C102961 A SERVICE STEERING GEAR

C102961-A Page 1 of 32

20.08.2008

DOC-1017-1

Steerprop Electric

Steering Gear

Service Manual

Revision history:

REV. DATE MODIFIER DESCRIPTION

0 2.4.2008

AaNi Created

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DOC-1017-1

STEERING GEAR SYSTEM ................................................................................................................ 4

SLEWING RING / TURNING GEAR ................................................................................................. 4

ELECTRIC DRIVEN STEERING GEAR ........................................................................................... 5

3.1

OW STEERING SPEED TEST

.............................................................................................................. 5

STEERING GEAR ................................................................................................................................. 6

4.1

INSTALLATION: ........................................................................................................................... 6

4.1.1

General instructions .................................................................................................................... 6

4.1.2

Installation instructions for flange mounted gear unit ................................................................ 6

4.2

CCESSORY INSTALLATION INSTRUCTIONS

..................................................................................... 7

4.2.1

Motor Assembly: .......................................................................................................................... 7

4.2.2

Motor shaft adapter ..................................................................................................................... 7

4.2.3

Accessory Assembly: .................................................................................................................... 7

4.3

MAINTENANCE: ........................................................................................................................... 7

4.3.1

Routine maintenance: .................................................................................................................. 7

ELECTRIC MOTOR ............................................................................................................................. 8

5.1

ANUAL TURNING

........................................................................................................................... 8

5.2

................................................................................................................................................... 8

DISC BRAKE .......................................................................................................................................... 9

6.1.1

Operation description .................................................................................................................. 9

6.1.2

Manual release (disengaging) ..................................................................................................... 9

6.1.3

Operation ..................................................................................................................................... 9

6.2

RAKE ASSEMBLY

.......................................................................................................................... 11

6.3

ANUAL LEVER ASSEMBLY

........................................................................................................... 12

6.4

ISMANTLING

................................................................................................................................ 12

6.5

OLTAGE SUPPLY

........................................................................................................................... 12

6.6

RAKE SERVICE

.............................................................................................................................. 13

6.7

PARE PARTS

.................................................................................................................................. 13

6.8

RAKE CONTROL MODULE

............................................................................................................. 14

6.9

RAKE CONTROL TEST

................................................................................................................... 14

FEEDBACK-TRANSMITTER (BR03) .............................................................................................. 15

FEEDBACK CABLE ........................................................................................................................... 16

8.1

LACK CABLE WITH NUMBERED CONNECTORS

E000678 .............................................................. 16

8.2

LACK CABLE WITH

LPHABET CONNECTORS

E000331 ............................................................... 17

8.3

ELLOW CABLE WITH NUMBERED CONNECTORS

E000202 ............................................................ 17

8.4

RIGINAL YELLOW CABLE WITH NUMBERED CONNECTORS FOR DELIVERIES

W0004,7,9,10

E000202 ...................................................................................................................................................... 18

ELECTRIC STEERING UNIT ESU (INVERTER, FREQUENCY CONVERTER) .................... 19

9.1

PERATION AT MAIN CONTROL

...................................................................................................... 19

9.2

PERATION AT REMOTE BACK

UP CONTROL

.................................................................................. 19

9.3

PERATION AT LOCAL CONTROL

.................................................................................................... 19

BRAKE RESISTOR (BRU) ................................................................................................................. 20

MOTOR CONTROL UNIT (SMU) .................................................................................................... 21

11.1

MERGENCY OPERATION

................................................................................................................ 21

ELECTRIC STEERING GEAR ALARMS TEST PROCEDURE .................................................. 22

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12.1

RAKE CONTROL VOLTAGE SUPPLY

............................................................................................... 22

12.2

TEERING MOTOR

FAN

................................................................................................................. 23

12.3

TEERING MOTOR

FAN

................................................................................................................. 23

12.4

LECTRIC STEERING GEAR

FAILURE TEST

................................................................................... 24

12.5

LECTRIC STEERING GEAR

FAILURE TEST

................................................................................... 24

12.6

LECTRIC STEERING GEAR

WARNING TEST

................................................................................. 24

12.7

LECTRIC STEERING GEAR

WARNING TEST

................................................................................. 24

