C101566 B installation

C101566-B Page 1 of 67

26.01.2006

DOC-1017-1

Steerprop

Propulsor

Installation

Manual

This is a general installation manual for Steerprop propulsors. The

more specified data is shown at drawings and other instructions.

Revision history:

REV. DATE MODIFIER DESCRIPTION

0 1.6.2005

Aani New

A 4.8.2005

AaNi Signal

directions

B 26.1.2006

Aani

Signal

directions

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DOC-1017-1

SAFETY INSTRUCTIONS, WARNINGS, ENVIRONMENT .......................................................... 6

1.1

ARNINGS

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

1.1.1

Rotating elements and shafts ....................................................................................................... 6

1.1.2

Hydraulic and lubrication ........................................................................................................... 6

1.2

AFETY

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

1.2.1

General ........................................................................................................................................ 6

1.2.2

Installation ................................................................................................................................... 6

1.2.3

Electric Work ............................................................................................................................... 6

1.2.4

Control circuits ............................................................................................................................ 6

1.2.5

Electric motors............................................................................................................................. 7

1.2.6

Alternating current circuits ......................................................................................................... 7

1.2.7

Low voltage.................................................................................................................................. 7

1.3

ARTHING AND EARTH FAULT PROTECTION

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

1.3.1

Control units ................................................................................................................................ 7

1.3.2

Control panels ............................................................................................................................. 8

1.3.3

Propulsor ..................................................................................................................................... 8

1.4

NVIRONMENT PROTECTION

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

1.4.1

Machine demolition ..................................................................................................................... 8

1.4.2

Ecology information .................................................................................................................... 8

1.4.3

Instructions for suitable waste treatment..................................................................................... 8

CODES AND ABBREVIATIONS USED IN THIS MANUAL .......................................................... 9

PROPULSOR NUMBERING ..............................................................................................................10

STORAGE..............................................................................................................................................11

4.1

ACKING AND PROTECTION

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

4.1.1

Propulsor ....................................................................................................................................11

4.1.2

Planetary gears...........................................................................................................................11

4.1.3

Heat exchangers .........................................................................................................................11

4.1.4

Control system and propulsors electronic components ..............................................................11

4.1.5

Supervision under storage time ..................................................................................................12

4.2

ND OF STORAGE

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

TRANSPORT.........................................................................................................................................13

5.1

ROPULSOR

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

5.2

YDRAULICS AND LUBRICATION MODULES

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

5.3

NTERMEDIATE SHAFTING

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

5.4

IGGER CONTROL UNITS

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

5.5

MALLER UNITS OR MODULES

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

BOTTOM WELL CASING MOUNTING ..........................................................................................15

6.1

RINCIPAL ARRANGEMENT OF BOTTOM WELL CASING MOUNTING

.................................................15

6.1.1

Rectangular casing .....................................................................................................................15

6.1.2

Circular casing ...........................................................................................................................15

6.2

ELDING PROCESS

..........................................................................................................................16

6.2.1

Description of items ....................................................................................................................16

6.2.2

Welding order .............................................................................................................................16

6.3

ELDING OF MOUNTING PLATES

....................................................................................................17

6.4

ELDING OF CASING FLANGE SUPPORTING PLATES

.......................................................................18

6.5

ELD DETAILS

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

6.5.1

Fillet weld ...................................................................................................................................19

6.5.2

Butt weld .....................................................................................................................................19

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INTERMEDIATE SHAFT ...................................................................................................................20

7.1

ARDAN SHAFT

...............................................................................................................................20

7.1.1

Installation ..................................................................................................................................20

7.1.2

Disassembly ................................................................................................................................21

7.1.3

Flange boltings ...........................................................................................................................22

7.1.4

Companion flanges .....................................................................................................................22

7.2

NTERMEDIATE SHAFT BEARINGS TYPE

SKF

SNL ..........................................................................23

7.2.1

Mounting.....................................................................................................................................23

7.3

OUNTING

SNL

AND

SNL

HOUSINGS WITH LABYRINTH SEALS

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

7.4

ULKHEAD SEAL

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

PROPULSOR METAL PART PAINTING INSTRUCTIONS .........................................................27

8.1

URFACE PRELIMINARY TREATMENT

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

8.2

ROPULSORS UPPER ASSEMBLY

(

SURFACES INSIDE SHIP

) ...............................................................27

8.2.1

Primed surfaces preliminary treatment ......................................................................................27

8.3

ROPULSORS LOWER ASSEMBLY

(

SUBMERGED SURFACES

) ............................................................28

8.3.1

Primed surfaces preliminary treatment ......................................................................................28

8.4

NTIFOULING PAINTING

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

8.5

ERVICE AND MAINTENANCE PAINTING

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

8.6

ORROSION CONTROL

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

ADHESSIVES AND SEALANTS ........................................................................................................29

9.1

HREAD LOCKS

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

9.1.1

Screw locking..............................................................................................................................29

9.1.2

Locking plugs and hydraulic couplings ......................................................................................29

9.1.3

Mechanical angle indicators ......................................................................................................29

9.1.4

Proximity sensors........................................................................................................................29

9.2

LANGE SEALANTS

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

PIPING ...................................................................................................................................................30

10.1

NSTALLATION AND PIPING

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

PROPULSOR SEAL OIL TANK INSTALLATION .........................................................................31

11.1

ROPULSOR SEAL SYSTEM

...............................................................................................................31

11.2

EAL OIL TANK

................................................................................................................................31

11.3

PRESSURIZED SYSTEM

............................................................................................................32

11.4

RESSURIZED SYSTEM

.....................................................................................................................33

OIL FILLING ........................................................................................................................................34

12.1.1

OIL PURITY GRADE .............................................................................................................34

12.1.2

OIL FILLING .........................................................................................................................34

12.1.3

FILLING AND BLEEDING THE PROPELLER SHAFT SEALING ......................................34

12.2

IL DRAINING AND PUMPING OUT

...................................................................................................34

12.3

HECKING OIL QUANTITY

...............................................................................................................35

HYDRAULIC SYSTEMS .....................................................................................................................36

13.1

ENERAL

.........................................................................................................................................36

13.1.1

Long service life and functional reliability of hydraulic systems and their components are

dependent on correct handling ................................................................................................................36

13.2

SSEMBLY

.......................................................................................................................................36

13.2.1

Assembly preparation.............................................................................................................36

13.2.2

Carrying out assembly............................................................................................................37

13.2.3

Lines and connections ............................................................................................................37

13.2.4

Filters .....................................................................................................................................38

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13.2.5

Hydraulic fluids......................................................................................................................38

13.3

OMMISSIONING

.............................................................................................................................38

13.3.1

Preparations for a trial run....................................................................................................38

13.3.2

Start-up...................................................................................................................................39

13.3.3

Trial run .................................................................................................................................39

13.3.4

The most common faults occuring during commissioning .....................................................42

13.3.5

Special operations after commissioning with the filters.........................................................43

13.3.6

Special operations after commissioning with the oil levels....................................................43

PROPULSOR COOLING SYSTEM INSTALLATION ...................................................................44

14.1

ONSTRUCTIONAL DIRECTIONS IN A PIPING DESIGN

. .....................................................................44

14.2

NSTALLATION AND START

........................................................................................................44

14.2.1

Receipt ....................................................................................................................................44

14.2.2

Installation..............................................................................................................................45

14.2.3

Start-up...................................................................................................................................45

ELECTRIC INSTALLATION .............................................................................................................47

15.1

IGNAL DIRECTIONS

........................................................................................................................47

15.2

OLTAGE SUPPLY

............................................................................................................................48

15.2.1

Control voltage supply ...........................................................................................................48

15.2.2

AC supply ...............................................................................................................................48

15.2.3

24 VDC supply for electric and control .................................................................................48

15.2.4

24 VDC supply for instruments (alarm transducers etc.).......................................................49

15.3

OCATIONS

......................................................................................................................................49

15.3.1

Control space .........................................................................................................................49

15.3.2

Machinery space.....................................................................................................................49

15.3.3

Outdoor space ........................................................................................................................49

15.4

EMC

COMPATIBILITY FOR CONTROL EQUIPMENTS

.........................................................................49

15.5

NVIRONMENT

................................................................................................................................49

15.5.1

Relative humidity ....................................................................................................................49

15.5.2

Salt contaminity ......................................................................................................................50

15.5.3

Oil...........................................................................................................................................50

15.5.4

Acceleration............................................................................................................................50

15.5.5

Vibrations ...............................................................................................................................50

CABLING...............................................................................................................................................51

16.1

ABLE TYPES AND NUMBERS

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

16.2

VDC

CABLE POWER TABLE

........................................................................................................52

16.3

AWG

DIMENSIONS

..........................................................................................................................53

16.4

ESIGN AND CABLING WORK

..........................................................................................................54

16.4.1

Power cables ..........................................................................................................................54

16.4.2

Frequency converter and brake resistor cabling ...................................................................55

16.4.3

Control cables ........................................................................................................................56

16.4.4

Control cable with twisted pairs and screen ..........................................................................56

16.4.5

Data cables.............................................................................................................................57

16.4.6

CAN bus cables ......................................................................................................................58

16.4.7

Distance of different type of cables ........................................................................................59

16.5

NSTALLATION AND CONNECTIONS

.................................................................................................59

16.5.1

Protection piping work ...........................................................................................................59

16.5.2

Wiring and terminals..............................................................................................................60

16.5.3

Plugs.......................................................................................................................................60

16.5.4

Cable glands...........................................................................................................................60

ELECTRIC UNIT INSTALLATION ..................................................................................................61

17.1

EMOTE CONTROL PANELS

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

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17.2

ONTROL UNITS

..............................................................................................................................62

17.2.1

Cooling ...................................................................................................................................62

17.2.2

Vibration absorber .................................................................................................................62

17.2.3

Cleanliness and purity............................................................................................................62

17.2.4

Condensed water ....................................................................................................................63

17.2.5

Control unit cabling ...............................................................................................................63

17.3

REQUENCY CONVERTER

................................................................................................................64

17.3.1

Ground connections ...............................................................................................................64

17.3.2

Vibration dampers ..................................................................................................................65

17.4

ROPULSOR CABLING

......................................................................................................................65

17.5

YDRAULIC POWER PACK CABLING

................................................................................................66

17.6

OTENTIOMETERS AND SENSITIVE COMPONENTS

...........................................................................66

C101566-B Page 6 of 67

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DOC-1017-1

1 S

AFETY INSTRUCTIONS

WARNINGS

ENVIRONMENT

1.1 W

ARNINGS

1.1.1 R

OTATING ELEMENTS AND SHAFTS

When you work, you should use suitable protection and safety wears and
barriers to prevent the danger of injury or death.

1.1.2 H

YDRAULIC AND LUBRICATION

Use proper personal protection equipment and clothes

Follow all safety measurements

Stop first the driving motor and/or engine

Prevent then the starting of driving motors or engines

Check that there is no high pressure present

The oil can be hot

Use only proper quality tools

Protect the environment

Due to safety considerations pipe fittings, connections and components
must not be loosened as long as the system is pressurized.

1.2 S

AFETY

1.2.1 G

ENERAL

These instructions are meant for professional use. Operation, service and maintenance
personal should be well-trained professionals.

1.2.2 I

NSTALLATION

The propulsor system is meant for fixed installations only.

1.2.3 E

LECTRIC

ORK

Do electric work only, when the supply isolation devices at main
switchboard are locked open.

Do not make temporary connections

Before connecting the electric supply, check that all devices are clean and
dry.

Open the protection devices and voltage switches of the control system
before you connect supply voltage.

1.2.4 C

ONTROL CIRCUITS

Do not touch the IC-circuits on the circuit boards. Static voltage discharge
may damage the components.

