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13S001332 Jiangsu Zhenjiang Shipyard Co., Ltd. Hull No VZJ6287-1301

The document is the Operating and Maintenance Manual for the Rolls-Royce Steering Gear SR, detailing the electrical and mechanical/hydraulic systems. It includes safety information, operational instructions, maintenance procedures, and troubleshooting guidelines. The manual is intended for use by personnel responsible for the operation and maintenance of the steering gear system on the specified vessel.

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0% found this document useful (0 votes)

41 views256 pages

13S001332 Jiangsu Zhenjiang Shipyard Co., Ltd. Hull No VZJ6287-1301

Uploaded by

ehabzeatter

We take content rights seriously. If you suspect this is your content, claim it here.

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Download as PDF, TXT or read online on Scribd

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OPERATING AND MAINTENANCE MANUAL

Rolls-Royce Steering Gear SR - Electrical and

Mechanical/Hydraulic System

Type :SR - FCP

Yard and hull no. :Jiangsu Zhenjiang SY : VZJ6287-1301
Project no. :13S001332
Date : 12. August 2014

© 2012 Rolls-Royce plc

The information in this document is the property of Rolls-Royce plc and must not be copied or communicated to a
third-party, or used for any purpose other than that for which it is supplied without the express written consent of
Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce
plc, no warranty or representation is given concerning such information, which must not be taken as establishing
any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated
companies.
THIS PAGE IS INTENTIONALLY LEFT BLANK

Page 2 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
REVISION HISTORY
Amendment
Description Date Signature
No.
1 Initial issue 26.09.2013 L.T

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 3 of 113

Page 4 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

1 INTRODUCTION .................................................................................... 13
1.1 Purpose ...........................................................................................................................13
1.2 Structure of this Manual ..................................................................................................13
1.3 Warranty ..........................................................................................................................13
1.4 Declaration of Conformity ................................................................................................13

2 MECHANICAL DESCRIPTION .............................................................. 14

2.1 Design .............................................................................................................................14
2.1.1 Rudder actuator ...............................................................................................................15
2.1.2 Pump unit ........................................................................................................................16
2.1.3 Cylindrical rudderstock connection..................................................................................16
2.1.4 Valve block ......................................................................................................................17
2.1.5 Feedback Unit .................................................................................................................18
2.1.7 Expansion Tank ...............................................................................................................19

3 ELECTRICAL DESCRIPTION ............................................................... 21

3.1 General Overview ............................................................................................................21
3.1.1 Control Panels .................................................................................................................22
3.1.2 Alarm Panel .....................................................................................................................22
3.1.3 Rudder Angle Indicator (RAI) ..........................................................................................22
3.1.4 Control System Cabinet ..................................................................................................22
3.1.5 Rudder Angle Indicator Amplifier.....................................................................................22
3.1.6 RUN/STOP/AUTO START Indication..............................................................................22
3.1.7 Motor Controller ...............................................................................................................22
3.1.8 Selector switch ................................................................................................................23
3.1.9 Frequency Converter .......................................................................................................23
3.1.10 Feedback Unit .................................................................................................................23
3.2 Control System ................................................................................................................23
3.2.1 Frequency Controlled Pump (FCP) .................................................................................24
3.2.2 Control Unit......................................................................................................................26
3.2.3 Main Steering Unit ...........................................................................................................26
3.2.4 Auxiliary Steering Unit .....................................................................................................26
3.2.5 Panel Units ......................................................................................................................27
3.2.5.1 Pump RUN/STOP/AUTOSTART Panel ..........................................................................27
3.2.5.2 Control Panel for Emergency Steering (from the Bridge)................................................27
3.2.5.3 High/Low Rudder Angle ..................................................................................................28
3.2.5.4 In Command ....................................................................................................................28
3.2.5.5 Follow-Up Controller ........................................................................................................29
3.2.6 Dimmer ............................................................................................................................29
3.2.6.1 Bridge Alarm Panel .........................................................................................................30
3.2.6.2 Dimmers mounted on panels ..........................................................................................30
3.2.6.3 External dimmer on Rudder Angle Indicators .................................................................30
3.2.7 Feed Back Unit ................................................................................................................30
3.3 Alarm System ..................................................................................................................30
3.3.1 AS02 Alarm System ........................................................................................................30
3.3.1.1 Solenoid monitoring and automatic stop function. ..........................................................32
3.3.2 AS02, NMEA 0183, VDR text message ..........................................................................32
3.3.3 Steering Failure Alarm (AS12) ........................................................................................33
3.3.4 AS12, NMEA 0183, VDR text message ..........................................................................34
3.4 Rudder Angle Indication System .....................................................................................35
September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 5 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
4 OPERATING INSTRUCTIONS .............................................................. 37
4.1 Pre operation check ........................................................................................................37
4.2 Steering Gear Operation .................................................................................................37
4.2.1 Normal Operation ............................................................................................................37
4.2.1.1 Steering Gear Control Panel (From Bridge) ....................................................................37
4.2.1.2 Auto Pilot .........................................................................................................................39
4.2.1.3 DP, Joystick, other...........................................................................................................39
4.2.1.4 Follow Up-Steering ..........................................................................................................39
4.2.2 Emergency operation ......................................................................................................40
4.2.2.1 From Bridge: ....................................................................................................................40
4.2.2.2 From Steering Gear Room ..............................................................................................41
4.3 Shut down prior to maintenance/start up after maintenance ..........................................44
4.3.1 Hydraulic system shut down prior to maintenance:.........................................................44
4.3.2 Hydraulic system start-up after maintenance: .................................................................44
4.3.3 Electric system shut down prior to maintenance: ............................................................44
4.3.4 Electric system start-up after maintenance: ....................................................................44
4.4 Actions on Alarm Occurring.............................................................................................44

5 MAINTENANCE INSTRUCTIONS ......................................................... 46

5.1 Maintenance Overview ....................................................................................................46
5.2 Maintenance Plan ............................................................................................................47
5.3 Preventive Maintenance ..................................................................................................49
5.3.1 Frequency Converter Error Log.......................................................................................49
5.3.2 Oil recommendations ......................................................................................................50
5.3.3 System oil volume ...........................................................................................................51
5.3.4 Inspect For Oil Level and Condition ................................................................................52
5.3.4.1 Oil Level:..........................................................................................................................52
5.3.5 Oil sampling .....................................................................................................................52
5.3.6 Internal leakage test ........................................................................................................55
5.4 Visual inspection..............................................................................................................56
5.4.1 Check the Limit Switches ................................................................................................56
5.4.2 Check the Solenoids Coil ................................................................................................56
5.4.3 Check of Feedback Potentiometer ..................................................................................57
5.5 Test of Emergency Steering ............................................................................................57
5.6 Check for Proper Earthing ...............................................................................................58
5.6.1.1 For testing on units with power on...................................................................................58
5.6.1.2 For testing on units without power...................................................................................58
5.7 Check for System Temperature ......................................................................................58
5.8 Corrective Maintenance ..................................................................................................59
5.8.1 Recovering From a Frequency Converter Trip Lock .......................................................59
5.8.2 Recovering From a Hydraulic Lock .................................................................................59
5.8.3 Repair the Frequency Converter .....................................................................................61
5.9 Dismantling and Reinstallation ........................................................................................61
5.10 Adjustments .....................................................................................................................61
5.10.1 Adjustment of Feed Back Unit Limit Switches .................................................................61
5.10.2 Adjustment of Control System and Rudder Indicator System Transmitter......................62
5.10.3 Adjustment of Control System Amplifier Card .................................................................63
5.10.4 Adjustment of FU-Controller 0-Point and Gain................................................................65
5.10.5 Adjustment of Dimmer .....................................................................................................66
5.10.6 Adjustment of Rudder Angle Amplifier ............................................................................67
5.10.7 Adjustment of Relief Valve Pressure ...............................................................................68
5.10.8 Adjustment of load control valves....................................................................................71
5.10.9 Adjustment of Proximity Switch (Sensors) ......................................................................73
5.11 Replacement ...................................................................................................................74
5.11.1 Replacement of Pump Control Card ...............................................................................74
5.11.2 Replacement of Limit Switch in Feed Back Unit .............................................................75
5.11.3 Replacement of Amplifier Card .......................................................................................76

Page 6 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

6 TROUBLE SHOOTING .......................................................................... 94

6.1 Introduction: .....................................................................................................................94
6.2 Non - Alarm Notified ........................................................................................................95
6.3 Alarm Notified ................................................................................................................102

7 SPARE PARTS .................................................................................... 109

7.1 Ordering Spare Parts ....................................................................................................109
7.2 Supplied standard spare parts ......................................................................................109
7.3 Recommended spare parts ...........................................................................................110
7.4 Preservation ..................................................................................................................110

8 TOOLS ................................................................................................. 111

9 DRAWINGS.......................................................................................... 112

10 CONTACT LIST ................................................................................... 113

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 7 of 113

Abbreviation Description
AC Alternating Current
Approx. Approximate
ºC Centigrade
DC Direct Current
Deg. Degree
DP Dynamic position
DOL Direct Online
DWT Dead Weight Tonnage
ECR Engine Control Room
FCON Frequency Conventional
FCP Frequency Controlled Pump
FEMG Frequency Converter for Emergency Mode
FU Follow-Up
kN Kilo Newton
LED Light Emitting Diode
mm Millimetre
NFU Non-Follow-Up
Nm Newton meter
RR Rolls-Royce
Qty Quantity
Sec Second
SGR Steering Gear Room
SR Spherical Rotor
VDR Voyage Data Recorder
V Volt

Page 8 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Safety Setup
UNDERTAKING ANY WORK MENTIONED IN THIS DOCUMENT MAY EITHER DIRECTLY OR
INDIRECTLY CREATE RISK TO EITHER:

UNDERTAKING ANY WORK MENTIONED IN THIS DOCUMENT MAY DIRECTLY OR

INDIRECTLY CREATE RISK TO EITHER:

 THE SAFETY AND HEALTH OF THE PERSON

 THE PRODUCT AND/OR ITS COMPONENTS.

MAKE SURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND
APPLIED IN ACCORDANCE WITH THE INSTRUCTIONS ON THIS MANUAL. THESE
CONTROLS ARE IN ACCORDANCE WITH THE RELEVANT STATUTORY, LEGAL AND
INDUSTRY REQUIREMENTS TO ENSURE THE SAFETY AND HEALTH OF THE PERSONS
UNDERTAKING THE WORK.

Safety Annotations
Obey all safety directions to avoid damage to personnel, environment and equipment. In this
manual, the following annotations are used:

WARNING

WARNINGS ARE USED TO ALERT THE USER THAT POSSIBLE HAZARDS

ARE ASSOCIATED WITH THE MATERIALS / PROCESSES / PROCEDURES /
LIMITS. THESE MAY CAUSE DEATH OR INJURY IN ANY FORM IF THE
INSTRUCTIONS IN THE OPERATIONAL OR PROCEDURAL TASK ARE NOT
FOLLOWED PRECISELY.
THE TEXT OF THE WARNING DESCRIBES THE HAZARDS AND THE
POSSIBLE IMPACT.

CAUTION

CAUTIONS ARE USED TO ALERT THE USER THAT DAMAGE TO THE

PRODUCT IS POSSIBLE IF THE INSTRUCTIONS IN THE OPERATIONAL OR
PROCEDURAL TASK ARE NOT FOLLOWED PRECISELY.
CAUTIONS DESCRIBE THE HAZARDS AND POSSIBLE IMPACT.

Note!

Notes are used to provide the user with additional information which is helpful.
Operational and procedural tasks can be made easier by the use of notes.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 9 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
General Warnings
Obey the general warnings given below while working on the Steering Gear Electrical and
Mechanical/Hydraulic components.

WARNING

USE OF LIFTING EQUIPMENT CAN BE HAZARDOUS TO PERSONNEL - SERIOUS

INJURY/LOSS OF LIFE CAN OCCUR IN THE EVENT OF LIFTING EQUIPMENT FAILURE
OR MISUSE. BEFORE USING ANY LIFTING EQUIPMENT, MAKE SURE THAT:

 IT IS THE CORRECT EQUIPMENT FOR THE TASK

 THE EQUIPMENT IS STABLE AND SUSPENDED FROM A SUITABLE LOAD

BEARING STRUCTURE

 IT IS SERVICEABLE AND HAS A VALID IN DATE TEST CERTIFICATE

 THE SAFE WORKING LOAD WILL NOT BE EXCEEDED

 IT IS CORRECTLY ATTACHED AND THE CENTRE OF GRAVITY OF THE LOAD

IS IDENTIFIED.

 THE APPROVED LIFTING EQUIPMENT PROCEDURE IS FOLLOWED.

 ALWAYS WORK IN PAIRS OR MORE WHEN PERFORMING HEAVY LIFTS.

OIL CAN BE HAZARDOUS TO PERSONNEL - IT CAN CAUSE DERMATITIS.

 ALWAYS WEAR THE PERSONAL PROTECTIVE EQUIPMENT APPROPRIATE

FOR THE TASK.

 FOLLOW THE SAFETY PRECAUTIONS IDENTIFIED ON THE CONTAINER

LABEL, THE SAFETY DATA SHEET AND LOCAL SAFETY INSTRUCTIONS.

 TAKE NECESSARY PRECAUTIONS TO AVOID OIL SPILL DURING UNPACKING

AND LIFTING OF THE EQUIPMENT AND MAKE SURE A SPILL KIT IS
AVAILABLE.

OPERATING THE STEERING GEAR WHEN INSTALLATION/MAINTENANCE IS BEING

PERFORMED CAN BE HAZARDOUS AND CAUSE INJURY/LOSS OF LIFE.

 MAKE SURE THAT THE SYSTEM/EQUIPMENT IS ISOLATED TAGGED OUT AND

LOCKED BEFORE ANY WORK IS UNDERTAKEN. ATTACH SIGNS TO
CRITICAL SWITCHES THAT STATE: "DO NOT OPERATE - WORK IN
PROGRESS".

ELECTRICAL EQUIPMENT CAN BE HAZARDOUS - A CURRENT OF 100MA PASSING

THROUGH THE HUMAN BODY FOR ONE SECOND CAN KILL; THIS CAN OCCUR AT
VOLTAGES AS LOW AS 35V AC OR 50V DC.

 MAKE SURE ALL ELECTRICAL POWER IS ISOLATED, TAGGED OUT AND

LOCKED WITH APPROPRIATE NOTICES, BEFORE ANY WORK IS
UNDERTAKEN.

Page 10 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

DAMAGED ELECTRICAL WIRING MAY SHORT-CIRCUIT THE CONTROL SYSTEM AND

LEAD TO INJURY/LOSS OF LIFE.

 MAKE SURE ALL ELECTRICAL POWER IS ISOLATED, TAGGED OUT AND LOCKED
WITH APPROPRIATE NOTICES, BEFORE ANY WORK IS UNDERTAKEN.

 ALWAYS VISUALLY INSPECT FOR DAMAGE BEFORE ANY WORK IS

UNDERTAKEN.

ALL FUELS AND MANY CHEMICALS ARE FLAMMABLE - THEY CAN CAUSE INJURY/LOSS
OF LIFE.

 DO NOT ALLOW NAKED FLAME OR SMOKING DURING INSTALLATION AND

MAINTENANCE.

 MAKE SURE THAT THE WORK AREA HAS GOOD VENTILATION.

 ALWAYS MAKE SURE FIRE PRECAUTIONS, ALARM SYSTEMS AND FIRE FIGHTING
MEASURES ARE IN PLACE.

USING OIL THAT HAS NOT BEEN RECOMMENDED BY ROLLS-ROYCE COULD CAUSE
EQUIPMENT MALFUNCTIONS AND INJURY.

 USE ONLY OIL THAT HAS BEEN RECOMMENDED BY ROLLS-ROYCE.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 11 of 113

Page 12 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

 Describes operating procedure required on board for the Steering Gear system.
 Gives the maintenance procedure required on board for maintaining the Steering Gear
system safely and correctly.

1.2 Structure of this Manual

Chapter Description
2 Description of mechanical system
3 Description of Electrical System
4 Operating Instructions
5 Maintenance Instructions
6 Troubleshooting
7 Spare Parts
8 Tools
9 Drawings
10 Contact List

1.3 Warranty
Refer to the contract document for the full details of the warranty. The product has a limited
warranty. Please note that the warranty will be void if the equipment is misused or not handled in
accordance to prescribed standards.

Dismantling the equipment to a level greater than described in this manual will void the warranty.

1.4 Declaration of Conformity

Rolls-Royce Steering Gear is designed and built as per requirements and conventions given by the
following organizations:

 International Maritime Organization (IMO)

 International Convention for the Safety of Life at Sea (SOLAS).
 The requirements of the following classification societies have been used to design
and build Rolls-Royce Steering Gear:
 Det Norske Veritas (DNV)
 American Bureau of Shipping (ABS)
 Lloyds Register of Shipping (LR)
 Germanischer Lloyds (GL)
 Bureau Veritas (BV)
 Royal Institute of Naval Architects (RINA)
 Class NK (Nippon Kaiji Kyokai)
 China Classification Society (CCS)
 Russian Maritime Register of Shipping (RS)
 Korean Register of Shipping (KR).

A Class Certificate is issued for each Steering Gear in alignment with the Class of the vessel.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 13 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
2 MECHANICAL DESCRIPTION
This chapter provides the technical description, functional overview and technical specification of
the equipment in the Steering Gear System. The function of the Hydro-Mechanical Steering Gear
Unit is to provide the rotational power to operate the rudder unit. The Steering Gear has a compact
design that minimizes pipe work during installation at the yard.

2.1 Design
The Rolls-Royce Steering Gear SR - FCP design is based on long experience. The unique
spherical design with cylindrical rudderstock is patented in most of the world.

The Steering gear consists of six main parts; rudder actuator [1] pump unit [2], cylindrical
rudderstock connection [3], valve block [4], cylindrical rudder stock [5], and feed back units.
Additionally the system consists of an expansion tank and if installed, emergency wheel pump.

Page 14 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

[1] = Rotor,

[2] = Ring shaped cylinder with vanes and dividing walls

fastened to the rotor,

[3] = Housing (upper and lower),

[5] = ”U” seal on each piston,

[6] = Spherical bearings situated on the rotor.

The vanes work in a ring shaped cylinder with the rudder

stock as the centre. The pistons [2] are fastened to the
rotor in a manner; which allows them to absorb and adjust
to the spherical deflection of the rotor due to misalignment
in installation or deflection of the rudder stock.

The housing [3] is a cast cylinder with oil channels [4] leading the oil to the different
chambers. The upper and lower housing parts are connected with several bolts.

The synthetic bearing pads maintain 100% surface contact

at all times even as the rudder stock flexes. It will also
absorb and suppress vibrations and shock pulses. The
bearing surface is continuously lubricated by the hydraulic
oil, which ensures long lifetime of the bearings.

The rudder actuator can be delivered with two or three

pistons, which give different rudder angles and developed
torque. The unit develops a constant torque over the full
rudder angle.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 15 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
2.1.2 Pump unit
The motor [2] for each pump unit starts when a rudder
command signal is given and stops when the rudder has
reached the desired position. The power for operating
control and steering systems are both hydraulically and
electrically separated and independent.

The power pump units consist of four main parts:

[1] = Reversible pump,

[2] = Electric motor,

[3] = Bell house,

[4] = Flexible coupling.

When both pump units are running the ship will achieve 100% speed condition in proportion to the
size of the pump units. The most common pump is the gear wheel pump. Some pump models
have extra accessories.

