ear Installation manual of! TYPE H2 steering geari Ist edition $M 80897C-N4F 74bt “ 7S Contents 1. Outline 1.1 Features of the type H2 Contrl &Power Box i 2. Installation procedure | 2.1 Steering gear check ; 2.3 Servo loop system check using the Test voluve 2.4 Power Unit (Mechanical stopper) acjustnent 2.5 Check tie lever Link mochanisa 2.6 w transmitter zero point adjustment 2.1 SERVO AAP PCB zeco and adjustnente 2.8 Dead baad check and adjustment 2.4 Check of rudder angle feedback sigal to the control stand + 2.:0 NF U rudder check 3. mw transmitter symchro zero point 4. Linealizer circuit adjustment 4.1 Multipl-er zero adjustment VR9 (Xo), VRI0 (Yo). VRI1 (Zo) Attached Figure 1. SERVO AMP PCB Attached Figure 2/ Block diagram for SERVO AMP PCB Attached Fisure 3. Block diagram for Control &Pouer Box ‘SM 80B22C-046tl This installation manual describes the adjustaent Procedire procedure for the Contrel. & Power Box (PC.21) used in the type PTLO0/200-H2. For she PT100/200 autopilot adjastment procedure, refer to the separately prepared SM 81B22M-O1E, |. Otline The type H steering gear is a control system steering gear by Power Unit in which the solemid valve on the rump unit is tumed ON and (FF by comaring the rudder angle order signal (6: +0. 12V/deg.)from tte autopilot control stand with the rudder angle feedback | signal from a w transnitter in the SERVO AMP PCB in the Control & Power Box. 1.1 Features of the tyse H2 Control Power Box © The Control &Power Box. power unit and steering gear can be adjusted, ever in the steering gear room @ 4 simulated signal can be generated by a Test volume ia the SERIO AMP PCE. cnstead of using a rudder agle order signal from the autopilot control stand. ‘© ‘he operating line of the type H2 Pover Unit is relatec with the "SYSTEM"switch on the control stand or pump operation signal from the steering gear starter. The “SYSTIN"switch of the control stand set tte FU-1 or FU-2 position (or pump «eration signal fron the steering gear starter) and operate the ump Unit by relay RUN). ‘SH 80B22C-04E&4i 2. Installation procedure Follow this procedure with the autopilot contro] stand power turned “OFF”. - 2.1 Steering gear check Tum “ON” the steerire gear pump (the Control &Power Box power is turned “JFF”). then check to see if the steering gear follows correctly when the steering gear is mved to PORT and STBD by the emergency steering wheel. 2.2 Power Unit operation check (1) Check the working oil level ty fluid level gauge and the stain. ‘The tank cayacity for the working fluid level visible unit is about 34 2. Only if the oil level is visible through round peep windy of the fluid level gauge, th: fluid quantity is within the proper range (34 2425 2 ). Clean in the tank’ before supplying the working >i1. Note : Standard working oil for using the Power Unit TSO VG 32 (0 ~60°C) --+--+ *Standard ISO VG 22 (-10 ~S0°C) ---- “For cold slace Q) In case of che operating Line of the Power Uni: is select by the “SYSTEM”switch on the control. stand. Short terminals U-MCA (TBI) on the terminal board of NO. \ Control Power Box. (Steering gear starter pump overation type, :Short terminals SGA-SCB (TB1)). (2) Tum “ON” the NOI sseering gear pump and NO.1 Control &Power Boo and NO. 1 Power Unit become operation. Note : If the Control &Pewer Boxes are turned ON with terminals U and MCA (TBI}on the terminal boards 0? both the NO.I/NO.2 Control &Pover Boxes shorted , boch the NO.1/NO.7 Power Units are operated to cause different Power Unit operations, thereby resulting in Power Unit trouble. Therefore, always disconnect U and WA (TBI) of the urused Power Unit. (4) Check the mctor revolution direction When an arrew and motor revolution direction is different, check the motor viring. (5) Tur “ON” the