R
Raytheon Marine GmbH High Seas Products Postfach 1166 D – 24100 Kiel Germany Tel +49–4 31–30 19–0 Fax +49–4 31–30 19–291 Email
[email protected] www.raymarine.com
Feedback Unit Rud Angle Transmitter Unit
Type 101 – 528 NG024 - NG029
SERVICE MANUAL
1 Installation and First Putting into Operation 2 Maintenance, Repair, Spare Parts Catalogue 3 Construction, Principle of Operation, Technical Data
3701E/101–528.DOC032
Edition: 28.AUG.2003
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Feedback Unit Service Manual
CONTENTS
Technical Documentation
Page
1 1.1
Installation and First Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.1 1.1.2 1.1.3
Lever Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Kit for Spark Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1.1.4
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1.2
First Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.2.1 1.2.2 1.2.3
Prerequisite for Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Adjusting the Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Zeroing of the Potentiometer R1 and R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.2.4
Adjusting the Micro Switch (Midship Indicator) (optional for all Versions) . . . . . . . 1–5
2
Maintenance, Shipboard Repair, Spare Parts Catalogue . . . . . . . . . . . . . . . . . 2–1
2.1 2.2 2.2.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.3 2.3.1
Repair – Exchanging of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.3.2 2.3.3
Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Microswitch (Mid Ship Indicator) (optional for all Versions) . . . . . . . . . . . . . . . . . . . 2–4
2.4 2.4.1
Spare Parts Catalogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 Notes on Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
3
Construction and Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 3.2 3.3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.4 3.4.1 3.4.2
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.3
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Annexes
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1
Installation and First Putting into Operation
1.1
Installation
Technical Documentation
Drilling scheme refers to Dimensional Diagram 101 D 528.HP005, Sheet 1 to 3. For suggestions for attachment of one and two feedback units, see the overview table in the annex. In any case of application, the consoles are to be supplied by the shipyard! 1.1.1
Lever Drive (Refer to Dimensional Diagram 101 D 528.HP005, Sheet 2 and Fig. A to C in the annex). The transmission ratio from the lever drive ist 1 : 1. The lever system consists of two driving levers, the connecting tube and two ball–and– socket joints. After the lever system has carefully been adjusted, the connecting tube between the two driving levers is to be shortened to the required length and jointly to be bored with the shafts of the ball–and–socket joints applied to both sides, e.g. dia. 4H11. Into these bores, the spiral pins supplied (DIN 7344) are to be pressed. Subsequently, the spiral pins must mechanically be secured on both sides (top and bottom) by punch–marking. Note: Systems of up to 2 feedback units require two lever systems, accordingly (see Fig. B in the annex).
1.1.2
Chain Drive (Refer to Dimensional Diagram 101 D 528.HP005, Sheet 3 and Fig. E and F in the annex). For rudder angles of max. +90°, the drive of the feedback unit should be via chain wheels and chain. The transmission ratio from the chain drive is 2 : 1. The tapholes (e.g. M6, depth 20 mm) required for fastening the chain wheel to the rudder stock are to be centered on the plane surface of the rudder stock. Then the chain wheel is to be screwed on and to be pinned by means of cylindrical pins. To ensure automatic chain tension, a chain tightener is to be mounted and to be placed in accordance with space conditions (chain tightener included in the scope of delivery). Note: For systems of 2 feedback units, two chain wheels – arranged in parallel – are to be centered and screwed on the plane surface of the rudder stock, and pinned (see Fig. F in the annex).
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1.1.3
Kit for Spark Suppression Preliminary remark On switching inductively acting components such as transformers or magnet coils of any type (contactors, solenoid valves), dangerous high voltage peaks are generated not only in the circuit concerned but also in the neighbouring cables. There is danger that semiconductor elements within the equipment might be destroyed by these high voltage peaks. Furthermore, heavy wear may occur on the electrical switching contacts. These effects and the resulting disturbances on the devices concerned may be avoided by installing varistors in the equipment. A package of three varistors and an instruction are attached to the device for different voltage ranges: NB03–923.01: NB03–923.02: NB03–923.03:
for circuits of up to 28V DC for circuits from 110V to 115V AC or DC for circuits from 220V to 230V AC.
