C102974 A SERVICE FAULT FINDING

C102974-A Page 1 of 65

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DOC-1048-1

Fault Finding

Revision history:

REV. DATE MODIFIER DESCRIPTION

0 4.4.2008

AaNi Created

C102974-A Page 2 of 65

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DOC-1048-1

Contents

GENERAL ......................................................................................................................................................................................................................................... 5

CONTROL VOLTAGE SUPPLY ................................................................................................................................................................................................... 5

2.1

ONTROL SYSTEM VOLTAGE ALARM

......................................................................................................................................................................................... 6

2.2

EFERENCE VOLTAGE SOURCE

AP01 ......................................................................................................................................................................................... 7

CONTROL SYSTEM ....................................................................................................................................................................................................................... 8

3.1

PLC

FAILURES AND THEIR INDICATIONS

.................................................................................................................................................................................... 9

3.1.1

Fault finding .......................................................................................................................................................................................................................... 9

3.1.2

PLC CPU indicators ............................................................................................................................................................................................................ 10

3.1.3

CPU Racks and Standard Expansion Racks Errors ............................................................................................................................................................ 13

3.1.4

Input Errors ........................................................................................................................................................................................................................ 14

3.1.5

Output Errors ...................................................................................................................................................................................................................... 16

3.1.6

Analogue unit indicators ...................................................................................................................................................................................................... 18

3.1.7

Indication combinations ...................................................................................................................................................................................................... 19

3.1.8

Special I/O Units Errors ...................................................................................................................................................................................................... 20

REMOTE ANGLE INDICATION ................................................................................................................................................................................................ 21

4.1

NGLE INDICATOR FAULT FINDING

(

BLACK TYPE

) .................................................................................................................................................................. 21

4.2

NGLE INDICATOR FAULT FINDING

RAY TYPE

) .................................................................................................................................................................... 22

REMOTE RPM INDICATION ..................................................................................................................................................................................................... 23

5.1

EMOTE RPM INDICATOR FAULT FINDING

LACK

YPE

) ....................................................................................................................................................... 24

5.2

EMOTE RPM INDICATOR FAULT FINDING

(

GRAY TYPE

) .......................................................................................................................................................... 25

MAIN CONTROL WITH CONTROL LEVER .......................................................................................................................................................................... 26

6.1

TEERING CONTROL

................................................................................................................................................................................................................. 26

6.1.1

Feedback transmitter at propulsor ...................................................................................................................................................................................... 27

6.1.2

Steering feedback transmitter RG10 or RG11 failure ......................................................................................................................................................... 27

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6.2

RPM

CONTROL

6.2.1

RPM control failure at main control ................................................................................................................................................................................... 29

6.3

ONTROL LEVER FAILURES

BACK-UP CONTROL ................................................................................................................................................................................................................... 31

7.1

AULT FINDING

AUTOPILOT .................................................................................................................................................................................................................................. 33

ELECTRIC STEERING GEAR ................................................................................................................................................................................................... 34

9.1

OW STEERING SPEED

9.2

AULT FINDING

9.3

LANETARY GEAR

9.4

ASIC MOTOR

9.5

9.6

OTOR

RAKE

9.7

RAKE RESISTOR

(BRU) .......................................................................................................................................................................................................... 42

9.8

OTOR CONTROL UNIT

(SMU) ................................................................................................................................................................................................ 42

9.9

TEERING GEAR INVERTER

ESU

REQUENCY CONVERTER

) .................................................................................................................................................. 43

9.9.1

Menu indications ................................................................................................................................................................................................................. 44

POWER TRAIN ............................................................................................................................................................................................................................. 51

10.1

BNORMAL OR FAILURE SITUATIONS

...................................................................................................................................................................................... 51

CLUTCH SYSTEM ........................................................................................................................................................................................................................ 52

11.1

AULT FINDING

LUBRICATION .............................................................................................................................................................................................................................. 55

12.1

AULT FINDING

12.2

UBRICATION PUMP DOES NOT GIVE OIL PRESSURE

................................................................................................................................................................. 60

12.2.1

Oil pressure is low ........................................................................................................................................................................................................... 60

12.3

UBRICATION SYSTEM PRESSURE AND TEMPERATURE TRANSMITTERS

................................................................................................................................... 61

12.3.1

Lubrication oil temperature transmitter failure .............................................................................................................................................................. 61

12.3.2

Lubrication oil pressure transmitter failure .................................................................................................................................................................... 62

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12.4

OOLING SYSTEM FAULT FINDING

........................................................................................................................................................................................... 63

SEAL OIL TANK ........................................................................................................................................................................................................................... 64

13.1

AULT FINDING

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1 G

ENERAL

The presented error and failure situations are based on FMEA analysis of the system and also from service feedback. The fault findings
are included to the same description as the system or module description.

There is more information included in the instruction of the each system.

2 C

ONTROL VOLTAGE SUPPLY

CODE

ALARM

ALARM OR FAILURE

FAILURE

TEMPORARY ACTION

200

Control voltage

Control system 220 V supply

Control system transfer automatically to
back-up supply

No action needed.

201

Control voltage

PLC 24 VDC supply

The main control of one propulsor does not
work

If you can’t run one propulsor, shift to
back-up control for this propulsor.

Steering stops

Transfer this propulsor to back-up
control.

Propeller motor rpm to minimum

Transfer this propulsor to back-up
control.

202

Control voltage

24 VDC back-up supply

If the 220 VAC main supply is working, main
control will continue to operate normally

No action needed. Be cautious.

203

Control voltage

24 VDC supply for remote angle
indicators

Remote angle indication stops

Watch the mechanical display at
propulsor.

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2.1 C

ONTROL SYSTEM VOLTAGE ALARM

FAULT EFFECT TEMPORARY

ACTION

CAUSE

REMEDY

Control system 220 VAC

supply

Control system transfer

automatically to back-up

supply.

Not needed.

Vessel switchboard supply switch

is open

Close switchboard switch

Wire is broken, short circuit or

connection is open

Repair cabling or wiring failure

Converter AP02 is broken

Replace the converter

PLC 24 VDC supply

(Indication HI17 does not lit)

-The main control of one

propulsor does not work
-Propeller motor rpm set is

going to zero

If you can’t operate with one

propulsor, use back-up
control for this propulsor.

Supply protection circuit breaker

F1 blown

Close circuit breaker

PLC power supply broken

Replace PLC power supply

Wire is broken, short circuit or
connection is open

Repair cabling or wiring failure

Control voltage switch is open. Close

control

switch

24 VDC back-up supply
failure

If the 220 VAC main supply
is working, main control will

continue operate normally

Not needed. Be careful.

Supply protection circuit breaker
F2 blown

Close circuit breaker

Vessel switchboard supply switch

is open

Close switchboard switch

Wire is broken, short circuit or

connection is open

Repair cabling or wiring failure

24 VDC supply for remote
angle indicators failure

The display does not
operate.

Follow the mechanical
display at propulsor.

Supply protection circuit breaker
F3 blown

Close circuit breaker

Vessel switchboard supply switch

is open

Close switchboard switch

Wire is broken, short circuit or

connection is open

Repair cabling or wiring failure

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2.2 R

EFERENCE VOLTAGE SOURCE

AP01

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

10 VDC reference supply AP01

failure, The green LED at AP01

module is not lit, Indication lamp HI17
and other indicating lamps are

blinking without clear reason.
Normally then the control station

indication lamps are blinking, but
there can be several other indication

lamps blinking.

The set signals from the

control levers are missing

or they are erroneous.

Transfer the propulsor to back-

up control.

Reference supply is loose

Close switchboard switch

Wire is broken, short circuit or
connection is open

Tighten and check that the
security bail is properly set

Reference supply is broken

Replace the converter

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3 C

ONTROL SYSTEM

CODE

ALARM

ALARM OR FAILURE

IND1

IND2

FAILURE

TEMPORARY ACTION

210

Control failure

PLC failure

The main control of one propulsor does
not work

If you can’t run one propulsor, shift to back-
up control for this propulsor.

Steering stops

Transfer this propulsor to back-up control.

Propeller motor rpm to minimum

Transfer this propulsor to back-up control.

211

Control failure

9.5 VDC reference

supply AP01

Propeller motor rpm control is not working Transfer this propulsor to back-up control.

