6
SECTION 3 - SOFTWARE SETUP
1. HVR Configuration Via The Default Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
1.1. L3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
1.2. Setting IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
1.3. Configuring Memory Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6
1.4. Changing Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
1.5. System Maintenance Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--10
1.6. System Information Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12
1.7. System Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--13
1.8. Trace Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--14

Initial Issue Page v
Jun. 01/02
TABLE OF CONTENTS
(Continued)
1.9. Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--14
1.10. Flag Decoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--16
SECTION 4 - HVR INTERFACE
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
2. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
2.1. The Client--Server Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--4
2.2. The Transmission Control Protocol (TCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--5
2.3. The TCP Client--Server Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--5
2.4. The HVR TCP Storage Interface Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--6
2.5. Write to Specified HVR Partition and the Storage Loop Model . . . . . . . . . . . . . . . . . . . 4--7
2.6. Read from Specified HVR Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--8
2.7. Status Query for Specified Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--10
2.8. Closing TCP Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--11
2.9. The Berkeley Socket Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--12
2.10. Socket Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--14
2.11. HVR Web (HTTP) Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--16
2.12. HVR FTP Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--17
2.13. HVR Trace Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--17
2.14. HVR Message Format Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--18
2.15. Write to Specified Partition: Wname . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--18
2.16. Read from Specified Partition: Rname . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--19
2.17. Status Query on Specified Partition: Sname . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--19
2.18. Response Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--20
2.19. Limitations on Reading and Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--20
SECTION 5 -- MAINTENANCE
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
2. Approved Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
2.1. Memory Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4

Initial Issue Page vi
Jun. 01/02
TABLE OF CONTENTS
(Continued)
2.2. Memory Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
2.3. Power and Processor Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
2.4. Power and Processor Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
2.5. Underwater Locator Device (Beacon) Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
LIST OF FIGURES
FIGURE TITLE PAGE

Figure 2--1. HVR Base Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--7
Figure 2--2. HVR Hull Grounding Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--8
Figure 2--3. HVR Ethernet Cable Pigtail Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--9
Figure 2--4. HVR AC Power Cable Pigtail Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--10
Figure 2--5. HVR DC Power Cable Pigtail Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--11
Figure 2--6. Ethernet Connection With Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
Figure 2--7. Ethernet Connection With RJ--45 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--13
Figure 3--1. HVR Website Home Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
Figure 3--2. HVR Website Login Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
Figure 3--3. HVR Website Network Setup Data Entry Form . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6
Figure 3--4. HVR Part Number HVR01--XXX--0X NAND--Flash Manager
Memory Setup Data Entry Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--7
Figure 3--5. HVR Part Number HVR00--XXX--0X NOR--Flash Manager
Memory Setup Data Entry Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
Figure 3--6. HVR Change Password Data Entry Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--10
Figure 3--7. HVR System Maintenance Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11
Figure 3--8. HVR System Information Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12
Figure 3--9. System Test Modes Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--13
Figure 3--10. Event Log Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--15
Figure 3--11. Flag Decoder Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--16
Figure 5--1. HVR Bell House Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
Figure 5--2. HVR Base Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6

Initial Issue Page vii
Jun. 01/02
LIST OF TABLES
TABLE TITLE PAGE

Table 1--1. Hardened Voyage Recorder Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
Table 2--1. Internal Power Terminal Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
Table 2--2. Internal Ethernet Terminal Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
Table A--1. HVR Maintenance Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--3

Initial Issue Page viii
Jun. 01/02
SECTION 1

INTRODUCTION

Initial Issue Page 1--1
Jun. 01/02
THIS PAGE IS INTENTIONALLY LEFT BLANK.

Jun. 01/02
1. INTRODUCTION
It has long been noted that the investigation of maritime accidents and incidents could
benefit from the recording of data and audible commands occurring aboard ships. In-
deed, many considered this an inevitable technological extension of the time-- honored
ships logbook. This desire has culminated in the development of an international stan-
dard governing the performance of a Voyage Data Recorder (VDR).
The IEC 61996 Shipborne Voyage Data Recorder Performance Requirements describes
data acquisition and storage functions and refers to a protective capsule and a final
storage medium. Architecture for complying with this standard has emerged that has
two major components. In the first, the ships interfaces, data acquisition, and soft re-
cording functions are encompassed in the Data Management Unit (DMU). The DMU is
intended for installation in the relatively benign environment of the bridge. The second
component is the Hardened Voyage Recorder (HVR) that encompasses the protective
capsule, final storage medium survivability and recoverability functions. The HVR is in-
tended for external installation on the bridge deck or on top of the superstructure.
The primary function of the Hardened Voyage Recorder (HVR), is a protective capsule
for the data acquired by the Voyage Data Recorder (VDR). The data will be used during
accident investigation.
1.1. Background
In 1974 the Safety of Life at Sea Convention (SOLAS) of the International Maritime Or-
ganization (IMO) acknowledged the value and expressed the desire of having recorders
on ships similar to the black box flight recorders for aircraft. Thus began the long pro-
cess of establishing international standards and requirements for a Voyage Data Re-
corder (VDR).
In 1996, VDR requirements, which had been debated for a long time, began to form in
the navigation and electronics subgroup (NAV) of the IMO. Anticipating an eventual
IMO resolution concerning VDRs, IEC TC80 formed WG11, which began structuring a
specification based on preliminary drafts of the NAV requirements. The IMO passed
resolution A.861 (20) in Nov. 1997 and the IEC standard 61996 was completed as a
Committee Draft for Voting in March 1999. The spec was published in August of 2000.

Jun. 01/02
1.2. Acronyms and Abbreviations

AAMM Audio Acquisition and Microphone Mixer
VDR Voyage Data Recorder
HVR Hardened Voyage Recorder
IEC International Electrotechnical Commission
IMO International Maritime Organization
TCP/IP Transmission Control Protocol/Internet Protocol
VHF Very High Frequency
RF Radio Frequency
RTCA Radio Technical Commission for Aeronautics
1.3. Reference Documents

ICS 6--1993 Industrial Control and Systems Enclosures
IEC 60945 Maritime navigation and radio communication equipment and
systems -- General requirements -- methods of testing and
required test results
IEC 61996 Shipborne Voyage Data Recorder (VDR) -- Performance
Requirements ---- Methods of Testing and Required Test Results.
First Edition 2000--07
IEEE 802.3 Institute of Electrical and Electronics Engineers, Part 3: Carrier
Sense Multiple Access with Collision Detection (CSMA/CD)
NEMA 250--1997 National Electrical Manufacturers Association, Enclosures for
Electrical Equipment (1000 Volts Maximum)
1.4. Characteristics
1.4.1 Performance Characteristics
The HVR Communicates with the VDR or host PC over Ethernet using TCP/IP. The
HVR is capable of recording, reproducing data and reporting BITE information. With the
HVR00--XXX--00 configuration, the total memory size is 1.5 gigabytes. The memory can
be configured with up to ten partitions with a minimum granularity of two devices (32
megabytes), into any configuration required by the data collection subsystem.
The HVR01--XXX--00 has an increased capacity of up to 6.8 gigabytes. The memory

technology is different than the HVR00--XXX--00, and can be configured with up to ten
partitions with a much smaller granularity of a minimum of two blocks of 16 kilobytes (32
kilobytes).
NOTE: The memory is expandable. If the application in use re-

quires more than 1.5 gigabytes of storage capacity, contact
L--3 Communications.

Jun. 01/02
1.4.2 Physical Characteristics
The HVR is composed of two subassemblies. A mounting base subassembly is directly

fastened to the ship and provides a water tight cable entry for power and Ethernet con-
nections. A removable hardened memory subassembly is attached to the mounting
base with a quick releasing v--band clamp. The HVR has an externally mounted under-
water location beacon, with dual activation sensors to avoid inadvertent activation due
to spray/rain/hosing off.
The HVR is painted a highly visible fluorescent orange with white reflective labels. The
reflective labels contain the required text: VOYAGE DATA RECORDER, DO NOT
OPEN, REPORT TO AUTHORITIES.
1.4.3 Interface Characteristics
The Ethernet interface is an autosensing 10/100base--T/STP (shielded twisted pair),

category 5 with flammability per IEC 95. All power and Ethernet connections are gal-
vanically isolated from the case.
The power connection supports both AC and DC supplies. Power consumption is

assumed to be less than 3 Watts. The maximum cable length should be 75 meters or
less. The recommended minimum wire gauge is AWG #20 or less, for 24 VDC opera-
tion. For 110/220 VAC the recommended minimum wire gauge is AWG #28 or less.
1.4.4 Environmental Characteristics
The Hardened Voyage Recorder is qualified for the exposed environmental qualification
categories of IEC 60945.
1.4.5 HVR Parts List
Table 1--1 provides a listing of HVR replacement components available from L-3 Com-
munications. Refer to Table 1--1 when ordering replacement parts. The Hardened Voy-
age Recorder, p/n: HVR00XXX-00 and p/n: HVR01--XXX--00, provides all of the
components listed in Table 1--1. If replacement parts are needed use the part number
associated with that component and not the top level part number.

Jun. 01/02
Table 1-- 1. Hardened Voyage Recorder Parts List
Part Number Description Quantity

HVR00--XXX-0X Hardened Voyage Recorder 1
or
HVR01--XXX-0X
169E--2400-0X Protective Capsule 1
166E--24XX--00 Label, Reflective, HVR 2
221--98--00074 O--Ring, Mesh, inner, 0.98XSECT, 1
ID 8.075
221--98--00075 O--Ring, Silicon, outer, 0.103XSECT, 1
ID 8.487
047--98--00101 Clamp, 9.06 ID V--Band, Q--RLS 1
418E--2711--00 Module, Power Supply & Processor 1
010E--2400--00 Mounting Base Assembly, HVR 1
279--98--00052 Cable Gland, Waterproof, Feedthru, 2
0.19 --0.25
024--98--00340 Cable, Shielded, CAT5 *
266--98--00011 Beacon, ULB, Dual Cont SW 1
980--98--00003 Spanner Wrench, ULB 1
980--98--00002 Vise Clamp, ULB 1
981--98--00002 Test Set, Dukane TS300 1
981--98--00001 Calibration Kit, TS300 1
011--98--00034 Kit, Beacon Battery, ULB 1
* Cable is measured in feet. When ordering, the customer must specify number
of feet required.
NOTE: The Maintenance Cover, p/n: 075E--2458--00, must be or-

dered separately. The Maintenance Cover is required to
perform maintenance on the internal components of the
HVR.
NOTE: Additional spare parts for the Dukane Underwater Locator

Beacon may be available. Please contact L--3 Communica-
tions for further information.