NO. 1 (NC. 2) steering gear pump and 10. { (NO. z)Control &Power Boc, then check to sce if the stecring sear Follows correctly when the steering gear is moved ‘to PORT and STBD by pushing the spool on solenoid vaive uith manual operation. ‘SH 80822C-04E:udde: ord stgnat Ruder feedoek aint me o « This Line is comaced to WCATIn cane of Sea *EYEOC itn wee for eperation sana Se ~ a, a mm ae a - joa | = Control &Powr Box 78 Figure 2-1 Shorting terninals during steering using the Test volume Shorting terminals . R ( Osysten stitch solectien{ ® Steering gear starte- Paw ‘operation signal shorting BEESBEEE F U node selection GLLEFEE ——--—~ Control &Power Box * © or @ shorting is arrarged by the ship's systen specification. Not : Do not short the NO. 1/§0.2 systen switches simultmeously. When the NO. (V0.2) Control & Power Box Test volume is used, discomect the wire for shorting the ™.2 (NO. 1) Control& Power Sox aystes switch or turn OFF the Contrs1.& Powe Box. Figure 1-2 Shorting terminals during steering using the Test volum ‘SM 808220-04EJbI 2.4 Servo loop system check using the Test volume Use the Test volume to check the steering gear fsilov up dircetion Follow the procedure described below when moving the steering g-ar by tuning the Test volume. (1) To select systen switch 1, short U and MCA (TBi)on the te-minal board of NO.1 Control &Power Bor. (tort terminals SGA and SGB(IBI) :Steering geax starter pump operation simal type). (2 To obtain the FU mods, short terminals ACU and FU (IB1)on the terminal boare. (3) Turn “ON” the NO.1 s:eering gear pump and N.1 Control &Power Box. (4) Set the input the simal change over switch S#1 in the NO. 1 Contre] &Power Box SERVO AM PCB to Test. from Nor. (6) Check to see if turning Test rolune VR6 in the N0. 1 Control &Power Box SERV) AMP PCB to the right and left moves thé rudder to SIBD and PORT respectively. (6) Nest. turn “OFF” the power in the NO.1 Control &Power Box. (1) Conduct shorting even in the M0.2 Control &Poser Box ir the same way as in (1) to (2) above. Note 1: If. the Control &Power Bor are turned ON with terminels U and MCA (TBI) on the terminal boards of both the ND. 1/N0.2 Control &Power Boxes shorted, bth the NO. 1/NO.2 Power Units are operated to cause different Power Unit are operations, thereby resultirg in Power Unit trouble. Therefore, always disconect U ond MCA (TBI) of the unused Porer Unit-or turned “OFE™ the power sourse of the unused Control &Powor Box. Note 2: If the steering gear drifts or moves in the opposite direction, ary of the following is Likely to be the cause. Dincorrect wiring between the Control &Power Box and the steering gear side solenoid valve. Dincorrest wiring between the Control &Power Box and 1~transaitter. Note 3! Connect a digital tester between CT4 and CT2 (COM) of a SERVO AMP FCB te simlate output obtained by turning the Test volume , then turn VR6 to output vo!tage equal to +. 0. 12V/deg. Turning the Test volume to the right (STBD) output plus voltage, shile turning of to the left (ORT) outputs minus voltage, A feedback signal from the 4 transmitter is converied to vo:tage.equel to ‘FO. 12V/deg. in the SERVO ANP PCB's Linearizer circuit. Moving the steering gear to STBD outputs 2 minus voltage, while turniig it to PORT outpats a plus voltage. SM RrRI90_nae ae2.4 Power Unit (nechanical stoxper) adjustment, (1) Operate the servo sylinder by pushing the solenoid vaive (Port or STBD )with manual and continue the eperation to stop the servo sylinder by touching the mechnical stopper. (2) Adjust the Power Unit mechanical stopper so that the zctual rudier angle is within 36.2 0.2 degree PORT/STBD with pushing the solenoid vaive by nanual. (Check tc see if the Power Unit servo sylinder touches the mechanical stopper when the steering handle is tumed to the extreme left and right.) (3) After fix the inside lock nut of mechanical stopper position , Fix the outside lock nut. Note : The stroke of the servo sylinder before the product is slipped is as follow. 