Simrad AS makes every effort to ensure that the information contained within this
document is correct. However, our equipment is continuously being improved and
updated, so we cannot assume liability for any errors which may occur.
Warning!
The equipment to which this manual applies must only be used for the purpose for which
it was designed. Improper use or maintenance may cause damage to the equipment or
injury to personnel. The user must be familiar with the contents of the appropriate
manuals before attempting to operate or work on the equipment.
Simrad AS disclaims any responsibility for damage or injury caused by improper
installation, use or maintenance of the equipment.
The information contained within this document remains the sole property of Simrad AS.
No part of this document may be copied or reproduced in any form or by any means, and
the information contained within is not to be communicated to a third party, without the
prior written consent of Simrad AS.
This manual is intended as a reference guide for correctly
installing and maintaining the RPU80, RPU160 and
RPU300 reversible pumps.
Please take time to read this manual to get a thorough
understanding of the reversible pump and its relationship to
a complete autopilot system.
Other documentation material that is provided with your
system includes a warranty card. This must be filled out by
the authorized dealer that performed the installation and
mailed in to activate the warranty.
Rev. D Page 1-3: Bosvik steering gear included. Page 3-1 and 3-2: Changes in notes. Page 4-2:
New warning added. Page 7-2: New subparagraph added to paragraph 7.3.
Rev. E Page 3-1 and 3-2: Changes in notes due to modification of RPU80. Page 4-2: Warning
removed. Page 7-1, Paragraph 7.3: Changed text in brackets. Page 8-1: Modified
drawing. Page 9-1 and 9-2: Spare part lists modified due to modification of RPU80.
Rev. F Minor corrections for rudder speed and rudder time in section 1 and 2.
Rev. G New layout. Steering gear table (Paragraph 1.2) revised. New fittings included, pages 17
and 31.
Rev. H Corrected part no. for valve block, page 32. New distributor list.
Rev. I Corrected formula on page 12. Added note on page 17. New distributor list.
Rev. J Added colour for the o-ring at pos. 18, page 33 to avoid mix up.
Rev. K Fig. 9.1. Pos 8. Spring. New part. no. 21100193. Added text and illustrations under
‘Siting’ page 17.
Rev. L Fracmo motors substituted by Lemac motors. All drawings in chapter 8 revised.
Rev. M New part no. on RPU80 Lemac motor, page 34. New distributor list.
Rev. N New paragraph under ‘Fault tracing’ regarding poor brushes. Updated with new
Note ! This manual does not cover a previous model RPU80 with serial
numbers 101-248. The model is covered by the RPU100
Reversible Pump Manual. Minor modifications where made to
the RPU100 model and they are described in a separate
"Technical Information" no. 01/94.
1.1 General
Hydraulic steering systems are now being used in every
category of small vessel. In many respects hydraulic steering is
preferable to mechanical steering.
Hydraulic systems normally comprise of two main components,
a steering wheel pump and steering cylinder(s). The steering
wheel pump may be either a gear pump or a plunger pump.
Which ever type is installed, steering is achieved by turning the
steering wheel in either direction causing oil from the wheel
pump to be supplied to the appropriate side of the cylinder. Oil
is returned via the opposite side of the cylinder back to the
pump.
The linear motion of the cylinder rod is transformed to a rotary
motion by the tiller, which turns the rudder shaft and rudder.
Check valves (non-return valves) are usually incorporated to
prevent the rudder driving the steering wheel pump.
If an autopilot is to be included in such a hydraulic steering
system, then the oil flow providing the rudder movement must
be controlled by electrical signals from the autopilot.
The maximum flow rate of RPU80, RPU160 and RPU300 is 0,8
l/min., 1,6 l/min. and 3,0 l/min. respectively, measured at a
pressure of 10 bar with nominal voltage (12 VDC) on the motor
terminals.
Note ! RPU300 measurements are based on charging voltage
(14,4VDC)
The flow rate is controlled by the output voltage from the
autopilot's junction unit/computer. When connected to autopilots
using the J300, J3000, all "X"-models of junction units and
ACXX Autopilot Computers, the output voltage that controls the
motor speed is proportional to the heading error from the
autopilot.