Jun. 01/02
SECTION 2
HARDWARE INSTALLATION

Jun. 01/02

Jun. 01/02
HARDWARE INSTALLATION
1. GENERAL
This section provides information for the minimum wiring requirements, ethernet cabling
requirements, setting the IP address, installation procedure, and configuring the memory
partitions of a Hardened Voyage Recorder.
2. HVR POWER CONNECTION REQUIREMENTS

The HVR operates from AC or from DC power, both of which can be active at the same
time. The stepped down and bridge rectified AC feeds the same storage capacitor that
is fed through a diode by the DC, so the higher voltage at the anodes will provide the
operating current. IEC 61996 paragraph 4.5.3 requires a two hour reserve uninter-
rupted power source (UPS). When connecting the ships UPS system to the HVR, ei-
ther the AC or DC input may be used. The primaries of the AC input transformer can be
strapped in parallel for 115 Vrms or in series for 230 Vrms by means of interconnecting
the designated wires at the end of the power wiring pigtail. Refer to Table 2--1.
The HVR uses approximately 2.5 Watts. The operating DC power input range is from
19.5 to 36.5 Vdc while the HVR will not be harmed by DC input voltages up to 100 Vdc
in either polarity. The operating AC power input range, when strapped for 115 Vrms, is
85 to 150 Vrms at 45 to 500 Hz while the HVR will not be harmed by AC input voltages
to 250 Vrms at 45 Hz, 280 Vrms at 50 Hz, or 300 Vrms at 60 Hz. The operating AC
power input range, when strapped for 230 Vrms, is 170 to 300 Vrms at 45 to 400 Hz
while the HVR will not be harmed by AC input voltages to 500 Vrms at 45 Hz, 560 Vrms
at 50 Hz, or 600 Vrms at 60 Hz.
Table 2--1. Internal Power Terminal Board Wiring
Terminal Name AWG Max. Comment

1 Hull Ground # 18 Connected to case and circuit boards.
2 24 VDC # 20 Steady load less then 0.2 amps.
3 24 VDC Return # 20 Ground for primary circuitry.
4 AC Ground # 28 Alternative ground for terminal 3.
5 AC Line 1 # 28 115 or 230 Vrms
6 AC Line 2 # 28 between
b t AC liline 1 and
d AC liline 2.
2
7 Primary 1 P # 28 Connect 1 P to 2 P and 1 M to 2 M for 115 Vrms.

8 Primary 2 P # 28
Connect 2 P to 1 M for 230 Vrms.
9 Primary 1 M # 28
10 Primary 2 M # 28

Jun. 01/02
The internal electronics are operated by the DC power from the secondary of the switch-
ing transformer, and is isolated from the AC and DC power lines. The secondary
ground, which is connected to the case and the ethernet shield, must be tied to the hull
to prevent voltage difference that could induce corrosion. The case is bonded to the hull
via external tooth lockwashers clamped between the bare metal of the mounting bosses
and the bared hull by the mounting bolts.
The Ethernet cable is shielded to help protect it from the expected intense RF fields.
The foil shield is clamped to the case after it has passed through the sealed pipe nipple
and the twisted pairs continue to their termination on the HVR Processor.
3. ETHERNET CONNECTION REQUIREMENTS
3.1. Ethernet Cable Connection

The Ethernet connection to the Hardened Voyage Recorder requires shielded Category
five (CAT5) cable and can be made one of two ways.
The most convenient way is to route the three meter weatherproof pigtail to a junction
box in a protected area. The shield of the CAT5 cable from the HVR must connect to
the shield of the CAT5 cable that goes to the PC, where it is then connected to the
grounded PC chassis.
Table 2--2. Internal Ethernet Terminal Board Wiring
Name Terminal--J3 RJ45--J2

HVR TX--LO 1 1
HVR TX--HI 2 2
HVR RX--HI 3 3
HVR RX--LO 4 6
The alternative is to open the HVR, disconnect the provided cable, remove the pipe nip-
ple containing it, place a new nipple, thread and bond a shielded cable to it and con-
nect; ensuring that the shield is clamped to the case.
The Ethernet cable supplied with the HVR has a stiff, tough, UV resistant, insulating out-
er layer. The next layer is corrugated copper whose corrugations, when supported by
the outer layer, enable gentle bends in the cable. When the supporting outer layer is
removed, the corrugations act as tear lines and slight bending of the unsupported shield
results in breaking the shield.
When it is necessary to connect to the shield, as one must when entering a shielded en-
closure, care must be taken to clamp the parts of the cable leading to the exposed
shield so that movement in the rest of the cable cant bend the exposed shield.

Jun. 01/02
3.2. Ethernet Grounding
The Ethernet cable needs careful protection from the severe RF environment in which it
must be installed. Shielded category 5 cable must be used with good RF grounds at
both ends.
At the HVR end, the Ethernet cable shield is well connected to the HVR housing by a
retaining clamp but it is the installers responsibility to ensure that the HVR housing is
RF grounded to the hull. This is done by baring the mounting surface of the hull around
the 3 mounting bolts so that the supplied stainless external tooth lockwasher contacts
the hulls metal while the other side of the lockwasher contacts the metal of the HVRs
mounting boss. Silicone sealant is applied to all the bared metal before assembling and
tightening.
In many installations an intermediate connection, such as a junction box, is placed be-

tween the HVR and the host. The RF environment on the bridge is nearly as severe as
on the deck (IEC 60945, Annex C, Table C.2). Testing has demonstrated that an un-
shielded terminal board where the entering and leaving shields are joined by wires to
the terminal board is not acceptable. A shielded RJ--45 jack is supplied for the installer
to connect to the end of the HVRs shielded category 5 cable. The socket, in turn, must
mate with a shielded RJ--45 plug that continues on to the host. If a terminal board is
necessary, it must be in a shielded enclosure where the entering and leaving Ethernet
shields are bonded to the shielding enclosure. The enclosure should be bonded to the
hull.
At the host end of the shielded category 5 Ethernet cable another good RF connection
to the hull is needed. A shielded RJ--45 plug can make a good RF connection to the
cable shield. The shielded RJ--45 plug must mate with a connector that carries that
shield carefully into the chassis of the host and the host must be well grounded to the
hull.
When installing the supplied shielded Ethernet jack to the shielded Ethernet cable, after
wiring the internal connections and wrapping the shields tabs snugly around the cables
corrugated shield, bend each tab firmly around the base of the opposite tab and solder
in place. The built--in hooks do not provide adequate adjustment. It is recommended to
also solder the tabs to the corrugated shield.

Jun. 01/02
4. INSTALLATION PROCEDURE
NOTE: Failure to follow installation and/or maintenance proce-
dures, will void the manufacturers warranty.
To install the HVR, perform the following:
(1) Verify the HVR lines up with the mounting brackets. Refer to Figure 2--1.
(2) Using the following steps, ground the HVR to the ships hull. Refer to Figure 2--2.
(a) Remove paint around mounting holes on HVR and Hull mounting brack-
ets.
(b) Apply RTV around mounting holes on HVR and Hull mounting brackets.
(c) Insert bolts through Hull mounting brackets.
(d) Install lock washers.
(e) Mount the HVR base to the deck.
CAUTION: Do not bend the Ethernet cable greater than 12 times the cable diameter
(e.g. 12 X 0.388 inches = maximum bend of 4.56 inches).
NOTE: If the Ethernet cable is installed on a system without a HUB, use

the cross--over cable connection wiring diagram. If a HUB is
installed in the system, use the straight--through cable connec-
tion wiring diagram.
(3) Connect HVR Ethernet cable to the ships Ethernet cable. Refer to Figure 2--3,
Figure 2--6, and Figure 2--7.
WARNING: Ensure that electrical power is de-- energized prior to connecting the HVR
electrical power supply.
(4) Connect HVR power cable to the ships power supply. Refer to Figure 2--4 and
Figure 2--5.
(5) Energize electrical power to the HVR.
(6) Set the HVR IP address (refer to Section 4 Paragraph 1.2.).
(7) Verify, through the Voyage Data Recorder (VDR), that the communications have
been established to the HVR.
(8) Define VDR memory partitions (refer to Section 4 Paragraph 1.3.), and verify that
the VDR can communicate with the HVR.

Jun. 01/02
3X
.530 in Diameter
(13.46 mm)
Diameter
7.000 in
(177.8 mm)
3X 2X
5.125 in 7.688 in
(130 mm)
(195 mm)
10.065 in 3X 120 Degrees

(256 mm)
Diameter
.500 in 2X
(1.27 mm) 2.563 in
(65 mm)
2X 4.438 in
(113 mm)
8.877 in
(225 mm)
10.926 in
(278 mm)
Figure 2--1.
HVR Base Mounting Dimensions

Jun. 01/02
HVR BASE
LOCKWASHER
SEALANT
BARE METAL
HULL
or
MOUNTING
BRACKET
A
Figure 2--2.
HVR Hull Grounding Technique

Jun. 01/02
CROSS-- OVER CABLE CONNECTION

SUPPLIED
SHIPS ETHERNET CABLE HVR ETHERNET CABLE
WHITE / ORANGE WHITE / GREEN

TX_LO RX_LO
ORANGE GREEN
TX_HI RX_HI
GREEN ORANGE
RX_HI TX_HI
WHITE / GREEN WHITE / ORANGE
RX_LO TX_LO
SHIELD
HOST Cable HVR Cable
TX--LO RJ--45 pin 1 WHITE/GREEN
TX--HI RJ--45 pin 2 GREEN
RX--LO RJ--45 pin 3 ORANGE
RX--HI RJ--45 pin 6 WHITE/ORANGE
* Pins 4, 5, 7, and 8 are not used.

STRAIGHT-- THROUGH CABLE CONNECTION
SUPPLIED
SHIPS ETHERNET CABLE HVR ETHERNET CABLE
WHITE / GREEN WHITE / GREEN

TX_LO TX_LO
GREEN GREEN
TX_HI TX_HI
ORANGE ORANGE
RX_HI RX_HI
WHITE / ORANGE WHITE / ORANGE
RX_LO RX_LO
SHIELD
HOST Cable HVR Cable

RX--LO RJ--45 pin 6 WHITE/GREEN
RX--HI RJ--45 pin 3 GREEN
TX--LO RJ--45 pin 2 ORANGE
TX--HI RJ--45 pin 1 WHITE/ORANGE
* Pins 4, 5, 7, and 8 are not used.
Figure 2--3.
HVR Ethernet Cable Pigtail Connection
NOTE: The Straight--Through cable connection is only used if a

HUB is installed in the system. Otherwise, use the Cross--
Over cable connection.