10 inch type (24mm) 12 ines type (304. 8m) ‘The length is 700mm +1nm From 4 transmitter to joint. : - ‘Stopper 1/2 Stroke Rod end ‘Stopper Figure 3 Stroke of servo sylinder SN B0BI2C-04E2.6 Check the lever link mechanism (1) Turn “ON" the steering gear pump and rudder set to the midship position. Q) Turn “OFF” the steering gear pump. (®) Coxfirm the midship position of the servo sylinder and » transmitter's lever. (@ If the servo sylinder and transmitter's lever positions: is no: mi¢ship, .adjust.¢ ‘the Length: of the bar. = f t\ (py = { Rod end’ ‘Nut: Bar’ Sut. Red end Figure 4 Rod end and bar 2.6 4 transmitter zero point aljustment: () Turn “ON the steering gear pump and set the rudder is midship position. (2) Tum “OFF” the steoring gear pump. (3) Corfirm the zero position of servo sylinder. (4h Check to see if the voltage between output terminals 451 to 4S2 of the « trensmitte> is less thar 0.5V AC. © Set the steering gear to the midship position. ‘© Loosen the synchro setscrew. © Disconnected the rudder angle scale vhich moves by following the synchro in the 4 transuitter frem the gear. then turn the synchro until the voltage be:ween cutput terminals 481 and 4Si less than 0.5V when measured with a circuit -ester. o not move the rudder angle scale.) © Screw in the synchro setscres. oN bb! ~ Note : There are Z locations where voltage between gmchro ouput teramals 451 and 4S2 . becomes 0 V per synchro motor revolution. . Incorrect zero point position causes different synchro signal plase with respect to the operation direction, thereby shifting the rugger. For details of synchro zerc point adjustnent.refer to item 3. SH 80322C-04E:eeteae 82 2.1 SERVO AMP ?CB zero and SPAN adjustments. 2.1.1 p feedback signal zero adjustaent in the Coitrol &Power Box. (1) Set the ridder to the nidship position and tun “OFF” che steering gear rump. (2) Connect a digital tester between CTT and C12 (00M) of the NO. 1 Control &Power Box. (3) Turn “ON” the NO. 1 Control &Pover Box. (4) Turn zero volume VAS (ZERO) until the voltage between CT7 and Cl2 (COM) cf the SERVO AMP PCB is leos than 0 +6ai. (5) Turn “OFF* the NO.| Control&Power Box. {6) Connect a digital cester between CTT and CT2 (COM) of the NO.2 Control &Porer Box. (1) Turn “ON” the NO.2 Control &Power Box. (8) Turn zero volume ¥R5 (ZERO) until the voltage between (IT and C12 (COM) of the SERVO AMP PCB ie lose than 0 £6. 2.7.2 u feedback signa. span adjustnent: (1) Set thé rudder to the PORT (or STBD) 20 degrees positior and turn “OFF” the steering sear punp. (2) Connect a digital tester be:ween CT? and CT2 (COM) of the NO.1 Control &2ower Box. (3) Turn “ON” the NO.1 Control %Power Box. (4) Turn span volume VB4 (SPAN) until the voltage between (T7 and CT2 (COM) of the SERIO WP PCB is less than £2. 4V+120V. (3) Turn “OFF” the NO.1 Control%Power Box. (6) Connect a digital tester between CIT and CT2 (COM) of the NO.2 Control &Power Box. (7) Turn “ON” the NO.2 Control XPower Box. {8) Turn span volune VE4 (SPAN) until the voltage between (TT and CTZ (COM) of the SERVO AP PCB is less then +2. 4VE120V. SM 80B12C-N4E83 Figure 5. SERVO AMP PCB-1 2.8 Dead band check and acjustment Dead band can be chected with the steering gear rump turned “OFF” and the Control & Power Bax turned “ON. It can be adjusted on both the PORT and STBD sides. Check terminal, Adjustnent volume | Standard dead band PORT side dead band | CT8 -CT: (COM) wre, GOaV x 12mV (0. Sdes.) STBD side dead band | CT9 -CT% (Com YR ~60n¥ + 12a (0. Sdex.) 3 » { Figure 6. SERVO ANP PCB-2 ‘sit 808220-04E— ewe B4 2.9 Check of rudder asgle signal feedback to the control stand : ‘The rudder angle feedback signal from the « transmitter synchro is converted to the corresponding current signal (¥ lmV/deg.) via the demodulator and Linealizer (F0. 