Steering is not working correctly

Transfer this propulsor to back-up control.

No alarm

One or more

indication lights are
blinking in error

Reference voltage source AP01

If you can’t run one propulsor, shift to back-
up control for this propulsor.

212

Control failure

Control system back-
up battery failure

No effect

Replace the battery

220

Control failure

Control system

failure alarm (see
also transmitter

failures)

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3.1 PLC

FAILURES AND THEIR INDICATIONS

3.1.1 F

AULT FINDING

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

PLC failure

Main control is not working

Use back-up control

Short circuit at output circuits

Find the reason. If the external failure has caused the

failure of the PLC, find it out and repair, because the
failure can happen again.

Vibration

Isolate the unit from vibration source.

High temperature at control unit

Lower temperature

Component failure

Replace the component

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3.1.2 PLC

CPU

INDICATORS

The PLC CPU unit has some indication LED, which indicates the status of PLC. The indication is also depending of the indication lamp
HI17 at remote control panel.

IND COLOR

STATUS

MEANING

HI17

RUN

Green ON

PLC is operating normally.

OFF

Flashing System download mode error or DIP switch setting error

OFF

PLC has stopped operating while in PROGRAM mode, or has stopped operating due to a fatal error, or is downloading data
from the system.

OFF

ERR/ALARM Red

PLC has stopped operating due to a fatal error, or a hardware error (watchdog) has occurred. The PLC turns all outputs

OFF.

OFF

Flashing A non-fatal error has occurred. The PLC will continue operating.

OFF

Flashing Battery voltage is below the monitoring level. You should change the battery. This has no influence to the operation of the

PLC. The PLC software is designed so, that it start from "Flash" memory after black-out.

OFF

PLC is operating normally.

OFF

INH

Orange ON

Output OFF Bit (A50015) has been turned ON. The outputs from all Output Units will turn OFF.

OFF

Output OFF bit (A50015) has been turned OFF.

PRPHL

Orange Flashing CPU

unit

is communicating (sending or receiving) via peripheral port.

OFF

CPU unit is not communicating via the peripheral port.

COMM

Orange Flashing CPU

Unit

is communicating via RS232C port

OFF

CPU Unit is not communicating via RS232C port

BKUP

Orange ON

User program and parameter area data is being backed up to flash memory in the CPU Unit or being restored from flash

memory. Do not turn OFF the power supply to the PLC while this indicator is lit.

OFF

Data is not being written to flash memory.

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MCPWR

Green

Power is being supplied to the Memory Card.

Flashing

Flashes once: Easy backup read, write, or verify normal
Flashes five times: Easy backup write malfunction

Flashes three times: Easy backup write warning
Flashes continuously: Easy backup read or verify malfunction

OFF

Power is not being supplied to the Memory Card.

BUSY

Orange

Flashing

Memory Card is being accessed.

OFF

Memory Card is not being accessed.

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3.1.2.1 I

NDICATOR

TATUS AND

RROR

ONDITIONS

IND. CPU

ERROR

CPU
STANDBY

FATAL
ERROR

NON-FATAL
ERROR

COMMUNICATION ERROR

OUTPUT OFF
BIT ON

PERIPH RS232

RUN OFF

OFF OFF ON ON

ERR/ALARM ON OFF

Flashing

INH OFF

PRPHL

OFF

COMM

OFF

OPERATION CPU

will

stop

The CPU Unit will not

start operation in RUN or
MONITOR mode.

The CPU Unit will stop

operating in RUN or
MONITOR mode.

The CPU Unit will

continue operating in
RUN or MONITOR

mode.

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3.1.3 CPU

ACKS AND

TANDARD

XPANSION

ACKS

RRORS

SYMPTOM CAUSE REMEDY

POWER indicator is not lit.

PCB short-circuited or damaged.

Replace Power Supply Unit.

Error in program.

Correct program

Power line is faulty.

Replace Power Supply Unit.

RUN output* does not turn ON., RUN indicator lit.

Internal circuitry of Power Supply Unit

is faulty.

Replace Power Supply Unit.

Serial Communications Unit or CPU

Bus Unit does not operate or malfunctions.

The I/O Connecting Cable is faulty.

The I/O bus is faulty.

Replace the I/O Connecting Cable

Replace the I/O Control Unit or I/O
Interface Unit.

Bits do not operate past a certain point.
Error occurs in units of 8 points.
I/O bit turns ON
All bits in one Unit do not turn ON.

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3.1.4 I

NPUT

RRORS

SYMPTOM CAUSE REMEDY

Not all inputs turn ON or indicators are not lit.

Power is not supplied to Input Unit.

Supply power

Supply voltage is low.

Adjust supply voltage to within rated range.

Terminal block mounting screws are loose.

Tighten screws.

Faulty contact of terminal block connector.

Replace terminal block connector.

Not all inputs turn ON (indicator lit).

Input circuit is faulty. (There is a short at the load or
something else that caused an overcurrent to flow.)

Replace Unit.

Not all inputs turn OFF.

Input circuit is faulty.

Replace Unit.

Specific bit does not turn ON.

Input device is faulty.

Replace input devices.

Input wiring disconnected. Check

input

wiring

Terminal block screws are loose.

Tighten screws.

Faulty terminal block connector contact.

Replace terminal block connector.

Too short ON time of external input.

Adjust input device

Faulty input circuit

Replace Unit.

Input bit number is used for output instruction.

Correct program.

Specific bit does not turn OFF.

Input circuit is faulty.

Replace Unit.

Input bit number is used for output instruction.

Correct program.

Input irregularly turns ON /OFF.

External input voltage is low or unstable.

Adjust external input voltage to within rated range.

Malfunction due to noise.

Take protective measures against noise,

such as:
(1) Increase input response time

(2) Install surge suppressor.
(3) Install insulation transformer.

(4) Install shielded cables between the Input Unit and
the loads.

Terminal block screws are loose.

Tighten screws.

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Faulty terminal block connector contact.

Replace terminal block connector.

Error occurs in units of 8 points or 16 points, i.e., for
the same common.

Common terminal screws are loose.

Tighten screws.

Faulty terminal block connector contact.

Replace terminal block connector.

Faulty data bus

Replace Unit.

Faulty CPU

Replace CPU.

Input indicator is not lit in normal operation.

Faulty indicator or indicator circuit.

Replace Unit.

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3.1.5 O

UTPUT

RRORS

SYMPTOM CAUSE REMEDY

Not all outputs turn ON

Load is not supplied with power.

Supply power

Load voltage is low.

Adjust voltage to within rated range.

Terminal block screws are loose.

Tighten screws.

Faulty terminal block connector contact.

Replace terminal block connector.

An overcurrent (possibly caused by a short at the
load) resulted in a blown fuse in the Output Unit.

(Some Output Units provide an indicator for blown
fuses.)

Replace fuse or Unit.

An overcurrent (possibly caused by a short at the

load), but fuses not blown

Try to find out short circuited or low resistance

component and remove and repair it. (eg. control
lever motors)

Faulty I/O bus connector contact.

Replace Unit.

Output circuit is faulty.

Replace Unit.

If the INH indicator is lit, the Output OFF Bit (A50015)
is ON.

Turn A50015 OFF.

Not all outputs turn OFF

Output circuit is faulty.

Replace Unit.

Output of a specific bit number does not turn ON or
indicator is not lit

Output ON time too short because of a
mistake in programming.

Correct program.

Bit status controlled by multiple instructions.

Correct program.

Output circuit is faulty.

Replace Unit.

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Output of a specific bit number does not turn ON
(indicator lit).

Faulty output device.

Replace output device.

Break in output wiring.

Check output wiring.

Terminal block screws are loose.

Tighten screws.

Faulty terminal block connector contact.

Replace terminal block connector.

Faulty output bit.

Replace relay or Unit.

Output circuit is faulty.

Replace Unit.

Output of a specific bit number does not turn OFF
(indicator is not lit).

Faulty output bit.

Replace relay or Unit.

Bit does not turn OFF due to leakage current or
residual voltage.

Replace external load or add dummy resistor.

Output of a specific bit number does not turn OFF
(indicator lit).

Bit status controlled by multiple instructions.

Correct program.

Output circuit is faulty.

Replace Unit.

cause remedy
Low or unstable load voltage.