Jun. 01/02
AC Power 100 to 120 Vrms with 24 Vdc

SHIELD
HULL GROUND
Ships Cable RED HVR Cable
24 VDC
BLUE
24 VDC RETURN
GREEN
AC GROUND
BLACK
AC LINE 1
WHITE
AC LINE 2
ORANGE
PRIMARY 1 P
Hull Ground -- The shield of the power WHITE / BLACK
PRIMARY 2 P
cable is bonded to the hull. RED / BLACK
PRIMARY 1 M
GREEN / BLACK
PRIMARY 2 M
AC Power 100 to 120 Vrms
ORANGE (1P) connects to WHITE/BLACK (2P)
RED/BLACK (1M) connects to GREEN/BLACK (2M) DC Power
AC safety ground connects to GREEN 19.5 to 36 Vdc
AC line 1 connects to BLACK + Vdc connects to the RED wire.
AC line 2 connects to WHITE Vdc gnd or return connects to the BLUE wire.
AC Power 200 to 240 Vrms with 24 Vdc

SHIELD
Ships Cable HULL GROUND
HVR Cable
RED
24 VDC
BLUE
24 VDC RETURN
GREEN
AC GROUND
BLACK
AC LINE 1
WHITE
AC LINE 2
ORANGE
PRIMARY 1 P
WHITE / BLACK
PRIMARY 2 P
RED / BLACK
Hull Ground -- The shield of the power PRIMARY 1 M
GREEN / BLACK
cable is bonded to the hull. PRIMARY 2 M
AC Power 200 to 240 Vrms

ORANGE and GREEN/BLACK (1P & 2M) are insulated
and left unconnected
WHITE/BLACK (2P) connects to RED/BLACK (1M) DC Power
AC safety ground connects to GREEN 19.5 to 36 Vdc
AC line 1 connects to BLACK + Vdc connects to the RED wire.
AC line 2 connects to WHITE Vdc gnd or return connects to the BLUE wire.
Figure 2--4.
HVR AC Power Cable Pigtail Connection

Jun. 01/02
NOTE: Figure 2--5 illustrates the HVR DC power connection; however,

DC power may be wired simultaneously along with AC power
(see Figure 2--4) to provide a backup power supply.
DC Power 19.5 to 36 Vdc Only

SHIELD
Ships Cable HULL GROUND
HVR Cable
RED
24 VDC
BLUE
24 VDC RETURN
GREEN
AC GROUND
BLACK
AC LINE 1
WHITE
AC LINE 2
ORANGE
PRIMARY 1 P
WHITE / BLACK
PRIMARY 2 P
RED / BLACK
PRIMARY 1 M
GREEN / BLACK
PRIMARY 2 M
DC Power
Hull Ground -- The shield of the power 19.5 to 36 Vdc
cable is bonded to the hull. + Vdc connects to the RED wire.
Vdc gnd or return connects to the BLUE wire.
Figure 2--5.
HVR DC Power Cable Pigtail Connection

Jun. 01/02
Jun. 01/02
STRAIGHT THROUGH CABLE CONNECTION

JUNCTION BOX ( FOR USE WITH A HUB )
RJ--45
HVR RJ--45
1 HOST TX LO WHITE/ORANGE 1
2 HOST TX HI ORANGE 2
3 HOST RX LO WHITE/GREEN 3
4 4
CONNECT 5 5
TO HUB 6 HOST RX HI GREEN 6
7 7
8 8
SHIELD SHIELD

HVR J3
HVR TX LO 1

HVR TX HI 2
HVR RX HI 3
HULL GROUND HVR RX LO 4
CROSS OVER CABLE CONNECTION HVR CASE
JUNCTION BOX ( NO HUB)

NOTE: BLUE/WHITE AND BROWN/WHITE
PAIRS NOT USED ON HVR
RJ--45
HVR RJ--45
1 HOST TX LO WHITE/ORANGE 1
2 HOST TX HI ORANGE 2
3 HOST RX LO WHITE/GREEN 3
4 4
CONNECT TO 5 5
NETWORK 6 HOST RX HI GREEN 6
CARD 7 7
8 8
SHIELD SHIELD
HVR J3
HVR TX LO 1
HVR TX HI 2
HVR RX HI 3
HVR RX LO 4
HULL GROUND
HVR CASE
Figure 2--6.
Ethernet Connection With Junction Box
STRAIGHT THROUGH CABLE CONNECTION
HOST COMPUTER RJ--45 RJ--45 PLUG HVR RJ--45 JACK HVR RJ--45
1 HOST TX LO 1 1 WHITE/ORANGE 1
2 HOST TX HI 2 2 ORANGE 2
3 HOST RX LO 3 3 WHITE/GREEN 3
4 4 4 4
CONNECT 5 5 5 5
TO HUB 6 HOST RX HI 6 6 GREEN 6
7 7 7 7
8 8 8 8

SHIELD SHIELD HVR J3
HVR TX LO 1
HVR TX HI 2

HULL GROUND HVR RX HI 3
HVR RX LO 4
HVR CASE
CROSS OVER CABLE CONNECTION

NOTE: BLUE/WHITE AND BROWN/WHITE
HOST COMPUTER RJ--45 RJ--45 PLUG HVR RJ--45 JACK PAIRS NOT USED ON HVR
HVR RJ--45
1 HOST TX LO 1 1 WHITE/ORANGE 1
2 HOST TX HI 2 2 ORANGE 2
3 HOST RX LO 3 3 WHITE/GREEN 3
4 4 4 4
CONNECT 5 5 5 5
TO HUB 6 HOST RX HI 6 6 GREEN 6
7 7 7 7
8 8 8 8
SHIELD SHIELD HVR J3

HVR TX LO 1
HVR TX HI 2
HULL GROUND HVR RX HI 3

HVR RX LO 4
HVR CASE
Jun. 01/02
Figure 2--7.
Ethernet Connection With RJ--45 Connector

Jun. 01/02
SECTION 3
SOFTWARE SETUP

Jun. 01/02

Jun. 01/02
SOFTWARE SETUP
1. HVR CONFIGURATION VIA THE DEFAULT WEB SITE
1.1. L3 Main Menu
Figure 3--1 shows the HVR Website homepage. The user can access the default web
site by using a web browser.
NOTE: The HVR is shipped with the following pre--set factory

defaults:
IP address: 192.168.0.2
Subnet Mask: 255.255.255.0
Default Gateway IP: 192.168.0.1
The homepage, L--3 Main Menu, provides the main entry point to HVR system configu-
ration setup via a web browser. The L3 Main Menu provides the links for several config-
uration options.
F Network Setup -- web page providing network hostname and IP address setup
data entry form. Refer to Figure 3--3.
F Flash Memory Setup -- web page providing memory partition setup data entry
form. Refer to Figure 3--4 and Figure 3--5.
F System Maintenance -- web page providing existing Flash Memory Setup. Re-
fer to Figure 3--7.
F Test Modes -- web page providing the ability to insert write errors into that data
stream. (THIS IS FOR VERIFICATION TESTING ONLY.) Refer to Figure 3--9.
F System Information -- web page providing specific HVR software and IP ad-
dress information. Refer to Figure 3--8.
F Set Password -- web page providing password setup data entry form. Refer to
Figure 3--6.
The main menu can be accessed without entering a password, but in order to change
any HVR system configurations, a password is required. The password is required to
access Network Setup, Flash Memory Setup, System Maintenance, Test Modes, Sys-
tem Information, and the Set Password pages. The password times out when idle for
300 seconds and must be re--entered to continue with HVR setup modifications. The
Login Screen will appear no matter which system configuration button is selected first.

Jun. 01/02
Figure 3--1.
HVR Website Home Page
1.2. Setting IP Address
In order to set the IP address for the HVR it is necessary to be able to access the inter-
nal Web pages of the HVR. This, of course, requires a host computer running a Web
browser such as Netscape or Microsoft Internet Explorer (Internet Explorer is the pre-
ferred browser). The host computer must be connected to the HVR via the Ethernet in-
terface. Furthermore, the browser must be directed to the home page of the HVR at
the default HVR IP address.
In order to satisfy the above requirements, the host computer and the HVR must both
be connected to a network which is consistent with the default settings of the HVR. In
the simplest case this can be a direct Ethernet 10--Base T connection between a host
computer and the HVR, with the host computer configured at a network--compatible IP
address which is different from the IP address of the HVR as shown below.
The HVR is shipped from the factory with the following settings:
IP address: 192.168.0.2
Subnet Mask: 255.255.255.0
Valid settings for the host computer would be:
IP address: 192.168.0.3
Subnet Mask: 255.255.255.0

Jun. 01/02
Note that the 192.168.x.x IP address has been chosen because it is part of a re-
served block of addresses intended strictly for networks that are not connected to the
Internet. Also note that unless the host computer is configured to an address in this
range, it will not be able to see the HVR, and will therefore be unable to access the
HVRs Web pages.
Once the host computer has been configured with a valid IP address, the Web browser
should be directed to http://192.168.0.2. This will bring up the home page of the HVR.
The user can now select the HVR Network Setup option. This will require a password
entry. The default password for the HVR is L3HVR. Refer to Figure 3--2
Figure 3--2.
HVR Website Login Page
NOTE: If the HVR system remains idle for 300 seconds, the system
will time out and require the reentry of the password. The
default 300 second time--out is a configurable parameter,
and may be configured to system specific requirements.
The network parameters can now be set as required. They will not take effect until the
HVR is powered down and back up. Once the settings have been made, the HVR can
be connected to the VDR network where it should respond at the configured IP address.
Refer to Figure 3--3.

Jun. 01/02
Figure 3--3.
HVR Website Network Setup Data Entry Form
1.3. Configuring Memory Partitions
The user can modify or set up the memory areas used for data storage on the HVR.
Each of these areas or partitions require that two parameters be specified: the partition
size and the partition name. (Refer to Figure 3--4 and Figure 3--5)
The page shows the number of currently available memory granules as well as the per
granule size in bytes. It is from the available granule pool the user partitions and allo-
cates the HVR memory data storage.
The configuration of the memory areas requires that the user specify the size of each
memory partition in granule units, expressed as the number of granules to be allocated
to that memory area. The partition size is thus the granule size multiplied by the number
of granules. The HVR system would internally allocate granules from its internal free
pool of granules in order to fill the request. Note that the partition configuration request
will be processed starting with partition 0 (ZERO) and proceed to partition 9 (NINE). The
partitions allocations cannot exceed the number of available granules. Partition alloca-
tions are processed until all available granules have been allocated.
NOTE: Each Stream Name must contain the number of granules

required for that stream to record 12 hours of data.

Jun. 01/02
Figure 3--4.
HVR Part Number HVR01--XXX-- 0X NAND-- Flash Manager Memory Setup Data
Entry Form
NOTE: Number of granules is dependent upon memory size. A 4

gigabyte memory is shown in Figure 3--4.

Jun. 01/02
Figure 3--5.
HVR Part Number HVR00-- XXX-- 0X NOR-- Flash Manager Memory Setup Data Entry
Form
NOTE: A 1.5 gagabyte memory is shown in Figure 3--5.