12V/deg.) circuits, then output to the control stand. This signal is used for the rudder signal direction Lam, servo loop systen wonitoring. bareraph distlay unit (P1200) and rudder angle/actuator argle display (PT200) , ete. The signal feedback to the control stand has already been adjusted prior to sroduct. shirment. Cantrol &Fower Box rudder angle feedback signél check md adjustaent procedures are described in the following. (1) Connect an anneter to terninal 4 (TB1) in the Contrcl &Pover Box. (@) Connect a digital tester between CTT and CT: (COM) on the SERVO AMP PCB, (8) Set the steering gear to the midship position, then check to se if the ameter connected to terminal (4 (TBI) indicates 0=0.1 mA when a voltage of O6nV (Set point) is passed botwoon (T7 and CT2 (COM). 3 If this adjustment is not appropriate, turn VR3 on ths SERVO AP POS until the current value is shown 0 =0. ta on an ameter connected. (4) Set the steering sear to the PORT (or STBD) 20 degree: position to see if the voltage between CT7 and CT2 (COM) ist: 2.4V 12aV(Set point) and the ameter comected to the ‘termunal 4 (IB1) shows +200. 2mA. 2X If this adjustmen: is not appropriate, turn YR12 on the SERVO AP PCB until the current value shors++ 20 40.2aA on the anneter. Control &Pover Box PEPER EEE To control signal Rudder feedback signal ( 41 mMVdeg,) PORT + ImA/deg. STBD = ImA/deg. To comparator Figure 7. Consecting diagram of ammeter ‘SM 80822C-04EBe es 10 2.10 N FU rudder check (1) Turn “ON” the stecring gear NC.1 pump. (2) Short terminals U and MCA (TBI) on terminal board TB1 in -he NO.1 Control &fower Box. (Steering gear starter type : Short terminals SG\ and SGB {TB1)) (3) Tura “ON” the NO.1 Control &Power BOX. (4) Check to see if the steering gear noves to PORT vith terminals ACU and NEP (Bl) on the Control &Power Boc terminal board shorted, and to STBI with ACC and NFS shorted. (5) Tura “OFF” the steering gear No.1 pump and NO. 1 Control &Fower Box. (6) Tura “ON” the steering gear NO.2 pump . (D Short terminals U and MCA (TBI, on terminal board TBI in the NO.2 Control &Pawer Box. (When there is a steering gear operation signal : Short terminals SiA and G3 (TBI) (8) Ture “ON" the NO.2 Control &Power BOK. (8) Check to see if the steering gear moves to PORT with terminals ACU and NEP (TBI) on the Control &Power Box terminal board shorted, ard to STBD with ACUI and NFS shorted. Shorting terminals ® Systen switch mete Cantrol &Power Box @ Steering gear starter pump —~—(} operation signal shorting hi 2] 5]a]?[8(s[s[5)-[=]z NF U mode selection © or @ shorting is arrangel by the ship's system specification. Figure 8. Shorting terminals for 4 F Ul steering ‘Si 80822C-04EW 4. p transmitter synchro zero adjustment Adjust the 4 transmitter symhro zero point as follors after mu transmitter disassembly and adjustasnt or 4 transmitter synch-o replacement. . In addition, prior to conducting adjustment, always disconnected the pin vhict connects the 4 transni:ter and steering gear to separate the j transmitter from Power Unit. RL (eH) @ Set the 4 transmitter to tte center position (Mechanical zero point}. @ Loosen the synchro setscrews, thea connect the synctiro terminals as shown in the above Figure. At this tise, the synchro to the gosition st which the voltage between SI and $2 13 about 36V. Note : At this time, leave terminils ¢S1.4S2 and 4S3 on the external terninal side, otherwis> exceeds voltage is applied to the §S1-4S2 circuit in the Control &Power Box to cause trowle. Do this vork with in a short tine. cor @ Nect, change the wiring as stow in the following Figure , then tum the synchro slowly until the voltage between SI and S2 reactes 0. This finishes synchr> zero point adjustment. (Fine adjustment) . RL CO SLD) . 