This will give slow and smooth rudder movements when
steering on a straight course in calm weather, but will also
ensure fast rudder response for bigger course changes or course
deviations caused by rough sea conditions.
An automatic "Rudder test" function in these autopilots will also
limit the output equivalent to a rudder speed of 8 degrees per
second which is optimum for autopilots with proportional rudder
control. (Equals to approx. 9 seconds for 35-0-35 degrees rudder
travel). Consequently when operating a steering lever or the
Port/Stbd push buttons on the autopilot in manual mode, the
rudder speed will be 8 degrees per second, whilst the rudder
speed when in "Auto" mode normally is less and proportional to
the heading error.
If the pump unit is used with older autopilot models like
AP2500, AP200 or AP45, using J1000B, J101A or J45A
junction units, the output level/flow rate is set by a
potentiometer within the junction unit.
External rudder speed control can be provided by a separate
potentiometer connected to J1000B/J101A/J45A and mounted
near the steering position.
The flow rate must be chosen such that optimum automatic
steering is obtained.
Experience has shown that a rudder time between 10 and 15
seconds hard over to hard over normally gives the best steering
performance. In order to achieve a rudder time within these
limits, the flow rate must correspond with the cylinder volume.
Some boats will perform good automatic steering even with a
hardover time of 20 seconds. The flow-rate, however, is reduced
by increasing load, i.e. increased pressure. It is therefore not
recommended to select a pump with a flow rate that is not able
to move the rudder hardover to hardover in 20 seconds as shown
on the nomogram on page 13. Study the tables on the following
pages for appropriate pump selection, and use the nomogram on
page 13 as a guideline.
On page 7 to 11 are listed some well known hydraulic steering
gears together with the corresponding values for the rudder time
hardover to hardover.
The values are calculated from the maximum flow rate at 10 bar
pressure.
If a specific system is not listed, the cylinder volume must be
calculated as explained in section 2.1.
Any well known hydraulic oil with viscosity between 15-70 cSt
at 40°C can be used with RPU80, RPU160 and RPU300.
2 MEASUREMENTS AND CALCULATIONS FOR
APPLYING THE RPU
2.1 Calculation of cylinder volume
The RPU80 is recommended for cylinders between 80-250 cm3
(4,9-15,2 cu. in.), RPU160 for cylinders between 160-550 cm3
(9,8-33,5 cu.in.) and RPU300 for cylinders between 290 -960
cm3 (17,7-58,5 cu.in.). These figures will give for a rudder angle
of 70 degrees (35°-0-35°) a hardover to hardover time of 6-20
seconds equivalent to a rudder speed of 11,6-3,5 deg./second.
Based on experience 6-8 deg./second seems to be the optimum
speed for autopilots with proportional rudder control. However,
a rudder speed between 11,6 deg./second and 3,5 deg./second
should normally cause no problem, particularly not the high
speed which will be reduced by the autopilot electronics.
Depending on type of autopilot the rudder speed is automatically
or manually adjusted during installation and commissioning.
Refer to page 1-1 and the autopilot manual for detailed
information.
The cylinder volume is calculated from the formula:
Volume =
Where
L = stroke length
D = internal cylinder diameter (= outside diameter – 0,6)
d = push rod diameter
π = 3,14
(All dimensions in centimeters)
22
dDL−
)(
4
2.2 Minimum rudder time adjustment
(Applies only for Junction units J1000B, J101A and J45A)
The minimum rudder time can be found as follows (see figure 2-
1):
Draw a horizontal line from the applicable value on the cylinder
volume axis. Rudder time may now be read on the horizontal
axis.
By means of potentiometer RV1 in the Junction unit the rudder
time can be increased.
Measurements and calculations for applying the RPU
Recommended rudder time: 10-15 seconds is normal for a 70°
(35°-0-35°) rudder angle. (The time will be shorter for smaller
angles and longer for larger angles.) A longer rudder time (20
sec.) should be chosen if the boat has a quick response.
Example:
The stroke length is measured to be 20 cm, D = 5.0 cm and d =
1.8 cm
22
)8,15(20
The cylinder volume is:
−
π
= 340 cm3
4
From the nomogram we find that the estimated rudder time in
seconds, hard over to hard over, will be 7 seconds for RPU300,
13 seconds for RPU160 and 25 seconds for RPU80.