Jun. 01/02
The partition name is required during the actual recording of data into a partition. The
partition/stream name is to be used by the client application wishing to establish a data
connection to the HVR for the storage of data to a particular partition. The connection
set up for a data stream requires the partition name.
NOTE: The VDR must use the same partition (stream) name estab-
lished during the HVR memory configuration in order to es-
tablish communication with that partition (stream).
NOTE: In the event that the HVR processor board is replaced, this
configuration information will be crucial for system opera-
tion. Be sure to save this set--up information on the HVR
Maintenance Sheet as shown in Appendix A. Once the infor-
mation on this page is configured, L--3 Communications will
not have a record of the changes to the configuration.
1.4. Changing Password
This page is designed to password protect the HVR system configuration. The HVR is
preprogrammed with a default password. The default password is L3HVR. To change
the password (Refer to Figure 3--6), perform the following:
(1) On the HVR website homepage, select the Set Password button.
(2) If the Login Screen is accessed, enter the existing password and click on the
Submit button.
(3) Once the Change Password page is accessed, enter the new password in the
first data entry field and repeat in the second data entry field. Click on the Submit
button.
NOTE: Remember to write the password down and keep in a se-

cure place. Once the password is changed, L--3 Commu-
nications will not have a record of the changed password.

Jun. 01/02
Figure 3--6.
HVR Change Password Data Entry Form
1.5. System Maintenance Page
The System Maintenance page provides the current system partitioning and indicates if
any errors are in existence. Refer to Figure 3--7.
NOTE: When the Partition Map must be reconfigured, refer to the

HVR Maintenance Sheet, as shown in Appendix A.

Jun. 01/02
Figure 3-- 7. HVR System Maintenance Webpage

Jun. 01/02
1.6. System Information Page
The System Information page provides the current system software, IP address, MAC
address settings for a quick reference of the HVR system.
Figure 3--8.
HVR System Information Webpage

Jun. 01/02
1.7. System Test Modes
Test modes can be used to force write errors. This is intended for verification of system
operation. Refer to Figure 3--9.
NOTE: This is not intended for any other purpose and should be
disabled during normal operation.
To activate or deactivate the simulate write errors function, perform the following:
(1) On the System Test Modes page, click on the box in the Change Setting column in
the Simulate Write Errors row.
(2) Type in the write interval in seconds in the bottom box of the Change Setting col-
umn.
(3) Click the Submit button.
Figure 3--9.
System Test Modes Webpage

Jun. 01/02
1.8. Trace Messages
Trace messages provide a view port into the operation of the HVR. These messages
contain information regarding the status of various processes within the HVR software.
While the meanings behind certain Trace messages are clear, others contain information
that is meaningful only to HVR developers. The Trace message log provides feedback
while writing to, or reading from, the HVR protected storage area.
To download Trace messages, perform the following:
(1) On the System Information page, Click on the Get Trace Log button on the Sys-
tem Information webpage.
(2) A pop--up window will appear and asks to open or save the trace file. Click on
Save.
(3) To close the window, Click on the X button in the upper right--hand corner of the
window.
1.9. Event Log
This page is accessed through system information. All system events including normal
and abnormal operation are logged here. This page is intended for L--3 Communica-
tions interpretation/diagnosis, not for general operations.
To download Event Log, perform the following:
(1) Click on Get Event Log button on the System Information webpage.
(2) A pop--up window will appear and ask to open or save the Event Log. Click on
Save.
(3) To close the window, Click on the X button in the upper right--hand corner of the
window.
NOTE: The events shown in Figure 3--10 are representative of

Events that will appear while the HVR is in use, but they
may vary per each installation.
To view the Event Log, access the Event Log webpage (as shown in Figure 3--10)
through the System Information webpage by performing the following:
(1) Click on View Event Log button on the System Information webpage.

Jun. 01/02
Figure 3--10.
Event Log Webpage

Jun. 01/02
1.10. Flag Decoder
This page is accessed by clicking on Flags column for a given partition. It will display
any flag conditions saved for that partition. This page is intended for L--3 Communica-
tions interpretation/diagnosis, not for general operations.
Figure 3--11.
Flag Decoder Webpage

Jun. 01/02
SECTION 4
HVR INTERFACE

Jun. 01/02

Jun. 01/02
HVR Interface
1. INTRODUCTION
The L--3 Communications Hardened Voyage Recorder (HVR) is a module that contains
solid--state nonvolatile memory in a protected enclosure. It is intended to function as a
mass store subsystem for a Voyage Data Recorder (VDR) system.
This document is intended to provide the developers of a VDR system with the neces-
sary background information for interfacing an HVR to the data acquisition component of
a VDR system. The document begins with a system overview, is followed by a discus-
sion of general concepts, and proceeds to more detailed explanations.
2. OVERVIEW
The interface to the HVR is a 10/100 Base--T Ethernet connection that supports the
standard TCP/IP protocol. (Note that early units supported only 10 Base--T Ethernet). All
setup and configuration of the HVR is done using a Web Browser such as Netscape or
Microsoft Internet Explorer (the latter is preferred) to access Web pages that are resi-
dent in the HVR. Once the HVR has been configured, it appears to the outside world as
a smart interface to a pool of nonvolatile memory. Before using the HVR for storage
and retrieval, however, the memory store must be allocated across a set of named data
partitions. The memory allocation Web page is basically a table form that an autho-
rized HVR system user fills in with partition names and memory allocation specifications.
The Web page keeps the user apprised of the current allocation assignments and re-
maining free storage area.
Once the HVR has been configured, application programs running on one or more VDR
data acquisition systems can utilize the allocated memory partitions for storage and re-
trieval purposes. Each partition is treated as a virtual storage loop in which new data
continuously overwrites the oldest data in the partition. The HVR processor keeps track
of the current write location in the virtual loop for each partition, and preserves this infor-
mation in nonvolatile storage through power cycles.
In order to store data in a previously allocated partition, or retrieve data from such a
partition, software in the VDR data acquisition system must open a TCP/IP Socket
connection to a Storage Interface Server in the HVR. This Server accepts Socket con-
nections to Port 5000 at the IP address assigned to the HVR. Once a connection has
been made to the HVR Storage Interface Server, the VDR acquisition software sends a
command that identifies the target partition and the requested operation using the name
that was specified for the partition during the configuration of the memory store. The
partition can be opened for read or write access, or to request status information. Once

Jun. 01/02
a socket connection has been established, and the appropriate command issued, data
is sent or received over the Socket connection. The HVR Storage Interface Server will
accept simultaneous socket connections from multiple client processes as well as multi-
ple socket connections from a single client process. This behavior results from the TCP/
IP Client--Server that is used by the HVR. This model will be described in subsequent
sections along with the HVR--specific application layer that sits on top of TCP/IP.
2.1. The Client--Server Model

An understanding of the HVR interface is not possible without a clear understanding of
the Client--Server concept. This label is applied extensively in the computing and net-
working field, and there are many different applications of the model. The intent of this
section is to provide a generalization that gets at the essence of the underlying con-
cepts. The specific application of the Client--Server model to the HVR product will follow.
The unifying characteristic of a Client--Server relationship is that it involves a Server en-

tity; i.e., a system or process that provides some sort of service to one or more Cli-
ents. A Server can be represented by a human being serving hamburgers, a physical
device such as a Personal Computer acting as an interface to one or more printers, or it
can be a software--only entity that provides access to information in a database. The
specifics of the underlying components of a Client--Server relationship are often ambigu-
ous such as when one speaks of a Web Server. In this case one can be referring to the
software that implements the HTTP protocol, or simply the machine executing the soft-
ware. In any case, the Client--Server model is clearly represented by a person using a
Web Browser on a PC to access Web Pages on the Internet. Here, the person is a Cli-
ent of the Website that contains the target Web Pages. The Web Browser is, in turn, act-
ing as a Client to the HTTP Web Server software running on a Server computer some-
where on the connected Internet.
In all cases the Server entity operates such that it is ready to provide some service to
one or more Clients. There may be issues of authentication that come into play, or the
underlying Service may be available to any Client that knows how to ask for it. The
relationship of the person using a Web Browser to access a particular Website on the
Internet provides a useful example. The HTTP Server software at the target Website
does not know who will wish to access its Web Pages or when this will come about, if
ever. Once up and running, however, the HTTP Server software is ready to entertain re-
quests for its services. When a User types the name of the target Website into the ad-
dress field of his Browser program, he is asking the Browser to contact the HTTP Serv-
er that is associated with the specified address, and request that the home page for
that Website be sent to the Browser for presentation to the User. The Browser does this
by establishing a Client connection to the HTTP Server and requesting the specified
Web Page. It may be worth mentioning that the Browser program is acting as a kind of
Server to the User. That is, the Browser program is waiting for address requests from

Jun. 01/02
the User. The service it provides is to fetch the requested Web Page, but to do so the
Browser must act as a Client to a particular Web Server.
2.2. The Transmission Control Protocol (TCP)
Once the generalized concept of the Client--Server model is understood one can pro-
ceed to a discussion of the specifics of the TCP Client--Server Connection. TCP stands
for Transmission Control Protocol, and is the underlying protocol used by Web Servers
and Browsers as well as many other services on the Internet. While TCP is used exten-
sively on the Internet, it can also be used on a Local Area Network (LAN) or even be-
tween processes in a single computer. TCP provides a bi--directional, error--free, com-
munications channel between a pair of nodes. Once a TCP connection has been es-
tablished, the two nodes can send data to each other in the form of byte streams. TCP
ensures that the data is delivered to the recipient exactly as sent, in the proper order.
When both nodes are situated on a LAN or within the same computer, error--free deliv-
ery of data is not much of a problem. On a connected internet, however, there are some
serious difficulties to overcome in order to provide the error--free connection of TCP. It is
the very difficulties peculiar to a widely distributed internet that led to the adoption of
TCP for a variety of Internet services. The Internet carries data, in the form of packets,
all over the world. Multiple packets sent from one particular node to another node via the
Internet may take different routes and arrive out of sequence. Packets may also be lost,
corrupted, or duplicated. It is typically TCP that ensures that a byte stream carried in
these packets is reassembled at the destination node in the proper order, without any
loss or duplication of data. Achieving this relies on protocol operations that involve posi-
tive acknowledgement of data, error detection schemes, sequencing information, and
retransmission of information when necessary. All of this logic is embedded in TCP and
is transparent to the application software that relies on TCP. When TCP is implemented
as part of the network protocol software on an internet--connected machine using the
Internet Protocol (IP), the entire subsystem is commonly referred to as TCP/IP.
2.3. The TCP Client--Server Connection
TCP implements a specific form of the Client--Server connection model discussed

above. The TCP connection is based on the idea that a Server process at some host
address will listen at a particular port for connection requests from Clients. The TCP
host address for the Service is the IP address of the machine that the Server process
is running on. The port address is an integer value that is known to the Clients that
need to use the service. In the case of a Web Server, for example, the well--known port
address is 80. Web Browsers are Client programs that are configured to contact Web
Servers at Port 80 of arbitrary host machines using TCP. The User of the Web Browser
supplies the target host IP address either directly, or symbolically using a URL domain
name. Web Servers, conversely, are Server processes that listen for connection re-