12.8

EW SYSTEMS FROM

6/2008 .......................................................................................................... 24

FAULT FINDING ................................................................................................................................ 25

13.1

ENERAL

........................................................................................................................................ 25

13.2

OW STEERING SPEED

.................................................................................................................... 27

13.3

LANETARY GEAR

.......................................................................................................................... 28

13.4

ASIC MOTOR

................................................................................................................................. 29

13.5

................................................................................................................................................. 29

13.6

OTOR

RAKE

............................................................................................................................... 30

13.7

RAKE RESISTOR

(BRU) ................................................................................................................ 31

13.8

OTOR CONTROL UNIT

(SMU) ...................................................................................................... 31

STEERING MOTOR SPARE PARTS ............................................................................................... 32

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1 S

TEERING GEAR SYSTEM

The steering gear consists of two electric steering motors connected via planetary
gears to the slewing ring. The steering gear is able to turn the propulsor continuously
360 degrees.

At emergency situation it is also possible to use only one steering gear, but the vessel
speed should be reduced.

Steering gears are also connected to propulsors lubrication system.

2 S

LEWING RING

URNING GEAR

The lubrication system belongs to lubrication before.

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3 E

LECTRIC

RIVEN

TEERING

EAR

Electric driven steering gear has following main modules:

Electric motor MTxx

Feedback incremental encoder BR03

Feedback cable

Electric steering unit ESUxx (inverter, frequency converter)

Brake resistor BRUxx

Motor control unit SMUx

3.1 L

OW STEERING SPEED TEST

Select Remote, at SCU cabinet, with control with SC01

Switch OFF the power supply for steering drives ESUx1 and ESUx2 at
vessel’s circuit breaker panel (switchboard)

Turn the lever at wheelhouse

Alarm “low steering speed” appears

See alarm at SED (service display at SCU cabinet or ECP panel): (alarm as
expected)

Switch ON the supply for steering drives ESU1 and ESU2 from vessel’s
switchboard.

At wheelhouse control, turn steering lever to position other than current

Propulsor start to follow lever

Alarm disappears

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4 S

TEERING GEAR

4.1 INSTALLATION:

4.1.1 G

ENERAL INSTRUCTIONS

INSTALL THE PRODUCT CAREFULLY FOLLOWING THE
STEPS LISTED BELOW:

When installing the Gear unit, make sure the oil pipes are
correct position and tight.

If the gear unit is supplied in the multi-disk brake
configuration, make sure that the brake oil, breather, level

and drain plugs are in the correct position. Their position will
vary according to the assembly position.

The brakes in general must be correctly connected to their
specific control circuit.

This steering gear assembly is provided with mounting
flange for connecting the motors to the gear unit.

Note: Because the steering gear is connected to the main

lubrication circuit it is not necessary to fill it with oil prior to
installation.

4.1.2 I

NSTALLATION INSTRUCTIONS FOR FLANGE MOUNTED GEAR UNIT

Follow instructions at assembly drawing provided by Steerprop

They must be attached to a clean support surface that is perpendicular to
the drive axis. The “steering gear” must be assembled to the housing
assuring that the mating faces are clean and oil free.

The spigots and the coupling surfaces of the gear unit must be clean
without any dents. The checks described above are particularly important
ensure perfect alignment between the driven shaft and the output shaft of
the gear unit.

Lubricate all the spigots of the gear unit and the housing seat with grease
or oil or anaerobic sealant depending of construction.

After having inserted the gear unit into its housing and having placed it in
the correct position, then tighten the attachment bolts (specified in
assembly drawing), applying torque as indicated in the assembly drawing,
making sure that such torque settings are compatible with the other parts
(nuts and / or structure). The final assembly is secured with Loctite 638.

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4.2 A

CCESSORY INSTALLATION INSTRUCTIONS

4.2.1 M

OTOR

SSEMBLY

Follow instructions at assembly drawing

4.2.2 M

OTOR SHAFT ADAPTER

The adapter is fastened to the motor shaft key joint using Loctite 638.

While assembling the motor to the gear unit, the coupling must be
lubricated with a thin layer of grease.