1000
60
900
55
50
800
45
700
40
600
35
500
30
400
25
20
300
15
200
10
100
5
0
(3
0
0
3
U
P
R
0
6
1
U
P
R
(
0
8
U
P
R
)
.
n
i
3
m
/
m
c
0
0
)
.
n
i
3
m
/
m
c
0
0
6
1
(
)
.
n
3
i
m
/
cm
0
0
8
RAM (CYLINDER) CAPA CITY
REVERSIBLE PUMP UNITS RPU80/RPU160/RPU300, CAPACITY NOMOGRAM AT 10 BAR PRESSURE.
RUDDER TIME (SEC.) H.O. TO H.O. FOR A GIVEN CYLINDER VOLUME.
5
67
1020
2515SEC.
Figure 2-1
Capacity nomogram for Reversible Pump
RPU80/RPU160/RPU300
Based on the above calculation and the nomogram, the
recommended pump type should be RPU160.
The pump comprises an electric permanent magnet motor, valve
block with reversible gear pump, non-return (check) valves on
outlet A and B and suction valves from both sides of the gear
pump to outlet C. Outlet C is connected to either the expansion
tank in the steering wheel pump or a separate expansion tank.
ACB
667
555
44
33
2
M
1
RPU80/RPU160/RPU300 PRINCIPLE DIAGRAM
Principle diagram RPU80/RPU160/RPU300
A
667
55 5
PREVIOUS RPU80 PRINCIPLE DIAGRAM
CB
33
2
M
1
Figure 3-1
1. Electric permanent magnet motor
2. Reversible gear pump
3. Suction valves
4. Pressure operated non-return valves
5. Stop cocks (Not supplied with pump)
6. A+B to main pipes
7. C to expansion tank
The previous model of the RPU80
Reversible Pump was simplified
according to the principle diagram
above. It had no check valves and
there was no spring in the suction
valves.
The simplified units have ser. no.
below 1317 H02 (P/N 21116165)
and 1805 H03 (P/N 21116181-US
version).
3.2 Principle of operation (ref. figure 3-1 and
figure 9-1)
RPU80/160/300 is reversible: that is the motor changes direction
of rotation and the gear pump delivers oil to that side of the
rudder cylinder dictated by the signal from the autopilot. The
pump runs until the signal from the autopilot ceases. The pump
unit has non-return valves on the outlets A and B. When
running, the pressurized (or delivery) side will hold both nonreturn valves open, using direct oil pressure upon the valve on
the delivery side. This oil pressure is also used to push a slide to
open the valve on the suction side.
When the motor stops, the spring (8) in the non-return valve on
the suction side returns the slide to the neutral position. Both
non-return valves are now closed and the rudder cylinder
locked. Both sides of the gear pump have suction valves to
outlet C.
Note !
If the rudder cylinder is loaded in the same direction as the
rudder command, the slide (10) precisely positions the nonreturn valve (suction side) such that the creation of a vacuum in
the rudder cylinder is prevented. (A vacuum in the rudder
cylinder would result in air being drawn past the seals round the
cylinder piston rod, since these stops the oil pressure only). At
that side of the valve block where the motor is connected, there
is mounted sealing ring (15) and support ring (16) in the valve
block. The support ring causes that the tank connection C can
hold a maximum pressure of 7 bar (Ref. Hynautic steering
systems).
1. A previous model of RPU80 Reversible Pump was simplified
according to the principle diagram. (Ref. figure 3-1 and
figure 9-2). The principle of operation was similar to that of
RPU160. The (suction) valves, however, operated as
combined suction and non-return (check) valves controlled
by internal pressure and direction of oil flow. The resulting
effect was a smoother non-return (check valve) function as
compared to the one with separate non-return valves.
2. It should be observed however, that the previous model of
RPU80 does not have the extra protection against internal
leakage (bypass) as the other models with separate check
valves.
This is an aluminum block with borings for non-return valves,
suction valves, slide, gear pump, motor coupling and all
necessary oil ways. The three outlets A, B and C are positioned
on top of the valve block.
3.4 Gear pump
This comprises of the driving gear wheel, which is coupled to
the motor shaft via a flexible shaft coupling, and meshed with
the driven gear wheel supported by the valve block (1) at one
end and by the pump cover (5) at the other.