You should use carefully transmitters and other instruments, because their
signal circuits can destroy at wrong connection

The potentiometers at control lever are very sensitive instruments. Be very
careful, when you test and connect them.

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DOC-1017-1

Static charges can damage electronic devices. Discharge the electrical
charge from your body before opening and configuring the device. To do
so, touch a grounded surface, e.g. the metal housing of the switch cabinet.

1.2.5 E

LECTRIC MOTORS

Before starting the motor, check that the motor is mounted properly and
ensure that the machine connected to the motor allows the motor to be
started.

Set the maximum motor speed (frequency) according to the motor and the
machine connected to it.

Before reversing the motor shaft rotation direction make sure that this can
be done safely.

Make sure that no power correction capacitors are connected to the motor
cable.

Make sure that the motor terminals are not connected to mains potential.

1.2.6 A

LTERNATING CURRENT CIRCUITS

Do not perform any measurements when the frequency converter is
connected to the mains.

After disconnecting the frequency converter from the mains, wait until the
fan stops and the indicators on the keypad go out (if no keypad is attached
see the indicators on the cover). Wait 5 more minutes before doing any
work on Converter connections. Do not even open the cover before this
time has expired.

Do not perform any voltage withstand tests on any part of Converter. There
is a certain procedure according to which the tests shall be performed.
Ignoring this procedure may result in damaged product.

Prior to measurements on the motor or the motor cable, disconnect the
motor cable from the frequency converter.

Before connecting the frequency converter to mains make sure that the
Converter front and cable covers are closed.

The components of the power unit of the frequency converter are live when
converter is connected to mains potential. Coming into contact with this
voltage is extremely dangerous and may cause death or severe injury.
The control unit is isolated from the potential.

The motor terminals U, V, W and the DC-link/brake resistor terminals –/+
and disc brake terminals are live when converter is connected to mains,
even if the motor is not running.

The frequency converter has a large capacitive leakage current.

1.2.7 L

OW VOLTAGE

The control I/O-terminals are isolated from the mains potential. However,
the relay outputs and other I/O-terminals may have a dangerous control
voltage present even when converter is disconnected from mains.

1.3 E

ARTHING AND EARTH FAULT PROTECTION

1.3.1 C

ONTROL UNITS

The frequency converter must always be earthed with an earthing
conductor connected to the earthing terminal.

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The control units must always be earthed with an earthing conductor
connected to the earthing terminal.

The earth fault protection inside the frequency converter protects only the
converter itself against earth faults in the motor or the motor cable.

Due to the high capacitive currents present in the frequency converter, fault
current protective switches may not function properly. If fault current
protective switches are used they must be tested with the drive with earth
fault currents that are possible to arise in fault situations.

The mounting rail must be connected to ground potential. This is the only
way to guarantee that the integrated surge voltage protection functions and
that the shield of the bus conductor makes contact effectively.

1.3.2 C

ONTROL PANELS

The control panels must always be earthed with an earthing conductor
connected to the earthing terminal.

1.3.3 P

ROPULSOR

The housings of electric steering and lubrication pumps should be
connected with an earthing conductor connected to the earthing terminal.

The propulsor should be connected with an 25 mm2 earthing conductor
connected to the earthing terminal.

1.4 E

NVIRONMENT PROTECTION

1.4.1 M

ACHINE DEMOLITION

If the machine must be scrapped, it, should become non-operational:

Disassemble the various parts.

Disconnect any motor unit.

But first after having completely emptied all the oil from propulsor unit and its auxiliaires
unit.

1.4.2 E

COLOGY INFORMATION

The disposal of unit packaging materials, replaced parts, components or the unit and
lubricants must comply with environmental restrictions, without polluting the soil, water
or air. The party receiving the materials is responsible for carrying out the operation in
conformity with the current standards in force in the country in which the machine is
used.

1.4.3 I

NSTRUCTIONS FOR SUITABLE WASTE TREATMENT

Iron, aluminium, copper materials: these are recyclable materials which
must be sent a to a special authorized collection center.

Plastic and rubber materials: these materials must be delivered to a dump
or to special recycling centers.

Used oils: deliver to a special authorized collection and recycling centers

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ODES AND ABBREVIATIONS USED IN THIS MANUAL

CODE DESCRIPTION

CODE

DESCRIPTION

ACU

AC/DC Converter Unit

SAI

Steerprop Angle Indicator

AIU

Alarm Indication Unit

SAP Steerprop Azimuth Propulsor

ALARM Alarm system

SCB Steerprop Propulsor Connection Box

Autopilot

SCL

Steerprop Control Lever

APC

Autopilot Command Unit

SCU Steerprop Control Unit

APD

Autopilot Distribution Unit

SJC

Steerprop Joystick Computer

BCP

Back-up Control Panel

SJD

Steerprop Joystick Display

BFU

Brake and Fan Control Unit

SJP

Steerprop Joystick Panel

BLD

Control System Block Diagram SOT Seal Oil Tank

BRU

Brake Resistor Unit

SRI

Steerprop Rpm Indicator

Bow Thruster

STB

SOT Connection Box

CPU

Clutch Pump Unit

STU Steerprop Transmitter Unit

CSU Clutch

Pump

Starter

TG Telegraph

Dynamic Positioning Systen

VDR Voyage Data Recorder

ECDIS

Electric map system

WCP Wheelhouse Control Panel

ECP

Engine Control Room Panel

Wheelhouse

ENGINE Diesel motor

WSP Wing Steering Panel

EPSS

Electric Power Supply
Switchboard

Engine Room control

ESU Electric

Steering

Unit

General Arrangement Drawing

GPS

Global Positioning System

GYRO Gyrocompass

HCB

Hydraulic Connection Box

HPU Hydraulic

Power

Unit

HSU

Hydraulic Starter Unit

JC Joystick

Control

System

LCR Local

Control

Switch

LLG

Lubrication Lower Gear Unit

LOR

Lubrication Oil Reservoir

LPU

Lubrication Pump Unit

LSU Lubrication

Starter

LUG

Lubrication Upper Gear Unit

MC Mission

Computer

PFU

Pump Motor Fan Control Unit

PM Propeller

Motor

PR Propulsor

Room

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3 P

ROPULSOR NUMBERING

The exact coding in the actual project is shown in the General Arrangement (GA) and
in the control system block diagram (BLD).

The propulsor and control unit numbering is always
shown at CONTROL SYSTEM BLOCK DIAGRAM.

There are following general principles:

PROPULSOR NUMBERING

Propulsor numbering starts from Bow Port Side

and ends to Stern Starboard

CONTROL STATION NUMBERING

Remote control panel numbering starts from Fore
Center station and the next is fore Port Side

station.

CONTROL PANEL WCP NUMBERING

First number is according propulsor

Second number is according control station

WING TYPE CONTROL PANEL WSP
NUMBERING

The controls of all propulsor are mounted into same
panel.

The number is according control station

CONTROL UNITS NUMBERING

The numbering follows the numbers of the
propulsors

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4 S

TORAGE

4.1 P

ACKING AND PROTECTION

4.1.1 P

ROPULSOR

A unused unit is kept inside.

If the storage period is longer than three moths, the unit is filled with oil. A unit filled
with oil is kept in a upright position.

4.1.2 P

LANETARY GEARS

For extended storage of more than 6 months, the rotating seals will no longer be
efficient. It is recommended to check them periodically by turning the internal gears by
and rotating the input shaft. For a negative multi-disk brake, release the brake by using
a hydraulic pump or similar device It is recommended to replace the gaskets when the
machine is started.

4.1.3 H

EAT EXCHANGERS

4.1.3.1 S

TANDARD CONSERVATION

(

CONTROLLED CONDITIONS

)

All heat exchangers supplied by Bloksma are treated with a rust preventive layer (on
both shell- and tubeside). This layer will protect the heat exchanger when it is stored at
controlled conditions, i.e. inside, in a dry room at constant temperature . When these
conditions are met, the heat exchanger can be stored without special treatment for a
longer period (up till 24 months). The rust preventive layer can be removed with a
mineral solvent (petroleum).

4.1.3.2 A

DVISE FOR CONSERVATION

(

UNCONTROLLED CONDITIONS

)

When the above mentioned storage conditions are not met, you will have to fill the heat
exchanger with an inert gas and all openings have to be closed airtight (additionally
silica gel can be added to absorb liquids). Alternatively, the heat exchanger can be
treated with a rust preventive liquid of a type suited for long term conservation. When
necessary contact a specialised company. Take the materials of the heat exchanger
(see specification sheet) into consideration. Be aware that in uncontrolled storage
conditions large amounts of water can accumulate in the heat exchanger as a result of
condensation.

4.1.4 C

ONTROL SYSTEM AND PROPULSORS ELECTRONIC COMPONENTS

All gears should be greased (Transmitter unit STU).

Place for storing electronic equipments have to have walls and cover. Equipment
should be placed 1 m above the floor to avoid moisture from the floor to get to
equipment. The place should be dry and warm enough (> 10

°C) but not too warm (<

°C). Also the temperature should be steady.

In the store with electronic equipment should not be any corrosive material (batteries
with acid).

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4.1.4.1 P

ACKAGES

Some packing material should be used, for example board chips. But in
some cases it is important that the chips can’t go inside for example control
levers and panels.

Control panels and equipments have to cover first with condense protecting
packing board or similar. Also packing should be steady enough and not
corrosive.

Inside every electronic unit and packing containing electronic equipment
should be moisture absorber to keep components dry. The absorber
material should be kept in order by changing it regularly.

Plastic should not touch straight to any metal and cause any condense and
prevent moisture reduction from packages.

If necessary, you should provide and use special packages meant for
electronic components.

All holes of electronic units should be blocked to avoid dirt and moisture
getting inside the unit.

Packing should be made so that electronic units and components can’t
move inside packing.

Moving and unnecessary opening of packing should be avoided. If packing
is opened it should be closed properly if storing continues.

4.1.5 S

UPERVISION UNDER STORAGE TIME

Frequent checking of store should be done.

4.2 E

ND OF STORAGE

4.2.1.1 C

HECKING

When you take the units from storage, you should check:

That there is no damaged devices or components

All part and components are left

That there do not appear corrosion or condensed corrosion

That lubrication or hydraulic systems do not have rubbish or water

4.2.1.2 C

LEANING

After storing the equipment should be checked that they are not damaged and they are
containing all needed components. Any dust, salt, etc. should be cleaned away with
cleaning cloth, which is not getting fluffy.

Also it is important to make sure that equipments are dry and clean before the supply
voltage is connected!

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5 T

RANSPORT

PREVENT

INJURIES

PERSONS

AND

DAMAGE

THE

PARTS

ALWAYS

MAKE

SURE

THAT

THE

PARTS

ARE

SAFELY

TRANSPORTED

AND

STORED

5.1 P

ROPULSOR

The propulsor is equipped with lifting eyes. During lifting operation you should be
careful, that you not damage projecting parts.

During transportation the propulsor should fasten and protect properly using
appropriate points. During transportation you should be careful.

If the unit does not have lifting eyes, you should lift and transport the unit on suitable
bed.

5.2 H

YDRAULICS AND LUBRICATION MODULES

The lifting is to be done with lifting linen.

Use strong nylon ropes or lifting belts. When using steel cords, protect the edges.

5.3 I

NTERMEDIATE SHAFTING

Use strong nylon ropes or lifting belts. When using steel cords, protect the edges.

Cardan shafts should be transported in a horizontal position (see illustration). For non-
horizontal transportation additional precautions must be taken to prevent the splined
parts from separating.

ANGER OF INJURY

Please consider the following precautions:

When lifting or putting down the shaft,
the moving parts (flange yoke and
journal cross) may tilt and lead to
injuries.
Keep hands away from the joint!
Danger of crushed hands!

Do not store or handle the shaft with
any stress or load on the spline
protection (1) or the seal (2).

