Detailed Introduction to Rolls-Royce WRC1021D Marine Remote Control Module
1. Product Description
The Rolls-Royce WRC1021D is a high-reliability remote control module belonging to Rolls-Royce Marine’s renowned WRC (Wireless Remote Control) Series—a specialized product line engineered for precision operation of shipboard deck machinery in maritime and offshore sectors. Designed as a “bridge-to-equipment” control interface, it enables seamless remote manipulation of critical deck systems including mooring winches, cargo handling winches, and shipboard cranes, eliminating the need for on-site operators near hazardous or hard-to-reach equipment .
What distinguishes this module from conventional marine control devices is its dual-mode operation capability (wired and wireless integration) and Rolls-Royce’s proprietary “Marine-grade Signal Stabilization” technology, which ensures <100ms command latency even in harsh maritime environments—critical for dynamic operations like offshore platform cargo transfer . Unlike basic remote switches, the WRC1021D functions as an intelligent I/O hub, processing sensor data (e.g., winch load, crane boom angle) in real-time to enforce safety limits (e.g., overload protection) while relaying operational commands .
Its ruggedized design (IP67-rated enclosure) withstands saltwater corrosion, extreme temperature fluctuations, and high vibration—essential for merchant ships, offshore supply vessels, and drillships . With built-in compatibility for maritime communication protocols (NMEA 2000, CANopen), it integrates seamlessly into Rolls-Royce’s Unified Bridge System and third-party vessel automation platforms, enabling centralized monitoring of all deck machinery from the ship’s bridge . Certified by DNV GL, ABS, and LR for marine safety standards, it is trusted in applications where operational precision and personnel safety are paramount.
2. Product Technical Specifications
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Specification Category
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Details
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Core Control Capabilities
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– Primary Functions: Remote winch/crane operation, load monitoring, emergency stop (E-stop) triggering, operational status feedback- Protection Features: Overload protection (programmable setpoints), signal loss fail-safe mode, short-circuit protection- Control Modes: Wireless (radio frequency), wired (Ethernet/CANbus), local manual override
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Electrical Parameters
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– Power Supply: 24 VDC (wide input range: 18-32 VDC) compliant with marine electrical standards- Power Consumption: Typical 8 W; Max 15 W (during wireless transmission)- Fuse Rating: 1 A slow-blow for power input; 0.5 A for I/O circuits
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Input/Output (I/O) Interfaces
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– Analog Inputs: 4 channels (12-bit resolution) for load cells (4-20 mA), pressure sensors (0-10 VDC)- Digital Inputs: 8 channels (24 VDC) for limit switches, emergency stop signals, equipment status sensors- Digital Outputs: 6 channels (24 VDC, 2 A max) for winch motor control, brake activation, alarm indicators- Communication: Wireless (2.4 GHz RF, 100 m line-of-sight range); Wired (CANopen, Ethernet, RS-485 Modbus RTU)
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Performance Metrics
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– Command Latency: <100 ms (wireless mode); <20 ms (wired mode)- Load Monitoring Range: 0-500 kN (compatible with 4-20 mA load cells)- Wireless Signal: 2.4 GHz ISM band, 100 m line-of-sight, AES-128 encryption- Safety Response Time: <50 ms for E-stop activation
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Physical & Environmental
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– Dimensions: 180 mm (W) × 120 mm (H) × 60 mm (D) (panel/mountable or handheld controller base)- Weight: 1.2 kg- Operating Temperature: -30°C to +70°C- Storage Temperature: -40°C to +85°C- Protection Rating: IP67 (enclosure); IP65 (connectors)- Vibration Resistance: IEC 60068-2-6 (10-500 Hz, 10 g peak)
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Reliability & Compliance
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– Certifications: DNV GL, ABS, LR marine type approval; CE (EMC/EMI compliance)- Mean Time Between Failures (MTBF): >80,000 hours (per IEC 61709)- Fault Logging: 150-event memory with timestamp (E-stop triggers, overload events, communication errors)
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3. Usage Instructions
3.1 Installation & Setup
- Pre-Installation Checks
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- Verify compatibility with target deck machinery (e.g., confirm winch motor control signal type matches module outputs); cross-check part number WRC1021D with the vessel’s machinery data sheet.
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- Inspect the module for shipping damage (cracked enclosure, bent pins) and ensure marine certification marks (DNV GL/ABS) are intact.
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- Prepare tools: Torque screwdriver (0.5-1.0 N·m), ESD wristband, marine-grade shielded cables (22 AWG for analog signals), and Rolls-Royce-approved wiring harness (part no. WRC-HAR-001).
- Mechanical Mounting
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- Location: Install in the machinery control room or near the deck equipment (if local mounting is required); maintain 30 mm clearance for ventilation. Avoid direct exposure to salt spray or standing water.
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- Securing: Fasten via M4 screws torqued to 0.8 N·m; use the provided gasket to enhance IP67 protection. For wireless operation, mount the RF antenna at least 1 m above metal surfaces.
- Wiring Connections
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- Power Wiring: Connect 24 VDC (positive to terminal PWR+, ground to PWR-) with a 1 A inline fuse; comply with SOLAS wiring regulations (color-coded marine cables).
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- Sensor/Feedback Wiring:
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- Load cell: Connect 4-20 mA signal to AI1 (+) and AI1 (-); use twisted-pair shielded cable, ground shield at sensor end.