Adjust load voltage to within rated range

Bit status controlled by multiple instructions.

Correct program.

Malfunction due to noise.

Protective measures against noise:

(1) Install surge suppressor.

(2) Install insulation transformer.
(3) Use shielded cables between the Output

Unit and the loads.

Terminal block screws are loose.

Tighten screws.

Faulty terminal block connector contact.

Replace terminal block connector.

Terminal block screws are loose.

Tighten screws.

Faulty terminal block connector contact.

Replace terminal block connector.

An overcurrent (possibly caused by a short at the

load) resulted in a blown fuse in the Output Unit.

Replace fuse or Unit.

Faulty data bus.

Replace Unit.

Faulty CPU.

Replace CPU.

Faulty indicator.

Replace Unit.

Short circuit at output circuit

Check and repair output wiring or component

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3.1.6 A

NALOGUE UNIT INDICATORS

LED

IND

MEANING

CPU RUN POSSIBLE REASON

RUN

Operating in normal mode.

OFF

Unit has stopped exchanging data with the CPU Unit.

ERC

Alarm has occurred (such as disconnection detection) or initial

settings are incorrect.

Alarm has occurred at the Analogue Input Unit.

Alarm has occurred (such as disconnection detection) or initial

settings are incorrect.

OFF

Check whether the initial settings for the Analogue Input

Unit are set correctly.

OFF Operating

normally.

ERH

Error has occurred during data exchange with the CPU Unit.

Error detected by CPU Unit

Error has occurred during data exchange with the CPU Unit.

OFF

Check whether the unit number is set correctly.

OFF Operating

normally.

ADJ

Flash

Operating in offset/gain adjustment mode.

OFF

Other than the above.

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3.1.7 I

NDICATION COMBINATIONS

RUN ERC ERH ADJ MEANING

ON ON

The output setting range has been exceeded.

A disconnection was detected. (1 to 5 V or 4 to 20 mA).

An EEPROM writing error has occurred while in adjustment mode.

ON ON Flash

In adjustment mode, offset or gain cannot be adjusted because input value is out of the permissible range for

adjustment.

In adjustment mode, adjustment cannot be performed because the specified input or output number is not set for use

or because the wrong input or output number is specified.

The PLC is in either MONITOR or RUN mode while the Analog I/O Unit is operating in adjustment mode.

When a PLC error occurs in the adjustment mode, Unit operations will stop operating. (The input and output values
immediately prior to the error will be held.)

The I/O number for the ratio conversion function has been set to be not used.

There is a mistake in the upper or lower limit setting when scaling is used. The set value is exceeded, the upper limit
equals the lower limit (not 0000), etc. A number outside of the 0 to 9999 BCD range has been specified for the ratio

set value.

The wrong output status for when conversion is stopped has been specified. The wrong number of samplings has

been specified for mean processing. The conversion time/resolution setting or operation mode setting is incorrect.

ON ON

Error has occurred during data exchange with the CPU Unit.

No response from CPU Unit during fixed period.

Error has been generated in CPU Unit.

No error will be detected by the CPU Unit or displayed on the Programming Console, because the CPU Unit is

continuing operation.

The same unit number has been assigned to more than one Unit or the unit number was set to a value other than 00

to 95. The Special I/O Units registered in the I/O table are different from the ones actually mounted.

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3.1.8 S

PECIAL

I/O

NITS

RRORS

SYMPTOM CAUSE

REMEDY

The ERH and RUN indicators on the
Special I/O Unit are lit.

I/O refreshing is not being performed for the Unit from the CPU
Unit (CPU Unit monitoring error). It’s possible that cyclic

refreshing has been disabled for the Special I/O Unit in the

Cyclic Refresh Disable Setting in the PLC Setup (i.e., the bit
corresponding to the unit number has been set to 1).

Change the bit corresponding to the unit number to 0
to enable cyclic refreshing, or make sure that the Unit

is refreshed from the program using IORF at least

once every 11 s.

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4 R

EMOTE

NGLE INDICATION

CODE

OTHER FAILURE SITUATIONS

FAILURE INDICATION

FAILURE

TEMPORARY ACTION

230

Steering angle indicator SAI

Indicator turns slowly CCW

The remote indicator does not work

Operate propulsor carefully and watch the
steering angle by using the mechanical
indicator at propulsor.
If only one indicator is failing, you can shift to
another control station and continue the
operation.

231

Steering angle indicator SAI

The indicator does not follow the

propulsor angle

The indicator does not follow the
propulsor

The operation should be interrupted to find the
cause.

4.1 A

NGLE INDICATOR FAULT FINDING

(

BLACK TYPE

)

FAULT EFFECT

TEMPORARY

ACTION

CAUSE REMEDY

The indicator does not follow the

propulsor angle

Steering gear failure

See: Steering gear

Steering gear failure

See: Low steering speed

Transmitter unit mechanical
failure

See: Transmitter Unit

Voltage supply is missing

See voltage supply

Transmitter failure

Replace transmitter

The remote angle indicator is
stepping slowly in CCW direction.

The system has found a CAN bus failure
and indicator turns continuously slowly

CCW reminding that the unit is out of
order.

Cable failure

Check and repair the
cabling, wiring or connector

Transmitter failure

Replace the transmitter

Indicator failure

Replace the indicator

Cable wrong connected,
change CAN_H/CAN_L

Check and repair the
cabling, wiring or connector

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4.2 A

NGLE INDICATOR FAULT FINDING

RAY TYPE

)

FAULT EFFECT

TEMPORARY

ACTION

CAUSE REMEDY

The indicator does not follow the

propulsor angle

Steering gear failure

See: Steering gear

Steering gear failure

See: Low steering speed

Transmitter unit mechanical

failure

See: Transmitter Unit

Voltage supply is missing

See voltage supply

Transmitter failure

Replace transmitter

The remote angle indicator alarm

LED is blinking and the indicator is
rotating continuously clockwise

When the alarm led is blinking, the

indicator self-checking system has found
a CAN bus failure. If failure is found, the

led is blinking and indicator turns
continuously slowly CCW reminding that

the unit is out of order.

Cable failure

Check and repair the

cabling, wiring or connector

Transmitter failure

Replace the transmitter

Indicator failure

Replace the indicator

Cable wrong connected,

change CAN_H/CAN_L

Check and repair the

cabling, wiring or connector

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5 R

EMOTE

RPM

INDICATION

CODE

OTHER FAILURE SITUATIONS

FAILURE INDICATION

FAILURE

TEMPORARY ACTION

235

Rpm indicator SRI

The dial is moving continuously

between 40 % and 80 %.

Rpm display is failing.

If only one indicator is failing, you can shift to another
control station and continue the operation.

Cabling failure

Check cabling

236

Rpm indicator SRI

Rpm display is continuously –20 %

Rpm display is failing

Watch the propeller rpm from the PM display

RPM transmitter failure

Check the transmitter / wiring.

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5.1 R

EMOTE RPM INDICATOR FAULT FINDING

LACK

YPE

)

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

RPM display is continuously -20 %

RPM Transmitter failure

Replace and adjust the transmitter

Transmitter loose

Tighten the fastening and adjust
the distance 0.5...1.0 mm

The running direction reverses. After that the

pointer is hunting around the centre of the scale
until the input signal (4-20mA) is available

The signal connections are

open

Check the wiring

The signal connections are
short cutted (= 0 mA)

Check the wiring

There is in 5 s no signal >4mA
available.

Check the wiring

Check signal from A1

The pointer is hunting around the centre of the
scale

There is no signal connected or
available

Check the wiring
Replace the indicator

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5.2 R

EMOTE RPM INDICATOR FAULT FINDING

(

GRAY TYPE

)

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

RPM display is continuously -20 %

RPM Transmitter failure

Replace and adjust the transmitter

Transmitter loose

Tighten the fastening and adjust
the distance 0.5...1.0 mm

The remote rpm indicator alarm
LED is blinking, and pointer is at

max. left hand position.

When the alarm led is blinking,
the indicator self-checking

system has found a failure. If
failure is found, the led is

blinking reminding that the unit
is out of order.

Reason: 4 mA signal is below 3
mA, indicator failure

Replace the indicator

The remote rpm indicator alarm
LED is blinking, and pointer is at

max. right hand position.