Avoid bumps and knocks during transport and storage.

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Use appropriate frames or racks for storage, so that the flange yokes are
not loaded.

Use chocks or blocks to prevent cardan shaft from rolling.

Secure shaft against falling over if it is stored in a vertical position.

Keep cardan shafts in a dry place.

5.4 B

IGGER CONTROL UNITS

All electronic equipment should be transported with care. Lifting should be done only
from marked places or from the bottom of packing.

IFTING LUGS

For the lifting of the bigger units there are special Lifting lugs / eyes.

SSEMBLY BRACKETS

Never use assembly brackets for lifting. Lifting destroys them..

There is not allowed to use to control unit the assembly brackets for lifting of the control
units.

5.5 S

MALLER UNITS OR MODULES

All equipment should be transported with care. Lifting should be done only from marked
places or from the bottom of packing.

Smaller do not have any special lifting eyes. Their lifting should be with palette or equal
or with manpower.

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6 B

OTTOM WELL CASING MOUNTING

6.1 P

RINCIPAL ARRANGEMENT OF BOTTOM WELL CASING MOUNTING

6.1.1 R

ECTANGULAR CASING

R1 Longitudinal

stiffener

R2 Bottom

frame

6.1.2 C

IRCULAR CASING

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6.2 W

ELDING PROCESS

6.2.1 D

ESCRIPTION OF ITEMS

ITEM DESCRIPTION

A Dimension

Circular casing diameter

Rectangular casing inner side length

Measured at several positions

W1 Stiffener

flange

W2 Stiffener

web

Mounting plate lap joint to stiffener web plate must be welded edge-by-edge in
sequential order as shown.

Weld throat thickness is determined by strength analysis (normally 25...40 % of plate
thickness).

W3 Bottom

well

casing

Mounting plate (same thickness as stiffener web plate)

All mounting plates must be welded to hull stiffeners before starting to weld to bottom
well casing.

Firstly casing is tack welded to all mounting plates,

After that casing flange flatness and dimension A are checked.

If tolerances are not exceeded, root runs are welded to each joint.

The flatness and dimension A are checked again.

If tolerances are not exceeded, the remaining runs are welded.

After welding is completed, flatness and dimension A are measured and documented.

As small as possible so, that welding can be done properly

W6 Bottom

plate

Working allowance to be cut off after welding

NOTE: Full penetration weld.

Flange supporting plate

W10

Machined surface must be protected during welding

W11

Flange supporting plate lap joint to stiffener flange must be welded edge-by-edge in
sequential order as shown.

Flange flatness and dimension A must be checked after root run has been welded.

After welding is completed, flatness and dimension A are measured and documented.

W12

NOTE: No root cap allowed. Supporting plate is pushed against casing flange and tack
welded at edge 5.

6.2.2 W

ELDING ORDER

Sequential welding order is described with numbers 1-2-3-4-5-6-7.

C101566-B Page 17 of 67

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6.3 W

ELDING OF MOUNTING PLATES

C101566-B Page 18 of 67

26.01.2006

DOC-1017-1

6.4 W

ELDING OF CASING FLANGE SUPPORTING PLATES

OTE

Flange supporting plates are normally not required. The need of supporting plates are
determined by strength analysis

OTE

All mounting plates must be welded before welding of flange supporting plates.

C101566-B Page 19 of 67

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DOC-1017-1

6.5 W

ELD DETAILS

If weld throat thickness exceeds 4 mm, multi-run welds must be used to minimize heat
generation and thus welding distortions.

Root run max. throat thickness 3 mm

Max. throat thickness of filling runs 4 mm

6.5.1 F

ILLET WELD

6.5.2 B

UTT WELD

B1 Filling

runs

B2 Root

run

C101566-B Page 20 of 67

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DOC-1017-1

7 I

NTERMEDIATE SHAFT

The intermediate shaft arrangement, dimensions and assembly instruction are given
GENERAL ARRANGEMENT (GA) drawing.

7.1 C

ARDAN SHAFT

See more and updated information from www.gwb-essen.de

GWB cardan shafts are delivered as complete units ready for installation. The shafts
are greased for operation. They are balanced and painted in accordance with the
technical information sheets.

The balance state of a cardan shaft must on no account be altered. An inadmissable
out-of-balance of a shaft may result in uneven running and premature wear of the joints
and the bearings of the units to which the cardan shaft is connected.

In extreme cases the cardan shaft could break and shaft components could be thrown
at speed from the vehicle or machine.

ANGER

INJURY

! P

ROVIDE

SAFETY

GUARD

DEVICE

7.1.1 I

NSTALLATION

In order to guarantee the properties of the cardan shaft as described in the information
brochure they must not be altered from its as-delivered state.

HENEVER

PEOPLE

MATERIAL

MIGHT

ENDANGERED

ROTATING

CARDAN

SHAFTS

THE

USER

MUST

PROVIDE

FOR

THE

CORRESPONDING

SAFETY

DEVICES

Suitable safety devices (e.g. catch bows, solid safety guards) must be provided to
prevent the parts of the shaft from being thrown around.

ANGER

LIFE

Cardan shafts are elastic and flexural bodies. Their flexural vibration and their critical
bending speed must be calculated. The maximum permissible operating speed must
be sufficiently below the critical bending speed of the first order.

For the smooth running and safety of the shaft the n x ß value (speed x deflection
angle) of the relevant shaft size must not be exceeded.
The faces and the centering diameter of the shaft flanges and companion flanges must
be free of dust, grease or paint to guarantee a safe connection.

Be careful when handling the cardan shaft. Freely moving flange yokes may cause
INJURIES!

Check position of the yokes (1) of the
shaft. Observe the arrow markings (2).
They must be in alignment. The splines
are fitted and must not be exchanged or
distorted.

C101566-B Page 21 of 67

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DOC-1017-1

Before installation remove the transport retainer device, if present. In case of doubt
please contact the supplier.

Check the radial and radial runout as well as the spigot fit of the mounted flanges and
the connected units.

Do not turn the joints of the cardan shafts with assembly levers because this may
damage the grease nipples or relief values.

Use nuts and bolts of the prescribed quality (strength).

Only use nuts and bolts in accordance with the supplier's specification.

The bolts should be evenly tightened crosswise with a torque wrench.

When using cardan shafts without length compensation, one of the connecting units
must be flexible in order to be fitted over the flange pilot. Variations in lenght which
may be caused by temperature changes must be allowed for by a suitable connecting
bearing.

If cardan shafts with length compensation are used, the companion flanges must be
firmly fitted on the shafts of the connected units.

Cardan shafts that have been stored for more than 6 month must be relubricated
before use.

For spray-painting the cardan shaft, make sure
that the sliding range of the seal (length
compensation La) is covered.

For spray-painting the shaft we recommend our paint standards (Please ask for them).

Protect rilsan coated splines (sleeve muff or sleeve yoke) against heat solvents
mechanical damage

When cleaning cardan shafts, do not use aggressive chemical detergents or
pressurized water or steam jets because the seals may be damaged and dirt or water
may penetrate.

Cardan shafts can be used in a temperature range between -25°C (-13°F) and +80°C
(+176°F), up to +120°C (+248°F) but only for limited periods and not on a frequent
basis. Please contact us if the operating temperature deviates from these values.

7.1.2 D

ISASSEMBLY

Before disassembly protect the cardan shaft from spline separation.

ECURE THE CARDAN SHAFT AGAINST FALLING DOWN BEFORE PULLING IT OFF

THE COMPANION FLANGE

THE FLANGE YOKE MAY TILT

ANGER OF INJURY

Observe the directions for transport, storage and installation of cardan shafts.

C101566-B Page 22 of 67

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DOC-1017-1

7.1.3 F

LANGE BOLTINGS

The flange bolting set can be supplied by GWB on request.
The bolt length given in the tables (with assembly papers) are
only suitable if the dimension 2 x G corresponding to the
double the flange thickness G is not exceeded (see data
sheets). If longer bolts are used, check whether the bolts can
still be inserted from the joint side.

We recommended a bolting set consisting of:

Hexagon bolt with short threat similar to DIN 931/10.9 (shaft length greater
than flange thickness)

Self-locking nut, similar to DIN 980/934-10.

The bolts allow fitting

a) partially from the joint side, i.e. the recessed diameter c does not prevent the bolt
from turning;
b) from the companion flange side. We recommend designing the recessed diameter c

as locate the bolt head.
See tables for insertion of bolts.
All bolts must be tightened with the specified torque. The tightening torques T

given in

the table are based on a 90% (80% hirth-serration) utilization of the elastic limit and
apply to slightly oiled bolts.
Do not use molycote paste or any other grease on the bolts and nuts. In case of
corrosion protected bolts and nuts (eg. Dacromet 500). Please contact us.
Max. permissible tolerance of DIN 25202 class B.

7.1.4 C

OMPANION FLANGES

In general, cardan shafts are connected to the driven units
by companion flanges. The companion flange material
must have a tensile strength of 750 N/mm².
The accurate running of a cardan shaft requires certain
tolerances for the axial and radial run-out.

The dimensions of the companion flanges correspond with those of the same size of
cardan shafts, except for the centring depth F

and the fit C

the depth of the keyway t

and the width b

. They can be taken from the following tables.

For better bolt locking we recommend designing the relief of the companion flange as a
bolt head surface and inserting the bolt from the companion flange side. In this case
the distance Z

min

must be met between the flange and the adjacent housing.

If it is not possible to insert the bolts from the companion flange side, we recommend
the use of stud bolts.

C101566-B Page 23 of 67

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DOC-1017-1

7.2 I

NTERMEDIATE SHAFT BEARINGS TYPE

SKF

SNL

See the more accurate and updated information from

www.skf.com

. This instruction is

a short version of SKF 5101 E- publication.

7.2.1 M

OUNTING

SNL housings together with SKF bearings are robust and operationally reliable bearing
arrangements, which have long lives. However, if they are to achieve their full potential
and not fail prematurely, they must be properly mounted. Incorrect procedures or
unsuitable tools can influence life negatively.

When mounting the housings it should be remembered that the housings are
asymmetrical internally and therefore the bearings are not always mounted in the
centre of the housing.

Vertical markings on the housing base end faces indicates the location of the centre of
the bearing seating.

7.2.1.1 M

OUNTING THE BEARING

The bearings can be mounted either on a tapered seating – normally for SNL housings
in the form of an adapter sleeve – or on a cylindrical seating. When a bearing is
correctly mounted on a sleeve there will be interference fits between the inner ring,
sleeve and shaft. The degree of interference is determined by how far the bearing is
driven up on the sleeve and either the internal clearance reduction or the axial drive-up
distance can be used as a measure. The clearance reduction in spherical roller
bearings can be measured using a feeler gauge, or the SKF drive-up method can be
used. Information will be sent on request.

For CARB bearings either the clearance reduction or the axial drive-up distance should
be measured. When using a feeler gauge to measure clearance reduction it is
important that the inner and outer rings of the bearing are not displaced with respect to
each other. The SKF drive-up method can also be applied.

Adapter sleeves with the designation OH ..

H in the product tables indicate that the sleeves are provided with the necessary ducts
to enable the bearings to be mounted using the oil injection method. Oil is supplied to
the nut side of the sleeve.

Bearings with cylindrical bore are normally mounted with an interference fit on the
shaft. Appropriate shaft tolerances should be selected (SKF General Catalogue). The
recommendations applying to spherical roller bearings also apply to CARB bearings.

Details of mounting tools as well as the SKF drive-up method can be found on the SKF
CD-ROM MP282 which will

be sent on request.

7.2.1.2 S

UPPORT SURFACE FOR HOUSING BASE

To guarantee long bearing service life it is recommended that the support surface for
the housing is finished to R

12,5 µm. The flatness (planicity) tolerance should be to

IT7. For moderate demands IT8 may be satisfactory.