2.1.3 Cylindrical rudderstock connection

The rudder stock connection is based on locking ring
assemblies. The expansion ring is situated between the
rudder stock and the rotor bore.

The locking ring connection consists of the following main

components:

[1] = Expansion rings,

[2] = Adjusting screws,

[3] = O-ring,

[4] = Rotor,

[5] = Rudderstock,

Additionally a cover and a V - ring.

An expansion ring [1] is illustrated in the picture.

Page 16 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

2.1.4 Valve block

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 17 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
The integrated valve block with filter units has fewer and less complex valves due to the
reversible pumps.The distributing valve housing is flanged to the housing of the Steering gear
and contains:

Non-return valves,

Load sense valves,

Solenoid operated isolating valves,

Relief valves,

Return filters unit.

The relief valves are adjusted at the factory to the design pressure stated in the technical
information.

Note!



 The relief valves are adjusted at the factory to the specified design pressure

2.1.5 Feedback Unit

1 Rudder angle transmitters 2 Limit switch

Figure 1 Feedback Unit

The function of the feedback unit (Figure 1) is to interface the rotary angle of the rudder, by angle
transmitters (1) to the indication and steering control system. It also includes electrical switches (2)
to limit the travel of the actuator to the maximum allowed.

The unit is installed at the factory to a bracket flanged on the top of the actuator. The Steering
Gear is equipped with two separate feedback units, one for each pump system.

Page 18 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

1 Gauge glass 6 Paired pump

connections
2 Level alarm switch 7 Paired pump
connections
3 Filler cap 8 Shut-off cocks
4 Storage tank connection 9 Drain plug
5 Actuator drain connection

Figure 2 Expansion Tank

The expansion tank (Figure 2) is the oil reservoir and header tank for the hydraulic system. Pipes
connect the actuator and pump units to the expansion tank through the shut-off cocks (8).

The expansion tank contains gauge glasses (1) to indicate the minimum and maximum allowed oil
level during normal operation of the Steering Gear. It also contains two electrical level switches
monitoring the oil level.

The lower section of the expansion tank is divided internally into two separate sections by a
dividing wall. This to prevent both pump units losing oil in the case of leakage from one unit or its
corresponding piping. The volume of the upper section is common for both pump units. In case of
leakage from one pump unit, the other can continue operating without interruption.

In addition to the pump and actuator connections, the tank also has connection to a storage tank
for filling, a drain plug, an inspection cover with filler cap, strainer, and air filter.

The expansion tank comprises the following parts:

 Filler cap
 Storage tank connection
 Level alarm switches
 Actuator and pump connections
 Shut-off cocks

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 19 of 113

Page 20 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3 ELECTRICAL DESCRIPTION
This chapter gives the technical description and functional overview of the Steering Gear Electrical
System and Equipment. The primary function of the electrical system is to control and monitor the
Steering Gear Unit.

3.1 General Overview

The block diagram (Figure 1) shows the location of the main electrical components in the Steering
Gear Room, Engine Control Room and Bridge.

Figure 3 Block Diagram of Steering Gear Electrical System

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 21 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
The following is a brief description of the Steering Gear Electrical System main components:

3.1.1 Control Panels

The control panels have the following function:

 Start/Stop/Auto start
 Override (Emergency Steering)
 High/Low Rudder Angle
 In Command
 Follow Up Controller.

Note!

 The above functions can be located in one panel or in multiple panels, based
on the specific installation.

3.1.2 Alarm Panel

The alarm panel provides indication of faults in the Steering Gear System to the Bridge and the
Engine Control Room. The alarm panel in the Engine Control Room has full lighting intensity. The
lighting intensity of the alarm panel on the Bridge can be adjusted.

3.1.3 Rudder Angle Indicator (RAI)

The Rudder Angle Indicator provides actual time position indication of the rudder.

The indicator is available in three types of mounting:

 Panel Mounting
 3 Face Ceiling Mounting
 Bulkhead Mounting.

3.1.4 Control System Cabinet

The Control System Cabinet is installed on the Bridge or adjacent to the Bridge. It receives input
from the control panel and the feedback unit and provides command signals to the Steering Gear.

3.1.5 Rudder Angle Indicator Amplifier

Rudder Angle Indicator Amplifier is installed on the Bridge or adjacent to the Bridge. It receives
rudder position signal from the feedback potentiometer and amplifies the signal to a suitable level
for the Rudder Angle Indicator.

3.1.6 RUN/STOP/AUTO START Indication

RUN/STOP/AUTO START Indication is provided in the Engine Control Room and shows the status
of the pump units.

3.1.7 Motor Controller

The Motor Controller is installed in the Steering Gear Room. It receives signal from the Control
System Cabinet and controls the pump unit.

Page 22 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
 Source on (white LED) light indicates if the main power is ON and if the main switch on
Motor Controller is switched to ON position.
 Heating (blue LED) light indicates if the heating for the motor is ON. The heating light
shall always be ON if the Steering Gear is not in run mode.
 Run (Green LED) light indicates if the Steering Gear is set to RUN mode either from
the Motor Controller or the control panel(s) from bridge.

3.1.8 Selector switch

Figure 4 Selector Switch

The selector switch (Figure 4) is located on the Motor Controller and has three positions.

 Position 1 - Remote control (Control from bridge)

 Position 2 - Stop
 Position 3 - Local control used for emergency steering from Motor Controller(s).

3.1.9 Frequency Converter

The Frequency Converter is installed in the Steering Gear Room and controls the speed and the
direction of the motor pump unit.

3.1.10 Feedback Unit

The Feedback Unit is installed in the Steering Gear Room and provides feedback about the rudder
position to the Control System and Rudder Angle Indicator System.

3.2 Control System

The Control System provides monitoring and control of the Steering Gear Unit.

The power supply to the Control System is from the corresponding Motor Controller.

The Control System consists of:

 Frequency Controlled Pump Unit

 Control Unit
 Panel Unit
 Feedback Unit.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 23 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3.2.1 Frequency Controlled Pump (FCP)
The frequency controlled pump units (Figure 5) provide smooth start and stop of the Steering Gear
and an accurate analogue Control System.

The pump units rotate only when a steering command signal is given. In this way, power saving is
achieved.

The system uses reversible electric motors driving hydraulic pumps, together with a Frequency
Converter to control the speed and direction of the pump.

Page 24 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1 Motor controller 4 Pump unit
2 Frequency converter 5 Steering gear
3 Feedback unit

Figure 5 Frequency Controlled Pump System

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 25 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3.2.2 Control Unit
The control unit controls the Steering Gear. It is rack based and includes the cards in the main
steering and auxiliary steering units (Figure 6).

3.2.3 Main Steering Unit

The main steering unit contains the pump control card for each pump.

The pump control card can be connected to the auxiliary steering unit.

3.2.4 Auxiliary Steering Unit

The auxiliary steering unit has the following:

 Selector cards (interface for 3 to 12 modes)

 Amplifier card (generates the steering signals)
 Back plane (internal wiring)
 Interface card (interface for feedback).
 Interface to external steering systems, DP, Autopilot, Joystick etc.

1 Pump control card 4 Back plane

2 Selector card 5 Interface card
3 Amplifier card

Page 26 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

3.2.5 Panel Units

The panel units are installed on the Bridge and in the Engine Control Room. There are varying
layouts for each section of the panels but the general functions of each section are detailed below.

A control panel has the following:

 Panel front
 Operating components connected to the printed circuit board
 Terminal plate connected (wired) to the control panel.

Each control panel can contain different modules depending on the required installation for the
vessel. Following are the main functions:

 Pump START/STOP/AUTO START

 Emergency Steering
 High/Low Rudder Angle
 In Command
 Follow-Up Controller.

3.2.5.1 Pump RUN/STOP/AUTOSTART Panel

The pump RUN/STOP/AUTO START panel (Figure 7) indicate status of each steering gear pump
unit. It also provides indication of the running status of each pump unit.

Figure 7 Pump RUN/STOP/AUTO START Panel

3.2.5.2 Control Panel for Emergency Steering (from the Bridge)

The Control Panel for emergency steering provides local steering control from the Bridge.

The main control panel has the PORT and STBD steering buttons for emergency steering control
(Figure 8). This control is of the Non-Follow-Up type i.e. the steering gear will continue to move in
the direction indicated on the button until it reaches its limit or is released.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 27 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
To operate the Steering Gear from the Bridge, at least one pump unit must be operational.

Figure 8 Emergency Steering Control Panel

3.2.5.3 High/Low Rudder Angle

The LOW ANGLE PUMP 1 and 2 lamp provides indication of reduced maximum rudder angle
(Figure 9). The “High/Low Rudder Angle” push button is to override this.

Figure 9 High / Low Rudder Angle

3.2.5.4 In Command

The IN COMMAND push button and lamp provides selection and indication of steering control
function (Figure 10).

Page 28 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

3.2.5.5 Follow-Up Controller

The Follow-Up Controller (Figure 11) is an analogue steering device. The IN COMMAND lamp will
illuminate when steering is available from this controller. When the Follow-Up Controller is set to
the desired rudder angle the Steering Gear will move the rudder to the selected angle and stop in
that position.

Figure 11 Follow Up controller

3.2.6 Dimmer
Dimmers can be found on different panels and indicators. The dimmers are used adjusting the
illumination on indications lights on panels, background lights on rudder indicators and Bridge
Alarm Panels.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 29 of 113

3.2.6.1 Bridge Alarm Panel

Dimmer is functioning by pressing the + or – buttons at the lower half of the panel. The backlight is
automatically switched off during daylight due to the panel is equipped with a photo-electric cell.

3.2.6.2 Dimmers mounted on panels

Dimmer is functioning by turning the potentiometer knob mounted on the surface off the panel.
This dimmer is often connected to many panels and indicators in the same area due to the dimmer
are connected to a dimmer module with 14 channels.

3.2.6.3 External dimmer on Rudder Angle Indicators

Dimmer have the same principle as the dimmer mounted on the panels, but this type is not
connected to a dimmer module it is only a potentiometer connected to the indicator which uses the
+/-12V signal trough the potentiometer for dimming.

3.2.7 Feed Back Unit

Refer to section 2.1.5

3.3 Alarm System

The alarm system provides indication of faults in the Steering Gear system to the Bridge and the
Engine Control Room.

There are two alarm systems available for the Steering Gear System:

 AS02 type Alarm System

 AS12 type Steering Failure Alarm System.

3.3.1 AS02 Alarm System

The AS02 alarm system monitors the status of the steering gear (Figure 12).

The main components of alarm system AS02 are:

 Bridge Alarm Panel

 ECR Alarm Panel
 CAN Bus
 The Alarm Interface card (Located inside the Motor Controller).

Alarm system AS02 can monitor two pumps.

Page 30 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1 Bridge alarm panel 4 Motor contoller
2 ECR alarm panel 5 Pump unit
3 CAN bus 6 Steering gear

Figure 12 AS02 Alarm System

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 31 of 113

The feature of solenoid coil current monitoring is to detect an emerging malfunction of the coil
giving an alarm, initiating the following sequence of events:

 A. One pump running:

o - Automatic Start of the standby pump.
o - Automatic stop of the pump with coil failure alarm.
o - Steering Gear operation is maintained.
 B. Two pumps running:
o - Automatic stop of the pump with the coil failure alarm.
o - Steering Gear operation is maintained.

The solution incorporates a 24V DC solenoid coil together with a 24VDC power supply. In order to
monitor current draw through the coil, a Siemens current monitoring relay is used.

3.3.2 AS02, NMEA 0183, VDR text message

NMEA 0183 VDR interface

The “VDR” text transmission from the Steering Gear AS02 alarm system is designed in
accordance with IMO performance standard A. 861(20) and IEC 61996.

Page 32 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3.3.3 Steering Failure Alarm (AS12)
The AS12 alarm system monitors the Steering Gear Follow-Up function.

The main components of the steering failure alarm system AS12 are:

 Steering failure alarm panel (Figure 13)

 Steering failure alarm unit
 Rudder angle transmitter and FU-steering transmitter (mounted in the Feedback Unit
and Follow-Up Controller respectively).

When Follow-Up control mode is selected, the alarm will trigger if the rudder position deviates from
the Follow-Up Controller position for a pre-determined time period.

The steering failure alarm system provides both audible and visual alarm indication on the Bridge.
An Alarm Acknowledge button will silence the alarm and a system test button is provided to test
the system.

Figure 13 Steering Failure Alarm Panel

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 33 of 113

NMEA 0183 VDR text transmission RS 422

The “VDR” text transmission from the steering gear AS12 deviation alarm is designed in
accordance with IMO performance standard A. 861(20) and IEC 61996

Page 34 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3.4 Rudder Angle Indication System
The Rudder Angle Indication System (Figure 14) displays the rudder angle position on the Bridge
and in the Engine Control Room.

The main components of the Rudder Angle Indicator System are:

 Rudder Position Feedback Unit (Mounted on the Steering Gear)

 Rudder Angle Indicator Amplifier
 Rudder Angle Indicator.

The Rudder Angle Indicator System has two amplifier units, which can be connected to a
maximum of five rudder indicators each. The amplifier units receive their signals from precision
potentiometers located inside the Feedback Units.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 35 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1 Rudder angle indicator 3 Feedback unit
2 Rudder angle indicator amplifier 4 Steering gear

Figure 14 Rudder Indication System

Page 36 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Note!

 Make sure that there is no maintenance activity with the Steering Gear
System before operation.

4.2 Steering Gear Operation

There are two modes of Steering Gear operation

 Normal operation
 Emergency operation.

4.2.1 Normal Operation

4.2.1.1 Steering Gear Control Panel (From Bridge)

1) In order to start the pumps, push the “START/RUN” button ( Figure 16) (1)) for the
required pump and the button illuminates.

Note!

 Make sure that the power supply is on; this is seen if there are lights
illuminated on the start/stop panel on the bridge. This confirms that there is
power from the Motor Controllers.
 Make sure that the selector switch (Figure 15 (1) is in remote control on the
Motor Controller and pumps are running before you start manoeuvring.

2) In order to set the desired steering mode, press the appropriate “IN COMMAND”
push button (2), the button illuminates.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 37 of 113

Figure 15 Motor Controller

1 Pump run buttons 2 In Command push buttons

Figure 16 Control Panel

3) In order to stop the pumps (See Figure 16) by push the "STOP" button then the red
light illuminates.

Note!

 If an alarm occurs, the stand-by pump starts automatically. The auto start
indication light illuminates for about 3 seconds.

Page 38 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The autopilot is an external steering system not supplied by Rolls-Royce Marine

In order to set the autopilot, push the “IN COMMAND AUTOPILOT” button on the control
panel.(See Figure 16)., button illuminates and the steering control is taken over by the autopilot
system.

4.2.1.3 DP, Joystick, other

The DP, Joystick, other are external steering system not supplied by Rolls-Royce Marine

In order to set the steering modes, activate the mode selector on the individual steering system.
Indication of activated steering mode is seen on the main control panel.

4.2.1.4 Follow Up-Steering

The Follow-up controller moves the rudder to the angle set by the operator. For a two rudder
system the "Follow-Up" function can be set to synchronized or independent operation of the rudder
(See Figure 17).

Use the “Follow-Up” controllers (3 and 4) to turn the Steering Gear system.

For synchronized operation of the rudder:

1) Push the “IN COMMAND SYNCHRO” button (1).

2) Use the controller (4) for synchronized operation of the rudder.
For independent operation of the rudder:

1) Push the “IN COMMAND INDEPENDENT” button (2).

2) Use the controllers ((3) and (4)) for independent operation of the rudder.

1 “IN COMMAND” synchro button 3 “Follow-Up” controller

2 IN COMMAND” independent button 4 “Follow-Up” controller

Figure 17 Control Panel

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 39 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
4.2.2 Emergency operation
It is the operation of Steering Gear in emergency condition where it is operated from Bridge and
Steering Gear Room.

4.2.2.1 From Bridge:

Note!

 In order to conduct any emergency operations the pumps must have power
and be activated

The primary control panel is normally supplied with Override Non-Follow-Up push buttons for
emergency steering (See Figure 18).

When the Override Non-Follow-Up push buttons are supplied with priority function:

1) Start one or both pumps from the Bridge.

2) Operate the Non-Follow-Up buttons marked port (4) and starboard (2) to move the
rudder.
3) Reset the audible alarm by pushing the “BUZZER RELEASE” button (1), when
audible alarm occurs.
4) To go back to normal steering operation set the override switch (3) to the “RELEASE”
position.

1 “BUZZER RELEASE” button 3 Override switch

2 Starboard Non-Follow-Up 4 Port Non-Follow-Up
button button

Page 40 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

When “Non-Follow-Up” emergency steering is not supplied with priority function:

1) Set the override switch (3) to the “OVERRIDE” position.

2) Push the non-follow-up buttons marked port (4) and starboard (2) to operate the
rudder.
3) To go back to normal steering operation set the override switch (3) to the “RELEASE”
position.

4.2.2.2 From Steering Gear Room

WARNING

 WHEN PERFORMING EMERGENCY OPERATION, ALWAYS BE IN RADIO

CONTACT WITH THE BRIDGE.

1) Set the selector switch (1) on the Motor Controller to position 3 “LOCAL CONTROL”
(See Figure 19).
2) The “RUN PUMP” (2) indication light comes on.
3) Push the manoeuvring buttons (3) in front of the Motor Controller to manoeuvre the
rudder.

Note!

 The power failure control will be monitored.

 Make sure to set the selector switch on both Motor Controllers to local control
(3). If not the control system will work against the local control steering/EMG
steering.

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 41 of 113

Figure 19 Motor Controller

Page 42 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Emergency
Equipment Normal Operation Indication
Operation
Steering Gear control
x
panel

Auto pilot x

Follow-up x

Non-Follow-Up
x
Override Control

Non-follow-up lever x

Dimmer x

Deviation alarm
x
panel (If fitted)

Operation from Engine Control Room:

Normal Emergency
Equipment Indication
Operation Operation
Indication panel x
Alarm panel x
Rudder Indicator x

Operation from Steering Gear Room:

Normal Emergency
Equipment Indication
Operation Operation
Emergency Steering from
x
Motor Controller
Rudder Indicator x
Alarm panel x
Local emergency Steering
x
cabinet (optional)

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 43 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
4.3 Shut down prior to maintenance/start up after maintenance
4.3.1 Hydraulic system shut down prior to maintenance:

 Check all cocks on the expansion tank are closed before doing maintenance or
disassembly of hydraulic pipes, pumps or actuator.
 Make sure that none of the hydraulic parts are contaminated by environment during
maintenance work. Contamination will affect Steering Gear performance.

Note!

 Be careful of oil spill during maintenance work.

 Wait for hydraulic fluid and mechanical parts to cool down before working on
the equipment.

4.3.2 Hydraulic system start-up after maintenance:

 After maintenance check all piping connections for tightness before start up.
 Make sure that the cocks on expansion tank are opened before start up.
 De-air the hydraulic system if any hydraulic parts have been replaced or pipes opened.
 Re-fill the expansion tank if any hydraulic fluid has been removed.

4.3.3 Electric system shut down prior to maintenance:

 Stop all the pumps on the Steering Gear before shut down of power supply.
 Wait for the Frequency Converter to discharge after shut down before doing maintenance
work.
 Turn off main switch for all cabinets before doing maintenance work.

Note!