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- Limit switches: Wire to digital inputs DI1-DI4 (24 VDC signal); DI1 reserved for main E-stop.
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- Actuator Wiring:
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- Winch motor controller: Connect digital outputs DO1 (start) and DO2 (stop) to the motor starter; use relay isolation for high-current circuits.
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- Brake solenoid: Wire to DO3; ensure brake releases only when motor is energized.
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- Communication Wiring: Connect CANopen terminals (CAN_H/CAN_L) to the vessel’s automation bus; terminate with 120 Ω resistor.
- Post-Installation Verification
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- Power on the module; check the “STATUS” LED (green = normal, flashing red = fault).
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- Test wireless communication: Pair the handheld remote (sold separately) and verify command response (e.g., winch activation within 100 ms).
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- Calibrate load cell: Apply a known 100 kN load and adjust AI1 offset in configuration software to match 4 mA (0 kN) and 20 mA (500 kN).
3.2 Configuration & Operation
- Initial Configuration via Rolls-Royce Marine Control Suite (RMCS)
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- Software Setup: Install RMCS (v4.1+ for Windows) and connect to the WRC1021D via USB service port.
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- Parameter Configuration:
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- Select machinery type (e.g., “mooring winch”) from the device library; load default parameters.
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- Set safety limits: Overload threshold (e.g., 450 kN for 500 kN-rated winch), E-stop response mode (brake engage + motor stop).
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- Wireless Pairing: Register the handheld remote’s serial number in RMCS to enable AES-128 encrypted communication.
- Normal Operation
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- Bridge Control: Activate “Wired Mode” via RMCS; send winch/crane commands from the Unified Bridge System. Monitor load and status via the bridge HMI.
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- Local Wireless Operation: Use the handheld remote to select “Winch 1” and press “Start”; the module relays the command and displays real-time load on the remote’s LCD.
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- Emergency Response: Press the red E-stop button on the remote or bridge panel; the module triggers an immediate stop and engages brakes within 50 ms. Reset via RMCS after fault investigation.
- Maintenance & Troubleshooting
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- Routine Checks:
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- Monthly: Inspect wiring terminals for corrosion; clean connectors with marine-grade contact cleaner.
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- Quarterly: Replace RF antenna battery (if applicable); download fault logs via RMCS to track overload events.
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- Common Faults:
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- Wireless Signal Loss: Check antenna connection; replace if signal range drops below 50 m.
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- No Actuator Response: Verify output relay (test with multimeter); replace DO channel fuse if blown.
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- Overload False Alarms: Recalibrate load cell via RMCS; check for sensor drift.
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- Firmware Update: Annual update via RMCS (download from Rolls-Royce Marine Service Portal) to enhance protocol compatibility.
4. System Introduction
The WRC1021D is a critical component of Rolls-Royce’s Integrated Deck Machinery Control System (IDMCS)—a scalable ecosystem designed to optimize maritime operations, enhance personnel safety, and reduce operational downtime. Deployed across merchant fleets, offshore platforms, and naval vessels, this system unifies remote control of winches, cranes, and hatch covers under a single monitoring interface .
4.1 System Architecture
- Sensing Layer: Comprises load cells, limit switches, and position sensors that feed real-time machinery data to the WRC1021D. Redundant E-stop sensors ensure fail-safe operation.
- Control Layer: The WRC1021D processes input signals, executes safety logic (e.g., overload prevention), and sends commands to actuators. It synchronizes with other WRC modules for multi-winch operations (e.g., coordinated mooring).
- Integration Layer: Connects to the ship’s Unified Bridge System via CANopen/NMEA 2000, enabling centralized monitoring. Data is also relayed to on-shore fleet management systems via satellite for predictive maintenance .
- Safety Layer: Embeds independent E-stop logic compliant with IMO SOLAS regulations; triggers global shutdown of related machinery in critical faults.
4.2 Key System Features
- Personnel Safety Enhancement: Eliminates on-deck operator exposure to moving machinery and hazardous conditions, reducing accident risk by up to 70% .
- Operational Efficiency: Wireless control reduces mooring/cargo handling time by 15% compared to manual operation; real-time load monitoring prevents equipment damage.
- Fleet Scalability: Link up to 16 WRC1021D modules for multi-machinery control (e.g., 8 winches + 2 cranes on a drillship).
- Predictive Maintenance: RMCS analyzes load cycles and actuator response times to predict component wear (e.g., winch brake replacement due date), enabling planned maintenance during port calls.
5. Recommended Related Models in the Same Series
For applications requiring specialized capabilities (e.g., long-range control, hazardous areas), the following WRC Series models are recommended:
- Rolls-Royce WRC1022D: Long-range wireless variant with 500 m line-of-sight RF range. Ideal for offshore supply vessels handling cargo transfers to platforms .
- Rolls-Royce WRC1021D-EX: Explosion-proof model (ATEX Zone 2, IECEx) with intrinsic safety barriers. Designed for chemical tankers and offshore drilling rigs .
- Rolls-Royce WRC1030D: Multi-channel expansion module with 16 digital inputs/outputs. Compatible with WRC1021D for large-scale deck machinery setups (e.g., container ship cranes).
- Rolls-Royce WRC2000D: Next-generation model with 4G/LTE connectivity for remote fleet monitoring. Integrates with Rolls-Royce’s digital twin technology for predictive performance analysis .
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