C101566-B Page 24 of 67

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DOC-1017-1

7.2.1.3 D

OWEL PINS

SNL housings are designed for loads acting vertically to the housing base support. If
they are to be subjected to moderate or heavy loads acting parallel to the base support,
a stop should be provided, or the housing should be pinned to its support.

7.3 M

OUNTING

SNL

AND

SNL

HOUSINGS WITH LABYRINTH

SEALS

Before starting installation work, the following
instructions should be carefully read.
1.

Ensure that the environment is clean. Check

the dimensional and form accuracy of the shaft
seating.
2.

Check that the surface roughness of the

support surface R

12,5 µm. The flatness

(planicity) tolerance should be to IT7. For

moderate demands IT8 may be satisfactory.
3.

If the bearing is mounted on an adapter

sleeve, determine the position of the housing.
The grease nipple
arranged at one side of the housing cap (for

improved lubrication) should always be at the
side opposite to the sleeve nut. It is necessary

to consider the complete housing as the base
and cap will only fit together as supplied.
4.

Position the housing on the support surface.

Fit the attachment bolts but do not tighten

them.
5.

Mount the first labyrinth seal on the shaft in

the correct position.
6.

Mount the bearing on the shaft – either

directly on a stepped shaft or using an adapter
sleeve. Completely fill the bearing with grease.

The housing base should be filled with grease
up to the markings in each corner inside the

base.
7.

Mount the second labyrinth ring on the shaft

in the correct position. If the housing is to be
used at a shaft end, the second labyrinth ring is
omitted and an end cover inserted in the

housing base instead.
8.

Lay the shaft with bearing and labyrinth

ring(s) in the housing base.

Put the locating ring(s) (when needed) at

each side of the bearing.
NB. Locating rings are only used for locating

C101566-B Page 25 of 67

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DOC-1017-1

bearing arrangements, except for CARB
bearings which, although always non-locating,
must always be mounted with locating rings.
10.

Carefully align the housing base. Vertical

markings on the housing base ends and side

faces showing the bearing seating centre can
facilitate this. Then lightly tighten the

attachment bolts.
11.

The housing cap should be placed over

the base and the cap bolts (to join cap and

base) tightened to the torque
specified in GA.
The cap and base of one housing are not

interchangeable with those of other housings.
The cap and base should be checked to see

that they bear the same consecutive number.
12.

Fully tighten the attachment bolts in the

housing base. Recommended tightening
torques are given in GA.
13.

Finally insert the hollow O-ring cords of

synthetic rubber in the grooves in the labyrinth
rings. This can be done
using a screwdriver while turning the shaft.

C101566-B Page 26 of 67

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DOC-1017-1

7.4 B

ULKHEAD SEAL

The sealing is self lubricating, but the sealing
tightening flange nuts should be kept in right
tightness as said below:

Check, that nuts are in right tightness. The
tightness is:

Tightened with fingers and ½ turns.

No locking adhesive

C101566-B Page 27 of 67

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DOC-1017-1

8 P

ROPULSOR METAL PART PAINTING INSTRUCTIONS

8.1 S

URFACE PRELIMINARY TREATMENT

All foreign matter with harmful affect to preliminary treatment and painting is to be
removed. All water based salts are to be removed with a dirt- and grease-removing
agent according to SFS-EN ISO 12944. The surfaces are pre treated according to
material, as follows:

Steel surfaces: Mill scale and corrosion is removed by blasting to tolerance Sa2½
(SFS-ISO 8501-1). The roughening of sheet metal increases the paint bonding to the
surface.

Priming:

TEKNOPLAST PRIMER 3 white .....................................................1 x 60

µm

8.2 P

ROPULSORS UPPER ASSEMBLY

(

SURFACES INSIDE SHIP

)

8.2.1 P

RIMED SURFACES PRELIMINARY TREATMENT

All foreign matter that has a harmful affect with painting (for example grease and salts)
is to be removed. The surfaces should be clean and dry. Old paint layers that have
exceeded the maximum coating time should be roughened. Damaged places are to be
primed according to the surface and maintenance painting requirements.

The schedule and place for priming is to be selected so that the surface is not
contaminated or wet before further treatment (SFS-EN ISO 12944, part 4).

Painting:

TEKNOPLAST PRIMER 3 gray ......................................................1 x 80

µm

TEKNOPLAST HS 150 RAL 6019 ..................................................1 x 80

µm

Total thickness of coat:

TEKNOPLAST PRIMER 3 white .......................................................... 60

µm

TEKNOPLAST PRIMER 3 gray ........................................................... 80

µm

TEKNOPLAST HS 150 RAL 6019 ....................................................... 80

µm

Total .......................................................................................... 220

µm

C101566-B Page 28 of 67

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DOC-1017-1

8.3 P

ROPULSORS LOWER ASSEMBLY

(

SUBMERGED SURFACES

)

8.3.1 P

RIMED SURFACES PRELIMINARY TREATMENT

The schedule and place for priming is to be selected so that the surface is not
contaminated or wet before further treatment (SFS-EN ISO 12944, part 4).

Painting:

INERTA 165 TM 102.....................................................................1 x 300

µm

Total thickness of coat:

TEKNOPLAST PRIMER 3 ................................................................... 60

µm

INERTA 165 TM 102.......................................................................... 300

µm

Total ................................................................................................... 360

µm

8.4 A

NTIFOULING PAINTING

Over coating of an INERTA 165 epoxy based paint layer has to be done in 24 hours. A
paint coat older than this must be roughened before further coats of paint are applied. If
painted with antifouling paint the procedure used is to be according to the antifouling
paint supplier.

8.5 S

ERVICE AND MAINTENANCE PAINTING

Service and maintenance painting have to do so that the total coat is built up like
instructed above.

Damaged places are to cleaned and roughened carefully. All foreign matter that has a
harmful affect with painting (for example grease and salts) is to be removed. The
surfaces should be clean and dry. The border between old new painting area should
grind smooth. No sharp edges.

8.6 C

ORROSION CONTROL

Cathode protection..............................................zinc or aluminum cathodes

It is not allowed to paint those cathodes.

There are cathodes:

Propulsor body

Nozzle

Bottom well

Propeller shaft seal (there is available a replacement kit)

Inside rope guard

C101566-B Page 29 of 67

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DOC-1017-1

9 A

DHESSIVES AND SEALANTS

9.1 T

HREAD LOCKS

9.1.1 S

CREW LOCKING

Loctite 243 general-purpose adhesive is used to lock screws, with the following
exceptions:

Stud bolt metal ends, Loctite 270 or 2701.

Adjusting screws, Loctite 222.

The screws of the outer ring of the slewing ring are leaved without locking
adhesive.

The lower assembly’s and slewing assembly’s cap nuts are locked with wire
by welding.

9.1.2 L

OCKING PLUGS AND HYDRAULIC COUPLINGS

Thread size R ¾” or smaller Loctite 542

Thread size R 1” or larger Loctite 577

9.1.3 M

ECHANICAL ANGLE INDICATORS

Lock the dial and scale screws with Loctite 542

9.1.4 P

ROXIMITY SENSORS

Lock the threads with Loctite 542

9.2 F

LANGE SEALANTS

Loctite 5910 is used as flange sealant.

C101566-B Page 30 of 67

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DOC-1017-1

10 P

IPING

10.1 I

NSTALLATION AND PIPING

You should follow the good approach of the servicing and assembly of hydraulic
systems.

You should take care of purity and cleanliness of piping and components and use right
materials and tools.

The final tightness of the system is achieved during the normal operation, when the
impact of the warn oil, vessel vibrations and play are become even.

C101566-B Page 31 of 67

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11 P

ROPULSOR SEAL OIL TANK INSTALLATION

11.1 P

ROPULSOR SEAL SYSTEM

The propeller shaft seal has a separate lubrication system equipped with a separate
seal oil tank.

11.2 S

EAL OIL TANK

The system consists of a head tank with low and high level alarm for monitoring
steering tube and propeller shaft seal condition.

The seal oil tank is situated above the waterline and air pressure is adjusted so that the
oil pressure in the blocking chamber is 0.3 bar higher than the water pressure outside
the seal and the oil pressure inside the propulsion unit.

C101566-B Page 32 of 67

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DOC-1017-1

11.3 N

PRESSURIZED SYSTEM

C101566-B Page 33 of 67

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11.4 P

RESSURIZED SYSTEM

C101566-B Page 34 of 67

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DOC-1017-1

12 O

IL FILLING

12.1.1 OIL

PURITY

GRADE

The purity grade of the used oil should be at least according to standard 17/14 ISO
4406. The oils from suppliers do not normally fulfill the required purity grade. To avoid
the impurities from barrel or tank to get into the unit the oil is pumped, when filling the
propulsor, through a 10-micron fine filter. The propulsors filling connection/valve is
located at the fwd part of the upper assembly.

12.1.2 OIL

FILLING

The propulsor and sealing oil tank have to be filled with oil before the propulsor or ship
is lowered in water. In addition, the piping from the sealing oil tank to the propulsors
seal is filled and bleeding carefully before lowering to water.

12.1.3 FILLING

AND

BLEEDING

THE

PROPELLER

SHAFT

SEALING

The filler and purge caps are located on the seal frame. The locations of the caps are
shown on the seals drawing you can find in a separate manual concerning the propeller
shafts seals maintenance instructions.

The rope guards are removed when filling seals or when bleeding.

12.2 O

IL DRAINING AND PUMPING OUT

OIL

DRAINING

FOR DRAINING, THE PROPULSOR IS TURNED TO Z-
POSITION (THE PROPELLER SHAFT IS ALIGNED WITH
THE DRIVE SHAFT, PROPELLER BACKWARDS.

At the shipyard, the plug at the bottom of the lower assembly carries out
the oil draining. There is a valve in the plug that prevents the oil from
leaking out, when the plug is removed. For draining the oil, an adapter
M000222A opens the valve when screwed into z-position. A hose is
connected to the pipe so the oil drains into a waste oil container.

The oil can be drained also when the ship is not at the shipyard with a
circulation / draining pipe situated inside the unit.

PUMPING

THE

OIL

OUT

For emptying the unit the suction of the external pump (ship equipment)
will be connected to the filling / emptying connection (1 1/2" BSPP female)
with ball valve.

Oil is pumped until it starts sucking air. Then the oil level is low enough to
open the flange where the ball valve is attached and there is a pipe, which

goes to the lowest point of the propulsor visible.

Steerprop toolset includes an adapter M000222A, which can be screwed
to that connection and attached to the suction hose. Pumping can be
continued until the propulsor is empty of oil.

C101566-B Page 35 of 67

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DOC-1017-1

12.3 C

HECKING OIL QUANTITY

For checking oil quantity there are sight gauges on the oil control unit at the aft
part of the upper assembly to indicate minimum level and maximum level. The oil
quantity is checked when the propulsor is not running and oil is cold. When
checking the oil level you need to consider:

When the unit is running the oil level is lower and is not shown in sight
gauges. The lower level switch is monitoring the oil level.

When unit is warm from operation but not running, the oil level is above the
maximum level because of thermal expansion.

C101566-B Page 36 of 67

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DOC-1017-1

13 H

YDRAULIC SYSTEMS

13.1 G

ENERAL

13.1.1 L

ONG SERVICE LIFE AND FUNCTIONAL RELIABILITY OF HYDRAULIC SYSTEMS

AND THEIR COMPONENTS ARE DEPENDENT ON CORRECT HANDLING

Long service life and functional reliability of hydraulic systems come from all parts of
the system. All components, equipment and pipes should be delivered clean and well
protected against all dirt that prevails at workshops and sites.

All ports of hydraulic power units, valves, cylinders and hydraulic motors
should be properly plugged.

