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Simran RPU80 manual

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Table of contents for the manual

  • Page 1

    INSTRUCTION MANUA L Simrad RPU80/160/300 Reversible Pump www.Busse-Yachtshop.de email: info@busse-yachtshop.de[...]

  • Page 2

    Note! Simrad AS makes every effort to ensure that the information contained within this document is correct. However, our equipmen t 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 mu st only be used for the purpose for which it was designe[...]

  • Page 3

    Instruction Manual 20220422N 1 Instruction Manual This manual is intended as a reference guide for correctly installing and maintaining t he 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 m[...]

  • Page 4

    Simrad Reversible Pump RPU80/160/300 2 20220422N Document revisions Documentation department Hardware/Software design Project/Product Management Rev Date Sign Date Sign Date Sign D 24/10-96 N.G. 24/10-96 I.K. 24/10-96 Th.H. E 20/2-97 N.G. 20/2-97 I.K. 20/2-97 Th.H. F 5/1-98 N.G. 5/1-98 I.K. 5/1-98 Th.H. G 20/1-99 N.G. 20/1-99 I.K. 20/1-99 Th.H. H 2[...]

  • Page 5

    Instruction Manual 20220422N 3 Contents 1 INTRODUCTION .................................................................................................. 5 1.1 General............................................................................................................ 5 1.2 Hydraulic steering gear suitable for the RPU80/RPU160/RPU300 .......[...]

  • Page 6

    Simrad Reversible Pump RPU80/160/300 4 20220422N 7.8 When on automatic steering, the boat sw ings from side to side without stabilizing after course changes ............................................................................. 27 7.9 Small and sudden heading change s while on automatic steering ................. 27 7.10 Rudder moves only in[...]

  • Page 7

    Introduction 20220422N 5 1 INTRODUCTION 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 s[...]

  • Page 8

    Simrad Reversible Pump RPU80/160/300 6 20220422N An automatic "Rudder test" function in these autop ilots will also limit the output equ ivalent to a rudder speed of 8 degrees per second which is optimum for aut opilots with proportional rudder control. (Equals to approx. 9 s econds for 35-0-35 degrees rudder travel). Consequently when op[...]

  • Page 9

    Introduction 20220422N 7 1.2 Hydraulic steering gear suitable for the RPU80/RPU160/RPU300 All cylinders are single and balanced type unless otherw ise specified. If the cylinder type in your boat is not listed, please refer to section 2. Estimated rudder time in seconds hard over to hard over Steering gear Cylinder volume cm 3 (cu.in.) RPU80 RPU160[...]

  • Page 10

    Simrad Reversible Pump RPU80/160/300 8 20220422N Estimated rudder time in seconds hard over to hard over Steering gear Cylinder volume cm 3 (cu.in.) RPU80 RPU160 RPU300 HYNAUTIC (con tinued) K-18 115 (7,0) 9 K-19 147 (9,0) 11 6 K-22, K27 218 (13,3) 16 8 K-28, K29 262 (16,0) 20 10 K-31 418 (25,5) 16 8 K-51 167 (10,2) 13 6 Old models K-25 218 (13,3) [...]

  • Page 11

    Introduction 20220422N 9 Estimated rudder time in seconds hard over to hard over Steering gear Cylinder volume cm 3 (cu.in.) RPU80 RPU160 RPU300 LECOMBLE & SCHMITT – Old models: VHM 32-DT 90 (5,5) 7 VHM 35-DTP 152 (9,3) 11 6 VHM 35-DT 129 (7,9) 10 5 VHM 45-DT 240 (14,6) 18 9 SEASTAR BA 125-7 118 (7, 2) 9 BA 150-7 167 (10, 2) 13 6 BA175-7 22 5[...]

  • Page 12

    Simrad Reversible Pump RPU80/160/300 10 20220422N Estimated rudder time in seconds hard over to hard over Steering gear Cylinder volume cm 3 (cu.in.) RPU80 RPU160 RPU300 SERVI (Norw egian) MA 60 141 (8, 6) 11 5 MA 120 29 4 (17,9 ) 22 11 6 MA 200 50 0 (30,5 ) 19 10 MA 300 750 (45,8) 1 5 SLEIPNER, HYDRIVE (Norwegian) LS 35 90 (5,5) 7 LC 55 12 9 (7,9)[...]