Mounting the varistors 1) Select the varistors that are appropriate to the operating voltage of the corresponding circuit. 2) Install a varistor in parallel and as close as possible to the inductive component concerned. 3) In case the connections cannot be made directly on the coil or transformer in question, the varistors are to be installed in the nearest junction box where the cables or adequate terminals can be reached. 4) Please keep remaining packages with varistors for a future extension where additional varistors might be required. 5) After installation, check all circuits for correct functioning. 1.1.4
Cabling See system–specific Cable Diagram as well as Wiring Diagram 101–528.HP050 for version NG024 101–528.HP053 for version NG027 101–528.HP054 for version NG029
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Technical Documentation
1.2
First Putting into Operation For putting into operation, a multimeter (internal resistance >20kOhm/V) is required.
1.2.1
Prerequisite for Putting into Operation The parts of the equipment are connected ready for operation according to the system cable and connection diagrams (see Section 1.1).
Caution! On performing work on the Feedback Unit, observe the electrical safety regulations! The following works are to be performed by authorized trained personnel only.
The following versions should be taken into consideration when carrying out adjustment work: Version NG029
Limit switch 1 set 45°
NG024 NG027 **) *)
2 set 45°
Midships indication (optional)
Application
1x
x
1x
(x)
RIA
2x
(x)
FU, RIA, NFU *)
FU or RIA
for secondary steering system (e. g. steering failure)
**)
1.2.2
–
Potentiometer
for rudder limitation units
Adjusting the Limit Switches Adjustment of the limit switches B2 and B4 (for large rudder angles with small speed) and B1 and B3 (for small rudder angles) is to be made in the feedback unit according to the ship–specific limit position of the particular rudder. The equipment must be switched on in order that the limit switches can correctly be adjusted. – Take off the protective hood of the feedback unit. – Release the fastening screws of the cams (see Fig. 1–1) – Set the cams so that they switch off before the mechanical limit position of the rudder is reached. – Screw down the headless pin in the cam disk. – Feedback unit is to be closed by the protective hood again.
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Earthing screw
Terminal strip
Angle
Micro switch
Limit Switches
Cam disk
Gear for potentiometer
B2
B4
Potentiometer
Cams
Fig. 1–1: 1.2.3
Feedback Unit – opened Divice
Zeroing of the Potentiometer R1 and R2 – Take off the protective hood of the feedback unit. With the rudder position exactly midships, disconnect the electrical connections of potentiometer R1 or R2 from the terminal strip (see Wiring Diagram 101 E 528.HP050, HP053, HP054). – Loosen the fastening of the potentiometer concerned. – Connect the multimeter to the respective connections 1 and 2 or 2 and 3 of the potentiometer to be zeroed. – Turn the casing of the potentiometer until the resistance between the connections 1 and 2 becomes the same as it is between the connections 2 and 3. Total resistance of the potentiometer: 5 kΩ +20%, – After zeroing, the potentiometer R1 or R2 is immediately to be re–fastened and its connections are to be re–established on the terminal strip L1. – Subsequently, the fastening screws are to be secured by means of varnish.
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Technical Documentation
Note: Slight tolerance–limit deviations in the mid–position of the potentiometer R1 can later be compensated by an offset compensation of the feedback input amplifier on the follow–up steering control amplifier PCB of the follow–up steering control amplifier by means of the potentiometer R15 ”RUDDER OFFSET”. For cases of application, where the feedback unit does not operate in conjunction with the follow–up steering control amplifier zeroing of the rudder feedback potentiometer should be performed according to the information given in the description of device or system description concerned! 1.2.4
Adjusting the Micro Switch (Midship Indicator),standard in NG029 (optional for all Versions) Pre–conditions: – Feedback unit must electrically be isolated. – Connect multimeter to the terminals L1.11 and L1.12. – Disconnected a possibly installed lamp circuit. – Set the rudder exactly to midship position. – Displace the shaft of the feedback unit no longer! – In this position, loosen the cam wheel (refer to Fig. 1–1) and turn it on the shaft in such a way that the probe roller of the microswitch is exactly positioned in the v–shaped notch of the cam wheel. – Then fix the cam wheel with its two headless socket screws, M4x8. – Adjust the angle of the probe in such a way that it switches on or off when turning the cam wheel within the area of the slopes of the v–shaped notch (when doing this, observe the overlap of the microswitch!) Permissible deviation from the rudder zero position: +2°. Monitor the switching function at the multimeter. – Once more fix the position of the angle. – After the adjustments have been made, re–establish all electrical connections. – Carefully cover the fixing screws of the angle, the microswitch and the headless socket screws at the cam wheel with glyptal. – Re–attach the protective hood. – Observe correct earth connection!