 Always check for voltage on wires before touching or doing maintenance work

4.3.4 Electric system start-up after maintenance:

 Make sure that the pumps are in local stop mode when switching on power supply.
 Check voltage from switch board before turning on isolation switch in all cabinets.


4.4 Actions on Alarm Occurring

If there is defect in the Steering Gear System, the alarm buzzer gets activated. The alarm light
starts to flash on both alarm panels independently.

To acknowledge the alarm follow the instructions:

1) Push the “ACK” button once. It switches off the local buzzer but the alarm lights will
continue flashing.

Page 44 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
2) Push the “ACK” button once again. If there is no defect, the alarm light goes off. The
flashing alarm light changes to steady light, if defect is still present.
Note!

 If the defect remains more than three second, the alarm gets activated.
 Alarm panel in ECR is not supplied with backlight.

Standard alarm functions Action

Overload pump Stop the faulty pump, and start the other pump
if not already running.
Phase failure pump Stop the faulty pump, and start the other pump
if not already running.
Power failure pump Start the other pump if not already running.
Power failure control Stop the faulty pump, and start the other pump
if not already running.
Low oil level pump Check the reason and refill oil.
Hydraulic lock alarm pump Stop the faulty pump, and start the other pump
if not already running.
Power failure auxiliary steering Steer by means of the emergency steering.
Isolation valve failure Start the other pump if not already running,
stop the faulty pump if not already stopped.
Optional alarm functions Reason for alarm / used when
Clogged filter pump (Class/Rolls-Royce Marine Sensor on the filter unit
requirement)
High oil temp pump (Class/Rolls-Royce Marine Start the other pump if not already running.
requirement)
Earth failure alarm pump (Customer Only activated when the motor is not running
requirement)
Rudder synch failure alarm (Customer Only used on vessels with two rudders
requirement)

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 45 of 113

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
5 MAINTENANCE INSTRUCTIONS
This chapter describes all relevant maintenance procedures and activities to be carried out by the
Crew.

WARNING

KEEP THE EQUIPMENT ON A STABLE AND SAFE SURFACE TO PREVENT

PERSONAL INJURY AND EQUIPMENT DAMAGE DURING MAINTENANCE.

A SERIOUS ELECTRICAL SHOCK HAZARD EXISTS WITHIN THE COVERS OF THE

COMPONENTS AND ON MARKED LOCATIONS INSIDE THE CABINETS (MARKED
WITH 220 VAC OR 24 VDC).

CAUTION

 IF A DEVICE IS DAMAGED OR FAILS TO FUNCTION CORRECTLY,

DISCONNECT IT FROM THE POWER SOURCE.

 THE LIFE SPAN OF ELECTRONICS CAN BE AFFECTED BY DAMAGE

CAUSED BY ELECTROSTATIC DISCHARGE. THIS CAN HAPPEN IF A
CHARGED TOOL OR PERSON TOUCHES A COMPONENT.
THEREFORE IT IS NECESSARY THAT ALL TOOLS AND PERSONNEL
ARE DISCHARGED BY TOUCHING A GROUNDED POINT BEFORE
THE PRINTED CIRCUIT BOARD OR ANY OF THE COMPONENTS
ARE TOUCHED. IT IS ALSO NECESSARY TO DISCHARGE THE
PACKAGE WITH THE NEW COMPONENT BEFORE OPENING IT

 DO NOT ATTEMPT TO REPAIR ANY SUB-COMPONENT YOURSELF

CONSULT A QUALIFIED ROLLS-ROYCESERVICE TECHNICIAN.

5.1 Maintenance Overview

Rolls-Royce Steering Gears are designed for safe operation with a minimum maintenance. To
prevent unexpected problems, it is recommended that the users maintain the Steering Gear
System at regular intervals.

For scheduled class survey for general overhaul or repair, it is recommended to seek the help of
engineers from Rolls-Royce or Rolls-Royce approved engineers. This will decrease the time of
repair to a minimum and ensure continuous safe operation. Steering Gear maintenance activity is
classified as follows:

 Preventive maintenance
 Conditional maintenance
 Corrective maintenance.

Page 46 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Sl. Every Every

Activity Daily Weekly Monthly
No 6 Month year

Check for abnormal noise

1 X
from the Pump and Valve.

Visual Check on oil leakage

2 X
and level in expansion tank

Check Frequency Converter

3 X
display for error message.

Conduct functional test of

steering modes from all
4 X
steering stations, normal and
emergency mode.

All operational personals

(Crew) must be trained to
operate the Steering Gear on
5 X
all operating modes and
emergency operating
procedures.

6 Perform visual check of filter. X

Perform visual check of pump

7 X
and motor coupling.

Make sure that all electrical

8 indication push button back X
light bulbs are Illuminated.

Test alarm system by

9 X
pressing the “test” button.

10 Replace filter element. X

September 2013 Rolls-Royce Steering Gear SR - Operating and Maintenance Manual Page 47 of 113

Check electrical connections

11 X
and insulations

Collect sample of hydraulic oil

12 X
from the hydraulic system.

Perform visual and smell

check of all Electrical
13 components included in the X
alarm, control and steering
system.

Check for internal leakage

14 X
(See chapter 5.4.1)

Check all electrical

components for proper
earthing of switches, cable
15 X
connections, and the
insulation properties the
motor.

Check communication system

16 between Steering Gear room X
and the bridge.

Page 48 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
5.3 Preventive Maintenance
Do the scheduled maintenance or the scheduled replacement to keep the equipment in operating
condition and to extend the life of the equipment.

Do the preventive maintenance on scheduled intervals such as daily, weekly, monthly and yearly.

5.3.1 Frequency Converter Error Log

Check that there are no obstructions to the flow of cooling air over the cooling ribs of the FC and
that the FC is not covered by dust. Check that the cover is properly secured

Press the alarm log push button on the frequency converter's local control panel. All incidents in
the alarm log are time stamped with running hours as reference. Use the up and down push
buttons to navigate in the alarm log. Press the Status push button to finish reading the alarm log
(See Figure 20).

Figure 20 Frequency Converter

Page 49 of 113 Rolls-Royce Steering Gear SV – Operating and Maintenance Manual March 2012

 Using oil other than that specified by Rolls-Royce Marine may cause
malfunctions when maneuvering the vessel. This may cause personal
injury and equipment damage.

 Before using other brands, please contact Rolls-Royce Marine.

Note!
The oil is one of the main components in a hydraulic steering gear, and must therefore be selected
and handled with this in mind. The performance of the unit is highly depended on the viscosity of
the oil. The surrounding temperatures of the hydraulic components when operating at extreme
temperature conditions, tropic or arctic waters, shall be taken into account when selecting type of
oil.

General requirement to the hydraulic fluids used on Rolls Royce Steering Gear should meet DIN
51524.

The viscosity index improve must not be broken down and effect flow and lubrication properties

Pour point should be below -30o centigrade.

The oil must contain the following additives.

Performance qualities:

a. Anti-wear properties

b. Water and foaming resistance

The following hydraulic oils are approved and recommended by Rolls Royce marine

Manufacturer Type
AGIP AGIP ARNICA 32
BEVEROL HV-ISO32
BP BARTRAN HV32
CALTEX RANDO HDZ32
CASTROL HYSPIN AWH-M 32
CENTURY NEVIS 7
CEPSA CEPSA HV 32
CHEVRON RANDO HDZ32
SHELL TELLUS T32
STATOIL HYDRAWAY HVXA 32
TEXACO RANDO HD Z32
YUKONG ZIC SUPERVIS X32

Page 50 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
Manufacturer Type
EXXON MOBIL DTE10 EXCEL 32
NYNÄS HYDOL 32
ESSO (Exxon) UNIVIS N 32
HISPANO
HYDRO DRIVE HP150
QUIMICA, S.A
LUB MARINE
VISGA 32
(TOTAL)
MOBIL SYNTHETIC MOBIL SHC 524

CAUTION!
Do not mix hydraulic oil with other types of oil. Even very small amounts of other oil in the hydraulic
oil, will considerably lower the quality of these oils.

Change the oil when laboratory tests show:

High neutralizing number

Low remaining amount of EP-additives

High amounts of insoluble particles in the oil

Oil cleanliness no longer is within 17/14 or better according to ISO standard 4406, class 8 or better
according to NAS 1638

If components of the hydraulic system have been broken down.

5.3.3 System oil volume

Model Oil volume

SR 562 Approx 35 litre
SR 622 Approx 45 litre
SR 642 Approx 50 litre
SR 662 Approx 65 litre
SR 722 Approx 125 litre
SR 723 Approx 120 litre
SR 742 Approx 160 litre
SR 743 Approx 150 litre

Page 51 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

WARNING

IT IS EXTREMELY IMPORTANT THAT OIL BOTTLE USED FOR OIL SAMPLING

IS CHEMICALLY PURE, AND THAT THE PROCEDURE IS PERFORMED WITH A
HIGH DEGREE OF CLEANLINESS.

5.3.4.1 Oil Level:

Examine the oil level in the expansion tank is correct, when oil is visible in the upper level gauge
glass. Correct oil level for a long time indicates no leakage. If the oil level is low, operate the pump
manually to refill the oil from the storage tank. Do visual inspections of all components including
pipes and connectors to find the cause for the low oil level. Repair the oil leak immediately.

Do the visual inspection regularly to find the oil leak and repair immediately.

5.3.5 Oil sampling

Spare parts Ref. no Special tools and test equipment Qty

Sample bottle 1
Sampling hose 1
Container/bucket 1

Reference documents Consumables Qty

Technical data chap. 5 Linen rag
Oil, as recommended in chapter 5

Note!
The hydraulic system must be running for a while before the oil sampling procedure is carried out.

The oil sampling points are located on the upper rear

valve block port and stbd.

Page 52 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

2. Remove the protecting cap [1].

3. Connect the pressure measuring hose [2] to the

measuring point while the Steering gear is
manoeuvred.

4. Flush the hose by letting some of the oil run through

the hose and in to a bucket.

5. Fill a clean sample bottle [4] with oil.

CAUTION!
It is extremely important that oil bottle used for oil
sampling is chemically pure, and that the procedure is
performed with a high degree of cleanliness.

6. Close the sample bottle.

7. Attach label to sample bottle indicating AQM type and

number.

Oil type

Date

Sampel taken by

Used for how long

8. Compare sample with new oil by visual examination

and smelling.

9. If oil colour or smell has clearly changed or there are

impurities in the oil, change the oil.

Page 53 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Note!
Use only recommended type of oil according to chapter 5.1

The oil must at all times meet the specification for actual type of oil used in the system. Take oil
samples regularly.

Follow the instructions regarding oil change intervals or the recommendations based on an oil
sample test.

Page 54 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
5.3.6 Internal leakage test
The procedure will rely on timing the movement of the rudder going from 30 deg on one side to 30
deg on the opposite side. The test is recommended to be done when vessel either is lying still,
alongside or in open waters.

1) On the Motor Controller Cabinet (See Figure 21) in the steering gear room - turn the

selector switch (1) to position 3 - Local Control.

2) Turn the selector switch on the other Motor Controller to position 2 " STOP".

3) Use the Emergency Steering push buttons (3) to operate the steering gear

4) Move the rudder to a position about 33 degrees angle to one side.

5) Start moving the rudder by using push buttons (3). Start timing when rudder passes 30

degrees angle and stop timing when position reaches 30 deg on the opposite side.

6) Release push button!

7) Repeat procedure in opposite direction.

8) Repeat step 1 to 7 for the other Motor Controller.

Direction Time
Pump no 1 Stbd to Port Sec
Pump no 1 Port to Stbd Sec
Pump no 2 Stbd to Port Sec
Pump no 2 Port to Stbd Sec

Page 55 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

5.4 Visual inspection

5.4.1 Check the Limit Switches
1) Open feedback unit and observe the limit switch activation when running the Steering
Gear (See Figure 22).
2) Check the set screws (1) are present and tight.
3) Activate the switches by hand to confirm spring and switch functionality.

Figure 22 Limit Switch

5.4.2 Check the Solenoids Coil

Check solenoid coil (See Figure 23) connection plug for water or moist that can cause earth fault
or short circuit.

Page 56 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

5.4.3 Check of Feedback Potentiometer

1) Open the feedback unit and observe the potentiometer (1) when running the Steering
Gear (See Figure 24).
2) Check the set screw (1) securing potentiometer shaft is secure.
3) Check for any loose wires.

Figure 24 Feedback Potentiometer

5.5 Test of Emergency Steering

Make sure that the crew is informed before doing emergency steering test operations.

While doing emergency steering operation always have radio contact with bridge.

Page 57 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1) Turn selector switch for both Motor Controllers to position 3 “LOCAL CONTROL” to
enable the emergency push buttons located on the Motor Controllers.

Figure 25 Selector Switch

2) Perform steering by pushing the Emergency Steering buttons on the Motor Controller
Cabinet (See Figure 26)

Figure 26 Emergency steering buttons

3) After the test is done, put both Selector switches back to position 1 "Remote Control"
to gain steering access on the bridge.

5.6 Check for Proper Earthing

5.6.1.1 For testing on units with power on

Use a universal instrument and measure the voltage between the component (El-Motor, Frequency
converter or Motor controller) and true earth. The reading must be 0 Volt, if there is a proper
earthing.

5.6.1.2 For testing on units without power

Use a mega ohm tester to check the resistance between the earth connection on the component
and true earth (neutral ground).

5.7 Check for System Temperature

While examining the hydraulic system it is recommended to measure the system temperature by
an infra-red thermometer. Examine and make sure that there is no sudden change in temperature
of the pump, valve block, steering gear housing or expansion tank. Systems have alarm sensors
that monitor the temperature as an alternative.

The usual system temperature will change from system to system according to ambient
temperature and the condition it operates under.

Page 58 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
The maximum permitted ambient temperature according to the class standard is 45 °C. Maximum
recommended short time peak temperature on the system is 70°C - 80 °C.

If the systems are cold (below 10°C - 20 °C) it is recommended to increase the ambient
temperature. If it is not possible to increase the ambient temperature, replace the hydraulic oil to
one viscosity grade lower.

5.8 Corrective Maintenance

Corrective maintenance is a maintenance task performed to identify, isolate, and rectify a defect.
Then the defective equipment is restored to its operating condition within the tolerance limit given
for in-service operations.

5.8.1 Recovering From a Frequency Converter Trip Lock

If a Frequency Converter goes into a trip lock condition, this will generate a Steering Gear Power
Failure Alarm.

Before resetting the FC trip lock condition, the reason for the Trip lock condition must be
investigated and fixed.

Do the following procedures to recover from the FC trip lock.

1) Turn the selector switch at the front door of the adjacent Motor Controller Cabinet to
position 2 “STOP”.
2) Open the front door of the Motor Controller Cabinet and locate the isolation switch
marked as S1.
3) Turn the isolation switch to “OFF” position.
4) Wait for a few seconds until all the lights of the FC goes off.
5) Turn the isolation switch to “ON” position.
6) Close the front door of the Motor Controller Cabinet and turn the selector switch to
“REMOTE CONTROL” position.
The system will now return to normal operation.

5.8.2 Recovering From a Hydraulic Lock

A Hydraulic lock alarm is initiated by several conditions:

 Stuck inlet valves

 Wrongly adjusted proximity sensors
 Broken proximity sensors
 Electrical noise picked up due to inadequate cabling or inadequate termination of
cable screening
 Broken hydraulic pump
 Broken motor-pump coupling
 Broken electric pump motor
 Faulty Frequency Converter
 Wrong Frequency Converter parameters
 Contact problem at intermediate relays
 Loose wires
 Broken Opto-coupler in the Pump control card
 Faulty Amplifier card.

Page 59 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
In order to clarify the reason for hydraulic lock alarm please read and understand below.

The hydraulic lock alarm is made as a combination of four signals, two from the steering control
system and two from the Steering Gear inlet valves.

All signals are connected in the Motor Controller, at unit U2, input 17, 18, 19 and 20. Inputs 17 and
18 come from the Pump’s control card opto-couplers, while 19 and 20 comes from the pump’s inlet
valve proximity switches.

Figure 27: Hydraulic Lock Circuit

The feedback unit’s limit switches will disconnect input 17 and 18 at the Steering Gear’s hard over
positions through K15 and K16 relays.

Please perform a port and starboard manoeuvre to check these signals. And also note the LED
condition without manoeuvre. Input is active when the input LED is on.

Correct conditions for the inputs are:

 Input 19 and 20 active without manoeuvre. In case 19 or 20 not come on, there is a
problem with one of the proximity sensors or inlet valves.
 Input 17 and 20 active with port manoeuvre
 Input 18 and 19 active with starboard manoeuvre
 Other than these conditions will activate the alarm after the preset delay of 5 sec.
 If input 17 or 18 is missing at normal manoeuvre, please check K15 and K16 relays.

Page 60 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
5.8.3 Repair the Frequency Converter
The Frequency Converter is not of Rolls-Royce make, after reseting if failure is permanent the
converter need service or repair from autorised instance, please contact Rolls-Royce for
clarification and arrangements.

5.9 Dismantling and Reinstallation

Reference is made to Installation Manual SR Mechanical & Hydraulic System, Chapter 7.8

5.10 Adjustments

WARNING

INCORRECT INSTALLATION, OPERATION, SERVICING OR REPLACEMENT OF

PARTS CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH, AND/OR
EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO
PERFORM ELECTRICAL AND MECHANICAL SERVICE.

5.10.1 Adjustment of Feed Back Unit Limit Switches

Tools and Equipment Quantity

Screw driver 1
Hexagonal key 2
1) Set the Steering Gear Motor Controllers Selector switches to position 3 “LOCAL
CONTROL” (See Figure 28).
2) Remove the cover of the feedback unit which limit switches are to be adjusted.
3) By using port push button, move Steering Gear to hard over mechanical stop.
4) Move the Steering Gear position 4 degrees back from mechanical stop.
5) Loosen the nut (1) installed on top of the cam rings.
6) Use a hexagonal key to open the locking screws (2) installed with the lower ring
(port).
7) Adjust the lower ring (Port) until the related limit switch is activated.
8) Tighten the locking screws (2) with the hexagonal key.
9) Perform steps 6 through 8 again for starboard locking ring (3), and if the low angle
setting (4), (5) and are installed.

Page 61 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1 Nut 4 Low angle port limit switch
assembly (if fitted)
2 Port locking screws 5 Low angle starboard limit switch
assembly (if fitted)
3 Starboard locking ring

Figure 28 Feed Back Unit (FCP)

10) Tighten the nut (1) installed on the cam rings.

11) Replace the feedback unit cover.

5.10.2 Adjustment of Control System and Rudder Indicator System Transmitter

Tools and Equipment Quantity

Screw driver 1
Ohm-meter 1

1) Set the selector switch on the Motor Controller to position 3 “LOCAL CONTROL"
(See Figure 29).
2) Move rudder to zero position with the port/starboard push buttons.
3) Set the selector switch on the Motor Controller to position 2 “STOP".

Page 62 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

4) Remove the cover on the feedback unit.

5) At the terminal block, disconnect the red wire (2) from the centre point of the
feedback potentiometer and the green (3) and yellow wires (4) from the end points
(See Figure 30).
6) Measure the resistance between red wire (2) green wire (3) and red wire (2) yellow
wire (4). The resistance must be equal at each point.
7) If necessary, loosen the locking screws (5) and turn the potentiometer (6) until
resistance between the end points and midpoint to each side is equal.

Figure 30 Potentiometer

8) Tighten the locking screws (5).

9) Reconnect the red wire (2), green wire (3) and yellow wire (4) to the terminal block.
10) Install the feedback unit cover.