100¥ AC 33H) Figure 10. ‘R2 (BK) Synchro @ Fic the synchro setscrews. ‘SM 80E22C-D4E12 4. Linearizer circuit adjustment ‘The rudder angle feedback signal from the m transaitter synchro is converted to DC voltage @ with respect to the angle having 2 sie characteristics by alteraavely turning the analog switch in the demodulator circuit ON and OFF. i * ‘The sigal after the synchronous rectification circuit becomes the absolute value of @ in the linealizer circuit and finally becones the signal of @in the 1ine-sognent circuit. The wultiplier miltiplies @ and BD (@X@®=©) to obtain signal © which hai good lineality. The L:nealizer circuit has alreaty been aijusted prior to product shipment ant should sever be touched during installation, since tiring the variable resistors relating to this circuit does not output the correct rudder aigle feedback signel. therety | disabling steering gear adjustment. : If the linealizer circuit gets out of order, adjust ‘t in accerdance with the following 1 eam Y SBD rot ‘STBD PORT ‘STBD POT @ Siguat after synchronous @ Signal, in the Lixe-segnen: © Signal after Linealizer rectification circuit as’ Figure IL. SERVO AMP PCB-3 4.1 Multiplier zero adjusment VR9(Ko) .VRLO(Yo)and YRII (Zo). This adjustment is made so that the following equation is establisted. Ve = Vx Vy /10 (1) Vell positioning ~ Conduct zero adjusteent with YRII so that becones V2 =(V at Vz=0V and Vy = This means, adjust zero drif: so as to becomes Vz =OVXOV/10 ~ Vz =0V @ Set the 1 transm:tter to che zero position - Ve =0Y @ Turn VR8 to the exwreme lef: @ Turn VRT until the voltage between CT and CT: (COM): is 0 10nV---- Yy=0¥ @ lext. turr VRII (Z.) until che voltage between CTT and CT2 (COM) is 0 10x¥ oe =oAg!» 8s “13! (2) 1R9 positioning Conduct zero adjustment witn VRY so that Vz=0V at Vx=0V and Vy = Woltege when \R7 is Uurned to the ectrene left and right). This means zero drift is adjusted so as to bevomes Vz=OVXmore than + 1¢¥/10 =V2=0¥ @ Set the transmitter to the zero position - Vx =0V @ lead the voltage between CT! and CT2(COM) when VR7 is turned to the extrene left and right. @ ‘Then, turn VR9 until the voltages at the left and right between CTT and (rz (COM) becone the mean va:ue in order to eliminate voltage deviation wen it is turned to the extream left aad right. (Vz=0V) @ lepeat the above adjustment untill the rated accuracy is obtained. (3) WR10 positioning “Conduct zero adjustment with VRIO so as to become Vz =OV at Vx= (Voltage at 4 transmitter 30 degrees) and Wr=W. This means zero drift is adjusted so as to becone Vz =Vx(Vcltage of 4 transaitter+t 30 degrees)/ 10 —-¥2=0V © Set the @ transmitter to FORT (or STBD) 30 degrees \k = Woltage at m tronsmittcrt30 degrees ) @® Turn VR1 wtil the voltage between C16 and CT2(COM) ic 1 +1taV @ Next, turn VRIG until the voltage between CIT and C12 (CM) is“OV +1007 (4) Sine correction’ volume adjustment j @ Set the yw transnitter tc PORT (or STBD) 20 degrees. Turn VRT until the voltage between CT7 and CT2 (COM) is #2. 4V+10nV. @Set the mu transuitter tc PORT (or STBD) 30 degrees. ‘turn VR6 until the voltage between CTT and CIZ (COM) is #3. 6V10nV. @ Repeat the above procedure untill the read ascuracy is obtained. ‘SM 80822C-D4EPun over load Tank low level yR6 TEST Volune 2 ‘SM 80822C-04E Rs. RI Volume VR Yo! Attached Figure VR3 Volume 1 VRT Volume ‘SERVO ANP PCB 8930 Attached Figure 2. Block diagram for SERVO AMP FCB ‘SH 80822C-04E91 ils Slelelelslel-1-18 Attached Figure 3 - Block diagram for Control & Power Box SH 80B79C-04E.