Plugs, caps or blind flanges should not be removed until absolutiy
necessary.

All pipes delivered to site must be free from scale, rust and pickling residue.

Ensure fault-free operation by taking note of:

The special installation and operating instructions for the system

In individual cases the special instructions

The technical data contained in the catalogue sheet

When selecting pipes, hoses and fittings / flanges, the correct pressure
rating has to be selected (wall thickness, material). Only cold drawn
seamless tube is to be used.

Do not use hemp and putty as sealing materials, as these can lead to
contamination and thus to malfunctions!

13.2 A

SSEMBLY

13.2.1 A

SSEMBLY PREPARATION

Ensure that the system is dean

13.2.1.1 F

OR THE ENVIRONMENT

Power units, pipe connections, components (e.g. pickling may be
necessary if a hot process has been carried out, e.g. welding, hot bending,
etc.), are to be kept dean, e.g. cleaned

13.2.1.2 F

OR THE PRESSURE FLUIDS

Watch out for contamination, dampness; contamination from the
environment must not be allowed to enter the tanks!

Fill oil tanks only via a filter preferably via system filters or portable filter
stations with fine filters.

Protective internal paint coatings, if used, must be resistant to the pressure
fluid to be used!

13.2.1.3 F

OR STOCK PARTS

Storage of parts which have not been filled or treated with anti-corrosion
fluid can lead to the build-up of resin. Dissolve the resin and renew the
lubricating film.

Check to see that all of the parts required for assembly are available!

C101566-B Page 37 of 67

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DOC-1017-1

Take note of any transport damage!

13.2.1.4 F

OR PUMPS

On pumps taken from stock, resin may have formed.

This must be removed by means of solvents. Then, the lubricating film must
be renewed. No special measures have to be taken for fire-resistant fluids.

13.2.2 C

ARRYING OUT ASSEMBLY

Make use of lifting facilities and transport equipment!

Do not use force. to minimise shearing forces and tension on pipelines and
components. The valve mounting surfaces must be flat. The fixing bolts
have to be evenly tightened to the stated torque.

Take care to ensure that the pipes are adequately fixed (pipe clamps)!

In order to avoid external leakage, take note of the installation instructions
of the pipe fittings manufacturer. We recommend the use of fittings with
flexible seals.

Make sure hose lines are correctly laid! Rubbing and abutting of the lines
must be avoided.

Availability of the correct pressure fluids

13.2.2.1 S

ELECTED ACCORDING TO SYSTEM REQUIREMENTS

PLEASE NOTE

Viscosity of the hydraulic fluid

Operating temperature range

Type of seals we don the components fitted

13.2.2.2 P

UMPS

Stress-free installation

In the case of prime movers, ensure that foundations are level

13.2.3 L

INES AND CONNECTIONS

13.2.3.1 S

UCTION LINES

Design and assemble suction lines according to the manufacturer’s
instructions.

Suction vacuum pressure or feed pressure are within the limits specified by
the manufacturer; filters and valves possibly installed must be taken into
account.

Take care that the suction lines are leak-free

The flow velocity in the suction line should not exceed 0.5 m/s.

The pipe ends should be cut at an angle of less than 45 degrees and
installed at a distance of at least 2.5 x the pipe diameter from the tank floor
in order to prevent the aspiration of deposits from the tank floor.

13.2.3.2 D

RAIN LINES

Use a sufficient nominal width in order to keep the backpressure in the
housing within the permissible limits.

When installing the line make sure that the housing is completely filled with
fluid, while taking care that a siphoning effect is avoided.

Pressureless return to the tank

Sufficient cooling and settling of the hydraulic fluid is achieved by directing
the hydraulic fluid to the tank wall.

C101566-B Page 38 of 67

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DOC-1017-1

Ensure a sufficient distance to temperature switches.

13.2.3.3 I

NSTALLATION INSTRUCTIONS

All lines have to be submerged at least 2.5 x the pipe diameter below the
lowest permissible fluid level, however, at least 100 mm in order to prevent
foaming.

Install the drain line higher than the suction line and take precautions that
the returned oil cannot be directly re-aspired.

The ends of the suction, return and drain lines must therefore be installed
with a distance of at least 200 mm from each other.

We recommend seamless precision steel pipes to DIN 2391 and releasable
pipe connections.

13.2.4 F

ILTERS

Whenever possible, use return line or pressure filters.

Use suction filters only in conjunction with vacuum pressure switches /
clogging indicators.

Depending on the pump type the required filter rating is 25 um to 40 um.

Recommendation: 10

µm filters prolong the service life under high load

conditions.

13.2.5 H

YDRAULIC FLUIDS

13.2.5.1 M

INERAL OILS

When using HL oils without wear-reducing additives, vane pumps (V3, V4,
PV7, PVV, PVQ) may only be operated at reduced pressure.

Oils containing polar additives (slide way oils) must not be used for pumps
with plain bearings, as the additives separate at 70 C and thus impair
cooling and lubrication of the bearings.

13.3 C

OMMISSIONING

When assembly has been carried out correctly, it is possible to proceed with
commissioning and functional testing.

13.3.1 P

REPARATIONS FOR A TRIAL RUN

Tank cleaned?

Pipelines deaned and correctly fitted?

Fittings, flanges, tightened?

Pipelines and components correctly connected in line with installation
drawings or circuit diagram? ...........................................................................

Is the accumulator filled with nitrogen? Nitrogen is to be filled until the pre-
charge pressure -- as stated in the circuit diagram, is reached. (On the fluid
side the system has to be at zero pressure’) It is recommended that the gas
pre-charge pressure is noted on the accumulator (e.g. sell-adhesive label)
and in the hydraulic circuit so that a compartory check may be made later if
required.

TTENTION

! O

NLY

USE

NITROGEN

THE

PRE

CHARGE

GAS

! T

ACCUMULATOR

MUST

COMPLY

WITH

THE

SAFETY

REGULATIONS

WHICH

APPLY

THE

PLACE

FINAL

USE

Are the drive motor and pump correctly assembled and aligned?

C101566-B Page 39 of 67

26.01.2006

DOC-1017-1

Is the drive motor correctly connected?

Does the filter comply with the required filter rating

Is the filter fitted in the correct direction of flow?

Has the specified pressure fluid been filled up to the maximum oil level?

THE

PRESSURE

FLUID

OFTEN

DOES

NOT

MEET

THE

REQUIRED

CLEANLINESS

FILLING

MUST

TAKE

PLACE

VIA

FILTER

. T

ABSOLUTE

FILTER

RATING

THE

FILLING

FILTER

SHOULD

LEAST

THAT

THE

FILTER

WHICH

FITTED

THE

SYSTEM

13.3.1.1 E

LECTRICAL OPEN AND CLOSED

LOOP CONTROL ELEMENTS

Observe voltage and current values

13.3.1.2 D

IRECTION OF ROTATION OF DRIVE

DRIVEN SHAFTS

Observe directional arrow

Testing of a unit filled with hydraulic fluid:

Switching the unit briefly on and off prevents damage in the case of the
wrong direction of rotation.

13.3.1.3 F

ILLING

Pump types V3, V4, PV7, PVV, PVQ are self-priming, the houses need not
to be filled. Internal gear pumps have to be filled prior to commissioning!
For all other pumps, verify whether the housing must be filled.

13.3.2 S

TART

Observe specific component instructions.

Set all valves, especially on the suction and supply side, to the free-flow
position.

Switch the motor briefly on and off several times in order to facilitate
bleeding. Only operate the pump under full load when it operates properly
and smoothly.

During initial start-up, bleed the pressure line to allow complete filling of the
pump.

Exceptions to this are pumps with automatic bleed valve.

When the system starts up, the fluid level in the tank must not fall below the
minimum suction level.

13.3.2.1 P

RESSURE LIMITATION

PRESSURE CONTROL

Always select the lowest settings for commissioning.

Carefully increase the pressure to the required values, but do not set to
unnecessarily high values.

If required, secure settings against unwanted adjustment.

13.3.2.2 T

EMPERATURE

Check the fluid temperature under normal operating conditions.

13.3.3 T

RIAL RUN

13.3.3.1 P

REPARATION FOR STARTING

For safety reasons only personnel from the machine manufacturer and
possibly maintenance and operating personnel should be present.

C101566-B Page 40 of 67

26.01.2006

DOC-1017-1

All pressure relief valves, pressure reducing valves and pump pressure
controllers are to be set to zero. The exception to this are TÜV set valves.

Are the isolator valves fully open!

Switch on briefly and check so see that the drive motors direction of rotation
matches that of the pump.

Check the position of the directional valves and, if necessary move them
into the required switched position.

Set the control valves to by pass.

Open the pump suction valves. If necessary, dependent on the design, fill
the pump housing with pressure fluid, to avoid the bearings and rotary
group components from running dry

If there is a pilot oil supply pump this should also be commissioned.

Start the pump, move it out of its zero position and listen for any noises.

Swivel the pump out a little. (approx. five (5) degrees) As far as possible
using the built-on controller otherwise operate with the full flow With
combustion engines they are to be run at the idle speed.

13.3.3.2 S

YSTEM BLEEDING

Bleed the system

Carefully loosen fittings (at high points in the system) or bleed screws.
When the escaping fluid is free of bubbles then the filling process is
complete. Re-tighten the fittings.

13.3.3.3 S

YSTEM FLUSHING

Before commissioning of hydraulic systems, it is necessary to flush out all
contamination in order to achieve long service life and trouble free function.
Cleanliness levels are specified by product manufacturer and should be
adheared to.

To carried out the flushing, using the system pumps, is generally
inadequate, as the flow velocities will be too low. Rushing procedures
require a proper flushing unit to obtain the correct velocities, temperatures
and pressures specifications.

Closed and semi-closed hydraulic systems must always be flushed with a
flushing unit.

REPARATION THE SYSTEM FOR FLUSHING

Before beginning with the flushing procedure, it is important to remember
that pumps, valves and actuators are bypassed using pipes, hoses or
flushing plates where possible.

Effective flushing is achieved if a turbulent flow is created. In straight and
smooth pipe the flow becomes turbulent if the Re > 4000 (Reynolds
number)

High flushing velocities and low viscosities increase the effect of flushing.
Recommended flushing temperature for mineral oils is 60 C. Minimum
viscosity however is determined by the flushing pumps. The flow velocity
should be at least twice the speed of normal operational speeds.

EFORE FLUSHING

Ensure the flushing unit is cleaned before starting. Flushing fluid must be
pumped trough a filter (5-10 ìm (3 ìm, âx = 100) into the tank of the flushing
unit and the function of all indicators must be verified (dogging indicators,
oil level switches and thermostats ) before start up. Filter elements

C101566-B Page 41 of 67

26.01.2006

DOC-1017-1

required, in accordance with oil cleanliness level which is to be obtained,
must be inserted into the flushing unit.

The piping system must be vented before starting of the flushing procedure.

LUSHING

Heat the fluid to the required temperature (viscosity).

With servo systems the servo valves are to be removed and replaced by
flushing plates or directional valves of the same nominal size. The actuators
are to be short circuited. During flushing the pressure fluid within the
hydraulic system should reach a temperature that is at least as high as the
subsequent operating temperature. The filter elements are to be replaced
as required.

Flush the system, if possible by short circuiting the actuators, until the filters
remain dean; Check the filters!

As a flushing time the following can be applied or until the required
cleaness class has been reached.

While flushing is in progress keep a dose watch on the dogging indicators
of the filters so that the elements can be changed at the right lime.

It is adviseable to reverse the direction of the flow after about an hour of
flushing, If changing of the flow direction is (in practice) impossible then
flushing must continue for at least 3-4 hours longer. When the clogging
indicators do not react after an hour, fluid samples should be taken to verify
particle count microscope examination for contamination with oppticle
particle counter). When it is possible to use an automatic particle counter
during the flushing process and the cleanliness of the returning fluid is
immediately known, then, when the required level of the cleanliness has
been achieved, flushing should be terminated.