Jun. 01/02
quests at Port 80 at the IP address of the host machine they are executing on. When a
Client, such as a Web Browser, wants to access a Service, it tries to make a TCP con-
nection to a particular host IP address at the port associated with that Service. This is
analogous to placing a phone call to a specific phone number. If there is a TCP Server
process listening at that port on the target host machine, the TCP software will establish
the requested connection. Once a TCP connection has been successfully created, the
Client and Server processes can reliably exchange data in the form of byte streams.
Once again, the model is well served by the telephone call analogy. That is, once the
connection is made, both ends are served equally; it doesnt matter which end initiated
the call. It is important to note that this bi--directional, full duplex connection imposes no
further constraints on the content of the data streams exchanged. At this point the Client
and Server processes must communicate in some agreed--upon language. In the case
of Web Browsers and Web Servers, this language is Hyper Text Transfer Protocol
(HTTP). It is worth emphasizing the fact that the HTTP exchanges are riding on top of a
TCP connection, but TCP has nothing to do with HTTP, nor does HTTP require TCP.
2.4. The HVR TCP Storage Interface Server

The preceding discussion leads, finally, to the specifics of the HVR Storage interface
Server. Leaving issues of configuration aside for the moment, the HVR is a conceptually
simple device. Once the mass store of an HVR has been properly configured, the stor-
age appears to a Voyage Data Recorder (VDR) as a set of individual, named storage
partitions, of some size. There can be from one to ten of these partitions, with the
available storage allocated as desired within the constraints of the partitioning granular-
ity of the underlying mass store media. Partitions can be of identical or differing sizes. All
of the available storage can be allocated to partitions, or a portion of the available stor-
age can remain unallocated. The HVR storage area need only be configured one time
before the HVR is put into service. An HVR, as delivered, will typically have all of the
storage in the unallocated state. It is necessary to allocate storage to one or more
partitions before data can be written to, or retrieved from HVR storage.
When an HVR has been powered up, the HVR TCP Storage Interface Server listens at
Port 5000. This is a TCP Server process identical to the examples discussed above.
The VDR system acts as a Client to the HVR by making connections to Port 5000 at the
HVR IP address. The services provided by the HVR Storage Interface Server include,
Write to a Specified Partition, Read from a Specified Partition, and Obtain Status
from a Specified Partition. It is important to understand that a single TCP connection is
required for each Read, Write, or Status Query operation, and each connection ap-
plies to a single named storage partition. These three types of operations will be dis-
cussed in more detail below.
Note that all VDR--HVR operations are initiated in the same manner. That is, the VDR
acts as a TCP Client and requests a connection to the HVR Storage Interface Server at

Jun. 01/02
Port 5000. For now, the details of how the VDR requests a connection and uses a con-
nection once it has been established are not important. It is the intent of this section to
describe these issues at a conceptual level only. Once a TCP connection has been es-
tablished, the VDR Client must send a valid command/request message over the open
channel and wait for a confirmation or rejection message on the channel. Once a con-
firmation has been received, the channel is used to carry the data that is specific to the
command/request. If a Write connection has been set up, the VDR simply sends data
to the target partition as a continuous byte stream. If a Read connection has been re-
quested, the HVR will send data from the specified partition to the VDR. If a Status
Query connection has been requested, the HVR will send a single status message to
the VDR.
2.5. Write to Specified HVR Partition and the Storage Loop Model
The fundamental function of the HVR module is to provide protected mass storage for a
VDR system. The VDR system sees the HVR module as a set of named storage parti-
tions of configured size. In order to write data to a particular partition, the VDR must es-
tablish a TCP connection to Port 5000, and then send a command that turns the con-
nection into a Write channel. This command also specifies the partition into which data
are to be written. There are some additional optional parameters that can be included in
this command. These will be detailed later.
A TCP connection is first established at the Client VDRs request, and then the Client
VDR sends the Write command along with the target partition name and any optional
parameters. If the command is valid, the HVR will send back a confirmation response.
The confirmation is a single G character, provided that a valid partition name has been
specified in the command/request message, etc. Possible error responses will be de-
tailed elsewhere. Once the Client VDR receives the confirmation, the open connection
simply becomes a conduit by which the VDR sends data in the form of a byte stream to
the HVR. The HVR stores the data, exactly as received, in the partition that was speci-
fied in the Write command. The partition storage is treated as a continuous loop. The
first time a Write connection is made to a partition, the first data byte is stored in the
first location of the storage allocated to that partition. This is considered the top of the
partition. Subsequent bytes are written to the partition storage in sequential order as
long as the connection remains open. If the VDR closes (terminates) the TCP connec-
tion, the HVR remembers where it stopped writing in that partition. This storage pointer
is saved internally in HVR nonvolatile memory. When a subsequent Write connection is
established by the VDR, the HVR continues writing at the saved location. Whenever the
HVR writes to the last allocated byte location of a partition, the pointer is set back to the
top of the partition. This loop scheme causes the HVR to always be overwriting the
oldest data in a partition.

Jun. 01/02
It is very important to understand that once a Write command has been received and
validated by the HVR Storage Interface Server and the confirmation response has been
sent back to the Client VDR, it is not possible for the Client VDR to send any further
command/request information over this particular TCP connection. That is, the Write
data is sent by the Client VDR over the open connection exactly the way the Write
command/request was sent, but the HVR Storage Interface Server itself has transitioned
into a state in which all subsequent data on the open connection channel is presumed
to be data to be stored in the target partition. The HVR Storage Interface Server does
not examine this Write data; it simply ensures that it is stored at the appropriate loca-
tion in the storage associated with the target partition. It is typically up to the VDR Client
to decide when to stop writing to a partition and to close the associated TCP connection.
There are, however, some exceptions to this that will be discussed later.
One of the optional parameters that can be specified in a Write command is to force
the write pointer for the partition back to the top location; that is, reset the write point-
er before starting to write. A second option is the No Wrap specification. This tells the
HVR Storage Interface Server to stop writing and close the TCP connection when it has
written to the last byte of the partition. Note that the No Wrap option also causes the
write pointer to be reset. This reset and no wrap combination provides a useful test fa-
cility for the HVR. It allows for a partition to be filled from the top of storage with known
data that can be retrieved and validated using similar options on a subsequent HVR
Read connection.
The detailed message formats for all HVR Storage Interface Server commands are pre-
sented later in this document.
A very important constraint imposed by the HVR Storage Interface Server is that there
can be concurrent active Write connections for all partitions at any time, but only one
active Write connection may be associated with each partition at any time. This re-
moves any ambiguity regarding the location of the write pointer for any partition.
2.6. Read from Specified HVR Partition
A Read command/request is similar to the Write command/request. A TCP connec-

tion is first established at the Client VDRs request, and then the Client VDR sends a
Read command along with the target partition name and any optional parameters. If
the command is valid, the HVR will send back a confirmation response. The confirma-
tion is a single G character, provided that a valid partition name has been specified in
the command/request message, etc. At this point the HVR Storage Interface Server
transitions into data retrieval mode. The open connection channel is used by the HVR
Storage Interface Server to send data from the specified partition to the Client VDR.
Once this transition has been made, the HVR Storage Interface Server ignores any fur-
ther traffic from the Client on the open TCP connection.

Jun. 01/02
In the simplest case (one in which no optional arguments were used by the Client VDR)
the HVR Storage Interface Server begins sending the oldest data from the specified
partition. This is the data that is stored at the location addressed by the write pointer for
that partition at the instant that the HVR Storage Interface Server processes the Read
command/request. That is, when a Read request is received and validated by the HVR
Storage Interface Server, a snapshot of the write pointer is obtained. This becomes the
initial Read pointer once the retrieval begins.
It is very important to note that the HVR process that is associated with an open Read
TCP connection is in no way synchronized with any process that might be writing to the
same partition due to an open Write connection. Depending on other activities in the
HVR and the VDR Client and the data rate on the write channel, it is possible for the
Read connection processing to vary between lagging behind the Write processing,
and moving ahead of it. If this occurs, the Client will be retrieving data that is a combina-
tion of old and new data. This, of course, is not a recommended retrieval
methodology.
Because of the issues discussed above regarding the relationship between concurrent
Read and Write processes on a particular partition, there are some useful optional
arguments associated with a Read command/request. The first of these is an offset
value specified in Megabytes. The offset option allows the starting location of the
Read pointer to be backed up relative to the current write location by some specified
number of Megabytes in the target partition. The data retrieval software of the Client
VDR is, in effect, saying, send data from the target partition beginning with the data that
was written n Megabytes ago. Remember that this is a positive value representing
backwards positioning. The next option is a transfer count that allows the Client to
specify the total number of Megabytes that the HVR should send. By using both of these
options, the Client VDR can ensure that the retrieved data does not become intermin-
gled with new data; that is, data that is written after the Read request was issued.
The retrieval can, instead, be constrained to the n Megabytes that were written exactly
prior to time that the request was issued. For example, the command can specify that
the retrieval begin 5 Megabytes back, and be exactly 5 Megabytes in length. Upon re-
ceipt of this request, the HVR Storage Interface Server will snapshot the write pointer
for the specified partition, then move back by 5 Megabytes in the partition storage area,
and send exactly these 5 Megabytes. If there is an active Write for the partition, the
write pointer will continue to advance from the location at which it was snapshotted,
but the retrieval will stop exactly prior to the original snapshot location. It is important to
note, however, that the data obtained by the Client for this form of request will be identi-
cal whether there is an active write or not.
When using the offset and transfer count options on a Read command, the Client
software must take into account the size of the target partition. For example, if the entire
partition allocation is only 4 Megabytes, a request to back up by 5 Megabytes is inap-

Jun. 01/02
propriate. HVR internal logic will prevent a backup and transfer count that is larger than
the size of the partition, but the result may cause confusion in the Client VDR retrieval
software if this issue is not considered. For example, if a value is specified which is larg-
er than the partition storage area, the Read location simply begins at the current Write
location. Also, if the partition has not been filled since the last time the Write pointer
was reset, then the offset will not be adjusted backwards beyond the top of the partition.
This is because data that follows the current Write location down through the bottom
of the partition is meaningless.
The Read command/request also supports the No Wrap option. This is the counter-
part of the No Wrap option that is available on the Write to Partition command. This
option causes the HVR to begin reading at the top of the partition, and stop reading
when the end of the partition is reached. This option may be used by Client software in
conjunction with the corresponding option for the Write command/request in order to
implement a fill and verify sequence. That is, a partition can be filled with a known
pattern beginning at the top of the partition storage using the No Wrap option on the
Write connection, then the data can be retrieved from the partition using this option on
the Read connection.
2.7. Status Query for Specified Partition

The Status Query command/request is used by the Client VDR to obtain the current
error counts and flag values for a specified partition. As for the Read and Write com-
mand/requests, a TCP connection is first established at the Client VDRs request, and
then the Status Query command is sent by the Client VDR along with the target parti-
tion name. There are currently no optional parameters for this command. If the com-
mand is valid, the HVR will send back a confirmation response, followed by a response
message indicating Loop Errors, Total Errors, and Flag Settings for the target partition.
This is an ASCII text string in which the numerical values are all zeros unless there are
error conditions to be reported. Note that the confirmation response that precedes this
information is identical to the confirmation response issued for a Read or Write con-
nection. It is a single G character provided that a valid partition name has been speci-
fied in the command/request message.
It is important to note that a single response message will be issued for a Status Query
command/request. The HVR Storage Interface Server will automatically close the con-
nection after sending the response. It is up to the Client VDR software to establish a
new TCP/IP connection each time it wishes to obtain the current status for the target
partition. Furthermore, only the status of a single partition may be retrieved for each
connection. The Status Query command/request itself identifies a particular HVR parti-
tion.