When the alarm led is blinking,
the indicator self-checking

system has found a failure. If
failure is found, the led is

blinking reminding that the unit
is out of order.

Reason: 20 mA signal is above
21 mA, indicator failure

Replace the indicator

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6 M

AIN CONTROL WITH

ONTROL LEVER

6.1 S

TEERING CONTROL

There is also a “Control System Alarm”.

CODE TRANSMITTER FAILURE

LOCATION

IND1

IND2

IND3

IND4

FAILURE

TEMPORARY ACTION

251

Control lever steering set

potentiometer

RG01 Fore

Steering stops

Transfer this propulsor to back-up

control.
Or use another control station.

251

Control lever steering set

potentiometer

RG01 Back

251

Control lever steering set
potentiometer

RG01 PS

251

Control lever steering set

potentiometer

RG01 SB

There is also a “Control System Alarm”.

C102974-A Page 27 of 65

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DOC-1048-1

6.1.1 F

EEDBACK TRANSMITTER AT PROPULSOR

CODE TRANSMITTER FAILURE

LOCATION IND1

IND2

IND3

FAILURE

TEMPORARY ACTION

250 Steering

feedback

failure RG10

Propulsor

Steering stops

Transfer this propulsor to back-up

control.

6.1.2 S

TEERING FEEDBACK TRANSMITTER

RG10

RG11

FAILURE

If the zero positions of RG11 and RG10 are not same, the control system will give control system alarm.

FAULT EFFECT

CAUSE

REMEDY

The internal failure

indication of the transmitter
has founded failure, signal is

2 mA

Steering stops.

Transfer the propulsor to back-up
control.

Transmitter does not work.

Replace transmitter

Transmitter does not work

Steering stops.
Transfer the propulsor to back-up

control.

Transmitter wiring

Propulsor is making steering
without command

Transmitter temperature is too high

Lower transmitter temperature adding cooling

The transmitter is loose and turns by itself

Tighten the fastening
And make new setting.

Signal is 0 mA

Steering stops.
Transfer the propulsor to back-up

control.

Transmitter voltage supply

Repair it

Transmitter wiring.

Repair

Transmitter zero positions
differ from each other

The transmitter is loose and the zero position
differs

Tighten the fastening
And make new setting.

C102974-A Page 28 of 65

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DOC-1048-1

6.2 RPM

CONTROL

CODE OTHER FAILURE SITUATIONS

FAILURE INDICATION

IND1

FAILURE

TEMPORARY ACTION

240

Rpm control failure at main

control at all control stations

The rpm control does not work at main

control at all

Propeller motor rpm control is not
working properly

Transfer control to back-up control.

241

Rpm control failure at main

control at one control station

The rpm control does not work at one

control station

Propeller motor rpm control is not
working properly

Transfer control to another control station.

245

Propeller motor does not

start

Motor does not start

Propeller motor is not running

Add oil to the propulsor, if the oil level is low.

There is also a “Control System Alarm”.

CODE TRANSMITTER FAILURE

LOCATION IND1

IND2

IND3

IND4

FAILURE

TEMPORARY ACTION

252

Control lever rpm set
potentiometer

RS01 Fore

Rpm control stops

Transfer the propulsor to another control
station.

252

Control lever rpm set
potentiometer

RS01 Back

252

Control lever rpm set

potentiometer

RS01 PS

252

Control lever rpm set
potentiometer

RS01 SB

C102974-A Page 29 of 65

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DOC-1048-1

6.2.1 RPM

CONTROL FAILURE AT MAIN CONTROL

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

RPM control is not working
properly, RPM control is working

properly from another control
station

Propeller motor rpm control
is not working properly

Transfer control to another
control station

Control lever potentiometer is
loose or broken

Tighten, change or adjust the
potentiometer

PLC I/O is not working properly Tighten, repair or change

PLC I/O module

Wiring or connection failure

Check and repair the

cabling, wiring or connector

RPM control is not working
properly, RPM control is not

working properly from another
control station. There is also a

“Control System Alarm”.

Propeller motor rpm control
is not working properly

Transfer control to back-up
control

Signal converter AC02 is
broken at control unit SCU

Replace and adjust the
signal converter AC02

PLC I/O is not working properly Tighten, repair or change

PLC I/O module

Wiring or connection failure

Check and repair the

cabling, wiring or connector

C102974-A Page 30 of 65

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DOC-1048-1

6.3 C

ONTROL LEVER FAILURES

FAULT EFFECT TEMPORARY

ACTION

CAUSE

REMEDY

Steering setting transmitter

Steering stops

Transfer the control to another

station.

Transfer the propulsor to back-up
control.

Transmitter failure.

Replace transmitter. After change

of the transmitter, adjust it

according instructions..

Transmitter wiring.

Repair wiring or connections

RPM setting transmitter

RPM control stops.

Transfer the control to another
station.

Transfer the propulsor to back-up
control.

Transmitter failure.

Replace transmitter. After change
of the transmitter, adjust it

according instructions..

Transmitter wiring.

Repair wiring or connections

Control lever does not follow Control lever follow does not

operate

Use another control station or system Lever motor failure. Motor

has short circuit .

Replace motor

Lever clutch failure.

Replace motor & clutch unit.

C102974-A Page 31 of 65

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DOC-1048-1

7 B

ACK

UP CONTROL

CODE

ALARM

ALARM OR FAILURE

FAILURE

TEMPORARY ACTION

Back-up control failure

CODE OTHER FAILURE SITUATIONS

FAILURE INDICATION

IND1

FAILURE

TEMPORARY ACTION

270

Back-up steering

Back-up steering does not work,
steering stops, Remote angle

indicator does not turn.

Back-up control is failing

Use local control.
Use main control.

271

Back-up steering

Back-up steering does not

selected

Back-up control is failing

Use local control.
Use main control.

C102974-A Page 32 of 65

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DOC-1048-1

7.1 F

AULT FINDING

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

Back-up steering does not work,

steering stops. Remote angle

indicator does not turn. Indication
lamp HI14 is lit.

Back-up control is not

working.

Use local control.

Use main control

Steering switch SC08 failure

Repair steering switch

Steering gear failure

See: Steering gear

Wiring or connection failure

Check and repair the
cabling, wiring or connector

Back-up steering does not select

Back-up control is not
working.

Use local control.
Use main control

Selection switch broken

Repair selection switch

Selection relay at SCU does
not work

Replace relay

Wiring or connection failure

Check and repair the

cabling, wiring or connector

Back-up supply failure

See voltage supply

RPM control is not working at

back-up control

Back-up control is not

working.

Use local control.

Use main control

Signal converter AC04 is

broken at control unit SCU

Replace and adjust the

signal converter AC04

10 V power supply AP03 does
not work

See control unit

Wiring or connection failure

Check and repair the
cabling, wiring or connector

Potentiometer at control lever

See control lever

Propeller motor control system

Repair motor control system

Other external or auxiliary
system

Repair

C102974-A Page 33 of 65

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DOC-1048-1

8 A

UTOPILOT

CODE OTHER FAILURE SITUATIONS

FAILURE INDICATION

IND1

FAILURE

TEMPORARY ACTION

280

Operator is trying to steer
with lever when autopilot is

Wrong operation

Autopilot control is failing

Use main control.

C102974-A Page 34 of 65

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DOC-1048-1

9 E

LECTRIC

TEERING GEAR

CODE ALARM

ALARM OR FAILURE

IND

FAILURE

TEMPORARY ACTION

300

Low speed

Low steering speed

Propulsor steering does not work properly

Use only one propulsor for steering.

331

Steering gear 1

Steering gear 1 is not running

The steering capacity is lowered. The alarming
steering gear is out of order.

You should lower the steering gear load.

332

Steering gear 2

Steering gear 2 is not running

The steering capacity is lowered. The alarming
steering gear is out of order.

You should lower the steering gear load.

C102974-A Page 35 of 65

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DOC-1048-1

9.1 L

OW STEERING SPEED

FAULT EFFECT

TEMPORARY

ACTION

CAUSE REMEDY

Low steering speed

The propulsor turns slowly.

Wiring or connection failure

Check and repair

Stop using this

propulsor

External object turns the

propulsor lower part or prevents
to turn it

If the external object has been
the cause, you should check,

has the propulsor other failures
due the object.