If the used flushing fluid is not the required hydraulic fluid for the system.
The fluid must be drained completely from the hydraulic system.( Ensuring
the correct fluid is filtered before being placed into the system)

FTER FLUSHING

At the end all bypass pipings, hoses and flushing plates must be removed.
The hydraulic system must be restored to its former condition. Keeping
cleanliness in mind.

Check the system functions without load, if possible control by hand; Cold
test the electro hydraulic controls.

After the operating temperature has been reached, test the system under
load; slowly increase the pressure.

Check monitoring and measuring devices!

Check the housing temperature of the hydraulic pumps and motors

Listen for noises!

Check the oil level, if necessary top up!

Check the settings of the pressure relief valves by loading or braking the
system.

Check for leaks

Switch-off the drive

Tighten all fittings even if there is no evidence of leakage.

TTENTION

! O

NLY

TIGHTEN

WHEN

THE

SYSTEM

NOT

UNDER

PRESSURE

Is the pipe fixing adequate even under changing pressure loads?

Are the fixing points correct?

Are the hoses so laid that they do not rub, also under pressure?

Check the pressure fluid level

C101566-B Page 42 of 67

26.01.2006

DOC-1017-1

Full functional test of the system. Compare the measured values with the
permissible or required data (pressure. speed, setting further control
components.)

Jerky movements indicate amongst other things, the presence of air in the
system. By briefly swivelling the pump in one or both directions with the
actuator in the loaded or braked condition, it is possible to eliminate certain
air pockets. The system is completely bled when all functions can be
carried out jerk-free and smoothly and there is no foaming on the surface of
the pressure fluid. In practice it has been found that foaming should have
ceased one hour after start-up.

Check the temperature

Switch-off the drive

Remove filter elements, off-line and main filters and inspect for residues.
Clean the filter elements or replace. Paper or glass fibre elements camot be
cleaned.

If further contamination is found then additional flushing is required in order
to prevent premature failure of the system components

All of the settings carried out should be documented in an acceptance
certificate.

OCUMENTS

All documentation from the flushing procedure must be put together Analysis of
cleanliness, description of flushing procedure, list of equipments used, personnel in
charge, etc.

13.3.4 T

HE MOST COMMON FAULTS OCCURING DURING COMMISSIONING

In conjunction with maintenance. commissioning is very decisive for the service life and
functional safety of the hydraulic system. That is why faults must, as far as possible. be
minimised during commissioning.

13.3.4.1 T

HE MOST COMMON FAULTS ARE

The fluid reservoir has not been checked.

The operating fluid was filed unfiltered.

The installation was not checked before commissioning (subsequent
conversion with loss of fluid!).

System components were not bled of air.

Pressure relief valves are set too close (slightly higher) to the working
pressure (switching pressure differentials not taken into account).

Hydraulic pump pressure controllers are set higher or to the same pressure
as the pressure relief valves.

The flushing time for servo systems was not adheared to.

Abnormal pump noises were not taken into account (cavitation, suction line
not air tight, too much air in the pressure fluid).

Shear loads on cylinder rods not taken into account (installation error!).

Hydraulic cylinders were not bled (seal damage!)

Limit switches adjusted too dose.

The pressure switch switching hysteresis was not taken into account during
setting up.

Hydraulic pump and hydraulic motor housings were not filled with pressure
fluid before commissioning.

The set values were not documented.

The adjustment spindles were not secured or sealed.

Unnecessary personnel were present at the system during commissioning

C101566-B Page 43 of 67

26.01.2006

DOC-1017-1

13.3.5 S

PECIAL OPERATIONS AFTER COMMISSIONING WITH THE FILTERS

During commissioning, in intervals of two to three hours and, if necessary
clean.

During the first week daily and if necessary clean.

13.3.6 S

PECIAL OPERATIONS AFTER COMMISSIONING WITH THE OIL LEVELS

Continuously during commissioning

For a short period after commissioning

C101566-B Page 44 of 67

26.01.2006

DOC-1017-1

14 P

ROPULSOR COOLING SYSTEM INSTALLATION

14.1 C

ONSTRUCTIONAL DIRECTIONS IN A PIPING DESIGN

Pay attention to the following points:

Level and square mounting possibility.

Bends in the piping have to be located at a distance of at least three times
the nominal diameter of the pipe from the inlet of the heat exchanger.

When a vaporizing cryogenic medium is used, the heat exchanger has to
be placed under an angle of 3° - 10°, in order for the vapor to be able to exit
the heat exchanger, helped by natural circulation.

Check if vent and drain connections are present in both circuits of the heat
exchanger (when not on the heat exchanger then make them in the piping).

Put a filter (with a permeability of 3 mm.) before the inlet of both circuits of
the heat exchanger.

Stress- and vibration free mounting possibility of the connections and the
supports (fit expansion bellows and/or silencer blocks when necessary).

Disassembling possibility of the tubebundle (and other parts like drain and
vent plugs).

Expansion possibility of lockable liquid circuits.

Danger of freezing of liquid circuits.

The design data of the heat exchanger on the the drawing. For instance
the flows: deviating from them can cause unacceptable high or low
velocities. A (temporary) lower flow is acceptable when caused by a control
system and a conditioned circuit is involved. Avoid standstill (unless the
heat exchanger is drained and flushed with fresh water).

When adding an inhibitor to one of the fluids in the heat exchanger, always
check whether this inhibitor can be harmful for the materials of the heat
exchanger (see specification sheet).

Make sure that in case of flow control (with conditioned circuits only) this is
done gradually (no ‘on-off-control’).

Although this will almost never occur in practice, Bloksma reserves the right
(according to TEMA RGP-RCB-2) to plug a maximum of 1% of the tubes.

Always check whether both fluids are compatible with the materials of the
heat exchanger; Bloksma chooses the materials judging on the fluids
specified by the customer, but is often not well informed about possible
contaminations, higher or lower than normal degrees of acidity and other for
the choice of materials important proprties.

Check whether the materials of the connecting piping are compatible with
the materials of the heat exchanger (when the materials of the bundle are,
from a corrosion point of view, weak in comparison with the materials of the
piping, the bundle will corrode faster than expected).

14.2 I

NSTALLATION AND START

14.2.1 R

ECEIPT

At receipt check the packaging and the heat exchanger:

report any damage to supplier

compare the data on the nameplate, confirmation of the order and on the
drawing

C101566-B Page 45 of 67

26.01.2006

DOC-1017-1

check whether or not the correct instruction manual is present by
comparing the article number on the cover sheet with the article number of
the instruction manual on the confirmation of order

Always store the heat exchanger in a dry room, free of large temperature
changes. When the heat exchanger is not being put into operation
immediately after receipt, follow the storage instructions.

14.2.2 I

NSTALLATION

Warning: Beware of any rust preventive layers (see “Instructions for conservation”) that
might still be present in the heat exchanger before proceeding.

Remove all protective plugs and covers from the connecting flanges prior to
installation of the heat exchanger.

A 1- or 3-pass model (tubeside) has to be mounted in such a way that shell-
and tubeside will be in counterflow.

Check whether the positions of the vent and drain connections on the heat
exchanger correspond with the mounting position of the heat exchanger.

In models with body side wire connections, check to see if the couplings
with which the lines are fastened do not touch the bundle.

Mount the heat exchanger level and square on a flat surface in order for the
pipe connections to be made without forcing.

Do not weld anything to the heat exchanger.

Mount one support in a fixed position, while the other one is mounted in
such a way that it is able to slide in the direction of the longitudinal axis of
the heat exchanger. The heat exchanger will thus be able to expand under
thermal stress.

Before connecting piping to the heat exchanger flanges, make sure that the
gasket surface is clean and free from scratches and other defects. Always
use new gaskets, of the correct type and tighten the bolts crosswise.

Take care when lifting the heat exchanger. Use at least two hoops around
the shell of the heat exchanger for lifting purposes.

Check for the presence and correct positions of drain/vent connections in
both circuits.

Install the heat exchanger and the piping in such a manner that there is still
enough room to disassemble (part of) the heat exchanger (tubebundle,
drain plugs, etc.).

14.2.3 S

TART

Do not exceed the design temperatures and design pressures as stated on the
nameplate and specification sheet. Avoid abrupt temperature fluctuations; these can
cause leaking of tube-to tubesheet or other connections.

Make sure that the cold medium circulation is established first, followed by
the gradual introduction of the hot medium.

Vent both circuits.

Vent both circuits again when the operating temperatures and pressures
are reached.

Check for leakage.

Do not deviate from the flows as stated on the specification sheet. Higher or lower
velocities can cause erosion or corrosion respectively. Avoid standstill: at non-
conditioned circuits this may cause corrosion. In case of standstill follow the
instructions for shut down periods. If the heat exchanger is equipped with anodic
protection (see specification sheet) you will have to inspect the anodes (or part that

C101566-B Page 46 of 67

26.01.2006

DOC-1017-1

functions as anode) when you are starting up the heat exchanger after a shut down
period.

C101566-B Page 47 of 67

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DOC-1017-1

15 E

LECTRIC INSTALLATION

15.1 S

IGNAL DIRECTIONS

The 4…20 mA angle feedback transmitter values are increasing CCW. The zero (12
mA) can be set externally.

C101566-B Page 48 of 67

26.01.2006

DOC-1017-1

15.2 V

OLTAGE SUPPLY

15.2.1 C

ONTROL VOLTAGE SUPPLY

The Steerprop control voltage supply is redundant and straightforward system. The
main control system is supplied from single phase AC network and from a back-up
battery. The indication and back-up control systems are supplied from battery. The
battery should be separate from the engines starting batteries.

15.2.2 AC

SUPPLY

Permanent frequency variations ..........................................± 5 % of nominal

Permanent voltage variations....................................... + 6/- 10 % of nominal

Frequency transients (5 s duration) ...................................± 10 % of nominal

Voltage transients (1,5 s duration) .....................................± 20 % of nominal

15.2.3 24

VDC

SUPPLY FOR ELECTRIC AND CONTROL

15.2.3.1 P

OWER SUPPLY VARIATIONS FOR EQUIPMENT CONNECTED TO

D.C.

SYSTEMS

Voltage tolerance continuous ............................................ 21.6 … 26.4 VDC

Voltage transients cyclic variation .......................................± 5 % of nominal

Voltage ripple ....................................................................± 10 % of nominal

15.2.3.2 P

OWER SUPPLY VARIATIONS FOR EQUIPMENT CONNECTED TO BATTERY POWER

SUPPLY

When using low voltage battery supply, the charging equipment, batteries and cables
are to keep the voltage at equipment terminals within below defined tolerances of the
nominal voltage during charging and discharging. The battery is not allowed to connect
to engine starting systems.

Voltage tolerance .................................................................. 19.2 … 30 VDC

Voltage transients (up to 2 s duration) ..............................± 20 % of nominal

Provisions are to be made for preventing reverse current from the battery through the
charging device.

C101566-B Page 49 of 67

26.01.2006

DOC-1017-1

15.2.4 24

VDC

SUPPLY FOR INSTRUMENTS

(

ALARM TRANSDUCERS ETC

15.2.4.1 P

OWER SUPPLY VARIATIONS FOR EQUIPMENT CONNECTED TO

D.C.

SYSTEMS

Voltage tolerance continuous ............................................ 21.6 … 26.4 VDC

Voltage transients cyclic variation .......................................± 5 % of nominal

Voltage ripple ....................................................................± 10 % of nominal

15.2.4.2 P

OWER SUPPLY VARIATIONS FOR EQUIPMENT CONNECTED TO BATTERY POWER

SUPPLY

Voltage tolerance .................................................................. 18 … 31.2 VDC

Voltage transients (up to 2 s duration) ..............................± 25 % of nominal

Provisions are to be made for preventing reverse current from the battery through the
charging device.