The gear wheels run in the pump housing. The gear wheels are
1/100-2/100 mm smaller than the pump housing.
O-rings are fitted to both the valve block and the pump cover to
provide oil tight seals on both sides of the pump housing.
The pump cover is held by 4 screws (25).
When the gear wheels rotate, oil is carried in the inter-tooth
spaces around the periphery of the pump housing from the
suction side to the pressure side.
3.5 Pressure operated non-return (check) valves
on outlet A and B
These are screwed into the valve block from both sides. The
valve comprise of valve housing (6), plug (7), ball (12), spring
(8), copper washer (17), O-ring (13) and copper washer (14).
The housing and plug are made of stainless steel.
3.6 Suction valves on outlet C
These are connected to both sides of the gear pump via oil ways
in the valve block. The valve comprises of a grub screw (21),
spring (9) and ball (20).
If the grub screw (21) is removed, it should be refitted with
Loctite 542 after degreasing the threads.
3.7 Slide (10)
This is located within the valve block in a cylindrical run
between the non-return valves for outlets A and B. The slide is
grooved to allow location of an O-ring (13).
The 3 outlets have fittings for 3/8" (US model) or 10 mm (EU
model) outer diameter pipe. The two outer outlets A and B
connect to the main pipes. The middle outlet C connects to the
bottom of the expansion tank in the steering wheel pump or a
separate expansion tank.
The pump unit should be sited where it is most practical
between rudder cylinder and helm pump, however, it should not
be mounted in a wet area. If the pump unit is sited higher than
the rudder cylinder, air bubbles in the oil coming from the
rudder cylinder could pass through the pump unit on the way to
the expansion tank in the steering wheel pump. This will disturb
the oil flow as the air bubbles pass through.
The pump unit should be mounted horizontally, with the pipe
connections/fittings pointing upwards. Use a 90° bracket if
mounted on a bulkhead. It could however be mounted directly
on a bulkhead, but never with the motor pointing downwards, as
oil leak/sweating from a poor shaft seal can easily penetrate the
motor and destroy it.
Fittings
For pump units manufactured before January 1999, the fittings
are factory mounted on the pump housing.
From January 1999 a different type of fitting is used. The new
fitting has an O-ring seal between the fitting and the pump
housing.
The threads are changed from ¼” NPT to 7/16”-20 UNF both on
the European and the U.S. version. The pipe connection remains
the same as before.
Note ! Because the threads are different the new fittings cannot be used
with an old pump and vice versa.
The fittings are easily inserted and less critical with regard to
tightening torque. Consequently the fittings need not be
mounted at the factory. They are now supplied with the pumps
in a plastic bag for mounting during pump installation.
Protection caps cover the threads in the pump housing during
transportation.
Note ! As these fittings have o-
ring sealing there is no
need for additional
sealing compound.
Use following procedure
when mounting the
fittings on the pump;
• Use the fingers and turn clockwise until a noticeable
increase in torque is required.
• Tighten further by 30 degrees (= 1/12 of a turn) using
necessary force (25-30 Nm/230-260 In.Ibs).
Pumps with new fittings have got new serial no. code and is
valid from the following s.no’s; RPU80: s.n. 2460 H06,
RPU160: s.n. 1560 H14, RPU300: s.n. 380 H28, RPU300, 24V:
s.n. 180 H29
Installation of pipes
Drain the oil from the steering gear by loosening the rudder
cylinder couplings. At a convenient point cut the pipes and
mount a T-coupling to each pipe. Cutting ring couplings of an
appropriate diameter should be used. Ensure that the pipe is cut
at a right angle as otherwise the ultimate tightness of the
coupling may be adversely affected. It is preferable to use pipe
cutting tool for this operation.
Note ! It is very important to remove ALL traces of metal filings and
other impurities from the pipes after cutting.