Propulsor steering gear has a

failure.
See steering gear

Mechanical failure at steering gear

Use only one propulsor for steering.

Take supply off the
corresponding

ESU, you can
operate with

remaining steering
motor.

Feedback transmitter BR03 at
steering motor broken

Change the transmitter

Feedback transmitter BR03 loose
at motor shaft

Tighten the fastening screws of the
transmitter.

Feedback transmitter BR03 cable
broken

Change the cable

Steering brake control failure

Check reason and repair

C102974-A Page 36 of 65

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DOC-1048-1

Low steering speed

The propulsor does not turn

Circuit breakers at SMU opened

Check reason and repair

Stop using this

propulsor

External object turns the

propulsor lower part or prevents
to turn it

If the external object has been
the cause, you should check,

has the propulsor other failures
due the object.

Propulsor steering gear has a

failure.
See steering gear

Mechanical failure at steering gear

Use only one propulsor for
steering.

Take supply off the

corresponding ESU

Feedback transmitter BR03 at
steering motor broken

Change the transmitter

Feedback transmitter BR03 loose at
motor shaft

Tighten the fastening screws of the
transmitter.

Feedback transmitter BR03 cable
broken

Change the cable

Planetary gear broken at steering
gear

Change the planetary gear

Steering brake control failure

Check reason and repair

Low steering speed

The propulsor does not turn with

back-up control

Take supply off the

corresponding

ESU, you can
operate with

remaining steering
motor.

Feedback transmitter BR03 at
steering motor broken

Change the transmitter

Feedback transmitter BR03 loose at
motor shaft

Tighten the fastening screws of the
transmitter.

Feedback transmitter BR03 cable
broken

Change the cable

C102974-A Page 37 of 65

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DOC-1048-1

9.2 F

AULT FINDING

FAULT EFFECT

CAUSE

REMEDY

Steering motor brake does not

”hold”

Propulsor turns freely, when steering

control is not active

The brake does not keep the propulsor

position.

Repair the brake. Normal operation

situation the steering function is active
and brake failure does not effect

operation.

Propulsor turns slowly when

steering control is not active.

See above

The brake does not keep the propulsor

position.

Repair the brake.

Propulsor turns slowly all the
time in remote and local control.

Steering speed of the propulsor is
greatly reduced.

The steering motor feedback transmitter
BR03 is loose from one motor shaft.

Repair or use only one steering motor.

The steering motor feedback transmitter

BR03 is broken.

Repair or use only one steering motor.

The steering motor feedback transmitter

BR03 cable is broken or loose from one
motor.

Repair or use only one steering motor.

Propulsor is not turning

smoothly. Torque values of the
motors are hunting.

Steering function operates, but roughly

and perhaps violently resulting in erratic
motor RPMs and torque values.

The steering motor BR03 feed-back

transmitters are swapped to wrong motor.
(i.e. inboard ESU connected to outboard

motor)

Connected the right cable to right motor.

Propulsor is steering
continuously to a certain point

then stopping and steering back
in the other direction.

It is not possible to steer with propulsor. Both steering motors are connected with the

wrong phase.

Repair and check connection.

Propulsor is turning first to one
way and then another way

It is not possible to steer with propulsor. The steering commands from SCU to ESU

units are wrongly connected.

Repair and check connection.

Propulsor is overshooting in

steering

Should be careful.

The braking capacity is lowered.

Check brake resistors and ESU brake

resistor function.

C102974-A Page 38 of 65

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DOC-1048-1

Propulsor is continuously rotating
in one direction.

It is not possible to steer with propulsor. The propulsor steering angle transmitter

gears are loose.

Repair and check.

Feedback transmitter RG10 is broken.

Continuous steering operations.

Propulsor steering has possible failure

There is possible planetary gear failure.

Check the gear. And replace the gear
with new one.

C102974-A Page 39 of 65

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DOC-1048-1

9.3 P

LANETARY GEAR

FAULT EFFECT

CAUSE

REMEDY

Metallic parts with

unusual

dimension in the
magnetic plug

Stop this propulsor to prevent further

damage until gear is replaced. Use other

propulsor for steering.

The gear can be worn

Repair or replace gear

With steering

gear motor
running the gear

output shaft
doesn’t run

Incorrect

motor

assembly

Check

coupling between gear unit and motor.

Internal malfunction

Take contact to Steerprop service

Oil leak from

seals

Damaged or worn seals

Take contact to Steerprop service

Stiffening of seals due the prolonged storage

Clean the area and check for leakage again after
a few days

Excessive noise

Internal malfunction

Take contact to Steerprop service

Excessive

vibrations

Gear unit incorrectly installed

Check the connection and in-line configuration

Coupling structure weak

Strengthen the structure

Internal malfunction

Take contact to Steerprop service

Excessive
heating

No ventilation

Remove fairing

High thermal power

Insert oil circulation

C102974-A Page 40 of 65

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DOC-1048-1

9.4 B

ASIC MOTOR

FAULT EFFECT

CAUSE

REMEDY

Motor is not

running

No steering

Use only another propulsor for steering.

Brake is engaged

See brake

The azimuth gear is jammed

Contact Steerprop service

Motor
temperature is

high

Steering power limited.
Be careful and lower the load

Brake is engaged and is dragging

See brake. Lower ship speed. The limitation is
not automatic.

The fan is not running

See fan .

Phase is missing on supply to motor resulting
in higher current draw. ESU will display and

signaling vessel’s alarm system as well.

Check and repair the cabling, wiring or connector

9.5 F

FAULT EFFECT

CAUSE

REMEDY

Motor fan is not

running

Steering gear load should be smaller, motor

load ability smaller. Steering motor will being
to rise in operating temperature.

Lower steering load, make steering with
another propulsor.

Voltage supply off

Steering gear load should be smaller, motor load

ability smaller.
Lower steering load, make steering with another

propulsor.
Find the reason and repair it

C102974-A Page 41 of 65

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DOC-1048-1

9.6 M

OTOR

RAKE

FAULT EFFECT

CAUSE

REMEDY

Brake not

disengaged,

motor brake does
not disengage

Propulsor does not turn or turns

slowly

The brake is dragging and will
“burn” causing brake assembly

and motor to overheat very
quickly potentially damaging

one or both.

Air gap too large

Check air gap and adjust

Brake not receiving electrical power

Check electrical connection and control circuit

Voltage to brake coil too small

Check connection voltage of brake coil

The brake is blocked to disengaged position

Remove mechanical blockage

Brake control voltage supply off

Connect supply

Circuit breaker at SMU open

Connect circuit breaker

No command signal to brake

Check the control signals between inverters and SCU, brake
is “on” as long as both direction signals are off.

Fan problem, short circuit

No steering direction command to steering

inverters

When the direction signals are “on”, the inverter takes care

of the position keeping.

Brake control module malfunctioning.

Measure input and output of module. Replace if necessary.

The brake has voltage supply through the

wrong circuit connection or operation

Check other brake control circuits

Check other inverter control circuits
Check wiring or connection and repair

Brake

disengaging
delayed

Air gap too large

Check air gap and adjust

Voltage to brake coil too small

Check connection voltage of brake coil

Brake not
activated, brake

is ”open”, brake
does not hold

The brake does not keep the
propulsor position.

Voltage to coil too low

Check connection voltage of brake windings

Brake is worn or wrong adjusted

Adjust the brake or replace friction surfaces or springs

Anchor plate mechanically blocked

Remove mechanical blockage

Brake activation

delayed

Voltage to coil too low

Check connection voltage of brake windings

C102974-A Page 42 of 65

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DOC-1048-1

9.7 B

RAKE RESISTOR

(BRU)

FAULT EFFECT

CAUSE

REMEDY

Slow braking

Steering braking speed is a little

lower.

Operate with care.

Brake resistor failure

Disconnect brake resistor from ESU and measure ohmic

resistance at resistor terminals. Correct value should be

labeled on resistor. If low then resistor failing and should be
replaced.

Brake chopper failure at inverter

See Vacon instructions

Resistor

overheating

Alarm “EXT fault” on ESU

keypad. Vessel’s alarm system
shows steering warning.

Faulty brake resistor. DC-link voltage of ESU

too high.