Jun. 01/02
2.8. Closing TCP Connections
The TCP Client--Server model makes it clear how connections are established. This was
discussed in detail in earlier sections of this document. Once a connection is made,
however, both ends of the connection are essentially equal. Data can be sent in both
directions creating the bi--directional, full duplex connection detailed above. This leads
to a question as to how connections are broken or terminated. It turns out that TCP
allows for either end of a connection to cause termination. There are, however, certain
conventions that have been established.
In the case of a request--response exchange over a TCP connection the sequence

would be as follows: The Client process initiates the connection request to a Server at a
well--known port address. When the connection is granted, the Client issues some sort
of request using an application--specific language or protocol. The Server process
then sends the appropriate response in the application--specific language. If this were a
single--response type of exchange, then the Server would normally close the connec-
tion. The HVR Status Query exchange is a good example of this sequence. In applica-
tions in which a single connection supports a multi--request exchange, typically it is the
Client side that determines when the exchange is complete. In these cases it is up to
the Client to close the connection.
The point here is that the issue of which end closes the connection is largely a function
of the particular application using the connection, and the context of the particular ex-
change taking place. Furthermore, it does no harm for both ends to close a connection.
One example of this might be the HVR--VDR Read connection when a specific number
of Megabytes have been requested. In this case the HVR closes the connection when it
has sent the last requested byte. The VDR side might also close the connection when it
has consumed the last requested byte. Alternatively, the VDR side might simply contin-
ue to read from the connection until the read fails due to the fact that the HVR side has
closed the connection. Either approach is acceptable.
In the case of a normal Write connection to the HVR, only the Client VDR knows when
it wants to close the connection. This is an example of an open--ended connection.
Once the Client VDR has established a Write connection to an HVR partition, it can
theoretically keep sending data forever. The loop model causes the data to constantly
overwrite the oldest stored data in the target partition, and this is represents normal
VDR--HVR operation. Assuming that the No Wrap option was not used when the
Write connection was established, there are no criteria for the HVR to use for terminat-
ing the connection (unless some internal HVR malfunction occurs). In this context it is
clearly up to the Client VDR to close the connection.

Jun. 01/02
2.9. The Berkeley Socket Interface
It is important to understand that the HVR is implemented as a set of TCP Server pro-
cesses that are connected to a network via a 10/100 Base--T Ethernet physical inter-
face. One or more Client systems can connect to the HVR Server processes simply by
providing the required physical access to the HVR, and by knowing the IP address as-
signed to the HVR during configuration, and the Port addresses of the various Servers.
Given the generalized description of the HVR--VDR interface that has been described so
far, there still remains the discussion of the specifics of this interface from the point of
view of a software developer of a VDR system. First of all, one should appreciate the
distinction between the TCP/IP layer and the Applications Programming Interface (API)
that is used to access the TCP/IP layer. For example, in a typical Windows environment,
there is a built--in software module called WinSock. This software provides all of the
TCP/IP functions that have been discussed. The details of the exchanges required for
establishing a connection and ensuring error--free delivery of data are encapsulated in
the WinSock module on a Windows PC. However, the applications programmer must
write software that interacts with the WinSock module in order to initiate and utilize TCP/
IP connections. The API provided by WinSock represents one implementation of a stan-
dard that has become known as the Berkeley Socket model for accessing and using
TCP/IP.
It is not the intent of this document to act as a reference source for the Berkeley Socket
interface, but rather to identify the fundamental interface functions and show how they
apply to the preceding discussions. The functions are presented schematically rather
than literally. That is, the discussions focus on the intended functionality of the interface
routines rather than the exact details of the associated argument list, etc. This discus-
sion is intended to introduce a programmer to the Socket interface. As for any complex
system interface, the details can only be mastered by studying the appropriate reference
material and examples. One needs also to realize that the Berkeley Socket interface has
been generalized to handle protocols besides TCP/IP, so there is complexity in the de-
tails that might not seem necessary. Furthermore, a particular VDR software develop-
ment environment may provide additional layers of encapsulation that hide and abstract
the Socket interface layer. None of this should cause serious difficulties once one under-
stands what the basic underlying operations are.
Before proceeding to the discussion of the Berkeley Socket model, it is worth mention-
ing that the Berkeley model provides one particular example of an API for an underlying
TCP/IP implementation. The fact that the Berkeley model is the most common interface
to TCP/IP should not cause it to be confused with TCP/IP itself. It should be understood
that from the point of view of the HVR, it is only important that the TCP/IP interface be
adhered to. It is theoretically possible (although by no means advisable) to create a
TCP/IP implementation on a Client VDR that presents a completely new and unique API

Jun. 01/02
to the software developer. This has only been mentioned in order to drive home the dis-
tinction between what happens at the TCP/IP layer in terms of establishing connections
and delivering data, and what is presented to the applications programmer by the Berke-
ley Socket interface.
There are three primary steps involved when a TCP/IP Client application wishes to
make a connection to a TCP/IP Server process:
(2) Create a Socket
(3) Set the Socket Options (characteristics)
(4) Connect to the Server at a Known IP Address and Port
Once these operations have been completed successfully, bi--directional full duplex data
transfer can begin. When the connection has fulfilled its intended purpose, either pro-
cess breaks the connection by closing the Socket.
A Socket object provides an identifier for a particular TCP/IP connection. It is analogous

to a file handle that is obtained when a file is opened. A Socket is represented by a
unique integer that is obtained when the Socket is created. The Socket value is passed
to all functions that operate on the Socket and associated connection. It may help to
consider that a Client VDR program would likely need to send data to several HVR parti-
tions concurrently. Each partition requires its own Write connection; therefore each
write stream is managed with a unique Socket identifier. Each Socket connection is
created by specifying the same target IP address (the HVR IP address) and Port num-
ber (5000). However, the client--side endpoint for each connection is unique. That is,
there are multiple unique pipes or channels from the Client VDR application process
to the HVR Storage Interface Server process. When the Client software sends data on a
particular Socket connection, it is intended for a specific HVR partition. This would be
similar if the Client software were writing concurrently to several open files.
The Socket creation for a TCP/IP connection is performed with the socket() function in
the Berkeley mode. The form of this C function call is:
s = socket (AF_INET, SOCK_STREAM, 0);
The return integer value from the function, s is the identifier used to access the Socket.
Note that there is no real connection associated with this Socket yet. A Client process
would use the connect() function to bind a destination to the Socket. The C function
call to do this would be of this form:
rc = connect (s, pSockAddr, AddrLen);
The rc return code is 0 if the connection is successful, and some negative value
otherwise. The s argument is the handle for the Socket created above, while the sec-

Jun. 01/02
ond and third arguments define a data structure that must be set up with the destination
IP address and Port number of the target Server process before invoking the connect()
function. Once again, the details of these function interfaces are beyond the scope of
this document and vary somewhat from environment to environment, but the underlying
concepts are universal.
Once a TCP/IP connection has been established, the Client and Server processes can
both send and receive data with a simple byte--stream--oriented interface. The send()
and recv() functions are commonly used on a TCP/IP connection for this purpose.
rc = send (s, pBuf, Len, Flags);
rc = recv (s, pBuf, Len, Flags);
These two functions have an almost identical interface. The rc return code represents
the number of bytes actually transferred (sent or received). The rc value is typically --1
if an error occurred. The s argument is, of course, the handle for the Socket associated
with the connection. The pBuf argument points to a buffer of 8--bit values to be sent, or
a buffer into which incoming 8--bit values are to be stored. The Len value represents
the number of 8--bit values to be sent or the maximum number of 8--bit values to be re-
ceived. The Flags value is normally 0 for a TCP/IP data transfer, but there are some
options available. These are not important for the purposes of this discussion.
Once the data transfer has been completed and the connection is no longer needed, the
connection can be broken by either the Client or Server process using the close() func-
tion.
rc = close (s);
The rc return code is 0 if the close operation is successful, and typically --1 if an error
occurred. The s argument is, of course, the handle for the Socket associated with the
connection that is being broken.
2.10. Socket Options
The fundamental Client operations for setting up a TCP/IP Client--Server connection

were outlined in the previous section. These operations are simple; first, a Socket is
created using the socket() function, then the Socket is bound to a Server process us-
ing the connect() function. There is, however, an optional step that is often inserted
between the two operations. This step establishes certain operating characteristics for
the Socket connection; that is, it sets the Socket options. This is an area in which the
specific system used for the Client VDR can have a large effect and must therefore be
well understood. In the absence of this step the Socket connection will assume the de-
fault characteristics for the system environment, and these defaults may vary from sys-

Jun. 01/02
tem to system. It must be realized that a meaningful discussion of these options requires
a fairly good appreciation of the TCP/IP connection model. This section will only address
a small subset of these options and no real attempt will be made to go into the details of
the function calls used to set them.
The first option to be discussed is the Keep--Alive mode of operation. One must under-
stand that once a TCP/IP Client--Server connection is established, there is no require-
ment that either end actually send any data. Suppose, for example, that the Client side
is represented by a console program by which a User can communicate with a Server
that provides access to some arbitrary host computer. If the User elects not to enter any
commands, there is no data traffic on the open connection. From the point of view of the
Server process, there is no difference between a person walking away from the console,
and the system going down because the wire connecting one end or the other has been
disconnected. For this reason there is often timeout logic built into the application soft-
ware to detect prolonged periods of inactivity. However, TCP/IP itself does not care
whether there is any traffic on an open connection or not. For this reason there is a
TCP/IP option to enable a periodic Keep--Alive exchange on an open connection.
When this option is enabled, the TCP/IP layer itself periodically generates a packet that
will be responded to by the TCP/IP layer on the other node. If the expected response is
not received, the TCP/IP layer presumes that the path to the other node has gone away
or the node itself has shut down or malfunctioned. In this case the connection is closed
and the application software is notified.
When setting the Keep--Alive mode, the application software must specify the time inter-
val of inactivity on the open connection before the TCP/IP layer will issue a Keep--Alive
probe packet. Additional parameters for the option specify the number of unanswered
probes to be sent before shutting down the connection, and the time interval between
probes. The HVR Storage Interface Server uses the Keep--Alive option with timeout val-
ues in the range of a small number of seconds. If the physical connection to an HVR is
broken during normal operation, the HVR software will detect the inability to communi-
cate with the Client VDR in a relatively short period of time.
A second TCP/IP Socket option that is worth looking at is the Linger option. This option
is used by a TCP/IP node that wants to delay the closing of a connection until all data
sent by that node has been delivered to the receiving process. One must keep in mind
that the sending end of a connection has no control over the rate at which the receiving
end consumes and processes data. Suppose, for example, that a burst of data is sent in
a couple of milliseconds, but does not actually get consumed by the remote node for
several seconds. During this interval portions of the data are stored in intermediate buff-
ers somewhere between the sending and receiving application layers. If the sending
end closes the Socket after it has done its last send, part of the data may not have
been delivered to the remote node yet. Without the Linger option, the TCP/IP layers
may simply discard this data. When the Linger option is used, however, a timeout val-