5.10.3 Adjustment of Control System Amplifier Card

Tools and Equipment Quantity

Screw driver 1

1) Start the pumps from the main control panel.

Page 63 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
2) Set the switch to follow-up steering (1) mode(See Figure 31).
3) Move the selected controller (2) to 30 degrees port or starboard side.

Figure 31 Main Control Panel

4) Adjust gain and amplifier card P20 (4) until the position of the Steering Gear is 30
degree (See Figure 32).
5) Increase sensitivity setting on adjuster P60 (3) (clockwise) until the follow-up system
starts oscillating on rudder commands. The oscillation can be observed on the 4 LED
(ordered signal port/starboard for each pump) on front of the amplifier card.
6) Adjust P60 (3) counter clockwise one half turn to remove oscillation.
7) Turn the controller and check for oscillation. If oscillations are present repeat step 6
until oscillation stops.

Figure 32 Control System Amplifier card

Page 64 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Screw driver 1

Reference Drawings Drawing Number

Cable diagram
1) Start the pumps from the main control panel (See Figure 33).
2) Push the corresponding “IN COMMAND “button (1) to engage the follow-up controller.

Figure 33 IN COMMAND Button

3) Operate the controller to mid-ship command and make sure that the rudder position
to mid-ship position is correctly aligned. If it is misaligned loosen the clamp screw (2)
adjust the 0-point and turn the potentiometer (1) until rudder mid-ship position is
correctly aligned (See Figure 34).

Page 65 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Figure 34 Potentiometer

4) Operate the selector controller to 30 degrees port or starboard direction.

5) Make sure that the rudder position is correctly aligned. If not, adjust the
potentiometer.
6) Tighten the clamp screw (2).

5.10.5 Adjustment of Dimmer

Tools and Equipment Quantity

Screw driver 1

1. On the control panel, adjust the dimmer to minimum

illumination.

2. Find the dimmer card located on the terminal list /plate

for the control panel.

Page 66 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3. Adjust the potentiometer P20 [1] using a screw driver
until a minimum of illumination is achieved.

5.10.6 Adjustment of Rudder Angle Amplifier

Tools and Equipment Quantity

Screw driver 1

Reference Drawings Drawing Number

Rudder Angle Indicator Refer Technical

amplifier drawing Specification
1) Check that the steering gear is in zero position according to the mechanical rudder
angle indicator on the actuator (See Figure 35) (1)).

Figure 35 Mechanical Rudder Indicator

2) If the rudder indicators are out of zero position, a zero adjustment can be done on the
rudder indicator amplifier adjuster P20 (2) (+/- 2 degrees) (See Figure 36).

Note!

Page 67 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

3) Operate the Steering Gear manually from the Steering Gear Room until the
mechanical rudder indicator reaches 35 degrees port.
4) If required, adjust the gain (P30) (3) on the rudder indicator amplifier until the one of
the rudder indicators show 35 degrees port. Additional rudder indicators can be
adjusted separately if necessary.

Note!

 Independent adjustment can be made on each rudder indicator by means of

integrated gain controls on each indicator

Figure 36 Rudder angle indication Amplifier

5) If required, adjust the galvanic isolated +/- 10V rudder position signal as follows:.
 Position the Steering Gear 5 degrees before the Steering Gear mechanical
stop.
 Adjust (P40) (4) until the rudder position signal equals 9V.

5.10.7 Adjustment of Relief Valve Pressure

Tools and Equipment Quantity

Hexagonal key 1
Adjustable spanner 1
Screw driver 1

Reference Drawings Drawing Number

Technical Specification

The adjustments must be done separately for the port and starboard side. The procedure below
describes the adjustment of the valves by running pump 1:

Page 68 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1) Turn selector switch (Figure 37(1)) on pump 1 Motor Controller to position 3 “LOCAL
CONTROL”.
2) Turn selector switch selector switch (2) on pump 2 Motor Controller to position 2
“STOP”.
3) Locate the load control valves (3) for pump 1.
4) Loosen nut (4) on both valves.
5) Set both valves to max pressure by fully screwing in adjustment screw (5).
6) Open the pressure gauge cocks (Figure 38(1)).
7) Operate the Steering Gear carefully using Port push button (2) of Motor Controller
No1 until the actuator is fully against the mechanical stop.
8) Keep Port push button pressed until the pressure on port pressure gauge (3) has
reached its maximum. Note the reading.
9) Release the pressure, by pressing the starboard button. If the pressure reading taken
in step 8 is correct proceed to step 14. If not, continue to step 10.
10) Locate relief valves (4).
11) Unscrew the cap nut on the port relief valve (5).
12) Repeat step 8 and adjust the relief valve (6) setting to the correct pressure using a
screw driver.
13) Refit the cap nut and recheck the pressure as detailed in step 8.
14) When port pressure is correct, operate the Steering gear in opposite direction and
repeat the procedure for stbd relief valve.
15) When the pressure is correct on both sides, the relief valve set point is finished.
16) Reset the load control valve see section 5.10.8

1 Selector switch (pump 1) 4 Lock nut

2 Selector switch (pump 2) 5 Adjustment screw
3 Load control valve

Page 69 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

1 Pressure gauge cock 4 Relief valves

2 Port push button 5 Port relief valve
3 Port pressure gauge 6 Adjustment screw

Figure 38 Relief Valve Pressure Adjustment

Page 70 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Hexagonal key 1
Adjustable spanner 1

Reference Drawings Drawing Number

Refer the Technical Specification

1) Set selector switch (1) on Pump 2 (Starboard) Motor Controller to position 2 “STOP”
(See Figure 39).
2) Set selector switch (2) on Pump 1 (Port) Motor Controller to position 3 “LOCAL
CONTROL”.
3) Open the pressure gauge cocks (Figure 38(1)).
4) Operate the Steering Gear carefully using Port push button (See Figure 39) of Motor
Controller No1 until the actuator is fully against the mechanical stop.
5) Keep Port push button pressed until the pressure on port pressure gauge (3) has
reached its maximum. Note the reading.
6) Release the pressure, by pressing the starboard button. If the pressure reading taken
in step 5 is correct proceed to step 10. If not, continue to step 7
7) Slacken the lock nut (6) and Operate the Steering Gear carefully using Port push
button (2) of Motor Controller No1 until the actuator is fully against the mechanical
stop.
8) Keep Port push button pressed and adjust load control valve adjusting screw (3) until
correct pressure is achieved.
9) Tighten the lock nut (7).
10) When port load control valve setting is correct, operate the Steering gear in opposite
direction and repeat the procedure for stbd load control valve.
11) Adjustment of “working pressure” on both port and starboard are now finished for
pump 1. Repeat the same procedure for pump 2.
12) Set selector switch on the Pump 1 Motor Controller to position 2 “STOP”, and
selector switch on Pump 2 Motor Controller to position 3 “LOCAL CONTROL”.
Repeat the procedure above using the push buttons on front of the Pump 2 Motor
Controller.

Page 71 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1 Selector switch (pump 1) 5 Starboard pressure gauge
2 Selector switch (pump 2) 6 Locknut
3 Adjustment screw 7 Adjustment screw
4 Starboard button

Figure 39 Load Control Valves pressure adjustment

Page 72 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Two proximity sensors are fitted for each pump on the port and starboard inlet valve. All sensors
are connected to the alarm system in motor controller (See Figure 40).

1) Use voltmeter to read the voltage in proximity connection box. Connect voltmeter to
terminal X1, 2-3 (port sensor), X1, 2-4 (starboard sensor).
2) Voltage is 24VDC without manoeuvre.
3) Unscrew sensor until there is a voltage drop to 0VDC, then turn the sensor 90
degrees CW (voltage will increase to 24VDC).
4) Do above adjustment on both the sensors on both the pumps.

Figure 40 Proximity Circuit

Page 73 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

WARNING

INCORRECT INSTALLATION, OPERATION, SERVICING OR REPLACEMENT OF

PARTS CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH, AND/OR
EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO
PERFORM ELECTRICAL AND MECHANICAL SERVICE.

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

FAILURE TO SECURE THE WIRING AND/OR COVERS MAY RESULT IN

PERSONAL INJURY AND/OR EQUIPMENT DAMAGE.

5.11.1 Replacement of Pump Control Card

Tools and Equipment Quantity

Screw driver 1
Ohm-meter 1

Parts Reference Number

Pump control card 5801-CS-PCC-01

Reference Drawings Drawing Number

Control system unit drawing Refer Technical

Specification

1) Switch off the main power supply to the control system. By disconnecting power
supply to the corresponding motor controller.
2) Open the control system cabinet.
3) Disconnect all connected wires (See Figure 41 (1)) from the pump control card.
4) Loosen the four screws (Figure 41 (2)) securing the pump control card.
5) Replace the faulty pump control card.

Page 74 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

6) Tighten the screws securing the card.

7) Connect all the wires.
8) Close the control system cabinet.
9) Turn on the main power supply to the control system.

5.11.2 Replacement of Limit Switch in Feed Back Unit

Tools and Equipment Quantity

Screw driver 1
Soldering kit 1

Parts Reference Number

Limit switch 5400-V3-9119M

Reference Drawings Drawing Number

Feedback unit drawing Refer Technical

Specification

1) Switch off the main power supply to Motor Controller by turning off the S1 isolating
switch inside the Motor Controller.
2) Remove the cover on the feedback unit (See Figure 42).

Page 75 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
3) Identify the defective limit switch (2).
4) Loosen the screws (1) on top of the switch assembly.
5) Using a soldering iron, release the wiring from the switch.

Figure 42 Feed Back Unit

6) Solder the wiring to the new limit switch.

7) Tighten the screws (1) on top of the switch assembly.
8) Turn on the S1 isolation switch inside the Motor Controller to Switch on the main
power supply to the Motor Controllers.
9) Adjust the limit switch as detailed in section 5.10.1.
10) Install the cover on the feedback unit.

5.11.3 Replacement of Amplifier Card

Tools and Equipment Quantity

Screw driver 1

Parts Reference Number

Amplifier card 5801-CS-AMP-01

Reference Drawings Drawing Number

Control system unit drawing Refer Technical

Specification
1) Turn off the S1 isolation switch inside each Motor Controller to switch off the main
power supply to the both Motor Controllers.

Page 76 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

 ELECTROSTATIC DISCHARGES CAN DAMAGE COMPONENTS.

 TO PREVENT DAMAGE ALWAYS USE A GROUNDED
ELECTROSTATIC DISCHARGE BRACELET WHILE WORK IS
BEING PERFORMED.

2) Open the control system cabinet.

3) Use an ESD wrist band.
4) Remove the faulty amplifier card (1).

Figure 43 Amplifier Card

5) Install the new amplifier card (1).

6) Turn on the S1 isolation switch inside the Motor Controller to Switch On the main
power supply to the Motor Controllers.
7) Close the Motor Controller doors.
8) Adjust the new amplifier card.

Page 77 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Screw driver 1

Parts Reference Number

Selector card 5801-CS-SEL-01

Reference Drawings Drawing Number

Control system unit drawing Refer Technical

Specification

1) Turn off the S1 isolation switch inside the Motor Controllers to switch off the main
power supply to both Motor Controllers.
2) Open the control system cabinet.

CAUTION

 ELECTROSTATIC DISCHARGES CAN DAMAGE COMPONENTS.

 TO PREVENT DAMAGE ALWAYS USE A GROUNDED
ELECTROSTATIC DISCHARGE BRACELET WHILE WORK IS
BEING PERFORMED.

3) Use an ESD wrist band.

4) Remove the defective selector card(s) (1) (See Figure 44).

Page 78 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

5) Set the jumper settings on the new card to the same as the defective card, and install
the new card (1).
6) Close the control system cabinet.
7) Turn on the S1 isolation switch inside the Motor Controllers to switch on the main
power supply to the Motor Controllers.

Page 79 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Screw driver 1

Parts Reference Number

Alarm system cards Refer to parts list

Reference Drawings Drawing Number

Alarm panel drawing Refer Technical

Specification
1) At the bridge distribution board, make sure that the power supply to the alarm system
is switched off.
2) Open the alarm system panel.
3) Loosen the alarm system card/cards connection.
4) Remove the alarm system card/cards.

Figure 45 Alarm System Cards

5) Set the X8 and X9 nodes on the new card to the same as the defective card and
install the alarm system card(s).
6) Tighten the alarm system card/cards connection.
7) Close the alarm system panel.
8) Turn on power supply.

Page 80 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Dismantling kit 2

Parts Reference Number

Bulb See parts list

Reference Drawings Drawing Number

Cable drawing Refer Technical

Specification
1) Remove the bulb cover with the dismounting tool (See Figure 46).
2) Remove the defective bulb with the tool.

Figure 46 Control Panel Bulb

3) Install the new bulb.

4) Install the bulb cover.

5.11.7 Replacement of Proximity Switch (Sensors)

Parts Reference Number

Proximity switch See part list

1) Turn off all the pump units. (Set the Selector switch on Motor Control Cabinet to
position 2 “STOP").
2) Close oil cock under expansion tank for feeder oil to enter the pump.
3) There will be slight oil spill. Place a suitable receptacle under the sensors to be
replaced.
4) Disconnect the wires in the connecting box for the sensor to be replaced. Note the
positions of the colored wires in the terminals.
5) Disconnect the armoured cable sleeve from the sensor's cable entry.
6) Unscrew the sensor/mounting plug (1) and remove it from the housing (See Figure
47).

Page 81 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
7) Install the new sensor/mounting plug and ensure minimum oil spill. Make sure that
the O-ring at the front end of sensor is in correct position.
8) Connect the new cable from the sensor to the connecting box through the armoured
cable sleeve. Trim the sensor cable to correct length.
9) Connect the armoured sleeve to the mounting plug.
10) Connect the 3 colored wires to the correct terminals in the connecting box.
11) Adjust the switch as detailed in section 5.10.9
12) Open the oil cock for the feeder pipe line.
13) Turn selector switch on Motor Controller to position 1 “REMOTE CONTROL".

Figure 47 Proximity Switch

5.11.8 Replacement of Relief Valve (Safety Valve)

Parts Reference Number

Safety valve See parts list

1) Close the valves on the expansion tank.

2) Set the switch on starter 1 and 2 to position 2 "STOP".
3) Use an applicable tool to remove the defective relief valve (1) (See Figure 48).
4) Carefully install the new relief valve. Torque the valve correctly (no torque value is
specified on the drawing).
5) Open the cocks on the expansion tank.
6) Set the starter switch to position 3 "LOCAL CONTROL”.
7) Adjust the valve as detailed in section 5.10.7

Page 82 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

5.11.9 Replacement of Filter Insert

Spare parts Ref. Special tools and test equipment Qty

no
Bucket 1

Reference documents Consumables Qty

Linen rag As req.

A clogged filter will be indicated either by an alarm, or

locally by an indicator [1] on the Steering gear filter, as
illustrated in the picture.

Note!
Normal system temperature important.

Page 83 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1. Turn the selector switch [2] on the current motor
controller to position 2 “stop”.

2. Turn the connecting oil chocks [3] on the expansion

tank to closed position.

3. Place a bucket underneath the filter bowl.

4. Unscrew the filter bowl [4], as illustrated in the picture

5. Refit a new filter bowl.

6. Open the connecting oil chocks on the expansion tank.

7. De-air by drain the top of distributing valve.

8. Turn the selector switch on the motor controller to position 1 “remote control”.

Page 84 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Adjustable spanner 1
Screw driver 1

Parts Reference Number

Solenoid See parts list

1) Set the selector switch (1) on the Motor Controller to position 2 “STOP” (See Figure
49).
2) Remove the solenoid nut (3).
3) Remove the Solenoid (2).
4) Remove the cable plug (4) from the solenoid using screw driver.

1 Selector switch 4 Cable plug

2 Solenoid 5 Emergency push buttons
3 Nut

Figure 49 Cable Plug

5) Install the cable plug.

6) Install the new solenoid and tighten the screw.

Note!

Page 85 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

7) Set the selector switch on the Motor Controller to position 3 “LOCAL CONTROL”.
8) Operate the emergency push buttons (5) on the Motor Controller.
9) If the test is ok, set the selector switch (1) on the Motor Controller to position 1
“REMOTE CONTROL”.

5.11.11 Replacement of Load Control Valve

Tools and Equipment Quantity

Allen key 10mm 1

Screw driver 1

Parts Reference Number

Balance valve See parts list

1) Set the selector switch on the motor controller to position 2 “STOP”.

2) Close the cocks on the expansion tank.
3) Remove the load control valve cartridge (1) (See Figure 50).
4) Install a new load control valve cartridge.
5) Tighten the load control valve cartridge socket-head screws to correct torque.

Note!

 Tighten the socket-head screws carefully to torque 130 Nm.

6) Set the selector switch on the motor controller to position 3 “LOCAL CONTROL”.
7) Open the cocks on the expansion tank.
8) Operate the emergency push button on the motor controller to bleed the steering
gear cylinders.
9) Continue operating the emergency push button on the motor controller.
10) If the test is ok, set the selector switch on the motor controller to position 1 “REMOTE
CONTROL”.
11) Set the load control valve as detailed in section 5.10.8.

Page 86 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

5.11.12 Replacement of Solenoid Valve

Tools and Equipment Quantity

Adjustable spanner 1
Screw driver 1

Parts Reference Number

Solenoid valve See parts list

1) Set the selector switch (1) on the Motor Controller to position 2 “STOP” (See Figure
51).
2) Close the shut-off cocks on the expansion tank.
3) Remove the solenoid nut (3).
4) Disconnect the power connector and remove the solenoid (2).
5) Remove the solenoid valve (4).
6) Install new solenoid valve.

Note!

 Tighten the valve carefully to the torque of 50 Nm.

Page 87 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
1 Selector switch 4 Solenoid valve
2 Solenoid 5 Emergency steering
buttons
3 Nut

Figure 51 Solenoid Valve

7) Install the solenoid, tighten the solenoid nut and re-connect the power connector.

Note!

 Tighten the nut carefully by a torque 5-8 Nm.

8) Open the shut-off cocks on the expansion tank.

9) Set the selector switch on the Motor Controller to position 3 “LOCAL CONTROL”.
10) Operate the emergency push button (5) on the Motor Controller.
11) If the test is ok, set the selector switch (1) on the Motor Controller to position 1
“REMOTE CONTROL”.

5.11.13 Replacement of Pump Unit

Tools and Equipment Quantity

Adjustable spanner 1
Screw driver 1

Parts Reference Number

Pump See parts list
1) Set the selector switch on the Motor Controller to position 2 “STOP” (See Figure 52).

Page 88 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

2) Switch off the power supply from main switch board to both motor controllers
3) Isolate pump and motor: Turn isolation switch (Figure 53) in Motor Controller cabinet
to position ‘0 OFF’.

Figure 53 Isolation switch

4) Close the shut-off cocks (2) on the expansion tank (See Figure 54).

Figure 54 Expansion Tank

5) Place a suitable container under the pipe connectors to catch hydraulic oil when
pipes are disconnected.
6) Take note of which pipes are connected to which pump to aid refitting.
7) Remove the connecting pipes (3) (See Figure 55).
8) Scribe lines across bell housing and electric motor to aid alignment when refitting.
9) Remove the bolts (4) that connect the bell housing to the electric motor.

Page 89 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

10) Remove the bell housing from the electric motor.

11) Remove the bolts (5) that connect the pump to the bell housing.
12) Remove the pump (6) with the flexible coupling from the bell housing.
13) Using a suitable sliding calliper, measure the distance between the two marked
surfaces shown in Figure 56 and keep for reference.