4.2.3 A

CCESSORY

SSEMBLY

To mount pinions, pulleys or couplings, use suitable equipment avoid seizing. As an
alternative, heat the piece to 80°-100° C. Lubricate the grooves with a thin layer of
grease or a no-grip lubricant and tighten attachment bolts applying the torque indicated
in the table "torque setting ".

4.3 MAINTENANCE:

ATTENTION: All maintenance activities must be carried out under safety conditions.

4.3.1 R

OUTINE MAINTENANCE

The operator is responsible for routine maintenance and must carry out the following
activities.

After a brief operating period of about 100 hours (breaking-in), check that
there are no metallic parts with unusual dimension in the magnetic plug of
the gear unit and in any multi-disk brake.

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5 E

LECTRIC MOTOR

1 Basic motor

2 Motor connection box

3 Disc Brake

4 Disc Brake Manual lever

5 Disc Brake monitoring (optional item, not used)

6 Feedback transmitter (see page 15)

7 Rotation nut (manual turning device)

The electric motor consists of following modules:

Motor

Disc brake

Feedback-transmitter

Fan

The electric motor gives the steering torque to the steering gear, which turns the
propulsor via slewing ring.

The electric motor has two shaft ends the one is connected to steering gear and the
one has feedback transmitter and disc brake (one motor).

The electric motor has thermistors for the temperature monitoring. The thermistor is
monitored by the frequency converter ESU. The ESU is connected to the vessel’s
alarm system and alerts operator when motor temperature is high.

5.1 M

ANUAL TURNING

The motor shaft non-drive-end has a provision for manual turning.

5.2 F

The motor non-drive end has an external cooling fan. The cooling fan has a separate
voltage supply from brake and fan control unit. The fan is only running when the ESU is
in run mode. The fans will stop when ESU goes to stand-by mode.

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6 D

ISC BRAKE

The brake motor is equipped with disc brake to keep the propulsor angle at black-out
situations.

The disc brake is also stopping device at over-speed situations. When ESU senses
over-speed via feedback encoder brake is applied.

Disc brake

Manual release device

Brake control module at motor connection box

6.1.1 O

PERATION DESCRIPTION

The ventilated electromagnetic spring-loaded brake is a fail-safe brake with two friction
surfaces because it is engaged in it’s de-energized.

The braking moment is produced by springs pressing the anchor plate against the
rotor, when brake is de-energized.

The fitted pressure springs (pos. 4) press the axially moveable anchor plate (pos. 2)
onto the rotor which is connected flush to the shaft and which in turn presses onto the
flange (pos 7.), friction plate (pos. 8) or motor flange.

The braking action is produced as follows:

A magnetic force is generated by applying a DC voltage to the excitation winding in the
magnet body (pos. 1.1) and this force pulls the anchor plate (pos. 2) onto the magnet
body (pos. 1.1). The brake rotor (pos. 3.1) is released and the brake is ventilated.

The standard version of the spring-loaded brake is supplied with permanently adjusted
braking moment Mbn. On all brake sizes this moment is produced by springs (pos. 4).

6.1.2 M

ANUAL RELEASE

(

DISENGAGING

)

The disc brake is equipped with manual disengage. The brake has hand release lever,
which you can use to disengage the brake at service situation and at emergency
operation.

The brake features a manual release assembly (pos. 5) enabling it to be ventilated
mechanically in the case of a loss of power for example.

Pressing the manual release lever (pos. 5) causes the anchor plate (pos. 2) to be
pulled onto the magnet assembly. This produces an air gap between the rotor (pos.
3.1) and anchor plate (pos. 2) and the brake is ventilated.

The adjustment of the manual release must not be tampered with for reasons of

safety.

6.1.3 O

PERATION

Applying a DC voltage to the excitation winding in the magnet body (pos. 1) induces a
magnetic force which pulls on the anchor plate. This plate is pulled across the air gap
"a" towards the magnet body (pos. 1) against the force of the springs (pos. 4).

The braking rotor (pos. 3) is released and the braking action is interrupted.

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The inclusion of a manual ventilation assembly enables the brake to be mechanically
ventilated.

Pressing the manual ventilation lever (pos. 5) causes the anchor plate (pos. 2) to be
pulled onto the magnet assembly (pos. 1). This produces an air gap between the rotor
(pos. 3) and anchor plate (pos. 2) and the brake is ventilated.