Check ohmic resistance of resistor. Investigate, why DC-link

voltage is high.

9.8 M

OTOR CONTROL UNIT

(SMU)

FAULT EFFECT

CAUSE

REMEDY

Circuit breaker

open at SMU unit

The SMU unit has two separate incoming power

supplies from vessel’s switchboard. The supply for
steering brake is automatically switched to the 2

supply if the 1

is disconnected, via changeover

contacts. Therefore the opening of one FB circuit

breaker does not make any influence to the operation
of the brake control.

Short circuit at brake

See brake

Short circuit at fan

See fan

Cabling or wiring

Find out the reason for possible short circuit and repair it.

The adjustment of the
circuit breaker is wrong.

Check the adjusting and adjust according load.

High temperature at

control unit

Lower temperature or change circuit breakers to bigger.

C102974-A Page 43 of 65

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DOC-1048-1

9.9 S

TEERING GEAR INVERTER

ESU

REQUENCY CONVERTER

)

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

Inverter is giving alarm

Voltage supply missing

Check voltage supply and restore it

Wiring or connection failure

Check wiring or connection and repair.

Inverter does not start

Wiring or connection failure

Check wiring or connection and repair

PLC I/O failure

See PLC

Inverter I/O failure

Check, repair or replace

C102974-A Page 44 of 65

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DOC-1048-1

9.9.1 M

ENU INDICATIONS

Code Failure

Possible cause

Correcting measures

Over-current

Frequency converter has detected too high a current (>4*In) in the
motor cable:

Sudden heavy load increase

Check loading.

Short circuit in motor cables

Check cables.

Unsuitable motor

Check motor size.

Subcode in T.14:S1 = Hardware trip

Check loading.

Subcode in T.14:S2 = Reserved

Subcode in T.14:S3 = Current controller supervision

Check loading.

Overvoltage

The DC-link voltage has exceeded the limits defined in.

Too short a deceleration time

Make the deceleration time longer.

High overvoltage spikes in utility

Check the supply and add filters or trafo supply side.

The voltage is leaking to motor cable screen.

Check the motor cable also in other motors,
because the voltage can go through ground circuit.

Subcode in T.14:S1 = Hardware trip

Check loading.

Subcode in T.14:S2 = Overvoltage controller supervision

Check loading.

Earth fault

Current measurement has detected that the sum of motor phase
current is not zero.

- insulation failure in cables or motor

Check motor cables and motor.

Charging switch

The charging switch is open, when the START command has been

given.
- faulty operation

- component failure

Reset the fault and restart.

Should the fault re-occur, contact the distributor near
to you.

Emergency stop

Stop signal has been given from the option board.

Possible failure at ESU control module, check it and
replace if needed.

C102974-A Page 45 of 65

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DOC-1048-1

Saturation trip

Various causes:

Cannot be reset from the keypad. Switch off power.
DO NOT RE-CONNECT POWER!

Contact factory.

If this fault appears simultaneously with Fault 1

Check motor cables and motor

Defective component

Cannot be reset from the keypad. Switch off power.

Brake resistor short-circuit or overload

Check the resistor and change if needed.

Disturbances in environment

Check the voltage supply.

The inductive means conducted disturbance.

Check the voltage supply.

Missing groundings in control cables

Check the cables.

Frequency converter continuous overload

Check the adjusting of the droop parameter. Check

parameters of ESU.

Frequency converter continuous overload

Environment temperature too high.

Frequency converter continuous overload

The cooling capacity of the frequency converter is
lowered.

Brake resistor continuous overload

Check the resistor and change if needed.

Brake resistor leaks to ground

Check the resistor and change if needed.

Steering gear broken

Check the steering gear condition.

System fault

- component failure
- faulty operation

Note exceptional fault data record

Reset the fault and restart.
Should the fault re-occur, contact the distributor near

to you.

S7= Charging switch

S8= No power to driver card

S9= Power unit communication (TX)

S10= Power unit communication (Trip)

S11= Power unit communication (Measurement)

C102974-A Page 46 of 65

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DOC-1048-1

Code Failure

Possible cause

Correcting measures

Under-voltage

DC-link voltage is under the voltage limits.

Most probable cause: too low a supply voltage

In case of temporary supply voltage break reset the
fault and restart the ESU. Check the supply voltage.

If it is adequate, an internal failure has occurred.

Frequency converter internal fault

Contact the distributor near to you.

Subcode in T.14:S1 = DC-link too low during run

Subcode in T.14:S2 = No data from power unit

Subcode in T.14:S3 = Under-voltage controller supervision

Input line
supervision

Input line phase is missing.

Check supply voltage and cable.

Output phase

supervision

Current measurement has detected that there is no current in one

motor phase.

Check motor cable and motor.

12 Brake

chopper

supervision

No brake resistor installed

Check brake resistor. Check ESU parameters.

Brake resistor is broken

Check brake resistor.

Brake chopper failure

If the resistor is ok, the chopper is faulty. Contact the
distributor near to you.

13 Frequency

converter under-

temperature

Heat sink temperature is under -10 C

14 Frequency

converter

over-temperature

Heatsink temperature is over 90 C (or 77 C, NX_6, FR6).
Over-temperature warning is issued when the heatsink temperature

exceeds 85 C (72 C).

Check the correct amount and flow of cooling air.
Check the heatsink for dust. Check the ambient

temperature. Make sure that the switching frequency
is not too high in relation to ambient temperature

and motor load.

C102974-A Page 47 of 65

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DOC-1048-1

Code Failure

Possible cause

Correcting measures

Motor stalled

Motor stall protection has tripped.

Check motor.

Motor

over-temperature

Motor overheating has been detected by frequency converter motor

temperature model. Motor is overloaded.

Decrease the motor load.

If no motor overload exists, check the temperature
model parameters.

Motor

under-load

Motor under-load protection has tripped.

Unbalance

Unbalance between power modules in paralleled units.

Should the fault re-occur, contact the distributor near
you.

Subcode in T.14:S1 = Current unbalance
Subcode in T.14:S2 = DC voltage unbalance

22 EEPROM

checksum fault

Parameter save fault

- faulty operation
- component failure

Counter fault

Values displayed on counters are incorrect

25 Microprocessor

watchdog fault

- faulty operation
- component failure

Reset the fault and restart.

Should the fault re-occur, contact the distributor near

to you.

26 Start-up

prevented

Start-up of the drive has been prevented.

Cancel prevention of start-up.

Thermistor fault

The thermistor input of option board has detected increase of the

motor temperature

Check motor cooling and loading
Check thermistor connection (If thermistor input of
the option board is not in use it has to be short

circuited)

31 IGBT

temperature

(hardware)

IGBT Inverter Bridge over-temperature protection has detected too
high a short term overload current

Check loading.

Check motor size. Make identification run.

C102974-A Page 48 of 65

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DOC-1048-1

Code Failure

Possible cause

Correcting measures

Fan cooling

Cooling fan of the frequency converter does not start, when ON
command is given

Check the condition of the fan.
Contact the distributor near to you.

34 CAN

bus

communication

Sent message not acknowledged.

Ensure that there is another device on the bus with
the same configuration.

Application

Problem in application software

Contact your distributor.

Control unit

NXS Control Unit can not control NXP Power Unit and vice versa

Change control unit

Device changed
(same type)

Option board or control unit changed. Same type of board or same
power rating of drive.

Reset
Note: No fault time data record!

Device added

(same type)

Option board or drive added. Drive of same power rating or same

type of board added.

Reset

Note: No fault time data record!

Device removed

Option board removed. Drive removed.

Reset
Note: No fault time data record!

Device unknown

Unknown option board or drive.

Check that you have installed the option board into
right slot.

Subcode in T.14:S1 = Unknown device

Contact the distributor near to you.

Subcode in T.14:S2 = Power1 not same type as Power2

IGBT temperature

IGBT Inverter Bridge over-temperature protection has detected too
high a short term overload current

Check loading.

Check motor size.

Brake resistor

over-temperature

Brake resistor over-temperature protection has detected too heavy

braking

Set the deceleration time longer.

Use external brake resistor.

C102974-A Page 49 of 65

14.08.2008

DOC-1048-1

Code Failure

Possible cause

Correcting measures

Encoder fault

Note the exceptional Fault data record. Additional codes T.14:
1 = Encoder 1 channel A is missing

2 = Encoder 1 channel B is missing
3 = Both encoder 1 channels are missing

4 = Encoder reversed

Check encoder channel connections.