Figure 56 Measuring location position

14) Remove the grub screw securing the coupling hub to the pump spindle.
15) Remove the flexible coupling from the pump spindle.

Page 90 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

16) Align the key of the pump shaft with the coupling, and install the coupling onto the
pump shaft.
17) Slide the coupling onto the pump shaft until it is in the same position as noted in step
13.
18) Apply Loctite 243 to the grub screw and secure the coupling to the pump shaft.
19) Install the flexible coupling to the pump.
20) Install the pump to the bell housing.

Note!

 Make sure that the pump and the flexible coupling is installed correctly inside
the bell housing.

21) Install and tighten the nuts that retain the bell housing to electric motor.
22) Install the connecting pipes.
23) Open the shut-off cocks on the expansion tank, and release the air from the circuit.

Note!

 Make sure to start locally and repeat de-airing.

24) Switch on the power supply from main switch board to both motor controllers
25) Turn isolation switch (Figure 53) in Motor Controller cabinet to position ‘1 ON’.
26) Set the selector switch on the Motor Controller to position 3 “LOCAL CONTROL”.
27) Operate the emergency push button on the Motor Controller to verify functionatlity of
the pump.
28) Set the selector switch on the Motor Controller to position 1 “REMOTE CONTROL”.
Page 91 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
Page 92 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Tools and Equipment Quantity

Adjustable spanner 1

Parts Reference Number

Flexible coupling element See parts list

1) Remove the pump as detailed in section 5.11.13.
2) Replace the flexible coupling element (Figure 58).

Figure 58 Flexible Coupling

3) Install the pump as detailed in section 5.11.13.

Page 93 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
6 TROUBLE SHOOTING
6.1 Introduction:
Troubleshooting is the process of searching for the possible causes of failure or malfunction of the
system. It is used on a complex system where the symptoms of a problem can have many
possible causes.

Finally, troubleshooting confirms the solution to restore the system to its working condition.

This trouble shooting section has been classified as follows:

 Non Alarm Notified

 Alarm Notified

Make sure this trouble shooting section is used effectively, when a faulty symptom arises. The
engineer should execute the immediate action and identify the possible cause and then proceed
with the verification/test and rectification action.

Page 94 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Table 1 Pump does not Operate (Bridge Control Panel)

IMMEDIATE FAULT
SYMPTOM POSSIBLE CAUSE RECTIFICATION ACTION
ACTION IDENTIFICATION
Green light in
start button
Red “STOP” light
does not come
Check for broken Broken signal goes off but
on when Replace the lamp.
lamp. lamp. Steering Gear
Pushed (but
operates normally.
the motor
operates).
Broken push Examine wire between
button or Connect internally – primary panel and
disconnected wire X3:1 to control system cabinet
between the –X3:2 on the and function of the
Green light in primary panel and pump control card START push button and
start button Make sure that the pump control to start the pump. replace the defective
does not come the other pump card. connection.
on when operates, if not OR
pushed and start the pump.
motor does not Connected internally
operate. –X3:1 to
Broken pump –X3:2 on the pump Replace the Pump
control card control card but Control Card.
pump does not
operate.
Stop the
defective pump Fault with the
The Motor Examine the coupling
and make sure flexible coupling
operates but Hydraulic lock connection. Replace or
that the other between the
the pump does alarm activated. fix the coupling
pump is running, electric motor and
not operate. connection.
if not start the the pump.
pump.

Table 2 Unable to select the Steering Mode

IMMEDIATE POSSIBLE FAULT

SYMPTOM RECTIFICATION ACTION
ACTION CAUSE IDENTIFICATION
Examine the
Problem with override ON/OFF.
the Steering Switch off the override
Gear mode Examine if the DP
Switch off DP or Joystick.
Unable to Keep the steering selection. or the Joystick is
select the mode used ”IN COMMAND”.
steering before, which OR
modes on stayed ”IN The
Bridge. COMMAND”. Defective
Examine the push Replace the selector card or
selector card
button. replace the push button.
or the push
button.
Local control Keep the steering Broken N/A Replace the selector switch.
in SGR. mode used selector
Page 95 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
before, which switch.
stayed ”IN
COMMAND”.
Defective
Contact Rolls-Royce Marine
override N/A
Keep the steering Tech Support.
module.
mode used
Override OR
before, which
control. The
stayed ”IN
COMMAND”. defective Contact Rolls-Royce Marine
N/A
pump control Tech Support.
card.

Table 3 Cross Feed Pump Motor Indication shows it is ON, but the Rudder does
not operate

IMMEDIATE POSSIBLE FAULT RECTIFICATION

SYMPTOM
ACTION CAUSE IDENTIFICATION ACTION
The Vessel is not Change the pump
turned and the control card.
Broken
Rudder Angle
amplifier card. Change the
Indicator pointer is
not moved. amplifier card.
OR
Turn on the
The Vessel is not
override
turned and the
Bridge Control according to the Broken Change the
Rudder Angle
faulty. emergency selector card. selector card.
Indicator pointer is
steering
not moved.
procedure.
OR
The Vessel is not
Make sure that
turned and the
Loose wiring the wires are
Rudder Angle
connections connected
Indicator pointer is
correctly.
not moved.
The Vessel is not
Broken NFU- turned and the
Replace the NFU-
FU push Rudder Angle
Use emergency FU push buttons.
buttons. Indicator pointer is
steering in SGR not moved.
Override Control according to the
OR
faulty. emergency
steering The Vessel is not
procedure. Broken turned and the Replace the
override Rudder Angle override module.
module. Indicator pointer is
not moved.
Stop the The Vessel is not
defective pump turned and the
Solenoid Replace the
and make sure Rudder Angle
Emergency control Malfunction. solenoid.
that the other Indicator pointer is
faulty. not moved.
pump is running
if not start the OR
pump. Loose wire The Vessel is not Make sure that

Page 96 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
connections. turned and the the wires are
Rudder Angle connected
Indicator pointer is correctly.
not moved
Stop the
defective pump Jammed
Contact RR
and make sure hydraulic
Hydraulic valves Marine Service
that the other valve (s) N/A
faulty. Technical
pump is running among
Support.
if not start the several.
pump.

Table 4 Limited Rudder Operation

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Stop the
The
defective pump
Defective
Rudder operation and make sure
speed Examine speed of the Replace the
speed that the other
signal from pump. amplifier card .
decreased. pump is
the amplifier
running if not
card
start the pump
Stop the
defective pump The
The available and make sure defective Visual inspection of
Replace the relay
Rudder angle that the other relay in the relay (K15 and K16) in
(K15 and K16) .
decreased. pump is Motor Motor Controller.
running if not Controller.
start the pump.
Stop the
defective pump Replace the limit
and make sure switch See
Broken limit Measure resistance of
that the other procedure for the
switch. the switch.
Operates in one pump is replacement of the
direction. running if not limit switch .
start the pump.
Contact RR Marine
Use the other Internal Do the internal leakage
Service Technical
pump system. leakage. Test.
Support.

Table 5 Limited Control Operation (Drift)

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Operate Steering Contact RR Marine
Internal Do the internal
Drift. Gear with the two Service Technical
leakage. leakage test.
pumps. Support.

Page 97 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Make sure that the broken
Replace the
Broken Rudder indicator is compared with
N/A Rudder Angle
Angle Indicator. the other Rudder Angle
Indicator.
Indicators.
OR
Defective Replace the
N/A rudder angle N/A rudder angle
amplifier. amplifier.
OR
Rudder Broken Replace the
N/A N/A
Indicator Fault. potentiometer potentiometer.
OR
Defective
Measure the power Correct the
N/A power supply
supply. power supply.
24 VDC.
OR
Loose
Adjust and
potentiometer Visual inspection of the
N/A tighten the
in the feedback Feedback Unit.
Potentiometer.
unit.

Table 7 Defective Dimmer Display/Dimmer Knob Operated but the bulb does not
dim

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
The dimmer
Make sure that 24 VDC
unit is not
is available between X1- Attach the 24
N/A sufficiently
1 and X1-2 on the VDC supply.
supplied with
dimmer module.
24 VDC.
Defective Dimmer OR
Display/ Dimmer
Blown fuse Make sure that 24 VDC
Knob Operated but
on the is available between X1- Replace the fuse
the Bulb Does not N/A
dimmer 3 and X1-4 on the F10, if blown.
Dim.
module. dimmer module.
OR
Defective
Order a new
N/A dimmer N/A
dimmer module.
module.

Page 98 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Defective
Make sure to refer the
contacts on Replace the switch if
Motor Controller
Operate in the selector broken.
drawing for the circuit.
Start Pumps local control switch S2.
Defect. on the other OR
pump. Defective Make sure to refer to the
Replace the start
start relay Motor Controller
relay if broken(K11) .
(K11) drawing for the circuit.

Table 9 Rudder Control does not operate from the Steering Gear Room

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
Rudder Control Operate in local Defective Make sure to refer the Replace the
Fault. control on the contacts on Motor Controller drawing selector switch if
other pump. the selector for the circuit. broken.
switch S2.
OR
Defective Examine relay contact on Replace the relay
relay (K12). K12. K12.

Table 10 Noise from the Pump

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
Noise from the Stop the The Examine the Frequency Contact RR Marine
Pump. defective Frequency Converter display for Service Technical
pump and Converter warnings or error Support.
Start the other does not messages.
pump. operate the
motor pump
correctly.
OR
Pump N/A Replace the pump.
Damaged.

Table 11 Noise from the Valves

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
Noise from the Stop the defective Defective N/A Replace the valve.
Valves. pump and Start the valve.
other pump.

Page 99 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
Pop up Indicator on Stop the defective Filter N/A Replace the filter.
Filter Activated. pump and Start blocked.
the other pump.

Table 13 Oil Leakage from the Hydraulic System

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
External leakage Examine the Leakage on N/A Contact RR Marine
on Steering Gear. expansion tank the rotor Service Technical
oil for the seals. Support.
correct oil level.
External leakage Examine the Damaged N/A Contact RR Marine
on the power pack. expansion tank seals. Service Technical
oil for the Support.
correct oil level.

Table 14 System Temperature too Hot

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
High-temperature Stop the Defective Make sure that the Contact RR
alarm on the defective cooling fan in cooling fan operates. Marine Service
Frequency pump and the Frequency Technical
Converter. Start the other Converter. Support.
pump, if not OR
already High ambient Examine ambient Decrease
running.
temperature. temperature. ambient
temperature.
High oil Stop the Broken Check solenoid coil. Contact RR
temperature. defective solenoid coil. Marine Service
pump and Technical
Start the other Support.
pump, if not OR
already Valve N/A Contact RR
running. Blockage. Marine Service
Technical
Support.

Page 100 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
Warnings on the Monitor the The Record the pattern of Contact RR
Frequency Frequency Frequency warnings on the Marine Service
Converter Converter Converter Frequency Converter Technical
Display. Display to see operated Display. Support.
if there is a with too
pattern in the much load.
warnings.

Table 16 If Alarms Listed In Frequency Converter Log get Activated

SYMPTOM IMMEDIATE POSSIBLE VERIFICATION/TEST RECTIFICATION

ACTION CAUSE ACTION
Alarms Listed In Record the N/A N/A Contact RR Marine
Frequency alarms found Service Technical
Converter Alarm in the Alarm Support.
Log. Log.

Table 17 Overflow of Oil from the Expansion Tank

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Two pumps Internal Contact RR Marine
Overflow of Oil from Do the Internal
operate the seals Service Technical
the Expansion Tank. leakage test.
Steering Gear. damaged. Support.

Page 101 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Table 18 Overload Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Replace the
The Visual/electrical
solenoid. See
Broken solenoid. inspection of the
procedure chapter
solenoid.
0) .
OR
Stop the defective
The Visual
pump and Start
Overload inspection of the Repair the
the other pump, if Motor overloaded.
Alarm. motor electrical connection.
not already
connection.
running.
OR
The Defective
Find the Frequency Contact RR Marine
connection in the
Converter alarm Service Technical
Frequency
entry. Support.
Converter unit.

Table 19 Phase Failure Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Make sure that the
primary power
Broken phase Replace the phase
supply is included in
failure relay. failure relay.
the deviation
Phase Check power between the phases.
Failure supply and motor OR
Alarm. phases. Make sure that the
primary power
Defective power Repair the power
supply is included in
supply. supply.
the difference
between the phases.

Table 20 Power Failure/Frequency Failure Alarm

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Missing supply Examine and
Examine the primary
from correct the cause
power supply.
Stop the switchboard. of missing power.
Power failure defective pump OR
/frequency and Start the Motor Examine the primary
Turn on the primary
failure Alarm. other pump, if not Controller switch in the Motor
switch.
already running. switched OFF. Controller cabinet.
OR
Blown fuse Examine fuses in the Replace the fuse.

Page 102 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
F45-F46. Motor Controller.
OR
Damaged Examine the display on Contact RR Marine
frequency the Frequency Service Technical
converter. Converter. Support.

Table 21 Power Failure Control Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
The defective
Examine the power Refer Power
power supply from
supply to the pump Supply, if
the Motor
control card. necessary.
Controller.
Stop the defective OR
Power failure pump and Start Examine the position
Motor Controller Set the selector
control the other pump, if of the selector switch
set to ‘STOP’ or switch to the
Alarm. not already on the Motor
‘LOCAL’ mode. ‘REMOTE’ mode.
running. Controller.
OR
Examine the PW
Defective pump Replace the pump
LED on the pump
control card. control card.
control card.

Table 22 Low Oil Level Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Measure the
Broken Oil level resistance of the Replace the oil
switch. level switch with an level switch.
Ohm meter.
OR
If the oil leak is
Low oil level Examine the oil found, close the
alarm. level. cock on the
expansion tank and
The Oil level is Examine the oil level
Stop the related
low. and oil leakages.
pump and make
sure to repair or
replace the
defective part.

Page 103 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Examine the different
Hydraulic lock
Electrical sensors input signal to the
clarifications of
Damaged. related Motor
signals.
Controller.
OR
Examine the different
Hydraulic lock
Stop the defective Incorrect input signal to the
clarifications of
pump and Start adjustment. related Motor
Hydraulic signals.
the other pump, if Controller.
lock alarm. OR
not already
running. Remove valve and
Cannot operate in one
Blocked inlet valve. investigate the
direction.
cause.
OR
Defective The Motor operates
Replace or fix
motor/pump flexible but the pump does not
flexible coupling.
coupling. operate.

Table 24 Clogged Filter Alarm

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Measure the
Broken pressure resistance of the Replace the
switch. pressure switch with Pressure Switch.
an Ohm meter.
Stop the OR
defective pump
Clogged filter Examine the filter
and Start the Clogged filter. Replace the filter.
Alarm. and the oil condition.
other pump, if not
already running. OR
Incorrect
Drain system and
hydraulic oil
Take oil sample. replace the
viscosity of the
hydraulic oil.
steering system.

Table 25 Isolation Valve failure

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION
Measure the
Stop the resistance of the Replace the
Broken solenoid
defective pump solenoid with an Solenoid
Isolation Valve Ohm meter.
and Start the
Failure Alarm.
other pump, if not OR
already running. Broken
Examine the relay Replace the relay.
monitoring relay.
Page 104 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
OR
Examine the power
Broken power Replace the
supply, check the
supply. power supply
output voltage.

Table 26 Auxiliary Steering Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Defective power
Examine the power
supply to the Replace the power
supply to the auxiliary
auxiliary steering supply unit (U3).
steering system (U3).
system.
Auxiliary Set the steering OR
steering mode to Override Examine the
Alarm. from the Bridge. Feedback Examine the connection between
malfunction with Feedback interface the feedback
the auxiliary card U10 and failure interface card and
steering system. of LED light. the feedback
potentiometer.

Table 27 High Temperature Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Check solenoid coil
Broken solenoid Replace the
magnetic field and
coil. Solenoid coil.
power supply.
OR
Measure the
resistance of the
Defective
temperature switch Replace the Switch.
Stop the defective temperature switch.
High used and the Ohm
pump and Start the meter.
Temperature
other pump, if not
Alarm. OR
already running.
Contact RR Marine
Defective load
N/A Service Technical
control valve.
Support.
OR
Contact RR Marine
Defective Solenoid
N/A Service Technical
valve.
Support.

Table 288 Synchronous Failure Alarm (Twin Rudder Vessels Only)

IMMEDIATE POSSIBLE RECTIFICATION

SYMPTOM VERIFICATION/TEST
ACTION CAUSE ACTION

Start all pumps. (The Rudder Examine which of the Keep same numbers
Synchronous
not moved Steering Gears are slower, of pumps operated

Page 105 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

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other than that for which it is supplied without the express written consent of Rolls-Royce plc.
Failure Alarm with constant set one pump each side on each side.
(Twin rudder speed) One and compare time. Change Replace the amplifier
vessels only) . pump the pump set and test card. If the speed
operated on again. signal is defective,
one side. then examine the
speed signal through
the circuit and
replace the defective
component.
OR
Keep same numbers
of pumps operated
on each side.
Examine which of the
Steering Gears are slower, Replace the amplifier
Defective card. If the speed
set one pump each side
speed signal signal is defective,
and compare time. Change
to the pump. then examine the
the pump set and test
again. speed signal through
the circuit and
replace the defective
component.
OR
Keep same numbers
of pumps operated
on each side.
Examine which of the Replace the amplifier
Defective Steering Gears are slower, cards (procedure
steering set one pump each side chapter 5.11.3) If the
control signal and compare time. Change speed signal is
to one pump. the pump set and test defective, then
again. examine the speed
signal through the
circuit and replace
the defective
component.
OR
Use the other
system or Fault in the Feedback Examine the system
switch to the transmission. for the fault.
other mode.

Table 29 Deviation Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Examine which of the
Rudder not moved Steering Gears are
with constant slower, set one pump
speed. When one Contact RR Marine
Deviation each side and
Start all pumps. pump operated on Service Technical
Alarm. compare time.
one side. Support.
Change the pump set
and test again Set the
defective pump in the

Page 106 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

OR
Examine which of the
Steering Gears are
slower, set one pump
each side and Contact RR Marine
Defective speed
compare time. Service Technical
signal to the pump.
Change the pump set Support.
and test again Set the
defective pump in the
'OFF position'.
OR
Examine which of the
Steering Gears are
slower, set one pump
Defective steering on each side and Contact RR Marine
control signal to the compare time. Service Technical
pump. Change the pump set Support.
and test again Set the
defective pump in the
'OFF position'.
OR
Fault in the
Examine the system
Feedback N/A
for the fault.
Use the other transmission.
system or switch OR
to the other mode. Fault in
Examine the system
potentiometers on N/A
for the fault.
FU controllers .

Table 30 Earth Failure Alarm

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
The Electrical
Earth Failure Do not start the Examine and correct
motor incorrectly N/A
Alarm. defective pump. the ground correctly.
grounded.

Table 30 Alarm Not Responding

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Alarm system Missing power Examine the power
Repair the power
not N/A supply to the alarm supply to the alarm
supply.
responding. system. system.

Page 107 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Missing power Examine the power
Restore the power
supply to the supply to U2 in the
If the Alarm system supply.
interface card. Motor Controller.
All the alarm malfunctions
monitor the steering OR
indicators are
illuminated. control system. Make sure that there
No signal on CAN- are no loose wires in Connect again the
BUS. the alarm system wires.
components.