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6.2 B

RAKE ASSEMBLY

The brake linings and braking surfaces must be carefully protected against
foreign matter. Under no circumstances must they come in contact with oil and
grease. Even low contaminants of this kind can greatly reduce the braking
moment.

Before commencing work on an installed spring-loaded brake always disconnect
or switch off the motor-side power supply from the vessel’s switchboard.

Tightening torque M

= 25 Nm

The brake is supplied pre-assembled.

Circlip, (pos. 14) to be fitted into the slot on
the shaft.

Fitted key (pos 15) fitted in the motor shaft.

Push hub (pos. 6.1) on to the shaft.

Secure hub, (pos. 6.1) using circlip (pos.
16).

If applicable, mount friction plate (pos 8),
or flange (pos. 7).

Push rotor (pos. 3.1) on to the hub (pos.
6.1)

Secure magnet assembly with three fixing
screws, for tightening torque see table

3.2.2.

Set air gap "a" = 0.4 mm

Check the air gap "a" at three places on

the circumference; if necessary, undo the
cylinder bolts (pos. 11) and correct the

airway by turning the threaded collars
(pos. 12). After making the adjustment re

tighten the cylinder bolts and recheck the
air gap "a".

Mount the dust ring (pos. 9) if applicable.

Electrical connection.

ALL MAINTENANCE AND REPAIR WORK MUST BE MADE BY SPECIALIST
PERSONNEL AND WITH THE POWER TO THE SPRING-LOADED BRAKE SWITCHED
OFF.

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6.3 M

ANUAL LEVER ASSEMBLY

Place the hand lever (pos. 5) on the magnet body

(pos 1.1 or 1.2) and push the two pins through.

Screw the cylinder bolt (pos. 20) with washer

(pos. 21)and spring (pos. 22) into the pins.

Note:

When screwing up the dimension "y = 1

mm" between the magnet housing
and the anchor plate must be kept uniform all
round (see table 3.2.2).

The adjustment of the manual ventilation must

not be altered at a later
date, even when the air gap "a" is readjusted.

6.4 D

ISMANTLING

Dismantling the spring-loaded brake and the manual ventilation is made in the reverse
order of the assembly.

6.5 V

OLTAGE SUPPLY

The electrical connection must only be made when the no power is connected.

The operating voltage (DC) of the brake is indicated on the magnet housing.

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6.6 B

RAKE SERVICE

Spring-loaded brakes are virtually maintenance-free.

The air gap "a" and thus the rotor wear must be checked at certain intervals and be
adjusted, if necessary, or the rotor replaced.

RESETTING THE BRAKING CLEARANCE

When looking in the direction of the arrow (see fig.)

the three fixing bolts (pos. 11) are to be undone by
half a turn.

The threaded collars (pos. 12) which surround the
fixing bolts (pos. 11) can then be screwed into the

magnet body (pos. 1) by turning anticlockwise.
Turning the 3 fixing bolts (pos. 11) clockwise allows

the magnet body (pos. 1) to be moved towards the
anchor plate until the nominal air gap is reached, as

measured using a feeler gauge.
The 3 threaded collars are then also screwed

clockwise out of the magnet body until they but up.
Finally, the fixing bolts (pos. 11) are retorqued.

The air gap must then be rechecked.

6.7 S

PARE PARTS

The brake code number (at the magnet body) should be always inform when ordering
spare parts

Magnet assembly (1.1)

Rotor cpl (3.1)

Springs (4)

Manual vent assy. Complete (5)

Manual lever (6)

Hub for rotor (6.1)

Flange (7)

Friction plate (8)

Dust ring (9)

Fixing bolt (11)

Hollow screws (12)

O-ring (13)

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6.8 B

RAKE CONTROL MODULE

The brake control module is installed into motor

connection box. The control module will transform
the steering gear AC supply voltage to the brake

control DC voltage. The brake action is not
depending of the direction of the DC-voltage.

6.9 B

RAKE CONTROL TEST

Select remote control with SC01 located on SCU cabinet.

Turn the switches at FB1 and FB2, located in SMU cabinet, to 0

The alarm “low steering speed” will appear.

See that alarm appears on SED (service display at SCU or ECP)

Turn the switches at FB1 and FB2, located in SMU cabinet, to 1

The low steering speed or wrong direction alarm will disappear.