Figure 4-1 Figure 4-2 Figure 4-3
Figure 4-1, 4-2 and 4-3 show the parts that form a cutting ring
coupling. It is important to note which way the cutting ring is
fitted, the following procedure should be followed:
a) Nut and cutting ring are slid over the pipe, figure 4-1.
b) A few drops of oil are first applied to the threads of the
coupling. The pipe is then inserted fully into the coupling and
held whilst the nut is tightened by hand until the cutting ring
rests against the cone (figure 4-2).
c) The nut is now tightened 1½ - 2 turns until the cutting ring
cuts into the pipe surface (figure 4-3). Ensure that the pipe is
held firmly in place whilst the nut is tightened. Release the
coupling and check that the cutting ring has successfully cut
into the pipe.
A clearly formed lip should be visible on the pipe in front of the
cutting ring. If this is not present, the nut should be tightened by
an additional ½ - 1 turn. Check once again as above. From the
T-couplings run a pipe 10x1 mm (US model: 3/8"), to the pump
unit. Avoid high points in the run that could allow air pockets to
form.
Sharp bends in the pipes (i.e. elbow bends) should be avoided as
these restrict the oil flow. For the same reason couplings should
not be fitted on bends, see Figure 4-4.
Pipes should be bent cold. Attempts to use blowtorch and sand
will lead to impurities entering the system, and should therefore
be avoided.
Figure 4-4
Stop cocks should be fitted to all pipes near the pump unit.
Sluice cocks or similar should be used, and not cocks of the
water supply type. Pipes should be fitted from the stopcocks to
the outlet A and B of the pump unit.
Connection to expansion tank
Most hydraulic steering gears have an expansion tank
incorporated in the steering wheel pump. At the bottom of this
tank is a drain plug, which should be removed and replaced by a
coupling which fits the expansion pipe (10x1 mm, US model:
3/8").Fit a 10x1 mm (US model: 3/8") pipe from the wheel
pump at a uniform, gradual, downward slope to the pump unit.
A stop cock should also be inserted in this pipe near the pump
unit.
Connection to separate expansion tank
If the steering wheel pump does not incorporate expansion tank,
a separate expansion tank must be installed. This tank should
have a volume of 1/4 liter (0.25 qt), and be placed at
approximately the same level as the steering wheel pump.
Lock valve for steering wheel pump
If the steering wheel pump is not provided with a lock valve
(they most often are), an adequate lock valve should be fitted.
The two leads from the motor are connected to the terminal
block marked "MOTOR" in the Junction unit/Autopilot
computer. There is no dedicated Port and Stbd output. The
autopilot will automatically set the correct direction during
"Rudder Test".
Refer to Autopilot manual for further details.
J1000B, J101A and J45A
The two leads from the motor are connected to the terminal
block in the Junction unit marked Motor A and B. Interchanging
of the two leads will change the rotary direction of the motor
(see paragraph 5.2).
The Reversible Pump units are operated from 12V DC via the
Junction unit. This 12V output can be reduced by internal trim
potentiometer (RV1) to reduce rudder speed (see paragraph 2.2).
When installing a pump unit, it is recommended that the whole
system be emptied and refilled. Use a well known oil of a
viscosity meeting the specification of the steering gear
manufacturer.
Start by opening all stop cocks in the pipes leading to the pump
unit. Simultaneously fill the steering wheel pump with oil whilst
turning the wheel itself, back and forth. Proceed by opening the
couplings at the rudder cylinder whilst still turning the wheel,
this will assist in creating pressure within the system, continue
until clean oil is seen at the couplings. Now tighten the
couplings. Then open the 3 couplings on outlet A, B and C on
top of the pump unit, and repeat the same procedure.
Installation
5.2 Testing
Set the autopilot to manual mode and use a remote control or the
Port/Stbd buttons on the control unit to run the rudder hard over
to hard over to check the operation of the system. Check that the
rudder goes to the same side as the signal you are giving by the
remote control. If not, interchange motor cable connections A
and B in the junction unit (J1000B, J101A, J45A). If necessary
top-up the expansion tank. Repeat the bleeding procedure
(paragraph 5.1) after the equipment has been used for about 5-10
hours.
In the X-series Autopilots (AP300X, AP35, AP20, AP21, AP22)
and the AP16, AP25, AP26, AP27 and AP50 autopilots,
checking motor rotation or interchange of cables in the junction
unit/autopilot computer is not necessary, because the autopilot
will determine the correct rotation automatically during the
"rudder test".