Table 32 The alarm indicators are slightly Illuminated

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
Examine the
All the diodes Grounded connection of the Grounded with one
N/A
illuminated. incorrectly. screen on the CAN- end only.
Bus cable.

Table 33 One or More LEDs not Indicating Upon Pressing Test Button

IMMEDIATE RECTIFICATION
SYMPTOM POSSIBLE CAUSE VERIFICATION/TEST
ACTION ACTION
One or more
Start the alarm and
LEDs are not
make sure that it is Replace the alarm
indicating upon N/A Defective LEDs.
shown in the other panel.
pressing test
panel (Bridge/ECR).
button.

Page 108 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
7 SPARE PARTS
This chapter gives information on Spare parts that is used during repair or replacement of
defective parts.

Figure 59 Sticker Inside The Electrical Cabinet

Figure 60 Steering Gear Name Plate

Note!
 Information regarding the Steering Gear type and installation
number is found on a name plate mounted on the Steering
Gear Housing. (See Figure 60).
 In Information regarding the Steering Gear electrical system is
found on a sticker inside the door on every electrical cabinet
(See Figure 59).


7.1 Ordering Spare Parts

When ordering spare parts give the following information to spares department (See Contact list).
 Project number (See first page)
 Vessel’s name
 Owner’s name
 Shipping address
 Invoicing address
 Drawing number
 Position number
 Article number
 Quantity.

7.2 Supplied standard spare parts

Sl. No. Part Number Description Qty

Page 109 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
SP-34014 Spare Part Kit -
1 53109 Fuse 5
2 10498 Fuse 5
3 10499 Fuse 5
4 000078951 Lamp 10
5 56075 Fuse 5
6 53004 Fuse 5
7 000079850 Mounting Tool 1
8 11127 Tool Kit 1
7.3 Recommended spare parts
Onboard spares can be ordered from our spares department (see Contact list).

 Project number (See first page)

 Vessel’s name
 Owner’s name
 Shipping address
 Invoicing address.

7.4 Preservation
Spare parts must be kept in a dry and dust free environment during preservation.

Page 110 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
8 TOOLS
The following tools are used during maintenance of the Steering Gear.

Sl. No. Description Qty

1 High pressure pipe 2

2 Mounting pump 1

3 Mallet 1

4 Blub Dismantling kit 1

5 Soldering kit 1

6 Screw driver 1

7 Adjustable spanner 1

8 Open end spanner 1

9 Socket wrench 1

10 Hexagonal key 1

* Tool will be delivered by Rolls-Royce Marine

Page 111 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

The information in this document is the property of Rolls-Royce plc and must not be copied, or communicated to a third party, or used, for any purpose
other than that for which it is supplied without the express written consent of Rolls-Royce plc.
9 DRAWINGS
Refer to the Technical Specification Manual for drawing details.

Page 112 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

Country Contact information

Rolls-Royce Marine AS
Deck Machinery and Steering Gear Brattvaag

Project/Contract management Tel: +47 815 20 070

Service dept: Sailing vessels Tel: +47 815 20 075
Norway
(Email: [email protected])
Fax: +47 70 20 86 00

Updated contact list can be found at:

http://www.rolls-royce.com/marine/contacts/

Page 113 of 113 Rolls-Royce Steering Gear SR – Operating and Maintenance Manual September 2013

TENFJORD
STEERING GEAR

Jiangsu Zhenjiang Shipyard Co., Ltd.

Hull No.: VZJ6287-1301

WHEN ORDERING SPARE PARTS, PLEASE STATE THIS NUMBER:

ORDER NO.: 13S001332

Rolls-Royce Marine AS,

dept. Steering Gear – Brattvåg, N-6270 Brattvåg, Norway
www.rolls-royce.com
INSTRUCTION MANUAL
APPENDIX B

APPENDIX A - TECHNICAL DATA SPECIFICATION

Rolls-Royce Steering Gear

TYPE SR622 FCP

Steering gear
Type 2xSR622 FCP
Shipyard Jiangsu Zhenjiang Shipyard
Co.,Ltd.
Hull No. VZJ6287-1301

Rudder Actuator:
Type SR622
Max. working pressure 100 bar
Design pressure 125 bar
Max. torque 56 kNm
Test pressure 188 bar
Rudder stock diameter 200 mm
Rudder angle electrical 2x45°

Rudder angle mechanical 2x47.5° (approx.)

Manoeuvring time one/two pumps 24/12 seconds (30°- 0 - 35°)
Setting of relief valves 125 bar

Expansion rings (Tenfjord F4):

Dimensions Ø200xØ260
Screw dimensions dG M14x44
Auxiliary thread dimension dD M18
Tightening torque MA 140 Nm

Pump unit:
Make Rolls-Royce
Type FCP-14
Pressure pump type Sauer Danfoss SNM2-14
Setting of relief valves 100 bar
Testing pressure 150 bar

Rolls-Royce Marine AS,

dept. Steering Gear – Brattvåg, N-6270 Brattvåg, Norway
www.rolls-royce.com
INSTRUCTION MANUAL
APPENDIX B

Electric motor:
Type NORM IEC 100LD - 4
Speed 1450 r.p.m.
Rating output 3,0 kW (S1)
Voltage 3x380 V, 50Hz
Protection class IP55
Insolation class F

Rolls-Royce Marine AS,

dept. Steering Gear – Brattvåg, N-6270 Brattvåg, Norway
www.rolls-royce.com
INSTRUCTION MANUAL
APPENDIX B

APPENDIX B – DRAWINGS/PART LIST

 FOLLOWING DRAWINGS ARE ENCLOSED:

Rudder actuator Dimension drwg. A-9903b

Rudder actuator Foundation design A-9145h
Rudder actuator Ass. drwg. w/part list A-9226d

Distributing valve Ass. drwg. w/part list A-10121b

Safety valve Ass. drwg. w/part list H-5713c

Pump unit Ass. drwg. w/part list A-8305h-14

Feed back unit Ass. drwg. w/part list A-10046c

Power take off Ass. drwg. w/part list A-9866f-45

Expansion Tank Ass. drwg. w/part list A-9818d

Piping diagram A-9172f

Hydraulic circuit diagram 0003-1714a

Spare part list mechanical

Rolls-Royce Marine AS,

dept. Steering Gear – Brattvåg, N-6270 Brattvåg, Norway
www.rolls-royce.com
Part List

Item ID SR622-9226 Revision I

Description Rudder Actuator Status RELEASED
Effective Date 12.08.2014 Levels 1
Level Pos Qty Unit Item ID Rev Description Size Extra information El-reference
0 piece SR622-9226 I Rudder Actuator SR622, Ø200, 2x45, FCP
1 0002 1 piece 60104-8023 A Lower Actuator Housing SR622 01
1 0004 1 piece 60204-9187-200 B Rotor SR622, Ø200 02
1 0006 1 piece 60304-9190 C Upper Actuator Housing SR622 03
1 0008 2 piece 60504-9947 A Dividing Wall SR622 KOMPL. 04
1 0010 16 piece 374-M14 # Lock Washer M 14 Ø14,5/Ø23,0X3,4 05
1 0012 8 piece 331-M14X070 # Socket Screw M14X70 06
1 0014 2 piece SR622-05-45 G Piston SR622, 2X45 07
1 0016 0 piece 63304-7786 C Support Segment SR622, piston seal 08
1 0018 0 piece SR620-06 # Piston Seal 09
1 0020 0 piece 212-0950-25 # O-Ring 95,00 X 2,50 10
1 0022 4 piece 61504-9464 # Sealing Retainer SR622 11
1 0024 4 piece SR620-13 # Adapter Sleeve SR622, Ø49/Ø16,5X26 12
1 0026 4 piece 331-M16X030 # Socket Screw M16x30 13
1 0028 4 piece 374-M16 # Lock Washer M16 Ø17,0/Ø25,4X3,4 14
1 0030 2 piece 336-T3.8 # Plug BSP3/8 " 15
1 0032 2 piece 801-038-13 A Seal Washer 400-023-4490 DOWTY 16
1 0034 0 piece SR620-12 C Support Segment SR620, 6x4x162 17
1 0036 44 piece 331-M20X070 # Socket Screw M20X70 18
1 0040 6 piece 63705-9266 A Distance Piece Ø16X1,5X54 20
1 0042 3 piece SR620-57 D Transport Bracket SR620, 70x55x5 21
1 0044 3 piece 331-M10X020 # Socket Screw M10x20 22
1 0046 1 piece 60804-9201 A Plate SR622, UPPER, Ø376/Ø305x12 23
1 0048 1 piece 191-329X293X3 # Flange Seal 329X293X3 24
1 0050 2 piece 218-295X339X20 # Seal Ring 295-339-20 UN 25
1 0052 2 piece SR620-26 A Distance Ring SR620, Ø355/Ø305x3 26
1 0056 1 piece 241-FM18L # Pipe Coupling FM18L, Ø18, EO2-Functional nut 28

Page 1 of 3 Print Date: 12.08.2014

Item ID SR622-9226 Revision I
Description Rudder Actuator Status RELEASED
Effective Date 12.08.2014 Levels 1
Level Pos Qty Unit Item ID Rev Description Size Extra information El-reference
1 0058 1 piece 60804-9229-200 C Rotor Cover SR622, Ø200 29
1 0060 8 piece 331-M10X025 # Socket Screw M10X25 33
1 0062 1 piece 219-V-200A # V-Ring V-200-A 31
1 0072 2 piece 801-038-09 A Seal Washer 400-021-4490 DOWTY 36
1 0074 2 piece 070049 A Plug 1/4" BSP 37
1 0076 4 piece 000071066 A Cylinder Seal SR622, segment 38 og 40
1 0078 2,68 meter 211-030 A Packing Cord 3,00mm 39 OG 41
1 0080 16 piece SR620-31 B Bearing Shell SR620 42
1 0082 4 piece 395-200 # Expansion Ring ø200/ø260x52 43
1 0084 16 piece SR620-32 B Bearing Shell SR620 44
1 0086 1 piece 212-07860-30 # O-Ring 786,00X3,00 45
1 0088 1 piece 212-07490-30 # O-Ring 749,00X3,00 46
1 0090 1 piece 212-07120-30 # O-Ring 712,00X3,00 47
1 0092 1 piece 212-06550-30 # O-Ring 655,00x3,00 48
1 0094 1 piece 212-2000-70 # O-Ring 200,00x6,99 49
1 0096 1 piece SR620-50 # Distance Ring SR620, Ø265/Ø240x3 50
1 0098 2 piece 218-230X270X16 # Seal Ring 230-270-16 UN 51
1 0100 1 piece SR620-33 B Plate SR620, Ø304/Ø239x12 52
1 0102 6 piece 331-M10X025 # Socket Screw M10X25 53
1 0104 2 piece 331-M06X025 # Socket Screw M6x25 54
1 0106 2 piece SR620-18 E Key 125X24X13,8 55
1 0108 0 piece SR620-07 B Plate SR620, PL3 56
1 0110 0 piece 333-M06X012 # Countersunk Screw M6x12 57
1 0112 13 piece SR620-30 D Bearing Shell SR620 58
1 0114 4 piece 321-M16X100 # Hexagon Head Screw M16x100 59
1 0116 8 piece 331-M14X090 # Socket Screw M14X90 60
1 0120 2 piece 415-10X14 # Needle Ø10x14 62
1 0122 2 piece 415-5X20 # Needle Ø5X19,8 63
1 0130 1 piece 69999-8068 C Nameplate 105x74x1 for steering gear 64
1 0150 6 piece 331-M10X025 # Socket Screw M10X25 66
1 0160 6 piece 375-10 # Spring Washer M10 67
1 0170 1 piece 69804-8226 B Adapter Plate SR600 68
1 0180 2 piece 212-0266-35 # O-Ring 26,58x3,53 69

Page 2 of 3 Print Date: 12.08.2014

Item ID SR622-9226 Revision I
Description Rudder Actuator Status RELEASED
Effective Date 12.08.2014 Levels 1
Level Pos Qty Unit Item ID Rev Description Size Extra information El-reference
1 0190 4 piece 241-GE22L # Standpipe Adapter Ø22 70
1 0200 2 piece 241-FM22L # Pipe Coupling FM22L, Ø22, EO2-Functional nut 71
1 0210 2 piece 290-000 # Filter SPIN ON 72
1 0220 2 piece 241-EVW22L # Elbow Ø22 73
1 0230 2 piece 63899-8316 # Pipe Section Ø22X2, 90DEG, 130X90 74
1 0240 0 piece 290-002-TF # Pressure Gauge 2.4bar, for Pall filter 75
1 0250 0 piece 290-001-TF # Filter Cartridge SPIN ON 76
1 0270 2 piece 000106336 A Hose SR622/642 FCP, drain hose 78
1 0280 4 piece 63819-9734 # Pipe Section Ø22X2, 90DEG, 350X280 77
1 0310 1 piece 241-SWVE18L # Pipe Coupling Ø18 32
1 0380 6 piece 331-M10X065 # Socket Screw M10x65 19
1 0390 1 piece SR620-47-01 A Scale SR622, 0-75 degree 35
1 0400 1 piece 62004-9230 # Pointer SR600, 85x65x3 61
1 0410 2 piece 333-M06X010 # Countersunk Screw M6x10 65
1 0420 0 piece 5421-RC861 # Pressure Switch 2.4bar, for Pall filter 79
1 0430 2 piece 289-001-TF # Gauge Valve 1/4-1/4 , straight nipple 27
1 0440 2 piece 289-000 # Gauge Valve 1/4-1/4 , straight stream w/wheel 30
1 0450 2 piece 292-000 # Pressure Gauge BSP1/4", 0-250bar 34
1 0460 4 piece 385-04.0X16 # Split Pin Ø4X16 80
1 0470 1 piece 335-M06X1 # Plug M6X1 81
1 0480 4 piece 343-M16 # Eye Bolt M16 82

End of Report

SR622 FCP

Date : 06.12.2013
Id : 20-13-01935
Rev : 00

Customer : Jiangsu Zhenjiang Shipyard Co., Ltd.

Customer reference : VZJ6287-1301-10NO
Shipyard : Jiangsu Zhenjiang Shipyard Co., Ltd.
Hull no. : VZJ6287-1301
Type of vessel : Anchor Handling Tug Supply
Class : ABS, +1A(E), Offshore Support Vessel (Supply, AH, Tow,
FFV 1, OSR-C2, DPS-2, SPS), UWILD, MLC-ACCOM;
+AMS for unrestricted service. Option notation:TCM.
Contract manager : Sussan Korsnes, [email protected]
ERP no. : 13S001332

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 1 of 9
Table of contents

01.00 System description ........................................................................................................... 3

02.00 Scope of supply/technical description ............................................................................... 4

02.01 General ....................................................................................................................... 4

02.02 Steering gear .............................................................................................................. 6

02.03 Start/stop and control system ...................................................................................... 7

02.04 Alarm system .............................................................................................................. 8

02.05 Rudder angle indicator system .................................................................................... 8

02.06 Spare parts and special tools pr. ship set. ................................................................... 9

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 2 of 9
01.00 System description

Rolls-Royce steering gear

Type: SR622 FCP

Rudder actuator
Effective torque : 56 kNm
Max working pressure : 100 bar
Allowable axial load : 200 kN
Allowable radial load : 400 kN
Rudder stock diameter : 200 mm
Max. mechanical rudder angle : 2x47.5°
Max. electrical rudder angle : 2x45°
Steering time at 30° - 0° - 35° : 24 s with one pump unit in line
Steering time at 30° - 0° - 35° : 12 s with two pump units in line

Electric motor
Power : 3.0 kW (S1)
Current : I N = 6.5 A
Rotational speed : 1440 rpm
Voltage : 3x415 V
Frequency : 50 Hz
Type : M3AA 100 LD-4
Protection : IP 55
Design : B35
Insulation class :F
Heating : Yes, (through the windings)

Start/stop and control system

Control panels for console mounting in the bridge
Control system unit for bulkhead mounting with interface to analogue autopilot, DP and joystick.
Panel for run/stop indication
Motor controllers for bulkhead mounting in the steering gear room
The system is powered internally from motor controllers
Limit switches and potentiometers for the follow-up system are mounted in feed back units

Alarm system
Panels for console mounting.
Interface to Voyage Data Recorder (VDR) and ship’s main alarm system
Interface to alarm sensor
24VDC external power supply (100W)

Rudder angle indicator system

Panorama type for ceiling mounting
Console mounting types
Rudder angle indicator amplifiers
Feed back potentiometers in feed back unit
Interface to VDR
Accuracy according to class 1.5
Type approved by MED (Marine Equipment Directive)
24VDC external power supply (50W)

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 3 of 9
Classification requirements
Society-notation: ABS (Notation according to project requirement).
The equipment is dimensioned in accordance with the above classification society rules valid on
the date of this specification.

Painting and colours:

According to RRCM standards if not other specified.
Panels : RAL 9011
Cabinets : RAL 7035
Electric motor : Munsel 8B, 4.5/3.25
Mechanical components : primer

Ambient temperature:
Max. ambient air temperature in the steering gear room is 45 deg C
Electrical equipment is designed and type approved for temperature +55 deg C.

02.00 Scope of supply/technical description

02.01 General

Equipment not supplied

Scope of supply is defined in the technical specification.

Not included in scope of supply are:

- Foundation and fastening bolts for equipment supplied (drawing: Proposal for foundation
and fastening can be supplied by Rolls-Royce)
- Autopilot, DP and joystick
- Piping
- Wiring

Technical information - Drawings

Dimension drawings, hydraulic diagram, electrical diagram and technical data for the steering
gear system will be delivered. All according to documentation list issued for each order.

Steering gear design

The steering gear design is based on well-proved technology as well as long experience.

Workshop testing

The steering gear system is workshop tested according to the class requirement and RRM
standard.

Corrosion protection and surface treatment

The steering gear actuator is provided with corrosion preventing coat, which is intended for
protection under normal transport conditions. The rotor is finish treated according to RRM
standard.

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 4 of 9
Shipment

Depending on transport methods and delivery times components may be shipped separately.
Installation into the ship and mounting of components are customer's responsibility if not
otherwise is stated.

Safe storage

All equipment are prepared for storage in dry and dust free environments up to 6 months from
delivery.

Piping and cabling

Connections between components supplied by RRM are the customer's responsibility. However,
type of pipes and cables are given in the diagrams and mounting instructions.

Installation, inspection, starting up and sea trial

Installation of the steering gear system in the ship and mounting of components are the
customer's responsibility if not otherwise stated.

Instruction manuals – Language

1 CD with English Approval/user(Final)/installation(Working) manuals

7 pcs. Approval manuals covering the mechanical/hydraulic parts in English language
7 pcs. Approval manuals covering the electrical parts in English language
7 pcs. Installation/working manuals covering the mechanical/hydraulic parts in English language
7 pcs. Installation/working manuals covering the electrical parts in English language
4 pcs. Users(Final) manuals covering the mechanical/hydraulic parts in English language
4 pcs. Users(Final) manuals covering the electrical parts in English language

All drawings, documents and sign plates on the equipment will also be delivered in English
language. All drawings will be delivered in PDF-format. Lay-out drawings of main equipment
can be delivered in dwg-format.

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 5 of 9
02.02 Steering gear

0010 2 pcs. Rudder actuator (rotary vane) type SR622 FCP

Complete with locking ring assembly for a cylindrical rudder stock (no cone, key or nut
required); spherical self-aligning rudder carrier; pressure pumps; non-return valves;
load control valves; valve block with sensors for hydraulic lock alarm; filter units and
mechanical rudder angle indicator; feed back units with limit switches, transmitters for
the steering control system and the rudder angle indicating system.
Fittings for connection of external piping included.
Oil included.