Check, that steering gear brakes are keeping the propulsor in this position

The system is ready for remote control

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7 F

EEDBACK

TRANSMITTER

(BR03)

For steering motor shaft speed and shaft angle
measurement is at motor shaft end a increment

transmitter.
Black cable with numerically labeled connector.

Feedback transmitter code E000727.

Black cable with alphabet labeled connector. The
transmitter colour can be also aluminium.

Feedback transmitter code E000459.

Yellow or black cable with numerically labeled
connector. Feedback transmitter code E000174

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8 F

EEDBACK CABLE

Feedback cable is between feedback transmitter at motor and Electric Steering Unit.
For the good working feedback system this cable should be installed with a continuous
cable (no connections between) from motor to ESU.

If the cable is broken, it should be changed, not repaired.

8.1 B

LACK CABLE WITH NUMBERED CONNECTORS

E000678

NUMBER WIRE

SIGNAL

FREQUENCY

CONVERTER

1 pink

inv

A5:4

2 blue

3 red

A5:5

4 black

inv

A5:6

5 brown

A5:1

6 green

inv

A5:2

7 violet

8 grey

A5:3

9 not

connected

10 white/green

negative

A5:9

11 white

warning

12 brown/green

positive

A5:10

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8.2 B

LACK CABLE WITH

LPHABET CONNECTORS

E000331

NUMBER WIRE

SIGNAL

FREQUENCY

CONVERTER

A pink

inv

A5.4

B blue

C red N

A5:5

D black

inv

A5:6

E brown

A5:1

F green

inv

A5:2

G violet

H grey

A5.3

M white/green

negative

A5:9

L white

warning

K brown/green

positive

A5:10

8.3 Y

ELLOW CABLE WITH NUMBERED CONNECTORS

E000202

NUMBER WIRE

SIGNAL

FREQUENCY

CONVERTER

1 green

inv

A5:4

2 not

connected

3 grey

A5:5

4 pink

N inv

A5:6

5 white

A5:1

6 brown

inv

A5:2

7 not

connected

8 yellow

A5:3

9 not

connected

10 blue Negative

A5:9

11 black

Early

warning

12 red Positive

A5:10

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8.4 O

RIGINAL YELLOW CABLE WITH NUMBERED CONNECTORS FOR

DELIVERIES

W0004,7,9,10

E000202

Newer yellow replacement cable has different pin/colour combinations. It is
recommended to use the black numbered cable as replacement cable to avoid the
numbering problems.

NUMBER WIRE

SIGNAL

FREQUENCY

CONVERTER

1 grey

inv

A5:4

2 not

connected

3 black

A5:5

4 pink

N inv

A5:6

5 brown

A5:1

6 green

inv

A5:2

7 not

connected

8 white

A5:3

9 not

connected

10 blue Negative

A5:9

11 black

Early

warning

12 red Positive

A5:10

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9 E

LECTRIC

TEERING

NIT

ESU

(

INVERTER

FREQUENCY

CONVERTER

)

The steering control is carried out with ESU. Using the basic inverter as hardware
Steerprop has developed a special software for propulsor steering control.

The ESU has a separate instruction.

9.1 O

PERATION AT MAIN CONTROL

The propulsor has two parallel Electric Driven Steering Gear systems. The steering
control is carried at Steerprop Control Unit, which gives speed and direction commands
to ESU.

If there is no direction commands, ESU will keep the steering angle.

9.2 O

PERATION AT REMOTE BACK

UP CONTROL

At remote back-up control the switch SC08 gives (wheelhouse) direction command to
the ESU. The steering speed is constant.

The steering speed is ca 50 % of the main control speed.

9.3 O

PERATION AT LOCAL CONTROL

At local control the switch SC02 gives (propulsor) direction command to the ESU. The
steering speed is constant.

The steering speed is ca 50 % of the main control speed.

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10 B

RAKE RESISTOR

(BRU)

The brake resistor converts the braking energy produced by steering motors to heat.

The brake resistor is equipped with overheat warning, that is connected to ships alarm
as “steering gear warning”.