The feedback unit can now be put into operation.
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2
Maintenance, Shipboard Repair, Spare Parts Catalogue
2.1
Safety Precautions
Technical Documentation
Warning! Use care during maintenance and repair to avoid contact with energized electrical conductors. Applicable safety regulations must be followed, such as VDE, VBG 4, OSHA 1919, and other consensus safety standards.
Caution! Maintenance and repair must be performed by trained and qualified personnel who are knowledgeable in equipment national safety requirements! Device may be damaged! Exchange of spare parts only with the supply voltage switched off.
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2.2
Care and Maintenance
The feedback unit is an important component within the steering control. In view of the ship’s safety, particular attention must therefore be given to its care and maintenance.
2.2.1
Maintenance Schedule
Con. No. 1
2
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Maintenance –
check the tight fitting of the fixing screws of the components in the feedback unit and re–tighten when necessary and cover with glyptal
–
carefully grease the toothed sides of the toothed wheels, e.g. with MOLYKOTER
–
check for exact alignment and correct switching function of the limit switch
–
check the shafts and the toothed wheels for mechanical loosening
–
check the correct function of the potentiometer
2–2
Intervall
Reference
every 2 years
1.2.2 every 3 years 1.2.3
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Feedback Unit Service Manual
2.3
Technical Documentation
Repair – Exchanging of Parts Pre–conditions: – Rudder is in midship position – Rudder equipment is electrically isolated – Driving element removed from the feedback unit – Protective hood removed.
2.3.1
Limit Switches – Mark the electrical connections – Loosen the electric terminal connections – Screw off the two fastening screws of the limit switch – Exchange the defective limit switch – Re–assembly in the revers order – Check the adjusting of the appertaining cam (refer to Section 1.2.2)
2.3.2
Potentiometer – Remove the trigger cam on the feedback unit shaft. – Carefully remove the PCB together with all its components (unscrew four fixing screws), observing cable connections! – Mark the electrical connections of the potentiometer and remove them at the terminal strip. – Loosen the toothed–wheel fixing at the potentiometer shaft and remove the toothed wheel. – – – –
2.3.3
Unscrew the fixing screws at the potentiometer. Replace the defective potentiometer. Re–assemble in reverse order. Align and set zero point in accordance with section 1.2.2 and 1.2.3.
Microswitch (Mid Ship Indicator) (optional for all Versions) – Screw off the two fastening screws of the microswitch – Draw off the electrical plug connections of the switch Do not pull at the electrical wires! – Exchange the defective microswitch – Re–assembly in the revers order – Check the adjusting of the microswitch (refer to Section 1.2.4)
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2.4
Spare Parts Catalogue
2.4.1
Notes on Ordering To ensure fast processing of replacement parts orders and to make sure that the correct replacement part is delivered, the following details are required: 1. Name of the ship 2. Raytheon Anschütz order number: e.g.: 610 0 61637 3. Device type (refer to type label) that the replacement part is required for: e.g.: Feedback Unit, Type 101–528 NG029. 4. Exact designation of the replacement part from the specifications given in the replacement parts catalogue
Example: Stock No.
Designation
Drawing No.
1.721059
Switch
1C65ZN
5. Required number of parts
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Rückmelder FEEDBACK UNIT Type 101–528 NG024–NG029
Ersatzteilkatalog SPARE PARTS CATALOGUE
1
2
3
6
14.614
5
4
1
Rückmelder FEEDBACK UNIT Type 101–528 NG024–NG029 POS. Lager-Nr. STOCK-NO.
Benennung DESIGNATION
Zeichnungs-Nr. PART-NO.
Ersatzteilkatalog SPARE PARTS CATALOGUE
Stck. in NG... QTY. in NG...