15.3 L

OCATIONS

15.3.1 C

ONTROL SPACE

Protection class for electric components................................................ IP 22

Ambient temperatures ...............................................+5°C to +45°C (+50°C)

15.3.2 M

ACHINERY SPACE

Protection class for electric components................................................ IP 44

Ambient temperatures ............................................................ +5°C to +55°C

15.3.3 O

UTDOOR SPACE

* Protection class for electric components ............................................. IP 56

* Ambient temperatures ........................................................ -25°C to +55°C

15.4 EMC

COMPATIBILITY FOR CONTROL EQUIPMENTS

To the test of the type approved components and systems has been included the
electromagnetic immunity and emission tests according relevant location of the
component in the vessel. The basic demand for components used at Steerprop control
system is CE-marking.

Also one complete Steerprop control unit has been tested for design verification
purposes.

15.5 E

NVIRONMENT

15.5.1 R

ELATIVE HUMIDITY

Relative humidity up to 95% +/-5 % at all relevant temperatures.

C101566-B Page 50 of 67

26.01.2006

DOC-1017-1

15.5.2 S

ALT CONTAMINITY

Salt-contaminated atmosphere up to 1 mg salt per m³ of air, at all relevant
temperatures and humidity conditions.

15.5.3 O

Mist and droplets of fuel and lubricating oil. Oily fingers.

15.5.4 A

CCELERATION

Acceleration caused by the vessel's movement in waves. Peak acceleration ±1,0 g.
Period 5 to 10 seconds.

15.5.5 V

IBRATIONS

Frequency range 3 to 100 Hz.

Amplitude 1 mm (peak value) below 13,2 Hz.

Acceleration amplitude 0,7 g above 13,2 Hz.

C101566-B Page 51 of 67

26.01.2006

DOC-1017-1

16 C

ABLING

The total system is completed in the vessel, where the cabling is the important factor in
the EMC means. The cabling procedures are described in Steerprop manual.

16.1 C

ABLE TYPES AND NUMBERS

Cable code consists of three sections A-B-CCC, where A is the number of the
propulsor and B is cable type (table below) and CCC is three digit running number.
Basically smaller cable numbers are always nearer to the propulsor.

SECTION CODE

DESCRIPTION

Cable connected between propulsors

Cable belongs to propulsor 1

Cable belongs to propulsor 2

B A

Alarm

cable

Alarm cable, screened, equipped with compact low impedance shield

B C

Control

cable

CAN-BUS cable, cores twisted into pairs and pairs into layers and wrapped

with foil. Cable is screened, equipped with compact low impedance shield.

Characteristic impedance 120 Ohm.

Control cable, cores twisted into pairs and pairs into layers and wrapped
with foil.Cable is screened, equipped with compact low impedance shield.

Control cable, screened, equipped with compact low impedance shield

Data cable cores twisted into pairs and pairs into layers and wrapped with
foil.Cable is screened, equipped with compact low impedance shield (mainly

for RS 422 or equal).

Indication cable, can also be BUS cable

CAN-BUS cable, cores twisted into pairs and pairs into layers and wrapped
with foil. Cable is screened, equipped with compact low impedance shield.

Characteristic impedance 120 Ohm.

B P

Power

cable

Power cable, screened, equipped with compact low impedance shield.

Frequency converter cable. Distance from control and alarm cables 500
mm.

Power cable, screened, equipped with compact low impedance shield

Running

number

C101566-B Page 52 of 67

26.01.2006

DOC-1017-1

16.2 24

VDC

CABLE POWER TABLE

Steerprop cabling list includes for cable calculation power or current information or
even needed cable diameter. Normally in 24 VDC circuits the current is so big, that it
has some influence for cable diameter. The cross section of the cable can be
calculated from known values of power and maximum voltage drop of cable.

For example if the minimum supply for Steerprop Control Unit (SCU) is 24 VDC 10 %
and the minimum voltage of device beyond the cable is 24 VDC 20 % then maximum
voltage drop of cable is 2.4 V.

The cable length is calculated at metres.

Diameter /mm2

Power

0,5 1 1,5

2,5 4 6 10 16 25 35

165 329 494

823

1317 1975 3291 5266 8229 11520 m

82 165 247

411

658 987 1646 2633 4114 5760 m

55 110 165

274

439 658 1097 1755 2743 3840 m

41 82

123

206

329 494 823 1317

2057

2880 m

33 66 99

165

263 395 658 1053

1646

2304 m

27 55 82

137

219 329 549 878 1371

1920 m

21 41 62

103

165 247 411 658 1029

1440 m

16 33 49 82 132 197 329 527 823 1152 m

14 27 41 69 110 165 274 439 686 960 m

12 24 35 59 94 141 235 376 588 823 m

10 21 31 51 82 123 206 329 514 720 m

9 18 27 46 73 110 183 293 457 640 m

100

8 16 25 41 66 99 165 263 411 576 m

125

7 13 20 33 53 79 132 211 329 461 m

150

5 11 16 27 44 66 110 176 274 384 m

175

5 9 14 24 38 56 94 150 235 329 m

200

4 8 12 21 33 49 82 132 206 288 m

225

4 7 11 18 29 44 73 117 183 256 m

250

3 7 10 16 26 39 66 105 165 230 m

275

3 6 9

15 24 36 60 96 150

209

300

3 5 8

14 22 33 55 88 137

192

350

2 5 7

12 19 28 47 75 118

165

400

2 4 6

10 16 25 41 66 103

144

450

2 4 5 9 15 22 37 59 91 128 m

500

2 3 5 8 13 20 33 53 82 115 m

C101566-B Page 53 of 67

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DOC-1017-1

16.3 AWG

DIMENSIONS

AWG DIAMETER AREA

RESISTANCE

NRO MM

MM2

OHM/KM

500 17,96 253

0,07

350 15,03 177

0,10

250 12,70 127

0,14

4/0 11,68 107,2

0,18

3/0 10,40 85,0

0,23

2/0 9,27

67,5

0,29

1/0 8,25

53,5

0,37

1 7,35 42,4

0,47

2 6,54 33,6

0,57

4 5,19 21,2

0,91

6 4,12 13,3

1,44

8 3,26 8,37

2,36

10 2,59 5,26

3,64

12 2,05 3,31

5,41

14 1,63 2,08

8,79

16 1,29 1,31

14,7

18 1,024 0,823

23,0

20 0,813 0,519

34,5

22 0,643 0,324

54,8

24 0,511 0,205

89,2

26 0,405 0,128

146

28 0,320 0,0804 232
30 0,255 0,0507 350
32 0,203 0,0324 578
34 0,160 0,0200 899
36 0,127 0,0127 1426
38 0,102 0,00811 2255
40 0,079 0,00487 3802
42 0,064 0,00317 5842
44 0,051 0,00203 9123

C101566-B Page 54 of 67

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DOC-1017-1

16.4 D

ESIGN AND CABLING WORK

The cabling diagrams are purposed for design, selection and installation of the cables
onboard.

16.4.1 P

OWER CABLES

PS TYPE:

The shield is connected at supplying end to the
ship’s hull.

C101566-B Page 55 of 67

26.01.2006

DOC-1017-1

16.4.2 F

REQUENCY CONVERTER AND BRAKE RESISTOR CABLING

FREQUENCY CONVERTER

The cable between frequency converter and
motor should be equipped with compact
low-impedance shield and intended for the
specific mains voltage.
Cable marking is
3 + scr
3 = number of wires
Scr = low impedance screen
More detailed instruction from inverter
manufacturers instructions.

BRAKE RESISTOR CABLING

The connection cable to the brake resistor
is to be screened / armoured. Always
connect the screen / armouring in both
ends.

16.4.2.1 F

REQUENCY CONVERTER CABLE SELECTION

FREQUENCY CONVERTER

SUPPLY

SIZE

CURRENT / A

FUSE / A

MAINS AND MOTOR CABLE,

CU TYPE

GROUND CONNECTOR

3*1.5 + 1.5 mm2

2.5 mm2

3*2.5 + 2.5 mm2

2.5 mm2

3*4 + 4 mm2

10 mm2

3*6 + 6 mm2

10 mm2

3*10 + 10 mm2

10 mm2

3*10 + 10 mm2

35 mm2

3*10 + 10 mm2

35 mm2

3*16 + 16 mm2

35 mm2

3*16 + 16 mm2

70 mm2

100

3*35 + 16 mm2

70 mm2

105

125

3*50 + 25 mm2

70 mm2

140

105

160

3*70 + 35 mm2

95 mm2

163

140

200

3*95 + 50 mm2

95 mm2

16.4.2.2 F

EEDBACK CABLE FROM ELECTRIC MOTOR TO FREQUENCY CONVERTER

For encoder cables - the cables should be without splices - one piece from encoder to
drive - shielded, pair twisted cable, shield earthed at both ends - every splice creates a
source of possible interference.

C101566-B Page 56 of 67

26.01.2006

DOC-1017-1

16.4.3 C

ONTROL CABLES

Screened cable equipped with compact low-
impedance shield. The shield is connected at
supplying end to the ground.
Normally the control cable minimum
dimensions are given by the society and
sometimes they demand more, than actually

needed.
Our recommendation for analogue control

cables is 0.75 mm2 due the connections.
Cable marking example in the cable list:

4 x 2 + scr
4 = 4 pairs
2 = pair
scr = cable has low impedance screen
So this cable has 4 x 2 = 8 wires

16.4.4 C

ONTROL CABLE WITH TWISTED PAIRS AND SCREEN

This cable type is used normally with

analogue signals. The cable screens are
connected at both ends to ground. The pair

shielding is connected to the ground only at
the supply end. Our recommendation for

analogue control cables is 0.5 mm2 or 0.75
mm2 (recommended) due the connections.
Cable marking example in the cable list:
4 x (2+1) + scr
4 = 4 twisted pairs
2 = pair
+1 = pair shield with ground connector
scr = cable has low impedance screen

So this cable has 4 x 2 = 8 wires

C101566-B Page 57 of 67

26.01.2006

DOC-1017-1

16.4.5 D

ATA CABLES

For serial data transmission is this cable

type used. The cable screens are
connected at both ends to ground. The pair

shielding is connected to the ground only at
the supply end. For RS422 cable should the
nominal impedance be ca 110...150 Ohm.
Our recommendation for data control cables
is 0.5 mm2.
Cable marking example in the cable list:
4 x (2+1) + scr
4 = 4 twisted pairs

2 = pair
+1 = pair shield with ground connector

scr = cable has low impedance screen
So this cable has 4 x 2 = 8 wires

C101566-B Page 58 of 67

26.01.2006

DOC-1017-1

16.4.6 CAN

BUS CABLES

CAN (Controller Area Network) was

developed for the networking of
automobiles, but in the meantime being

used more and more in industrial
application. CAN is internationally
standardized according to ISO 11898. The
maximum length for the Bit-rate of 125 kBit
is 500 m used in marine applications.
¾

STRUCTURE RECOMMENDATION

Bare copper wire conductor

Cores twisted into pairs and pairs into
layers

Wrapping of plastic foil

Screen braiding of copper wire

Outer sheath

Peak voltage 250 V

Testing voltage 1500 V

Characteristic impedance 100....150

Ohm

Cable resistance < 40 mOhm/m

Cable diameter 0.5...0.6 mm2 or
AWG20.

CABLE CONNECTION

Steerprop cabling does not have D-sub

connectors. The cables should be
connected to the normal connectors. The
CAN bus cable contains normally 5 wires (if
the voltage supply lines are going with the
same cable). The CAN-L, CAN-H and GnD
Wire start on one end of the total network, a
terminator of 120 Ohm terminator resistor is
connected between CAN-L and CAN-H.