Jun. 01/02
ue is specified. The TCP/IP layer waits for all data to be delivered, or the specified time-
out to expire, before actually terminating the connection. This scheme provides reason-
able assurance that all data sent by one node is actually processed by the other node
before the connection is broken.
2.11. HVR Web (HTTP) Server
Although the Storage Interface Server process associated with Port 5000 provides the
central functionality for the HVR, there are a few additional Server processes that com-
prise the HVR operational software. The first to be discussed is the integrated Web
(HTTP) Server. This Server process listens at Port 80, the standard HTTP Server port,
and provides the HVR with a User Interface for configuration and system status display
purposes. The HVR Web pages can be accessed with a standard Browser program at
the IP address assigned to the HVR. The preferred Browser is Microsoft Internet Explor-
er since most of the testing has been done using it. When a Browser is directed to the
HVR IP Address, a connection is made to the HVR Web Server at Port 80. The HVR
Web Server automatically serves up the home page for the HVR. This page contains
links to the rest of the HVR Web pages.
One of the HVR Web pages is used to configure the HVR Network interface, including
the HVR IP address. Of course it must be realized that the Client Browser cannot ac-
cess this Web page unless it already is able to access the HVR at its current IP address.
The HVR is shipped with an IP address of 192.168.0.2, a Subnet Mask of
255.255.255.0, and a Gateway IP address of 192.168.0.1. These settings correspond to
a private network IP address, and have been selected because they will not conflict
with any IP addresses on the Internet. The system running the Browser that is to be
used to configure the HVR Network interface must itself be properly configured to be
able to connect to the HVR at this private address before it can reconfigure the IP ad-
dress, Subnet Mask, and Gateway IP address of the HVR. Once the HVR has been re-
configured to Network settings that are not consistent with the private address range,
the system used to reconfigure it will no longer be able to connect to the HVR Web
Server interface. For this reason the new Network settings in the HVR do not take effect
until the HVR is powered down and up again.
Since it is possible for an HVR to have been set to an IP address that has been forgot-
ten, the HVR software provides a method of forcing the Network settings back to the de-
fault values indicated above. This is done by installing a jumper wire on the HVR Proc-
essor board and powering the system up.
A second Web Page provided by the HVR Web Server is used for partitioning and other-
wise configuring the HVR Memory Store. This Web Page allows the User to allocate the
available storage space to partitions and assign names to these partitions. These parti-
tion names must be made available to the Client VDR software that has been discussed

Jun. 01/02
in the earlier sections of this document. A System Administrator or Software Developer

typically configures the Memory Store of an HVR one time. The assigned partition
names are then made available to the Client VDR software for establishing the connec-
tions for writing to, reading from, or obtaining status for the partitions.
2.12. HVR FTP Server
The HVR also contains a simple FTP Server. This Server listens for TCP/IP connections
at Port 21, the standard FTP Port. While FTP is typically used for file transfers between
systems, the HVR does not really contain an internal file system. The FTP interface,
however, provides a convenient interface for downloading the HVRs internal Event Log.
This is a log that is stored in a special nonvolatile area internal to the HVR, and is in-
tended primarily for use by the HVR developers for diagnosing problems and monitoring
the operation of an HVR. An FTP Client program can connect to the HVR FTP Server at
the HVR IP address and request a download of the file, event.log. This will cause the
HVR FTP Server to send the internal Event Log in standard ASCII (readable text) as if it
were a file stored on the HVR. No other FTP file transfer currently has any meaning to
the HVR FTP Server.
2.13. HVR Trace Server
The HVR contains an additional, special purpose Server process, the HVR Trace Serv-
er. This Server listens for connection requests at Port 5001, and provides a Client with
access to the HVR internal trace output. This is another facility intended primarily for
use by the HVR developers for diagnosing problems and monitoring the operation of an
HVR. The HVR operational software constantly generates trace messages that identify
operations as they occur. The messages are ASCII text strings with the appropriate end
of line delimiters for display with a simple text editor, etc. The trace messages are stored
in an internal volatile (RAM) buffer beginning at each powerup. When the buffer fills up,
subsequent trace messages are discarded. However, if a TCP/IP connection is made to
the HVR Trace Server, the Server will send the content of the buffer to the Client. Fur-
thermore, as long as the connection remains open, subsequent trace messages are
sent live to the Client process. Since the internal RAM buffer used for trace messages
is relatively large, a connection to the HVR Server within a reasonable time following
powerup will result in trace messages being retrieved by the Client without any loss at
all. Each trace message line is time stamped with an elapsed time since powerup that
the message was generated.

Jun. 01/02
2.14. HVR Message Format Details
All messages sent to the HVR on an open TCP/IP Socket connection begin with a
single--byte message length value. This first byte represents the number of bytes (char-
acters) in the remainder of the message. For example, the message for opening a write
connection to a partition named VDR_Radar would consist of a byte value of 0x0B (11
characters in the remainder of the message), followed by the ASCII characters:
WVDR_Radar, followed by a Null terminator (byte value 0x00). Note that the partition
name, VDR_Radar is a 9--character ASCII sequence that is to be followed by a Null
terminator character. Including the W character that precedes the partition name, the
total message is 11 characters in length. There must be no additional spaces or other
characters within the message. The count byte can be thought of as a specification of
exactly how many more characters will be following in order to complete the message.
Since the count specification is a single byte, the maximum message length is 255
characters. Certain HVR messages can include one or more optional arguments. In all
cases the optional arguments follow the Null terminator of the base message string.
Each optional argument is, itself, a Null--terminated ASCII string. Numerical values con-
tained in optional arguments are ASCII--decimal strings. An example of an optional ar-
gument that includes a decimal value would be one that limits the amount of data to be
sent by the HVR in response to the Read from Stream command. In this case the add-
ed argument might be the string X25. The X character indicates that this is the Xfer
Count argument, and the 25 is a two--character ASCII--decimal value which repre-
sents 25 Mbytes. The X25 string represents four additional bytes of the complete com-
mand (there must be a Null terminator), and would be so reflected in the message
length byte that precedes the base message string. It is essential that the base mes-
sage string, and each optional argument string be followed by a Null terminator byte.
There are some optional arguments that consist of a single ASCII character, and these
too must be followed by the Null terminator byte. Since the message length byte that
precedes a request message tells the HVR exactly how many additional bytes must be
consumed from the Socket stream in order to obtain the request, that byte must reflect
all of the strings and their associated Null terminators. Otherwise the HVR will not con-
sume the entire message before attempting to interpret it.
2.15. Write to Specified Partition: Wname
The Write to Partition command is sent by the acquisition Client as the first data on a
successfully opened TCP/IP Socket connection. This command consists of an upper or
lower--case w, followed by the partition name that was specified when the partition was
allocated, followed by a zero value to terminate the partition name string. Note that the
command must be preceded by the count byte as described above. If the HVR Stor-
age Interface Server finds this to be a valid partition name and the partition is currently
in service, it will reply with a single character response of G. If there is a problem with

Jun. 01/02
the attempt to establish write access, one of several error responses will be sent. Once
the acquisition Client has received a G response, it can begin to send data on the open
socket connection stream. Optional arguments for the Write to Partition command are:
N, for No Wrap mode, and R for Reset Pointer. Neither option takes any additional
parameters. See the HVR Message Format section for further discussion regarding the
format of message options, and refer to the earlier section for Write to Specified Parti-
tion command for the meaning and usage of these options.
2.16. Read from Specified Partition: Rname
The Read from Partition command is sent by the acquisition Client as the first data on
a successfully opened TCP/IP Socket connection. This command consists of an upper
or lower--case r, followed by the partition name that was specified when the partition
was allocated, followed by a zero value to terminate the partition name string. Note that
the command must be preceded by the count byte as described above. If the HVR
Storage Interface Server finds this to be a valid partition name, it will reply with a single
character response of G. If there is a problem with the attempt to establish read ac-
cess, one of several error responses will be sent. Once the acquisition Client has re-
ceived a G response, it can begin to read data from the open socket connection
stream. Optional arguments for the Read from Partition command are: N, for No
Wrap mode, O for specifying an Offset in Mbytes at which the reading should begin,
and X for specifying the total number of Mbytes to be sent by the HVR. The N option
takes no additional parameters, and the O and X options are similar in that they are
both followed by an ASCII--decimal value that represents a number in Mbytes. See the
HVR Message Format section for a detailed example of the X option format as well
as a generalized discussion regarding the format of message options. Refer to the earli-
er section for the Read from Specified Partition command for the meaning and usage
of these options.
2.17. Status Query on Specified Partition: Sname
The Status Query on Partition command is sent by the acquisition Client as the first
data on a successfully opened TCP/IP Socket connection. This command consists of an
upper or lower--case s, followed by the partition name that was specified when the
partition was allocated, followed by a zero value to terminate the partition name string.
Note that the command must be preceded by the count byte as described above. If the
HVR Storage Interface Server finds this to be a valid partition name, it will reply with a
single character response of G. If there is a problem with the attempt to establish sta-
tus query access, one of several error responses will be sent. If the G response is re-
ceived, it will be followed by a Status Response message that conforms to the mes-
sage format described for commands to the HVR. That is, the remainder of the re-
sponse will consist of a count byte followed by a Null--terminated string. The string will