Hersteller-Code MFRC
024 027 029 Versorgungs-Nr. NATO-STOCK-NO. 1
1.504 178
Mikroschalter MICRO SWITCH
NB 14-230.00-061
0
0
1
D 2865 5930-12-307-9339
2
1.721 059
Schalter SWITCH
1 C 65 ZN
0
2
4
D 2865
3
3.500 814
Nocken CAM SET
101-528.00-038
2
2
4
D 2865
4
1.508 706
Zahnrad z = 152 GEAR WHEEL z = 152
101-528.00-017
1
1
1
D 2865 3020-12-349-2741
5
3.601 012
Sensorpotentiometer POTENTIOMETER
101-528.14
1
2
1
D 2865
6
1.500 313
Zahnrad z = 76 GEAR WHEEL z = 76
101-528.00-034
1
2
1
D 2865
All depicted items which are not mentioned in the text are not applicable for this unit. Since further development may necessitate making modifications to existing equipment, its conformity with the relevant illustrations and drawings is not always ensured. RAYTHEON MARINE will be under no liability whatever that may arise from any such differences.
14.614
RA/S–SU 0308 EDITION 01
2
Feedback Unit Service Manual
3
Construction and Principle of Operation
3.1
General
Technical Documentation
The feedback unit is a part of the control loop of a steering control system. Limit switches switch the steering gear off after the end position of the rudder has been reached, and a microswitch (optional) signalises the midship position of the rudder. With some types of the feedback unit, an electrical signal proportional to the rudder angle is also delivered. This signal is required for the follow up (FU) via an autopilot and for the display at an actual rudder position indicating unit (RIA). The feedback unit can be directly attached at the shaft of the rudder or at a regulating unit of the steering gear by means of corresponding attachment assemblies.
Fig. 3– 1: Feedback Unit with Lever Drive System
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3.2
Construction Fig. 3– 2 shows the construction of the feedback unit. For the equipping of the individual variants, refer to the ’Technical Data’. The following components are mounted on a PCB: – Limit switches B1 and B4 – Potentiometer R1 and R2 – Microswitch B5 (optional for all versions) and – Terminal strip The PCB is fixed in the casing with four screws. The casing has six bore holes on its topside for cable bushings and an earthing screw. The feedback unit shaft carries cams for activating the limit switch and a toothed wheel for adjusting the potentiometer, which has a corresponding toothed wheel on its shafts. The casing is sealed with a protective hood against environmental influences. Earthing screw
Casing Terminal strip
Angle
Micro switch
Limit Switches Plate
Feedback gear with gear Gear for potentiometer
Potentiometer
Fig. 3– 2: Construction of the Feedback Unit
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3.3
Technical Documentation
Principle of Operation A lever support or chain drive transfers the movement of the rudder to the shaft of the feedback unit. Thus, the cams are turned with the feedback unit shaft. When a pre–determined rudder position is reached, the cams then switch off the solenoid valves of the steering gear via the limit switches. Some versions of the rudder feedback unit comprise 2 sets of limit switches, to switch off respectively the solenoid valves on exceeding a large rudder angle (for small speed e. g. in confined waters) and on exceeding a small rudder angle (during normal speed); with this, the switching off is controlled by the rudder limit unit, Type 105–108. With some types of feedback unit, the rudder movement is transmitted to the potentiometers R1 and R2 via toothed–wheel gears with a transmission ratio of 1:2. These generate an independent voltage from the rudder position, which is then redirected as a rudder position signal to, e.g. an autopilot or a actual rudder position indicator. Option for all versions: A microswitch is activated via a cam wheel on the shaft of the feedback unit; the microswitch probes the rudder zero position (midship indicator). By closing or opening a circuit with the microswitch, a status report can be transmitted.