Check the encoder board.
Encoder BR03 cable connector loose or cable is
broken.
Encoder BR03 is broken.

Code Failure

Possible cause

Correcting measures

Device changed

(different type)

Option board or control unit changed. Option board of different type

or different power rating of drive.

Reset

Note: No fault time data record!
Note: Application parameter values restored to

default.

Device changed
(different type)

Option board or drive added. Option board of different type or drive of
different power rating added.

Reset
Note: No fault time data record!

Note: Application parameter values restored to
default.

Analogue input Iin
< 4mA (sel.

signal range 4
to 20 mA)

Current at the analogue input is < 4mA.

Control cable is broken or loose

Check the current loop circuitry.

Signal source has failed

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DOC-1048-1

Code Failure

Possible cause

Correcting measures

External fault

Digital input fault.

52 Keypad

communication
fault

The connection between the control keypad and the frequency

converter is broken.

Check keypad connection and possible keypad

cable.

Fieldbus fault

The data connection between the fieldbus Master and the fieldbus

board is broken

Check installation.

If installation is correct contact the nearest Vacon
distributor.

Slot fault

Defective option board or slot

Check board and slot. Contact the nearest Vacon

distributor.

56 PT100

board

temp. fault

Temperature limit values set for the PT100 board parameters have

been exceeded

Find the cause of temperature rise

C102974-A Page 51 of 65

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DOC-1048-1

10 P

OWER TRAIN

CODE OTHER FAILURE SITUATIONS

FAILURE INDICATION

FAILURE

TEMPORARY ACTION

110 Power

transmission

Propeller does not run on full power

Propulsor is not giving full power

Check clutch and lower power, if
needed.

10.1 A

BNORMAL OR FAILURE SITUATIONS

FAULT EFFECT TEMPORARY

ACTION

CAUSE

REMEDY

Power transmission gives
abnormal noise

Can destroy propulsor

Probably the failure demands
to stop propulsor

immediately to prevent
bigger damages.

Can be several reasons

Take contact to Steerprop
service

Additional power loss at

power train

Lubrication oil temperature

is rising and the propulsor
load capacity is lowered.

Probably the failure demands

to stop propulsor
immediately to prevent

bigger damages.
If lube oil pressure is low and

the lubrication start oil level is
low the operator must reduce

prop RPM until lubrication start
oil level returns to normal.

Lubrication system has a failure or

damage, which produce heat

Take contact to Steerprop

service

C102974-A Page 52 of 65

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DOC-1048-1

11 C

LUTCH SYSTEM

Code Alarm

Alarm or Failure

IND1

IND2

IND3

500

Low pressure

Clutch oil pressure low

501

Filter

Clutch oil filter clogged

510

Clutch is slipping

520

High temperature

Clutch oil temperature high

520

High temperature

Clutch oil temperature high, cooler is not working
properly

525

Pump

Clutch control pump alarm

C102974-A Page 53 of 65

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DOC-1048-1

11.1 F

AULT FINDING

FAULT EFFECT

TEMPORARY

ACTION

CAUSE

REMEDY

Clutch control pump

alarm

Inverter is giving alarm

See inverter

Inverter does not start

See inverter

Clutch oil pressure low

Clutch oil pump is not giving pressure

See pump at lubrication part

Oil leak

Find and repair

Pump cavitates

See pump at lubrication part

Clutch release valve malfunction (valve malfunction)

Clutch oil pressure filter See

filter

Pressure transmitter failure

See transmitter at lubrication
part

Clutch oil temperature

high

Do not use slipping

clutch

Pump is not working

See pump at lubrication part

Low oil amount

Add oil

Oil leakage

Cooler is not working

See cooler

Transmitter is broken

See transmitter

Additional power demand

for clutch

Propeller is braking or wind milling with too high load.

Change the clutch use

Clutch system has a failure or damage, which produce

heat.

Take contact to Steerprop

service

Something gives additional load to the clutch system

Check power line, propeller and

repair

C102974-A Page 54 of 65

14.08.2008

DOC-1048-1

Propeller does not give
full power, Clutch is

slipping

Clutch pressure low

Check and repair hydraulic
system

Clutch internal failure

Check the clutch condition and

repair

Wiring

Check wiring and connections

Transmitter is broken

See transmitter

Propeller does not give

full power, Clutch is
continuously disengaged

Clutch pressure low

Check and repair hydraulic

system

Clutch internal failure

Check the clutch condition and

repair

Wiring

Check wiring and connections

Clutch control valves

Check and repair

Transmitter is broken

See transmitter

C102974-A Page 55 of 65

14.08.2008

DOC-1048-1

12 L

UBRICATION

CODE ALARM

ALARM OR FAILURE

IND1

IND2

IND3

FAILURE

TEMPORARY ACTION

400

Low pressure

Lubrication oil pressure
alarm

Propulsor cooling capacity is lowered.
When the oil is reduced too much;
bearings, seals and gears can be
damaged.

Lower propulsor load. Watch the propulsor oil
temperature and keep it below the alarm limit. Make
sure that the running oil level is not going too low.

401

Filter

Lubrication oil filter

clogged

Lubrication oil filter can be clogged due
impurities or cold oil, which is pumped
with high pressure through the filter. If
the filter does not filtrate impurities from
the oil, it can cause damages to the
power train.

No immediately action needed. If the reason is cold oil,
warm-up the propulsor. If the filter is clogged by
impurities, change the filter.

410

Start level low

Lubrication start oil level

low

Propulsor cooling capacity is limited.
When the oil level is going too low;
bearings, seals and gears can be
damaged. Don’t start the propeller
motor.

Checking
If the propulsor oil level is going down, find the
cause, repair it and add more oil.

Slowing down
If the lubrication oil pressure is low or the
lubrication start oil level is low, the operator must
reduce prop rpm until lubrication start oil level
returns to normal.

Shutting down
If the lubrication oil pump stops or the lubrication
oil pressure is low and there is a temperature alarm
for the lubrication oil, the operator must shut down
the Steerprop system.

C102974-A Page 56 of 65

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DOC-1048-1

CODE ALARM

ALARM OR FAILURE

IND2

IND3

FAILURE

TEMPORARY ACTION

411

Start level low

Lubrication start oil level
low, level transmitter

failure

No effect.

Watch the oil level through the propulsor oil view ports,
when the propulsor is stopped.

420 Lubrication

high

temperature

Lubrication oil

temperature high,
additional power loss at

power train

Lubrication oil temperature is rising and
the propulsor load capacity is lowered.

Probably the failure demands to stop propulsor

immediately to prevent bigger damages.

Slowing down
If the lubrication oil pressure is low and the
lubrication start oil level is low, the operator must
reduce prop rpm until lubrication start oil level
returns to normal.

421 Lubrication

high

temperature

Lubrication oil

temperature high, cooler
is not working

Propulsor cooling capacity is limited.
Bearings, seals and gears are in danger
to be damaged due to overheating.

Adjust propulsor load lower and follow the propulsor oil
temperature and keep it below alarm limit.

430 Running

level

low

Lubrication oil running

level low

Propulsor cooling capacity is limited.
When the oil level is too low, the
bearings, seals and gears are in danger
to be damaged.

Checking
If the propulsor oil level is going down, find the
cause, repair it and add more oil.

Shutting down
Stop the propulsor.

431 Running

level

low

Lubrication oil running

level low, level
transmitter failure

No effect.

Watch the oil level through the propulsor oil view ports,
when the propulsor is stopped.

C102974-A Page 57 of 65

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DOC-1048-1

CODE ALARM

ALARM OR FAILURE

IND2

IND3

FAILURE

TEMPORARY ACTION

441 Lubrication

pump 1 failure

Lubrication pump 1 is not
running

Propulsor cooling capacity is lowered.
Alarming pump is out of use. The
lubrication is with immersion principle and
the cooling with natural circulation.
Bearings, seal and gears are in danger to
overheating.

Adjust propulsor load lower and follow the propulsor oil
temperature and keep it below alarm limit.