Jun. 01/02
be of the form: L:n T:n F:0xhhhhhhhh. Note that the quotes are NOT part of the re-
sponse, but are shown to emphasize that the entire response is an ASCII, Null--termi-
nated string. The letter n indicates an ASCII--decimal representation of the appropriate
error count. The first n value is the Loop Error Count and represents the number of
write errors that occurred on the current pass through the specified partition. This value
is cleared automatically at the start of each pass through the partitions memory loop.
The second n represents the Total Error Count, and is the accumulated number of
errors since the counters were last cleared (manually or as a result of setting up the
partition map). The letter h represents a hexadecimal digit, and the digits following the
F:0x sequence of the Status response represent flags for the partition. Various flag
conditions for the partition are represented by nonzero values in this sequence. The flag
bits may be decoded using the HVR System Maintenance Web Page.
2.18. Response Messages
The response to a W, R, or S command is a single ASCII character. There is no

count byte or Null terminator. If the partition name is valid and access has been estab-
lished, the response is a G character. If the partition name is not recognized, the re-
sponse is an S character. If the partition has no devices allocated to it, the response is
an E character. If the partition is busy the response is a B characters. This can indi-
cate that another Client is already reading or writing in the partition, or the HVR system
is still initializing. If a partition is out of service for some other reason (failed devices,
etc.), the response is an O character. Note that the response to the S command is
somewhat unique in that it follows the single ASCII character form, but if a valid re-
quest was made, continues with a full message type of response. See the description
of this command interface, above, for more details.
2.19. Limitations on Reading and Writing
The HVR allows only one Client to be writing to a particular partition at a time. That is,
only one W connection will be allowed for each in--service partition. The response to a
W command, for a partition that already has an active W connection, is the B mes-
sage (busy). The HVR will also accept one or more R connections for a partition, even
if there is currently an active W connection. Issues related to the effects of multiple con-
nections on performance (system throughput) must be carefully considered. Also, refer
to the section on the Read from Specified Partition for a discussion of issues involving
simultaneous reading and writing in a partition

Jun. 01/02
SECTION 5
MAINTENANCE

Jun. 01/02

Jun. 01/02
MAINTENANCE
1. GENERAL
This section is intended to contain information required to restore a worn or damaged
part to a serviceable condition. However, the Hardened Voyage Recorder (HVR) is a
completely solid-state device that does not contain any electro-mechanical moving
parts. The HVR 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 tech-
niques, therefore, such PWAs are not field-repairable.
As a result, the HVRs maintenance philosophy is replacement of failed assemblies. In

the case of the HVR, the replaceable assemblies are the Power and Processor Module,
and the Memory Module (Bell). There are no special calibration or overhaul require-
ments for the HVR.
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 L--3 Com-
munications factory for repair or replacement. Extreme care should be used when han-
dling these assemblies.
NOTE: Attempts to repair any of these assemblies will void the

warranty.
CAUTION: THE HVR CIRCUIT BOARDS ARE SUSCEPTIBLE TO ELECTROSTATIC

DESTRUCTION (ESD). PRIOR TO HANDLING PWAs, ENSURE PROP-
ER PERSONNEL GROUNDING TECHNIQUES ARE USED. ENSURE
THAT CARDS ARE PLACED INTO STATIC SHIELDING CONDUCTIVE
BAGS WHEN HANDLING OR STORING.

Jun. 01/02
2. APPROVED MAINTENANCE
Since the HVR has only two modules that can be replaced in the field, these procedures
will cover the removal and installation of the Memory Module and the Power and Proc-
essor Module.
NOTE: Failure to follow maintenance procedures, will void the

manufacturers warranty.
2.1. Memory Module Removal
(1) Secure power to the HVR.
(2) Remove the V--clamp on the HVR unit.
WARNING: The Memory cable has a maximum lenth of 6.5 inches. Extreme care
must be taken when removing the Memory Module to avoid damaging
the J10 connector. Refer to Figure 5--1.
(3) Remove the Memory Module from the HVR base.
(4) Disconnect the Memory Module J10 connector. (Refer to Figure 5--2.)
(5) If a replacement Memory Module is not available, install the Maintenance Cover on
the HVR base. (L--3 Communications p/n: 075E2458--00)
2.2. Memory Module Installation
(1) If the Maintenance Cover was installed, remove the Maintenance cover from the
HVR base.
must be taken when installing the Memory Module to avoid damaging the
J10 connector. Refer to Figure 5--1.
(2) Connect the Memory Module J10 connector, and place the Memory Module on the
HVR base. (Refer to Figure 5--2.)
(3) Install the V--clamp on the HVR unit.
been established to the HVR, and that the partitions are configured according to
the data record in Appendix A.

Jun. 01/02
WARNING: Maximum cable

length is 6.5 inches.
WARNING: Extreme care must be

taken when opening
HVR. Stress on cable
will break connector.
Figure 5--1. HVR Bell House Removal

Jun. 01/02
Hold Down
Screws
Ethernet Terminal
POWER SUPPLY MODULE Block
Memory Module 418--E2711--0X
SN: XXXXXXXXX
J10 Connector DATE XX/XXXX
communications
Sarasota, Florida, USA
DANGER CAUTION
ELECTROSTATIC
SENSITIVE
DEVICES
DO NOT OPEN OR HANDLE
EXCEPT AT A
STATIC--FREE WORKSTATION
HIGH Hold Down
HVR RX LO ( WH/GR )
VOLTAGE
HVR TX LO ( WH/OR )
Screw
HVR RX HI ( GR )
HVR TX HI ( OR )
ETHERNET
Ethernet RJ45
5 AC LINE 1
6 AC LINE 2
POWER
3 24 V GND
2 +24 VDC
4 AC GND
230
Connection
1
4
1 HULL
115
115
10
7
8
9
Power Cable Terminal Block
Grounding Clamp
Hold Down Hold Down
Screw Screw
NOTE: Wires to teminal

ommitted for clarity.
Cable Gland
Connectors
Figure 5--2.
HVR Base Top View

Jun. 01/02
2.3. Power and Processor Module Removal

(1) Secure power to the HVR.
NOTE: Refer to Figure 5--2 for steps (4) through (7).
(4) Disconnect the Memory Module J10 connector.

(5) Disconnect the power cable from the terminal block.
(6) Disconnect the ethernet connection.
NOTE: The Power and Processor Module hold down screws are
spring loaded captivated screws. When removing these
screws from the HVR base, the spring will push the screw
upwards once the screw is disconnected from the HVR
base.
(7) Disconnect the six (6) Power and Processor Module hold down screws from the
HVR base (do not unscrew the hold down screws from the Power and Processor
Module).
(8) Remove the Power and Processor Module from the HVR base.
(9) If a replacement Power and Processor Module is not available, reinstall the
Memory Module on the HVR base.
2.4. Power and Processor Module Installation

(3) Place the Power and Processor Module in the HVR base.
(4) Utilizing the Power and Processor Module hold down screws, attach the Power and
Processor Module to the HVR base.
NOTE: Refer to the to Figure 5--2 for steps (5) through (8).
(5) Connect power cable to terminal block (refer to Table 2--1 for terminal connections).
(6) Attach the RJ45 ethernet cable connector onto the ethernet cable end.

Jun. 01/02
(7) Plug the ethernet cable into the RJ45 socket.
HVR base.
(10) Set the HVR IP address (refer to Section 3 Paragraph 1.2.).
been established to the HVR.
(12) Define VDR memory partitions (refer to Section 3 Paragraph 1.3.).
(13) Remove the V--clamp from the HVR.
(14) Remove the Memory Module from the HVR base, and disconnect the Memory
Module J10 connector (disconnect the Memory Module J10 connector only if re-
quired by space constraints).
(15) Install RTV on the power cable terminal block and the ethernet RJ45 connections.
HVR base.
2.5. Underwater Locator Device (Beacon) Cleaning
The HVR 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 HVR 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

Jun. 01/02
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 acti-
vated, to prevent inadvertent activations due to weather
conditions.
As an added note, the beacons battery has an expected life of six year. L--3 Commu-
nications keeps selected beacon parts in stock, contact L--3 Communications for more
information. To obtain new beacon batteries, contact Dukane Corporation.
The approved beacon is the Dukane beacon, P/N DK480. A new replacement beacon
may be ordered, if needed, directly from L--3 Communications using p/n: 2669800011.
As a general rule, the beacon should be removed from service on or before the expira-
tion date printed on the beacon. The batteries installed in the DK480 beacons are field
replaceable. Refer to service information provided by the Dukane Corporation for servic-
ing and recertification.
Dukane Corporation
(Cage Code 94970)
SeaCom Division,
2900 Dukane Drive
St. Charles, IL 60174

Jun. 01/02

Jun. 01/02
APPENDIX A
HVR MAINTENANCE SHEET

Initial Issue Page A--1
Jun. 01/02

Jun. 01/02
Table A--1
HVR MAINTENANCE SHEET
Network Parameters
HVR IP Address
HVR Subnet
Default Gateway IP
HVR Memory Partition Configuration

Total Granules in Crash Module
Number of Bytes Per Granule
Currently Unassigned Granules
Granule Allocation and Stream Names

Position Number of Granules Stream Name
0
1
2
3
4
5
6
7
8
9
NOTE: This information should be recorded at the time of installa-
tion, to provide a record of the HVRs configuration. Howev-
er, if this information was not recorded at setup, this infor-
mation must be recorded prior to maintenance being per-
formed. L--3 Communications does not keep records of
each individual HVR configuration.

Jun. 01/02

Jun. 01/02

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Consilium S-VDR/VDR

Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Notes and Updates

1. How to use this manual

The sections in the Technical Manual are grouped as follows:

(F) Contains - Annex with Ship Specific Documents, such as:

Voltages within this equipment are sufficiently high to endanger life.

First Aid in Case of Electric Shock

4. Pinch victims nostrils

Do not give liquids until the patient is conscious.

Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Notes and Updates

VDR M4 System performance data

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

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

Main Unit (MU)

Radiated Noise: According to IEC 60945

Power Supply Unit (PSU2)

Power Supply Unit (PSU3)

Max current at lowest input 5A RMS

Power Supply Unit (PSU24)

System indicator SD4-6

Data Acquisition Unit DAU

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

Color Fluorescent International Orange

Regulatory Specifications IEC-61996, 60945, IMO A.861(20)

Final Recording Medium Type B / 707150, L3 HVR01-xxx-xx

See L3 capsule installation and operation manual, 707262, Chapter D 15 in this

Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Notes and Updates

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

System Control Unit (SCU) Remote Control and Alarm Panel

VDR M4.0 Main Unit

RS 485, USB VHF

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

VDR M4 System Process

Messages, total number

Back-up Setting DIM

Consilium Navigation AB P.O. Box 5021 SE-131 05 NACKA SWEDEN

Notes and Updates

1 VDR M4 Quick Guide

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

Messages, total number

Back-up Setting DIM

VDR M4.0 Main Unit USB Memory Stick

Regarding procedure at investigation on board from authorities after accidents, see

1.1.3 Annual performance test (APT)

2.2 Carriage requirements and data items to be recorded

2.3 Resistance to tempering and Continuity of operation

2.4 Ownership of VDR information

2.5 Annual performance test (APT)

3 Incidents and Accidents

3.1 Download to an USB stick

3.1.1 Capsule type A

Incident Back-up (not IMO mandatory)

NOTE: Therefore always make as a routine to transfer the USB-stick data to

3.1.2 Capsule type B

3.2 Download to a temporarily LAN connected external laptop

3.3 Download to a permanently LAN connected external ship computer or

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

4 Alarms and warnings