Flange Gear wheel z1 (z=152) Gear wheel z2 (z=76)
Potentiometer R1 or R1 + R2
Mounting surface Lever drive system
Fig. 3– 3: Drive by Means of a Lever Drive; Range of Rudder Angle: from ± 30° to ± 45°
Mounting surface Flange Chain wheel, small
Chain wheel, large Chain
Fig. 3– 4:
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Rudder stock
Drive by Means of Chain and Chain Wheels; Range of Rudder Angle: from ± 45° to ± 90°
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3.4
Technical Data
3.4.1
Mechanical Data Dimensions: Weight:
see Dimensional Drawing 101 D 528.HP005 approx. 4 kg
Mounting position:
optional
Keys (Limit switches):
max. 4 peaces
Accuracy:
< 1° (incl. hysteresis)
Absolute accuracy:
< 1/3°
Resolution:
< 0,1°
Air and creepage pathes for limit switches:
acc. to VDE 110, insulation class C, for voltage up to 220VDC
Midship switch group: Switching range:
3.4.2
approx. +2°, adjustable
Potentiometer:
5 kΩ + 20%,
Electrical Data Input voltage:
+15VDC
Output voltage: tion)
0VDC ... approx. +10VDC (dependent on rudder posi-
Scaling of the scale factor:
in the follow–up steering control amplifier for +10VDC max. rudder angle
Permissible switching power via limit switches (e.g. for solenoids): Minimal switch current
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< 50W inductive load (with 24VDC /110VDC, 110 / 220VAC) 10mA / 24V DC
3–4
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3.4.3
Technical Documentation
Environmental Conditions Ambient temperature – storage:
–35°C ... +70°C
– operation:
–25°C ... +63°C
Shock resistance:
acc. to BV 043
Resistance to vibration: (with 2 ... 25Hz:
acc. to GL and BV 044 + 1,6 mm)
(with 10 ... 100Hz:
50m/s2
+ 4,0 g)
Type of enclosure:
IP56
GL test number:
95 594 HH 1986 (not for modifications)
EMC:
see Declaration of Conformity
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Technical Documentation
ANNEXES Mounting Proposals for one and two feedback units,
Diagrams: Dimensional Drawing: Hydraulic Unit:
101 D 528.HP005 Sheet 1 to 3 115 D 430.HP005
Wiring Diagram:
101 E 528.HP050 (for NG024) 101 D 528.HP053 (for NG027) 101 D 528.HP053 (for NG029)
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Annex I
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Feedback Unit Service Manual
1 FU 1 1
1
FU 2
3
FU 1 Legend for Fig. A, B and C 1 Feedback unit (FU) 2 Lever drive 3 Console (from shipyard) 4 Rudder stock
4
Technical Documentation
3
4
3
FU 3
FU = Feedback Unit
2
FU 1
Legend for Fig. E and F 1 Feedback unit (FU) 2 Chain drive 3 Console (from shipyard) 4 Rudder stock 5 Chain tightener
4
1 3 5
3 4
3
4
3
3
4 +α
1
–α
+α
2
4
Fig. E: Mounting Proposal for one Feedback Unit Drive from rudder stock via chain and chain wheels, Type 148–341 Rudder angle: +60° ... +90° (and ...360° with rudder propeller)
Fig. C: Mounting Proposal for 3 Feedback Units Drive from rudder stock via lever system, Type 148–442 Rudder angle: +30° ... +45°
1 FU 1
2
2
Fig. A: Mounting Proposal for one Feedback Unit Drive from rudder stock via lever system, Type 148–442 Rudder angle: +30° ... +45°
FU 1
1
FU 2
3
1 3
1
3
2
–α
FU 1
2
2
FU 2
1 2 4
3
3 1
4
3 5
3
3
5
2
5 3
3 4
+α
4
–α
2 Fig. B: Mounting Proposal for 2 Feedback Units Drive from rudder stock via lever system, Type 148–340 Rudder angle: +30° ... +45°
2
Legend for Fig. D 1 Feedback unit (FU) 2 Lever drive 3 Holder
1 4 5
Console (from shipyard) Hydraulic cylinder
Fig. F:
1 Mounting Proposal for 2 Feedback Units Drive from rudder stock via 2 chains and chain wheels, Type 148–342 Rudder angle: +60° ... +90° (and ...360° with rudder propeller)
Fig. D: Mounting Proposal for one Feedback Unit Drive from hydraulic cylinder via lever system, Type 148–442
Mounting Proposals for Feedback Units (Schematic Representation) Edition: 28.AUG.2003
Annex 1
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