Drawing numbers: A-9903, A-9145 and W-1602-00-06, 0002-1515, 0002-5397

0020 2 pcs. Expansion tank

25 litres without oil, with gauge glasses, low oil level switches, cocks and fittings.

Drawing number: A-9814

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 6 of 9
02.03 Start/stop and control system

0030 4 pcs. Motor controllers (FCP) (IP44)

For bulkhead mounting in the steering gear room. Plastic cable glands included.
Power supply from main/emergency switch board 3x415V, 50Hz
Motor controller is numbered from the port side.

Drawing numbers: 0003-5799 and L-1799-00-16

0040 4 pcs. Frequency converters (IP44)

For bulkhead mounting in the steering gear room with ammeter, hour counter
indication and power supply for heating of electrical motor through the windings.
Vibration dampers included.

Drawing numbers: 0000-0319 and 0000-0320

0050 2 pcs. Control system unit (IP44)

For bulkhead mounting in the bridge with interface to analogue autopilot, DP and
joystick(for details see electrical cable diagram). Plastic cable glands included.

Drawing numbers: W-1223-02-00 and L-1299-00-01

0060 1 pc. Control panel (IP22)

For desk mounting in the forward bridge console with start/stop push buttons, dimmer,
steering mode selections, non-follow-up push buttons for emergency steering and
follow-up controllers for independent and/or simultaneous steering of the rudders.

Drawing numbers: 0002-0638 and L-1340-01-06

0070 1 pc. Control panel (IP22)

For desk mounting in the aft bridge console with start/stop push buttons, dimmer,
steering mode selections, non-follow-up push buttons for emergency steering and
follow-up controllers for independent and/or simultaneous steering of the rudders.

Drawing numbers: 0002-0634 and L-1340-01-04

0080 2 pcs. Indication panel (IP22)

For run/stop/autostart indication and for desk mounting in the engine control room
console.

Drawing number: 0002-1030, 0002-1251

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 7 of 9
02.04 Alarm system

0090 2 pcs. Alarm panel (IP22)

For desk mounting in engine control room with alarm lights for overload, phase failure,
low oil level, power failure and hydraulic lock and push buttons for alarm test, alarm
acknowledge, alarm buzzer and with one common steering gear failure alarm contact
(voltage free) to ship’s main alarm system.

Drawing number: W-1802-00-01

0100 2 pcs. Alarm panel (IP22)

For desk mounting in bridge console with alarm light and push buttons for alarm test,
alarm acknowledge, alarm buzzer and with interface to VDR on RS422 NMEA.

Drawing number: W-1802-00-01

0110 2 pcs. Alarm panel (IP22)

For desk mounting in aft bridge console with alarm light and push buttons for alarm
test, alarm acknowledge, alarm buzzer and with interface to VDR on RS422 NMEA.

Drawing number: W-1802-00-01

02.05 Rudder angle indicator system

0120 4 pcs. Rudder angle indicator amplifier

For mounting inside the console.

Drawing number: W-2010-00-01

0130 2 pcs. Rudder angle indicator, 144x144 (IP22)

For desk mounting in forward bridge console.

Drawing number: 0001-0365

0140 2 pcs. Panorama rudder angle indicator, Ø370 (3-face) (IP22)

With dimmer for overhead mounting in the wheelhouse.

Drawing number: W-1430-00-06

0150 2 pcs. Rudder angle indicator, 144x144 (IP22)

For desk mounting in aft bridge console.

Drawing number: 0001-0367

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 8 of 9
02.06 Spare parts and special tools pr. ship set.

0160 1 set Standard spare parts

Set of Standard Spare parts.

1 set Manuals

1 CD with English Approval/user(Final)/installation(Working) manuals

7 pcs. Approval manuals covering the mechanical/hydraulic parts in English language
7 pcs. Approval manuals covering the electrical parts in English language
7 pcs.Installation/working manuals covering the mech./hydr. parts in English language
7 pcs. Installation/working manuals covering the electrical parts in English language
4 pcs. Users(Final) manuals covering the mech./hydr. parts in English language
4 pcs. Users(Final) manuals covering the electrical parts in English language

Piping diagram: A-9172

Cable diagram: 0003-7283

Cable list: 0003-7280

Terminal diagram: 0003-7281

Power consumption list: 0003-7279

Circuit diagram: 0003-7282

Configuration steering gear: 0003-7278

Emergency steering procedure: 0003-5976

Interface description: 0003-5990

Electrical installation: DMN227-061

This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.

Tech.spec. 13S001332 (Master rev. 03.2010-03-17) generated: 30/09/2013

Page 9 of 9
Doc. ID: 0003‐7278 Rev: A

Rolls‐Royce Steering Gear

Doc. Name: Configuration of Steering Gear
Doc. Type: Manufacturing Instruction
SG type: Frequency Controlled pumps, FCP

Circuit diagram alarm system W‐1006‐00‐02

Classification drawing control system W‐1007‐00‐01
Classification dwg. Rudder ind. System 0003‐3673

Power consumption pump unit 3,0Kw

Voltage pump unit 415V
Frequency pump unit 50Hz
Current pump unit 6,5A

Yard Jiangsu Zhenjiang

Shipyard Co., Ltd.
Hull no. VZJ6287‐1301

Rolls Royce Marine order no. 13S001332

Software alarm panel 5250‐W18020001‐1

Software motor controller 5250‐W18020001‐2
Classification society: ABS
One man bridge operation? No
Emergency steering procedure Doc. No. 0003‐5976

Originator: T.Bjo Verifier: H.Mol Page 1 of 9

Doc. ID: 0003‐7278 Rev: A

Alarm List Steering Gear

Alarm List Port Steering Gear
Description Al.No. Light Al.No. Description
STEERING GEAR STEERING GEAR
PUMP NO. 1 PUMP NO. 2
Overload 10 ⃝ 20 Overload
Phase Failure 11 ⃝ ⃝ 21 Phase Failure
PW/Freq Failure 12 ⃝ ⃝ 22 PW/Freq Failure
Power Failure Control 13 ⃝ ⃝ 23 Power Failure Control
Low Oil Level 14 ⃝ ⃝ 24 Low Oil Level
Hydraulic Lock 15 ⃝ ⃝ 25 Hydraulic Lock
Not used 16 ⃝ ⃝ 26 Not used
Not used 17 ⃝ ⃝ 27 Not used
Isolation valve failure 18 ⃝ ⃝ 28 Isolation valve failure
Aux. Steering 19 ⃝ ⃝ 29 Aux. Steering

Alarm List Stbd Steering Gear

Jumper setting for control system

Jumper setting for Pump Control Card:
Jumper Description Setting

JP1 (+U1) St. Signal Common +/‐ + (Tennfjord)

JP2 (+U1) St. Signal Common +/‐ + (Tennfjord)
JP3 (+U1) NFU Main St. Priority NO (Note 1)
JP4 (+U1) NFU St. Priority (Note 0) NO (Note 1)

Additional straps (all CSs):

from/to ‐U1‐X2:23 ‐U2‐X3:21

from/to ‐U1‐X3:21 ‐U2‐X2:23

Gain Adjustment External Equipment:

Steering
Description Internal Connection
mode

(‐X10:1) DP ‐X10:5 To ‐U11:11

(‐X10:2) Joystick ‐X10:6 to ‐U11:24
(‐X10:3) Autopilot ‐X10:7 to ‐U11:37
(‐X10:4) Not used ‐X10:8 to

Originator: T.Bjo Verifier: H.Mol Page 4 of 9

Doc. ID: 0003‐7278 Rev: A

Jumper Setting for AUX Steering:

Steering Description Jumper Setting CSA CSB
(‐U10) Feed back connected JP20 = Yes
(‐U41) Feed back connected JP60 = Yes

1 (‐U42) DP JP50 = FU EXT, JP51 = Slave Slave

2 (‐U42) Joystick JP60 = FU EXT, JP61 = Slave Slave
3 (‐U42) Autopilot JP70 = FU EXT, JP71 = Master Slave

4 (‐U43) Main Synch JP50 = FU EXT, JP51 = Master Slave

5 (‐U43) Main Indp. JP60 = FU EXT, JP61 = Master Slave
6 (‐U43) Aft Synch. JP70 = FU EXT, JP71 = Master Slave

7 (‐U44) Aft Indp. JP50 = FU EXT, JP51 = Master Slave

8 (‐U44) Not Used JP60 = FU EXT, JP61 = Master Slave
9 (‐U44) Not Used JP70 = FU EXT, JP71 = Master Slave

Note: For Jumper setting on backplane, see drawing for control system

Note 0: If NFU Steering is not used apply internal connection X6:3 to X6:6

JP2 Override light dimmed NO
JP3 Buzzer Connected NO (Note 6)

Jumper setting for dimmer module:

Jumper Description Setting

JP30‐Ch.9 Supply to channel External

JP30‐Ch.10 Supply to channel External
JP30‐Ch.11 Supply to channel External
JP30‐Ch.12 Supply to channel External
JP30‐Ch.13 Supply to channel Internal
JP30‐Ch.14 Supply to channel Internal

Note 5: 'YES' if two rudders and EMG/OVR panels on bridge. If only one, 'NO' External override.
Note 6: "NO" if jumper setting for control system (pump control card, JP3 and JP4) is "NO"

Aft Control Panel:

Jumper setting for override modules:
Jumper Description Setting

JP1 External override YES (Note 5)

JP2 Override light dimmed NO
JP3 Buzzer Connected NO (Note 6)

Jumper setting for dimmer module:

Jumper Description Setting

JP30‐Ch.9 Supply to channel External

JP30‐Ch.10 Supply to channel External
JP30‐Ch.11 Supply to channel External
JP30‐Ch.12 Supply to channel External
JP30‐Ch.13 Supply to channel Internal
JP30‐Ch.14 Supply to channel Internal

Note 5: 'YES' if two rudders and EMG/OVR panels on bridge. If only one, 'NO' External override.
Note 6: "NO" if jumper setting for control system (pump control card, JP3 and JP4) is "NO"

Originator: T.Bjo Verifier: H.Mol Page 8 of 9

Doc. ID: 0003‐7278 Rev: A

Configuration of additional items on CS & MC (glands/dampers/lamps/lifting ears etc..)

Cable Glands: CSA CSB MCA1/B1 MCA2/B2

M20 12 13 8 5
M25 16 15 6 6
M40 3 2 2 2
M50
M63

Number of glands calculated from Cable lists, and summarized in this table.

Originator: T.Bjo Verifier: H.Mol Page 9 of 9

Steering Gear Brattvaag™

Interface for Steering Gear

Signals from Steering Gear control system:
Run indication, pump xn (x=A-B, n=1-2)
Signal type Terminal Group name Common NO NC
Potential free switching contact CO +CSx-Un-X2: 17 18 19
Potential free switching contact CO +CSx-Un-X2: 20 21 22
Potential free contact NO +CSx-Un-X2: 23 24
Potential free contact NO +MCxn-X2: 9 10
x=A-B, n=1-2

Power indication, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common NO NC
Potential free switching contact CO +CSx-Un-X2: 25 26 27
x=A-B, n=1-2

Autostart indication, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common NO NC
Potential free switching contact CO +CSx-Un-X2: 28 29 30
x=A-B, n=1-2

Port order, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common NO NC
Potential free contact NO +CSx-Un-X2: 13 14
x=A-B, n=1-2

Stbd order, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common NO NC
Potential free contact NO +CSx-Un-X2: 15 16
x=A-B, n=1-2

Follow up selected, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common NO NC
Potential free contact NO +CSx-Un-X2: 34 35 36
x=A-B, n=1-2

Follow up selected, rudder x (x=A-B)

Signal type Terminal Group name Common NO NC
Potential free switching contact CO +CSx-U10: 20 21 22
x=A-B

Override signal, rudder x (x=A-B)

Signal type Terminal Group name Common NO NC
Potential free switching contact CO +CSx-U10: 1 2 3
Potential free switching contact CO +CSx-U10: 4 5 6
x=A-B

Sign.: NGO : 16.08.13 Appr. 0003-5990, rev. B Page 1 of 5

® Rolls-Royce Marine AS
Steering Gear - Brattvaag
Årsundveien 24, N-6270 Brattvåg, Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Order signal output, rudder x (x=A-B)
Signal type Terminal Group name 0V +/-10V
Analog +/- 10V +CSx-U10: 7 8
x=A-B
Note: Order signal +/-10V is available to VDR system.

Ready signal steering modes, rudder x (x=A-B)

Note: only B when 2 rudders
Mode Signal type Terminal Group name Common NO NC
1 Potential free switching contact CO +CSx-U11: 7 8 9
2 Potential free switching contact CO +CSx-U11: 20 21 22
3 Potential free switching contact CO +CSx-U11: 33 34 35
4 Potential free switching contact CO +CSx-U12: 7 8 9
5 Potential free switching contact CO +CSx-U12: 20 21 22
6 Potential free switching contact CO +CSx-U12: 33 34 35
7 Potential free switching contact CO +CSx-U13: 7 8 9
8 Potential free switching contact CO +CSx-U13: 20 21 22
9 Potential free switching contact CO +CSx-U13: 33 34 35
10 Potential free switching contact CO +CSx-U14: 7 8 9
11 Potential free switching contact CO +CSx-U14: 20 21 22
12 Potential free switching contact CO +CSx-U14: 33 34 35
x=A-B

Pulse signal, leaving DP/DP3/Joystick

Signal type Terminal Group name Common NO
Potential free switching contact CO +CSx-Kn, 15 18
x=A-B, n=2-4

Remote/Stop/Local indication, pump xn (x=A-B, n=1-2)

Signal type Terminal Grp. name Common Remote Stop Local
Potential free contact +MCxn-X2: 11 12 13 14
x=A-B, n=1-2

Motor voltage supply, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name L1 L2
Motor voltage Supply 1 +MCxn-X1: 1 2
Motor voltage Supply 2 +MCxn-X1: 3 4
x=A-B, n=1-2

High/Low Rudder angle indication, pump xn (x=A-B, n=1-2)

Signal type Terminal Group name Common Low High
Potential free switching contact CO +MCxn-X4: 12 13 14
x=A-B, n=1-2

NMEA-signal from alarmpanel APxn (x=A-B, n=1-2)

Signal type Terminal Group name TD+ TD- GND
NMEA-0183 signal (RS422) +APxn-X2: 7 8 9
x=A-B, n=1-2
Note: NMEA-0183 only activated when 5801-RRC485 card is installed in the alarm panel
NMEA-0183 signal from bridge alarm panel is provided to VDR system.

Sign.: NGO : 16.08.13 Appr. 0003-5990, rev. B Page 2 of 5

® Rolls-Royce Marine AS
Steering Gear - Brattvaag
Årsundveien 24, N-6270 Brattvåg, Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
E0-Alarm from alarmpanel APxn (x=A-B, n=1-2)
Signal type Terminal Group name Common NO
Potential free contact NO +APxn-X3: 1 2
x=A-B, n=1-2

Autostart signal from alarmpanel APxn (x=A-B, n=1-2)

Signal type Terminal Group name Common NO
Potential free contact NO, to pump x1 +APxn-X4: 1 2
Potential free contact NO, to pump x2 +APxn-X4: 3 4
x=A-B, n=1-2

External buzzer alarmpanel APxn (x=A-B, n=1-2)

Signal type Terminal Group name (+) (-)
24VDC 50mA +APxn-X3: 3 4
x=A-B, n=1-2

Rudder angle indication from RAI-amplifier, RAxn (x=A-B, n=1-6)

Signal type Terminal Group name (0V) (+/-10V)
+/- 10V +RAxn+U10-X4 1 2
x=A-B, n=1-6
Note: One of these signals are available to VDR system.

Rudder angle indication from Feedback-unit FBxn (x=A-B, n=1-2)

Signal type Terminal Group name Clockw. Wiper Counter Clockw Mid.point
5kohm potmeter 2 +FBxn 5 6 7 8
5kohm potmeter 3 +FBxn 9 10 11 12
x=A-B, n=1-2
Note: Only for use as rudder indication to DP
Check Cable diagram for occupied potmeters ( e.g. to CS or RAI in SGR )

Sign.: NGO : 16.08.13 Appr. 0003-5990, rev. B Page 3 of 5

® Rolls-Royce Marine AS
Steering Gear - Brattvaag
Årsundveien 24, N-6270 Brattvåg, Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Signals to Steering Gear control system from external equipment
In command pulse for modes CSx (x=A-B)
Signal type Terminal Group name Common NO
Potential free contact, pulse NO +CSx-U11: 1 2
Potential free contact, pulse NO +CSx-U11: 14 15
Potential free contact, pulse NO +CSx-U11: 27 28
Potential free contact, pulse NO +CSx-U12: 1 2
Potential free contact, pulse NO +CSx-U12: 14 15
Potential free contact, pulse NO +CSx-U12: 27 28
Potential free contact, pulse NO +CSx-U13: 1 2
Potential free contact, pulse NO +CSx-U13: 14 15
Potential free contact, pulse NO +CSx-U13: 27 28
Potential free contact, pulse NO +CSx-U14: 1 2
Potential free contact, pulse NO +CSx-U14: 14 15
Potential free contact, pulse NO +CSx-U14: 27 28
x=A-B

Eneable request from DP/Joystick CSx (x=A-B)

From Signal type Terminal Group name Common NO
DP/Joystick Potential free contact, pulse NO +CSx-X10: 9 10
DP/Joystick Potential free contact, pulse NO +CSx-X10: 13 14
DP/Joystick Potential free contact, pulse NO +CSx-X10: 17 18
x=A-B

Request from DP/Joystick CSx (x=A-B)

From Signal type Terminal Group name Common NO
DP/Joystick Potential free contact, pulse NO +CSx-X10: 11 12
DP/Joystick Potential free contact, pulse NO +CSx-X10: 15 16
DP/Joystick Potential free contact, pulse NO +CSx-X10: 19 20
x=A-B

Analog steering signal, +/-10V CSx (x=A-B)

Mode Signal type Common Signal in Adjusted signal To mode in CS
1 Analog +/- 10V +CSx-U11:13 -X10:n -X10:n +CSx-U11:11
2 Analog +/- 10V +CSx-U11:26 -X10:n -X10:n +CSx-U11:24
3 Analog +/- 10V +CSx-U11:39 -X10:n -X10:n +CSx-U11:37
4 Analog +/- 10V +CSx-U12:13 -X10:n -X10:n +CSx-U12:11
5 Analog +/- 10V +CSx-U12:26 -X10:n -X10:n +CSx-U12:24
6 Analog +/- 10V +CSx-U12:39 -X10:n -X10:n +CSx-U12:37
7 Analog +/- 10V +CSx-U13:13 -X10:n -X10:n +CSx-U13:11
8 Analog +/- 10V +CSx-U13:26 -X10:n -X10:n +CSx-U13:24
9 Analog +/- 10V +CSx-U13:39 -X10:n -X10:n +CSx-U13:37
10 Analog +/- 10V +CSx-U14:13 -X10:n -X10:n +CSx-U14:11
11 Analog +/- 10V +CSx-U14:26 -X10:n -X10:n +CSx-U14:24
12 Analog +/- 10V +CSx-U14:39 -X10:n -X10:n +CSx-U14:37
x=A-B n=1-4 n=5-8
Note: The signal is routed through a potentiometer for individual adjustment.
There are 4 available potentiometers, hence only 4 analog inputs can be used.
Connect the signal to terminal –X10:1-4
Connect terminal –X10:5-8 to the correct mode

Sign.: NGO : 16.08.13 Appr. 0003-5990, rev. B Page 4 of 5

® Rolls-Royce Marine AS
Steering Gear - Brattvaag
Årsundveien 24, N-6270 Brattvåg, Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Enable Digital steering (NFU Override) for pump xn (x=A-B, n=1-2)
Signal type Terminal Group name Common NC
Potential free switching contact +CSx-+Un-X5: 3 4
x=A-B, n=1-2
Connect to NC switch if used. Open switch to enable.
NB! Must be closed/strapped (disabled) if not used.