The CAN BUS cable is one line going
through the system, normally without or

short T connections. The star connection is
not allowed. On the other end of the cable

again a resistor of 120 Ohm connected
between the CAN lines. The CAN BUS

cable has special demand of the 120 Ohm
characteristic impedance. The voltage
supply can be a normal control cable with
screen.

C101566-B Page 59 of 67

26.01.2006

DOC-1017-1

16.4.6.1 A

PPLICABLE

CAN

BUS CABLES

MAKER CODE

TYPE

SPECIFICATION

U.I.Lapp 2170

266

UNITRONIC

BUS CAN

1x2x0.5

U.I.Lapp 2170

267

UNITRONIC
BUS CAN

2x2x0.5

U.I.Lapp 2170

269

UNITRONIC
BUS CAN

1x2x0.75

U.I.Lapp 2170

270

UNITRONIC

BUS CAN

2x2x0.75

HelkamaBica

DAMA-HF

4x(2+1)x0.5

16.4.7 D

ISTANCE OF DIFFERENT TYPE OF CABLES

Different type of cables should be assembled apart from each other to avoid
electromagnetic interference (EMI). If different type of cables crosses each other there
should be 90 angle between cables.

CABLE TYPE

FROM POWER CABLES

FROM CONTROL CABLES

FROM HIGHLY EMI

GENERATING CABLES

Power cable

O,1 m

O,5 m

Control cable

0,1 m

0,5 m

Highly EMI
generating cable

0,5 m

O,5 m

16.5 I

NSTALLATION AND CONNECTIONS

16.5.1 P

ROTECTION PIPING WORK

If protection pipes or similar are used for cables they

should be assembled so that water and other liquid can
come out from pipe.

C101566-B Page 60 of 67

26.01.2006

DOC-1017-1

16.5.2 W

IRING AND TERMINALS

Bend
here

Hole

The internal wiring is wired-up to terminal strip or
equal. The terminal block for external cabling has
equipped with spring clamp type connection
elements, which are vibration tolerant construction.
It is possible to connect up to four wires to one

terminal except power terminals where are places
for two wires per terminal.

Connect only one wire per spring. To open the
terminal use screwdriver and put it in square hole

and bend it to open the terminal. When terminal is
open put the wire in circle hole and release the
spring by taking screwdriver away from terminal.

16.5.3 P

LUGS

The Steerprop propulsor and its auxiliary
systems like hydraulics are equipped
with Harting type of plugs.

16.5.4 C

ABLE GLANDS

There are no cable glands on electronic units except on

terminal boxes of propulsor and hydraulic power unit for
their internal wiring.

C101566-B Page 61 of 67

26.01.2006

DOC-1017-1

17 E

LECTRIC UNIT INSTALLATION

17.1 R

EMOTE CONTROL PANELS

PROTECTION DURING INSTALLATION

Panels should be protected during assembly
work to avoid scratches and damages. Keep
them always in right position (levers, meters,

push buttons up). Do not use them as an
assembly plate or place for tools.
¾

CUTTING THE OPENINGS FOR
CONTROL PANEL TO THE CONTROL

CONSOLE

The dimension drawings include the cut-out

drawing. The panel should be protected under
cutting the hole to the console or panel. You
should be very careful, when you cut wooden

material. There is a risk, that the sawdust can
harm the operation of the control equipments.
¾

CLEANING

After assembly clean all sawdust, plastic dust,

etc. away. Do not use air pressure for cleaning
but some cleaning cloth, which is not getting

fluffy. The pressurized air can take up those
impurities inside of the control equipments.
¾

GROUNDING

The mounting rail must be connected to ground
potential. This is the only way to guarantee that
the integrated surge voltage protection
functions and that the shield of the bus
conductor makes contact effectively.

C101566-B Page 62 of 67

26.01.2006

DOC-1017-1

17.2 C

ONTROL UNITS

ASSEMBLY DIRECTION

Assembly direction (top and bottom) is shown
on dimension / assembly drawing of unit.
¾

SUPPORT FRAME

When you design the support frame for control
units, take care of that those frames are stabile
and stiff enough to prevent extra vibrations and
shocks.
¾

WALL MOUNTING

Use units wall brackets for mounting the unit on

the wall. Do NOT drill any assembly holes
through units back! In any cases all kind of

drilling and similar work should be avoided
inside the unit. If you should use the internal
assembly holes of the control unit, do not drill
through the control unit. Make the fastening
holes to the bulkhead or equal first and fasten

after that. All units are designed for wall
assembly.

ASSEMBLY BRACKETS

Never use assembly brackets for lifting. Lifting destroys them..

17.2.1 C

OOLING

For cooling there should be some free space around the electronic units. Normally the
dimension drawings of the motor controllers have also reservation for cooling space
around the controller. All heat producing equipments (diesel motors, boilers, etc.)
should be at least 1 m away from units and not under the units. Their cooling air outlet
should not blow against control unit.

17.2.2 V

IBRATION ABSORBER

Vibration absorber should be used if electronic unit is mounted near to machinery or
place where noticeable vibration might occur. Make sure that the mounting base for
unit is steady enough. When you select the vibration absorber, you should be careful,
that those vibration absorbers does not make the vibration amplitude bigger and
destroy the devices.

17.2.3 C

LEANLINESS AND PURITY

Keep always the control unit doors closed when you do not work with it to avoid
impurities to go inside of the control unit. If somebody is working near of the causing
impurities or equal, prevent these impurities go inside of the control units. All filters of
units should be replaced about 3 months after the commissioning

Try to avoid any oil mist to getting inside units. Keep the doors closed and/or put some
protection around the units.

C101566-B Page 63 of 67

26.01.2006

DOC-1017-1

To keep the units clean the doors should be closed all the time when there is no work
to do with units. When assembly and connection works have done, all trash should
clean away from units. Use cleaning cloth, which is not getting fluffy.

17.2.4 C

ONDENSED WATER

To avoid condense keep the doors closed during assembly work. Also the temperature
should be steady and warm enough (>15 C). After assembly work when the control
voltage can be connected it is good to keep the voltage on all the time if the condition is
bad. Then the components stay at operating temperature and dry.

17.2.5 C

ONTROL UNIT CABLING

CABLE GLANDS

There are NO cable glands on
electronic units. Cable glands
should be metal and correct size
to get tight connection to cable.
Also it is highly recommend to
use EMC glands where the
cable shield can be connected
to ground through gland.
¾

CABLING DIRECTION

All electronic units are designed

so that cables go to unit trough
bottom. Cables should be

supported near to unit.

GROUNDING

The control units must always be grounded with an grounding conductor
connected to the grounding terminal.
¾

GROUNDING BOLT

All units are equipped with bolt for grounding. The bolt is under the box as
shown at picture.

C101566-B Page 64 of 67

26.01.2006

DOC-1017-1

17.3 F

REQUENCY CONVERTER

17.3.1 G

ROUND CONNECTIONS

The frequency converter must always be grounded
with an grounding conductor connected to the

grounding terminal.

The control units must always be grounded with an

grounding conductor connected to the grounding
terminal.

The earth fault protection inside the frequency
converter protects only the converter itself against
earth faults in the motor or the motor cable.

Due to the high capacitive currents present in the

frequency converter, fault current protective
switches may not function properly. If fault current

protective switches are used they must be tested
with the drive with earth fault currents that are

possible to arise in fault situations.

The mounting rail must be connected to ground

potential. This is the only way to guarantee that the
integrated surge voltage protection functions and
that the shield of the bus conductor makes contact
effectively.

GROUNDING BAR

GROUND CONNECTION, SMALLER UUNITS

C101566-B Page 65 of 67

26.01.2006

DOC-1017-1

GROUND CONNECTOR, BIGGER UNITS

17.3.2 V

IBRATION DAMPERS

We do not usually recommend the use of vibration dampers - they have a tendency to
increase vibration at the resonance frequency. If you want ot use dampers, use as stiff
a damper as possible - a rubber mat or equivalent.

17.4 P

ROPULSOR CABLING

Propulsor internal cabling is made to
connection box. For the external cabling
there is three plug connectors
¾

TRANSMITTER UNIT

for feedback cable is plug XP01

for indicator separate CAN-BUS
cable is plug XP05

STEERPROP CONNECTION BOX
SCB

for alarms and indications is plug
XP02

for clutch control XP03

GROUNDING

The housings of electric steering and
lubrication pumps should be

connected with an grounding
conductor connected to the
grounding terminal.

The propulsor should be connected
with an 25 mm2 grounding conductor
connected to the grounding terminal.

C101566-B Page 66 of 67

26.01.2006

DOC-1017-1

17.5 H

YDRAULIC POWER PACK CABLING

for controls and alarms is plug XP04.

17.6 P

OTENTIOMETERS AND SENSITIVE COMPONENTS

Potentiometers shouId be carefully handled by you bearing always in mind that
potentiometer is a kind of precision instrument.

Collision among products, drops onto desks or floor splashing of medicine and water
disclosure of direct rays of the sun and etc. cause breakage of terminal part
deformation of setting part, looseness of binding bands bend of shaft immersion inside
of corruption, raise of housing temperature and etc., which will further incur the second
and third failures and accidents.

OUNTING

EMOVING OF

OTENTIOMETERS

When wiring after mounted of the panel of potentiometer, we would kindly request you
to take your care of the following matters

into your account.

As for the potentiometers having a pilot part, it is necessary to drill the hole
for the pilot, and mount it without any play.

As for the potentiometers having anti-rotation pin on the panel, it is
necessary to drill the adequate hole for the pin and mount to put it in the
hole. At that time as well as when removing, please do not load over- force
on the housing in order to avoid some causes of failure such as twisting of
the housing, damage of the housing and an idling of the binding band.

In case of the bushing mount type potentiometers, it is absolute necessary
to keep the specified value of the fastening the mounting nut and do not
load over-force on fastening. When fastening with overloaded force, it may
cause a damage of screw thread and an increase of rotating torque.

When mounting the panel by screws, it is absolutely necessary to use the
screws in accordance with those specified in this catalogue, especially the
length of screws. If the length of screws is longer, it may damage the
resistive element inside and if the shorter, it may damage the screw
threads.

When mounting and/or removing a knob, gear, pulley and coupling on the
shaft, please duly take care to avoid over force (over 1 kg) on the shaft.
Especially, when removing, if you use a hammer to make a hitting and
striking, it may cause a failure inside.

C101566-B Page 67 of 67

26.01.2006

DOC-1017-1

ERMINAL WIRING

When wiring to the terminals, please duly note the following matters:

Wiring to the terminals has enough length is reserve and if not, an
excessive force to be caused by vibration, shock and etc. may lead a
damage of terminals part and disconnect inside connections.

When soldering to the terminals, it is absolute necessary to use a soldering
iron with below 60 W (iron part with below the temperature of 350 ºC)
applying within 3 seconds in order to avoid the solder into the housing
body. Moreover, when soldering, the solder may spray and drip and
therefore, please keep your face from such soldering process more than
25cm.

In order to remove the flux of soldering, please do not washing the whole
product and if a wash immerses into the housing, sliding noise and similar
problems may appear, which may make failures.

The strength of terminals is below 1 kgf in directions of pushing, pulling and
bending.

HECKING

When checking the resistance value of the output terminal of the potentiometer, please
do not use the analogue type ohm-meter but use the digital type ohm-meter.

When the wiper position sets near the ends, the analogue type ohm-meter may be
burnt out the resistive element and wiper.

When checking the insulation resistance di-electric strength with high voltage, please
duly note to do so in case of motor-potentiometer and components with a circuit board.

The motor we use has a withstand voltage of 100V and with a terminal of “GND” has a
setting the earth to the housing, of which facts please take into your account.

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