If fault develops, the source and location must be traced. Close
all stop cocks to the pump unit and check whether the steering
gear functions normally using only the steering wheel pump. If
so, then the fault is most probably in the pump unit or junction
unit/autopilot computer.
The following faults may be tested for:
7.1 Pump (motor) is not running/not responding
to rudder command
Probable reason:
Brushes sticking or worn out. Remove the brushes and check.
Sticking brushes should be wiped clean and any carbon dust
should be removed from the brush holders. Check that the
brushes move without restraint before they are secured.
7.2 The piston rod does not move with rudder
commands
Probable reason:
1. Check that the stop cocks are open.
2. The pump is sucking air. Check outlets A, B and C for
leakage. If the fault is not found here, check the non-return
valves for leakage, especially the copper gaskets between the
end plug and the valve housing.
Leakage may also occur in the threads of the suction valves
grub screws (21). Check both. If leakage is present, the
pump unit has to be dismantled. See paragraph 7.10 for
dismantle and cleaning of the suction valves.
3. See also paragraph 7.10.
7.3 Excessive noise from the pump unit
Probable reason:
1. Air in outlet C to expansion tank. Ensure that the stop cocks
are open, if so, loosen the nut on the coupling and check that
the oil is flowing normally.
7.4 The rudder does not stay in off-midship
position, but drifts towards midship due to water
pressure on the rudder
Probable reason (Does not apply for the previous model of
RPU80):
1. The non-return valves are leaking. Shut the stop cocks to the
pump unit, and operate the steering gear by means of the
steering wheel pump. If the steering is normal by hand
operation, the fault must be in the non-return valves or the
slide.
If the slide is locked because of oil contamination, the nonreturn valve may be held open.
If the fault is not found on the slide, both of the non-return
valves have to be disassembled. Check the ball seat in the
valve housing for wear etc. Replace the O-ring and copper
gaskets. After having assembled the ball, spring, gasket and
plug, check that the spring pressure on the ball is sufficient
to keep the ball seated. The spring needs a certain preloading to bring the slide back to neutral position.
2. If the problem appears on an RPU80 installation, the reason
may be oil contamination or worn ball seals in the suction
valves. Remove the steel balls for inspection and check the
seals for possible wear. Refer to paragraph 7.10.
3. If the steering gear does not function normally by hand with
the pump unit isolated from the system, there must be a fault
in the steering gear. In order to trace a fault of this nature,
use the instructions given by the manufacturer of the steering
gear.
7.5 Steering wheel is turning while pump unit is
operated
Probable reason:
1. Leaking lock valve in the wheel pump. Check as described
under paragraph 7.4.2.
2. Lock valves are not fitted. Attach lock valve.
7.6 The piston rod of the rudder cylinder does not
move smoothly.
Probable reason:
1. Air in the steering system. Repeat bleeding procedure
7.10 Rudder moves only in one direction (with
pump running)
Probable reason:
Suction valve not working (pos. 20, 9, 21) on one side. This is
most probably caused by metal fragments that have entered into
the suction valve(s) through the tube fitting for the return line
(C) during installation. Ref. figure 3-1.
The suction valve (3) on the side that is not giving pressure must
be opened and thoroughly cleaned, and for safety reasons the
other valve should also be inspected and cleaned before
reinstalling the pump unit.
For disassembling and cleaning of the suction valves please use
following procedure (Ref. figure 9-1):
1. Unscrew the grub screw - pos. 21.
2. Remove the spring - pos. 9, and the steel ball - pos. 20.
3. Thoroughly clean the valve seat and the threads in the valve
block (1). Also clean the removed steel ball (20), spring (9)
and grub screw (21). Use Loctite "Super Clean" or similar.
Reassemble as follows:
1. Put the steel ball (20) into the valve block.
2. Put the spring (9) onto the grub screw (21) before it is
screwed into the valve block.
Note ! Use Loctite 542 or similar on the threads to prevent oil leakage.
If Loctite 747 "Activator" is sprayed on the threads before
applying Loctite 542, this will speed up the hardening
process.(With Loctite 542 only, you have to wait 4 hours before
the pump unit can be put in operation again. Using Loctite
"Activator" reduces the hardening time to 1 hour).
3. Make sure the grub screw (21) is screwed in until it is flush
with the valve block (1). This will ensure correct spring
tension in the suction valve.