  • Page 13

    Introduction 20220422N 11 Estimated rudder time in seconds hard over to hard over Steering gear Cylinder volume cm 3 (cu.in.) RPU80 RPU160 RPU300 VETUS (continued) MT 225 500 (30, 5) 19 10 MT 340 750 (45, 8) 15 MT 450 1000 (61, 0) 20 Outboard e ngine cyli nders: OB 35 106 (6,5) 8 OB 85 170 (10, 4) 13 6 Old models: MT 30 81 (4,9) 6 MT 50 142 (8, 7) [...]

  • Page 14

    Simrad Reversible Pump RPU80/160/300 12 20220422N 2 MEASUREMENTS AND CALCULATIONS FOR APPLYING THE RPU 2.1 Calculation of cylinder volume The RPU80 is recommended for cylinders between 80-250 cm 3 (4,9-15,2 cu. in.), RPU160 for cylinders between 160-550 cm 3 (9,8-33,5 cu.in.) and RPU300 fo r cylinders between 290 -960 cm 3 (17,7-58,5 cu.in.). These[...]

  • Page 15

    Measurements and calculat ions for applying the RPU 20220422N 13 Recommended rudder time: 10-15 seconds is normal for a 70° (35°-0-35°) rudder angle. (The ti m e 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 measure[...]

  • Page 16

    Simrad Reversible Pump RPU80/160/300 14 20220422N 3 DESCRIPTION OF RPU80/RPU160/RPU300 3.1 Construction The pump comprises an electric perm anent magnet m otor, valve block with reversible gear pum p, non-return (ch eck) valves on outlet A and B and suction valves from both sides of the gear pump to outlet C. Outlet C is c onnected to either the ex[...]

  • Page 17

    Description of RPU80/RPU160/RPU300 20220422N 15 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 deliv ers oil to that side of the rudder cylinder dictated by the signal from the autopilot. The pump runs until the signal from the autopilot ceas[...]

  • Page 18

    Simrad Reversible Pump RPU80/160/300 16 20220422N 3.3 Valve block This is an aluminum block with borings for no n-return valves, suction valves, slide, gear pump, motor coupling and all necessary oil ways. The three out lets A, B and C are positioned on top of the valve block. 3.4 Gear pump This comprises of the driving g ear wheel, which is couple[...]

  • Page 19

    Description of RPU80/RPU160/RPU300 20220422N 17 3.8 Pipe connections 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. www.Buss[...]

  • Page 20

    Simrad Reversible Pump RPU80/160/300 18 20220422N O-ring European type fitting US type fitting Pump housi ng 4 INSTALLATION 4.1 Mechanical Installation Siting 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 th e pump unit is sited higher than the rud[...]

  • Page 21

    Installation 20220422N 19 • 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. 1[...]

  • Page 22

    Simrad Reversible Pump RPU80/160/300 20 20220422N 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 [...]

  • Page 23

    Installation 20220422N 21 Figure 4-5 Connection to hand hydraulic steering gear Drw.no. 3-110101 Figure 4-6 Connection to Capilano steering gear Drw.no. 3-110115 www.Busse-Yachtshop.de email: info@busse-yachtshop.de[...]

  • Page 24

    Simrad Reversible Pump RPU80/160/300 22 20220422N 4.2 Electrical installation J3000X, J300X, J300X-40, J50, J50-40, AC10, AC20, AC40 The two leads from the motor are connected to the term inal block marked "MOTOR" in the Junction unit/Autopilot computer. There is no dedicated Port and Stbd output. The autopilot will automatically set the [...]

  • Page 25

    Installation 20220422N 23 5 PREPARATION AND TESTING 5.1 Oil filling and bleeding 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 specific ation of the steering gear manufacturer. Start by opening all stop cocks in the pipes leading to the pump unit. Simult[...]

  • Page 26

    Simrad Reversible Pump RPU80/160/300 24 20220422N 6 MAINTENANCE 6.1 Dismantling After approximately 1000 operating hours, the pump unit should be removed for examination. Close the stop cocks to the pump unit, remove the nuts on the 3 couplings and all retaining nuts. Screw out the 2 fixing screws (24) located on each side of the pump cover which h[...]

  • Page 27

    Fault tracing 20220422N 25 7 FAULT TRACING If fault develops, the so urce 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 proba bly in the pum p unit or junction unit/autopilot computer. The following faults ma[...]

  • Page 28

    Simrad Reversible Pump RPU80/160/300 26 20220422N 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 leaki ng. Shut the stop cocks to the pump unit, and operate the steering gear by means o[...]