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11 M

OTOR CONTROL UNIT

(SMU)

The propulsor is equipped with a motor control unit SMU. This unit takes care of the
control of the motor fans and disc brake of one propulsor and lubrication pump. The
fans are working parallel.

This unit has three power supplies and one AC voltage supply for main control
voltage. If you make service, you should switch off all supplies. This unit has also
circuit breakers for fan and disc brake circuits.

Through this unit can both ESU units control all the disc brakes of one propulsor. By
means of change over contacts, inside the SMU, both ESU units can operate the disc
brake in the event that one ESU is disconnected from it’s power supply.

11.1 E

MERGENCY OPERATION

If there is no malfunction with the steering motor or steering gear operation itself, you
can continue to operate with caution.

If circuit breaker FF1 and/or FF2, for steering fans, has tripped try to resetting it.

If circuit breaker FB1 and/or FB2, for steering brake, has tripped try to resetting it.

The following situations are acceptable to continue operation taking caution:

Steering motor fan(s) inoperable

The temperature of the motor will rise without cooling air flow. When

motor has reached unsafe operating temperature alarm will be displayed
on ESU.

The brake has hand release lever and you can lock it to disengaged
position.

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12 E

LECTRIC STEERING GEAR ALARMS TEST PROCEDURE

This test will be started with a propulsor, which voltage supplies are on, then the
voltage supply switch SS01 is on and local control SC01 is switched to remote control
also electric supplies for pumps and steering gears are on.

This test should be started with the system in the following state:

All control voltage supplies on

Switch, at SCU, SS01 is on

Switch, at SCU, SC01 is switched to the REMOTE position

Both steering drives ESUx1 and ESUx2 power supplies are on

The vessel alarm and automation systems are running.

12.1 B

RAKE CONTROL VOLTAGE SUPPLY

Turn the switch at FB1 to 0

Contactors KB1 and KB3 will open

Contactors KB2 and KB4 will close

The voltage supply will transfer to FB2

SED (service display), at SCU or
ECP, indicates that “Circuit breakers
open”. To find, select STATUS from
main screen. Scroll though pages to
SMU functions page

Turn the switch at FB2 to 0

Contactor KB4 and KB4 will open

SED indicates “Circuit breakers open”

Steering brake drops down, if it has
been open. Steering brake will de-
energize and engage the friction rotor,
preventing the motor for spinning.

Turn the switch at FB1 to 1

Contactors KB1 and KB3 will close

The voltage supply will transfer back
to main supply of FB1

SED will indicate “Brake switch open”,
if ESU is in run mode

SED will indicate “Brake closed”, if
ESU is in stand-by mode

Turn the switch at FB2 to 1

SED indicates “Circuit breakers
closed”

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12.2 S

TEERING MOTOR

FAN

Turn the switch at FF1 to 0, circuit
breaker for fan open.

Fan at motor 1 will stop, if they are
running

SED indicates “Circuit breakers open”

Turn the switch at FF1 to 1, circuit
breaker for fan closed.

Fan at motor 1 will start

SED indicates “Circuit breakers
closed”

12.3 S

TEERING MOTOR

FAN

Turn the switch at FF2 to 0, circuit
breaker for fan open.

Fan at motor 2 will stop, if they are
running

SED indicates “Circuit breakers open”

Turn the switch at FF2 to 1, circuit
breaker for fan closed.

Fan at motor 2 will start

SED indicates “Circuit breakers
closed”

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12.4 E

LECTRIC STEERING GEAR

FAILURE TEST

Switch OFF the supply for steering drives ESU1 from vessel’s switchboard.

The steering gear 1 failure will appear. The steering gear failure will appear
on vessel’s alarm system as well as on SED (service display) page for
steering drive status, at SCU or ECP.

Switch ON the supply for steering drive ESU1.

The alarm will disappear.

12.5 E

LECTRIC STEERING GEAR

FAILURE TEST

Switch OFF the supply for steering drives ESU2 from vessel’s switchboard.

The steering gear 2 failure will appear. The steering gear failure will appear
on vessel’s alarm system as well as on SED (service display) page for
steering drive status, at SCU or ECP.

Switch ON the supply for steering drive ESU2.

The alarm will disappear.

12.6 E

LECTRIC STEERING GEAR

WARNING TEST

Open the wire at terminal X1:T1 at SMU.