442 Lubrication

pump 2 failure

Lubrication pump 2 is not

running

C102974-A Page 58 of 65

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DOC-1048-1

12.1 F

AULT FINDING

FAULT EFFECT

TEMPORARY

ACTION CAUSE

REMEDY

Oil filter clogged

The filter does not filtrate impurities

from oil circulation, which can cause

damages at power train.

Change switch DV to another filter

element

Oil filter clogged

Replace filter

Cold oil

Wait oil to warm up

Oil level too high

Oil circulation failure

Check and repair

Air in system

Remove air

Too much oil

Remove oil

Amount of oil is

reducing

Propulsor cooling capacity is lowered.

When the amount of oil is reducing
too much, are bearings, seals and

gears are in danger to damage.

Adjust propulsor load lower and

follow the propulsor oil
temperature and keep it below

alarm limit. Follow, that the amount
oil (run oil) is not going to go too

low.

Oil leakage, Oil leakage can

also cause, that water is mixing
with oil

Locate the leakage and repair it

and add oil

Piping broken or loose

Locate the reason and repair it

and add oil

Lubrication start oil
level low,

lubrication oil level
low

Propulsor cooling capacity is limited.
When the amount of oil is reducing

too much, bearings, seals and gears
are in danger to damage. Prevent to

start to propeller motor.

See separate procedure

Transmitter failure

Change

Oil leakage

See above

Not enough oil

Add oil

Piping broken or loose

See above

C102974-A Page 59 of 65

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DOC-1048-1

Lubrication oil
temperature high

Propulsor cooling capacity is limited.
When the amount of oil is reducing

too much, bearings, seals and gears
are in danger to damage.

Reduce the power of the
propulsor, see procedure

Pump is not working

Change to immersion lubrication

Low oil amount

Add oil, see above

Oil leakage

See above

Additional power loss at power

train

Find out reason and repair

Cooler is not working

Find out reason and repair,
check valves

Transmitter is broken

Replace

Oil pressure low

Propulsor cooling capacity is limited.
When the amount of oil is reducing

too much, bearings, seals and gears
are in danger to damage. Prevent to

start to propeller motor.

Reduce the power of the propulsor
or stop it, see procedure

Pump is not working

Change to the immersion
lubrication

Oil leakage

See above

C102974-A Page 60 of 65

14.08.2008

DOC-1048-1

12.2 L

UBRICATION PUMP DOES NOT GIVE OIL PRESSURE

FAULT EFFECT

TEMPORARY

ACTION CAUSE

REMEDY

Lubrication pump

does not give oil

pressure

Check the pump produce oil

pressure using local control

Lubrication pump is not running See below
Pressure transmitter failure See

transmitter

Amount of the oil is reducing

See 12.1

Lubrication pump is

not running

Check the motor condition

Voltage supply missing

Check voltage supply and

restore it

Wiring or connection failure

Check wiring or connection and
repair

Inverter failure

See inverter

Motor does not drive the pump

Check shaft and coupling

Motor is broken

See motor

12.2.1 O

IL PRESSURE IS LOW

FAULT REASON

CAUSE

REMEDY

Pressure level is low

Pressure relief valve is operating at too low level
because of incorrect adjustment or weak spring

adjust correct operating pressure

Pressure relief valve doesn't close up because of
impurities

clean the valve by adjusting it fully open while both
pumps are running and then adjust it to correct operating

pressure

C102974-A Page 61 of 65

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DOC-1048-1

12.3 L

UBRICATION SYSTEM PRESSURE AND TEMPERATURE TRANSMITTERS

There is also a “Control System Alarm”.

CODE TRANSMITTER FAILURE

LOCATION IND1

IND2

IND3

FAILURE

TEMPORARY ACTION

253

Lubrication oil temperature

transmitter

BT02 Propulsor

Lubrication oil temperature

measurement is failing

The propulsor operation can be

continued with care. You should follow
the temperature using the gauge

mounted on propulsor.

254

Lubrication oil pressure

transmitter

BP02 HPU1

Lubrication oil pressure

measurement is failing

The propulsor operation can be

continued with care. You should follow
the pressure using the gauge mounted

on propulsor.

12.3.1 L

UBRICATION OIL TEMPERATURE TRANSMITTER FAILURE

FAULT EFFECT

TEMPORARY

ACTION CAUSE

REMEDY

Lubrication oil
temperature

transmitter failure

Lubrication oil temperature
measurement does not operate.

The operation with propulsor can
continue with care. You should

follow the temperature using the
gauge mounted on propulsor.

Transmitter wiring.

Check and repair wiring and
connectors

If the signal is 0 mA, can the

failure at voltage supply of the
transmitter

Check and repair supply

Pressure transmitter failure Replace

transmitter

Internal failure at transmitter
gives 2 mA signal

Replace transmitter

C102974-A Page 62 of 65

14.08.2008

DOC-1048-1

12.3.2 L

UBRICATION OIL PRESSURE TRANSMITTER FAILURE

FAULT EFFECT

TEMPORARY

ACTION CAUSE

REMEDY

Lubrication oil
pressure

transmitter failure

Lubrication oil pressure measurement
is not working.

The operation with propulsor can
continue with care. You should

follow the pressure using the
gauge mounted on propulsor.

Transmitter wiring.

Check and repair wiring and
connectors

If the signal is 0 mA, can the

failure at voltage supply of the

transmitter

Check and repair supply

Pressure transmitter failure Replace

transmitter

Internal failure at transmitter
gives 2 mA signal

Replace transmitter

C102974-A Page 63 of 65

14.08.2008

DOC-1048-1

12.4 C

OOLING SYSTEM FAULT FINDING

FAULT EFFECT

TEMPORARY

ACTION CAUSE

REMEDY

Cooler is not

working

Propulsor cooling capacity is limited.

Due overheating, are bearings, seals

and gears are in danger to damage.

Adjust propulsor load lower and

follow the propulsor oil

temperature and keep it below
alarm limit.

Cooler is blocked partly or

totally

Clean cooler

There is not enough water at

cooling circuit

Add water to cooling circuit

Water circulation pump is not
running

Check, that water circulation
pump is running and start it

Water leakage

Tighten connectors

Cooling water temperature too
high

Measure cooler input and output
water temperature, lower

temperature

C102974-A Page 64 of 65

14.08.2008

DOC-1048-1

13 S

EAL OIL TANK

CODE ALARM

ALARM OR FAILURE

IND2

IND3

FAILURE

TEMPORARY ACTION

Low pressure

Seal oil tank pressure alarm

Pressure air supply missing

450

Seal tank

Seal oil tank

Seal system is not working properly

13.1 F

AULT FINDING

FAULT EFFECT

TEMPORARY
ACTION

CAUSE REMEDY

Seal oil level is lowering
continuously, when the shaft is not

rotating

Low oil consumption up to 1 % of
the seal size (l/d) is not an

indication for a fault in the seal.
The seal needs a little oil for

lubrication.

Oil leak in the tank, piping
or somewhere else

Add oil after finding out the reason for
lack of oil and repairing faults.

Tank height or pressure is

not right

Check the seal tank height and

pressure and adjust, if needed.

Seal oil level is lowering
continuously, when the shaft is

rotating

Tank height or pressure is
not right

Check the seal tank height and
pressure and adjust, if needed

Malfunction in the seal
system

Check the seal condition and repair it

Seal oil level is rising continuously,

when the shaft is not rotating

Tank height or pressure is

not right

Check the seal tank height and

pressure and adjust, if needed

Seal oil level is rising continuously,

when the shaft is rotating

Tank height or pressure is

not right

Check the seal tank height and

pressure and adjust, if needed

Malfunction in the seal
system.

Check the seal condition and repair it

C102974-A Page 65 of 65

14.08.2008

DOC-1048-1

Water in seal oil circulation

The oil color can be grey.

Water in seal oil

Change the oil or separate water from
oil.

Malfunction in the seal

system

Repair the seal system

Tank height or pressure is

not right

Check the seal tank height and

pressure and adjust, if needed

Seal tank pressure low

There are not enough
pressurized air

Check and repair air supply

Air leakage in the circuit

Check and repair the tightness of the

system

Air filter clogged

Replace filter

Regulating valve does not

work properly

Adjust or repair the regulating valve

Relief valve malfunction

Adjust or repair the relief valve

The shut-off valve is

closed

Open valve.

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