Digital steering signal (NFU Override) for pump xn (x=A-B, n=1-2)

Signal type Terminal name Port (NO) Common Stbd (NO)
Potential free switching contact +CSx-+Un-X5: 7 8 9
x=A-B, n=1-2

From speed log to select low rudder angle, to panel i (i=1-4)

Pump no Signal type Terminal Group name Terminal
A1 Potential free switching closed when high speed +CPi-X130: 1 2
A2 Potential free switching closed when high speed +CPi-X130: 7 8
B1 Potential free switching closed when high speed +CPi-X131: 1 2
B2 Potential free switching closed when high speed +CPi-X131: 7 8
i=1-4

Only to be used when Start/Stop panel is not includedd in RR scope of supply:

Digital Start/Stop signal for pump xn (x=A-B, n=1-2)
Signal type Terminal Group name Common NO
Start +CSx-+Un-X3: 1 2
Stop +CSx-+Un-X3: 1 3
Start +CSx-+Un-X3: 10 11
Stop +CSx-+Un-X3: 10 12
Start +CSx-+Un-X3: 19 20
Stop +CSx-+Un-X3: 19 21

Only to be used when Oil Transfer Pump is included in RR scope of supply:

Digital Start/Stop (auto-release button) signal for transfer pump, xn (x=A-B, n=1-2)
NO, Close to run pump
Signal type Terminal Group name L1 L2
Start/Stop +MCxn-X12: 1 2

Sign.: NGO : 16.08.13 Appr. 0003-5990, rev. B Page 5 of 5

® Rolls-Royce Marine AS
Steering Gear - Brattvaag
Årsundveien 24, N-6270 Brattvåg, Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Rauma Brattvaag™
227-061

GUIDELINES
FOR
ELECTRICAL INSTALLATION

Table of contents:
1. GUIDELINES FOR INSTALLATION ACCORDING TO EMC ................................................................................. 2
2. DOCUMENT REVISIONS ............................................................................................................................................ 3
3. INTRODUCTION .......................................................................................................................................................... 4
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or

4. POWER CABLES .......................................................................................................................................................... 4

4.1 General................................................................................................................................................................... 4
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

4.2 Redundant power supply........................................................................................................................................ 4

4.3 Frequency converter cables.................................................................................................................................... 4
5. CONTROL CABLES ..................................................................................................................................................... 4
5.1 Control of solenoid valves ..................................................................................................................................... 4
6. SIGNAL CABLES ......................................................................................................................................................... 4
6.1 Dig. feedback signal (from valves / starters) ......................................................................................................... 4
6.2 Analog signal (from valves / transmitters) ............................................................................................................. 5
7. BUS CABLES ................................................................................................................................................................ 5
7.1 Ethernet COAXIAL ............................................................................................................................................... 5
7.2 Ethernet TWISTED PAIR ..................................................................................................................................... 5
7.3 ProfiBus ................................................................................................................................................................. 5
7.4 Can Bus.................................................................................................................................................................. 6
7.5 RS-422/485 Transmissions .................................................................................................................................... 6
7.6 FIBRE OPTICAL .................................................................................................................................................. 6
8. INSTALLATION ........................................................................................................................................................... 7
8.1 General................................................................................................................................................................... 7
8.2 Cabinets ................................................................................................................................................................. 7
8.3 Motors .................................................................................................................................................................... 7
8.4 Encoders ................................................................................................................................................................ 7
8.5 Power cables .......................................................................................................................................................... 7
8.6 Control cables ........................................................................................................................................................ 7
8.7 Signal cables .......................................................................................................................................................... 7
8.8 Bus cables .............................................................................................................................................................. 8
8.9 Connecting load cells ............................................................................................................................................. 8
8.10 Installation of frequency converters....................................................................................................................... 8
9 REFERENCES ............................................................................................................................................................... 8

Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 1 of 8

® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
1. GUIDELINES FOR INSTALLATION ACCORDING TO EMC
The following 10 rules are the basics for designing systems in compliance with EMC. Rules 1 to 7 are generally valid.
Rules 8 to 10 are especially important to limit noise emission.

Rule 1 All metal parts of the switch cabinet should be connected with one another through the largest possible
surface area so that the best electrical connection is established (no paint on paint!). If necessary, use contact
or scraper discs. The cabinet door should be connected to the cabinet using the shortest possible grounding
straps.

Rule 2 Signal, line supply, motor and power cables should be routed away from another (this eliminates mutual
interference!). The minimum clearance is 30 cm. Barriers should be provided between power and signal
cables. These barriers should be grounded at several locations.

Rule 3 Contactors, relays, solenoid valves, electromechanical operating hour counters etc. in the cabinet must be
provided with noise suppression devices, e.g. using RC elements, diodes, varistors. These devices must be
connected directly at the coil.

Rule 4 Non-shielded cables belonging to the same circuit (feeder and return cables) should be twisted with the
smallest possible distance between them. Wires, which are not used must be grounded at minimum one end.

Rule 5 Generally, noise which is coupled in, can be reduced by routing cables as closely as possible to g rounded
steel panels. For this reason, cables and wires should not be routed freely in the cabinet, but as closely as
possible to the cabinet itself and the mounting panels. This is also true for reserve cables. Connect the
reserve cables/conductors to ground at both ends to achieve an additional shielding effect.
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or

Rule 6 Incremental encoders must be connected using shielded cables. The shield must be connected at the
incremental encoder and at the AC drive converter through the whole circumference of the screen to ensure
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

best high frequeny cable contact. The shield may not be interrupted, e.g. using intermediate terminals.

Rule 7 The shields of signal cables must be connected to ground at one end only, through the whole circumference
of the screen, to establish a good electrical connection (transmitter and receiver). If the potential bonding
between the screen connections is poor, an additional potential bonding conductor with a cross-section of at
least 10 mm² should be connected in parallel with the shield to reduce the shield current. The shields can be
connected to ground at several locations, e.g. on the cabinet housing and on cable trays. Foil shields are not
recommended. Braided screens provide a better shielding effect (factor of 5).

Rule 8 Always place a radio interference suppression filter close to the noise source. The filter is to be connected
flush with the cabinet housing, mounting plate, etc. The best solution is a bare metal mounting panel (e.g.
stainless steel, galvanized steel), because the complete mounting surface can be used to establish good
electrical contact. The incoming and outgoing cables of the radio interference suppression filter should be
separated.

Rule 9 All variable-speed motors should be connected using shielded cables, whereby the shield is connected at
both ends to the housings through the largest possible surface area to minimize the inductance. The motor
feeder cables should also be shielded outside the cabinet, or at least screened using barriers. Cables with steel
shields are not suitable.
To connect the shield at the motor, a suitable cable gland with shield connection must be used. It should be
ensured that the connection between the motor terminal box and the motor housing has low impedance.
Otherwise, use an additional grounding strap between them. Never use Plastic motor terminal boxes!

Rule 10 Installing components such as output reactors, sinusoidal filters, motor filters, fuses, contactors, etc may not
interrupt the shield between the motor and the frequency converter. The components must be mounted on
mounting panels, which also simultaneously serve as the shield connection for the incoming and outgoing
motor cables. Metal barriers may be required to shield the components.

Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 2 of 8

Change Date Sign Description

D 28.11.05 RHj Update of document.
Added information regarding selection of “fire resistance” or “flame
retardant” cable type. (Ch. 3)
E 12.01.07 RHj
Added new requirements regarding cables for frequency converter
duty. (Ch. 4.2)
F 12.03.05 bten Corrected outdated IEC norms with new norms
Added information regarding recommendation og “Halogen free
G 29.06.07 RHj cable” (Ch. 3) and specified insulation level on power cables for
frequency converter duty. (Ch. 4.2)
H 14.01.09 RHj Updated reference to project specific cable list.
I 08.06.11 RHj Adjusted to include steering gear. (Info from TS)

K| 19.11.13 SL Update of document regarding minimum clearence and shield

grounding.
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 3 of 8

® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
3. INTRODUCTION
This instruction gives requirements and guidelines regarding the electric installation of the winch control system and
the Steering Gear system.

The instruction also gives guidelines for the selection of cables between different communication network node points
within winch control system. Cable type and requirements are listed up below.

This instruction refers in most cases to cables of type “fire resistance”, however cables of type “flame retardant” can
be selected if similar specification.

This instruction refers to cables of type “Halogen Free”, if other cables are used this could lead to damage on
equipment.

NOTE!
All project specific requirements, such as dimension are described in the project specific cable list.

General requirements:
Twisted pair cables to comply with: IEC 60092-376, 60332-3-22, 60754-1/60754-2, 61034-1/61034-2
Power cables to comply with: IEC 60092-353, 60092-350, 60332-3-22, 60754-1/60754-2, 61034-1/61034-2

4. POWER CABLES
4.1 General
For power cables, it is required using a shielded cable with braided screens (0-1000V).
All phases are to be represented in each cable.
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or

Cable dimension: According to documentation.

used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

4.2 Redundant power supply

Where redundant supply is required, the supply must be in separate feeders from the main switchboard.
If required by the class, one of the supplies must be taken from the emergency source of power.

4.3 Frequency converter cables

For power cables, it is required using a shielded cable with braided screens of type
BFOU (VFD) or similar. All phases are to be represented in each cable.
Cable dimension: According to documentation.

Recommended insulation requirement:

General: 2 x nominal DC voltage
(Nominal DC voltage at 690 VAC supply approximately 950 VDC)
Note!
This include supply cables to frequency system, and cables from frequency system to electrical motor.
See also Frequency converter installation manual.

5. CONTROL CABLES
5.1 Control of solenoid valves
For control of solenoid valves, it is required using a shielded cable.
(Coil voltage. 24V / 110V / 230V)
Cable Data: Pair, shielded, 1,5 mm² min. (60 or 250V)
(for cable length >100m 2,5mm²)

For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type, BFOU(C) type or similar.
TCX- pair cable can be supplied in 1, 2, 4, 7, 10, 14, 19 and 24 pair. (Acc. to data sheet)

6. SIGNAL CABLES
6.1 Dig. feedback signal (from valves / starters)
For dig. feedback signal, it is required using a shielded pair cable. (24V DC)
Cable Data: Pair, shielded, 0,75 mm² min. (60V)
Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 4 of 8
® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
PWM signal must have separate cables (for each consumer).
For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type, BFOU(C) type or similar.
TCX- pair cable can be supplied in 1, 2, 4, 7, 10, 14, 19 and 24 pair. (Acc. to data sheet)

6.2 Analog signal (from valves / transmitters)

For analogue signal, it is required using a shielded pair cable. (0-24V)
Cable Data: Pair, shielded, 0,75 mm² min. (60V)

We recommend not mixing digital and analog signals in the same cable.
For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type, BFOU(C) type or similar.
TCX- pair cable can be supplied in 1, 2, 4, 7, 10, 14, 19 and (24) pair. (Acc. to data sheet)

7. BUS CABLES
7.1 Ethernet COAXIAL
For coaxial Ethernet it is recommended to use a ”Thinnet” or ”Cheapernet” cable for LAN 10 base 2. Cable shield
must be connected to ground at the computer end (UN 900), and terminators must be used at both ends.
Cable Data:
Type: LAN 10 base 2 DEC Coaxial
Cable outer diam.: 4.65 mm
Impedance: 50 Ω
Capacity (nom): 88 pF/m
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or

7.2 Ethernet TWISTED PAIR

For Ethernet with twisted pair it is recommended to use a 10BASE-T of S-FTP (Braid and foil screened Twisted Pair)
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

cable of category 5 or higher.

Cable Data:
Type: 2x2x0.5mm²
Impedance: 100 ± 15 Ω (1-100MHz)
Range: Max. 90 m.

A recommended category 6 cable is LANmark-6 F2TP Cat.6 LSZH from Nexans:

Type: Twisted pair, shielded, 4x2x0.55 mm (cable diameter)
Cable outer diam.: 6.5 mm
Impedance: 100 Ω ± 15 Ω (1-100MHz)

7.3 ProfiBus
End- terminators must be used in both ends.

External – Yard installed cable

Siemens brand – DNV approved cable.
Cable Data SIENOPYR-FR PROFIBUS M-02Y(ST)CHX:
Type: Twisted pair, shielded, 1x2x0.325 mm² (22 AWG)
Cable inner sheath: ø 8.0 mm
Cable outer diam.: ø 10.0 mm
Impedance: 150 ± 15 Ω
Capacitance: max. 30 pF/m

Internal – In cabinets / cabins only

Lapp Muller SAS
Cable Data : M-02Y(ST)CHX L2/FIP-DP
Type: Twisted pair, shielded, 1x2x0.34mm²
Cable outer diam.: ø 8,65mm
Impedance: 150 ± 15 Ω
Capacitance: max. 32 pF/m

Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 5 of 8

® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
7.4 Can Bus
For the CAN bus, it is required using a shielded twisted pair cable. According to the ISO 11898-2 standard, cables to
be chosen for CAN bus lines should have a nominal impedance of 120 Ohm, and a specific line delay of nominal 5
ns/m. Line termination is provided with 120 Ohm resistors terminated at both ends of the line. The length related
resistance should have 70 mOhm/m. All these mentioned AC and DC parameters are suitable for a 1 Mbit/s
transmission rate at 40 m segment length. With increasing segment length, a higher cable cross-section must be used
(see recommended values of ISO 11898).
Can-H and Can-L connected to one pair, Can-GND to the other pair.

This type of bus do not require any special type of cable, so most common twisted pair cables available can be used.
Cable Data:
Type: Twisted pair, shielded, low capacity, 0,75 mm² min.
Cable outer diam.: max 14 mm (when connector is used).

Impedance: 120 Ω (min. 108 Ω, max. 132 Ω)

Capacitance: max. 60 pF/m.
Resistance: max 40 Ω/km.
Range: Max 300m.

A recommended cable is :
Manufacture : Lapp Muller - France
Description : MARINEBus M-O2Y(st)CHX2Y 1x2x0.75mm+0.75mm.
Conductor : 1 x 2 x 0.75q + 0.75q
Cable outer diam. : 11.1 mm.
Impedance : 120 Ω.
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or

Capacitance (800 Hz) : max. 40 pF/m.

used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

Approved by : DNV certificate E-9274

Part No. manufacture : 67106
Maximum cable length : 300m
Supplier worldwide : Miltronic AS - Norway
Part No. Supplier : 1111646

7.5 RS-422/485 Transmissions

For wiring of RS-422/485 signals, it is recommend using a shielded twisted pair cable. RS-422/485 signals do not
require any special type of cable; so most twisted pair cables can be used. On the other hand, the transmission range
will increase if a cable with lower capacitance and larger diameter is used.
Sign-A and Sign-B connected to one pair, Sign-GND to the other pair.
Cable Data:
Type: Twisted pair, shielded, low capacity, 0,75 mm² min.
Cable outer diam.: max 14 mm (when connector is used).
Resistance: Max 100 Ohm totally on bus.
Capacity: 42pF/m maximum.
Range: Max 1200m.

For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type or similar.

Note! Special for Steering gear delivery

Screened twisted pair (0.5 mm2 minimum).

Impedance 120 ohm min 108 maks 132.
Termination at the end of the line at the receiver.

7.6 FIBRE OPTICAL

The fibre optical cables must be of multimode type with a core diameter of 50 or 62.5 µm, and cladding diameter 125
µm. ST connectors (also known as BFOC) are to be used in both ends of the cable. Each fibre optical link requires a
duplex connection, i.e. a total of four single fibres for each connection box.
Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 6 of 8
® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
Cable Data:
Type: Multimode.
Cable Core Diameter 50 or 62.5 μm.
Cladding Diameter: 125 μm.

Recommended cables:
Nexans Gx-62,5 QIQI-ø3.7-R1.0 or Gx-62,5 QIQG-ø3.7-R1.0,
Draka Gx-50/125 AXXI-I/O-W or Gx-62.5/125 AXXI-I/O-W
Optronics OM1LST08UBK

8. INSTALLATION
8.1 General
According to classification requirements.

The following precautions must be taken in regards to cabling:

 Ensure that there is sufficient space for the cables and cable-ducts used.
 Ensure that there are no cable bends that reduce cable performance,
 special attention to optical cables.
 Ensure that power and signal cables are separated.
 As a general rule, the minimum distance between power cables and signal cables is 0.3 meter.
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or

 Avoid routing of cables near power generator cables.

 Ensure that cables are secured inside cabinet.
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

 Cabinet to be grounded.
 Ensure that cable screens are terminated correct according to the system drawings

All cables are to be according to requirement by the classification society and relevant directives.

For installations with DNV classification please check against the DNV document “Classification Notes No. 45.1”
(December 1995), tables 4.1 and 4.2.

8.2 Cabinets
The steel cabinets must be properly earthed (Bonded). Cabinet doors and flanges are connected electrically with the
cabinet. Do not remove flanges or cable glands from el. cabinets; this to maintain the electromagnetic screen.

8.3 Motors
The motors must be properly earthed (Bonded). Junction boxes and flanges are connected electrically with the motor.
Do not remove flanges or cable glands from el. motor; this to maintain the electromagnetic screen.

8.4 Encoders
The cable screen is connected to the earth-bar in the cabinet, and to the screen in the encoder cable in the other end.
It must not be connected to earth in any other places (Earth terminals in junction boxes not to be used).
Each wire pair must be connected according to documentation. Unused wires must be connected to earth.

8.5 Power cables

Power cable shield grounded in both ends.

8.6 Control cables

Signal cable shield grounded in one end only (see documentation for shield grounding).

8.7 Signal cables

Signal cable shield grounded in one end only (see documentation for shield grounding).

Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 7 of 8

® Rolls-Royce Marine AS Rolls-Royce Oy Ab
Deck Machinery and Steering Gear - Brattvaag P.O. Box 220, FIN-26101 Rauma, Finland
Årsundveien 24, N-6270 Brattvåg, Norway Tel. +358 (0) 2 83 791. Fax +358 (0) 2 8379 4913
Tel. +47 70 20 85 00. Fax +47 70 20 86 00
8.8 Bus cables
Communication cable shield grounded according to documentation.
Each wire pair must be connected according to documentation.

8.9 Connecting load cells

All cables connecting load cells has to be connected to terminals in special terminal boxes placed on winch. This
work has to be carried out under supervision by Rolls- Royce Marine.

Signal cable shielded connected to terminals (see documentation for shield grounding).

8.10 Installation of frequency converters

Regarding installation of frequency converters, see instruction manual under section for installation.

9 REFERENCES

IEC 60092-353
IEC 60092-376
IEC 60092-350
IEC 60332-3-22
IEC 60754-1/60754-2
IEC 61034-1/61034-2
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or
used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.

Prep. by/date: RHj/28.11.05 227-061, rev.K KRAV Page 8 of 8

Item ID 000109892 Revision B

End of Report

Page 1 of 1 Print Date: 12.08.2014

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