The warning will appear. The steering gear warning will appear on vessel’s
alarm system as well as on SED (service display) page for steering drive
status, at SCU or ECP.

Connect the wire at terminal X1:T1 at SMU.

The warning will disappear after ~20 s.

12.7 E

LECTRIC STEERING GEAR

WARNING TEST

Open the wire at terminal X2:T1 at SMU.

The warning will appear. The steering gear warning will appear on vessel’s
alarm system as well as on SED (service display) page for steering drive
status, at SCU or ECP.

Connect the wire at terminal X2:T1 at SMU.

The warning will disappear after ~20 s.

12.8 N

EW SYSTEMS FROM

6/2008

ESU unit has testing parameter. More details from Vacon’s new manual.

C102961-A Page 25 of 32

20.08.2008

DOC-1017-1

13 F

AULT FINDING

13.1 G

ENERAL

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 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.

C102961-A Page 26 of 32

20.08.2008

DOC-1017-1

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.

C102961-A Page 27 of 32

20.08.2008

DOC-1017-1

13.2 L

OW STEERING SPEED

FAULT EFFECT

TEMPORARY

ACTION

CAUSE REMEDY

Low steering speed

The propulsor turns
slowly.

Wiring

connection

failure

Check and repair

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

C102961-A Page 28 of 32

20.08.2008

DOC-1017-1

13.3 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

C102961-A Page 29 of 32

20.08.2008

DOC-1017-1

13.4 B

ASIC MOTOR

FAULT EFFECT

CAUSE

REMEDY

Motor is not

running

No steering

Use only another
propulsor for steering.

Brake is engaged

See brake 6

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 6. Lower ship

speed. The limitation is not
automatic.

The fan is not running

See fan 5.2

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

13.5 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

Circuit breakers open

Broken fan motor

Clogged fan

C102961-A Page 30 of 32

20.08.2008

DOC-1017-1

13.6 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

C102961-A Page 31 of 32

20.08.2008

DOC-1017-1

13.7 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.

13.8 M

OTOR CONTROL UNIT

(SMU)

FAULT EFFECT

TEMPORARY

ACTION

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

disconnected, via

changeover contacts.
Therefore the

opening of one FB
circuit breaker does

not make any
influence to the

operation of the brake
control.

See 11.1

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.

C102961-A Page 32 of 32

20.08.2008

DOC-1017-1

14 S

TEERING MOTOR SPARE PARTS

MOTOR

CODE

SPARE

MOTOR

CODE

BRAKE

RECTIFIER

DISC

BRAKE

HAND

LEVER

FAN FEEDBACK

ENCODER

20 M

FEEDBACK

CABLE

50 M

FEEDBACK

CABLE

001551 E000689 E000436 E000722 E000721 E000438 E000174 E000678 E000202
001552 E000690

E000438 E000174 E000678 E000202

E000305 E000693 E000736

E000733 E000459 E000343 E000331

E000306 E000694

E000733 E000459 E000343 E000331

E000313 E000689 E000736 E000446 E000716 E000442 E000459 E000343 E000331
E000314 E000690

E000442 E000459 E000343 E000331

E000345 E000689 E000736 E000446 E000716 E000442 E000459 E000343 E000331
E000522 E000689

E000442 E000459 E000343 E000331

E000603

E000736 E000686

E000687

E000741 E000678 E000202

E000603

E000736 E000686

S000220

E000741 E000678 E000202

E000689

E000736 E000732 E000731 E000442 E000727 E000678 E000202

E000690

E000442

E000727 E000678 E000202

E000693

E000736 E000732 E000735 E000733 E000727 E000678 E000202

E000694

E000733

E000727 E000678 E000202

E000826

E000736 X

E000727 E000678 E000202

E000827

X E000727

E000678

E000202

E000839

E000736 X

S000214 E000727 E000678 E000202

E000840

S000214

E000727 E000678 E000202

E000841

E000736 X

S000214 E000727 E000678 E000202

E000842

S000214

E000727 E000678 E000202

E000843

E000736 X

S000214 E000727 E000678 E000202

E000844

S000214

E000727 E000678 E000202

Supply 220 VAC, 50 Hz

Supply 220 VAC, 60 Hz

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