  • Page 29

    Fault tracing 20220422N 27 7.7 Rudder movement stops as water pressure on the rudder increases. (J1000B, J101A, J45A only) Probable reasons: 1. Overload. Check whether the r.p.m . of the mo tor is too low. Eventually turn potentiome ter RV1 in junction unit clockwise (CW) until rudder m ovement is recovered. 7.8 When on automatic steering, the boat[...]

  • Page 30

    Simrad Reversible Pump RPU80/160/300 28 20220422N 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 tu be fitting for the return line (C) during installati on. Ref[...]

  • Page 31

    Technical Specifications 20220422N 29 8 TECHNICAL SPECIFICATION S 8.1 Specifications Note ! RPU300 measurements at charging voltage RAM CAPACITY MODEL MOTOR VOLTS * JUNCTION UNIT/ AUTOPILOT COMPUTER ** MIN cm 3 (cu. in.) MAX cm 3 (cu. in.) FLOW RATE AT 10 bar cm 3 /min (cu.in/min) MAX PRES- SURE bar PWR. CONSUM- PTION *** BOAT LENGTH RPU80 12 V J30[...]

  • Page 32

    Simrad Reversible Pump RPU80/160/300 30 20220422N 8.2 Dimensions Figure 8-1 RPU80 Dimensions Drw.no. N3-111836 Figure 8-2 RPU160 Dimensions Drw.no. N3-111835 www.Busse-Yachtshop.de email: info@busse-yachtshop.de[...]

  • Page 33

    Technical Specifications 20220422N 31 Figure 8-3 RPU300 Dimensions Drw.no. N3-111834 8.3 RPU80 performance AMPS 3 6 9 0.5 PRESSURE (BAR) CAPACITY (l/min) 1.0 1.5 0 10 20 30 40 50 60 0 Capacity versus pressure Current versus pressure www.Busse-Yachtshop.de email: info@busse-yachtshop.de[...]

  • Page 34

    Simrad Reversible Pump RPU80/160/300 32 20220422N 8.4 RPU160 performance AMP S 11 17 23 0.5 PRESSU RE (BAR) CAPAC IT Y (l/ min ) 1.0 1.5 0 10 20 3 0 40 50 60 5 2.0 Capacity versus pressure Current versus pressure 8.5 RPU300 performance* AMPS 10 15 20 PRESSURE (BAR) CAPACITY (l /min) 1.0 1.5 0 10 20 30 40 50 60 5 2.0 25 30 2.5 3.0 3.5 Capacity versu[...]

  • Page 35

    Spare Parts 20220422N 33 9 SPARE PARTS 9.1 RPU80/RPU160/RPU300 Pos. Qty. Gear pump parts Part no. 1 1 Valve block 21100250 2 3 Fitting complete 7/16-20UNF 44166767 2 3 Fitting US model complete: Nut 3/8” with 5/8”x18 SA E Fitting SAE 5/8”-18-7/16-20UNF 21101399 44155927 44166775 5 1 Pump cover RPU80/ 160 Pump cover RPU300 21101191 21111018 6 [...]

  • Page 36

    Simrad Reversible Pump RPU80/160/300 34 20220422N 13 2 O-r ing 9,25x1,7 8 Nitrile 4414964 9 14 2 Copp er washer Ø10,2x14x1,5 44149706 15 1 Oil seal 8x2 2x7 44149722 16 1 Support rin g 21100185 17 2 Copp er washer Ø10,2x14x1 44148146 18 1 O-ring 9,25x1,78 Silicon, red 44154656 20 2 Steel ball Ø6, 35 44118552 21 2 Grub. Scre w sock. head M 8x10 44[...]

  • Page 37

    Spare Parts 20220422N 35 9.2 RPU80 – Previous model gear pump RPU80 Reversible Pump with ser. no. 1317 H02 onwards (P/N 21116165) and 1805 H03 onwards (P/N 21116181 – US version) have identical gear pump with the RPU160 (see figure 9-1). Pos. Qty. Gear pump parts (Previous RPU8 0 model) Part no. 1 1 Valve block, Previ ous m odel 211162 56 2 3 F[...]

  • Page 38

    Simrad Reversible Pump RPU80/160/300 36 20220422N 10 SALES AND SERVICE WORLDWIDE 010304 EUROPE AUSTRIA Allroundmarin-Alltechnik GesmbH Rheinboldtstrasse 11-13 A-2362 Biedermannsdorf b.Wien Tel.: +43 2236 646 760 Fax: +43 2236 63135 www.allroundmarin.com BENELUX Simrad BV P. O. Box 587 3200 AM Spijkenisse Tel.: +31 181 600234 Fax: +31 181 626688 www[...]