The machine installation can be done in differently desired directions, for this purpose an iron or a solid wooden Mounting Platform must be prepared and fixed firmly to the hull at the required height and perfectly square with the rudder stock.
A : Fastening of the iron base:
Before drilling the mounting platform, with the base ( already drilled), make sure that:
1) The rudder is in a symmetrical position with the boat
2) The cylinder rod is in the intermediate position of its course (1/2 way)
3) The support base axis in parallel with the boat axis
4) The support base is at the correct distance from the rudder centre; “Distance between Centres” to be respected after which the mounting platform may be drilled and the support base tightened with bolts.
B : Alignment between rudder axis and cylinder axis:
Before tightening the bolts, suitable thicknesses of packing should be used, (if the mounting platform could not be planed before ) in a way that the inclination between the cylinder axis and the two gudgeon pins (tiller arm base), is not above 2°; errors within this range are compensated for by the ball joints on the cylinder rods.
A good alignment is to be preferred as well as the welded stops at the base angles, after tightening the bolts.
It is advisable to use steel tubing without welding (Mannesman) of different diameters as indicated in the drawing “Hydraulic Scheme”.
The various connections must be made with steel flanges to be welded electrically to the tube, or threaded steel pipe fittings or welded steel pipe fittings; do not use hemp on the threaded pipe fittings but an appropriate Teflon tape, found on sale.
Check to see that the tubes are internally clean before assembling, fasten well with brackets so that they will not vibrate and do not pass inside the cold stores, even if the oil used is at a low freezing point.
The position of the tube connections “1” and “2” which go from the hydraulic transmitter to the device and then to the actuator must not be inverted.
The flexible tubing should be mounted with the external fitting, using two spanners so no deformation occurs.
They should be free of any contact, so no rubbing occurs during working.
The transmitter consists of an axial piston pump, mounted on a pedestal or directly on the consol using an anodized aluminium plate; manually operated by a wooden steering wheel, which sends oil to the actuator.
The “fixed” type of transmitter, consists of a water-tight aluminium box in which are mounted two micro switches, these work by a spring lever which returns to the centre..
The “portable” type of transmitter, consists of a water-tight aluminium casting with handle where the red and green operating buttons are installed.
It provides the actuator with the hydraulic power necessary to steer the rudder within the conditions and time regulated by RINA or as agreed upon at time of order.
The execution of the pumping sets are as follows:
“W” transmission from onboard motor;
“X” transmission with independant electric motor;
“Y” transmission with compact electric motor.
The “Y” version represents the standard version, the tank acts as a base for the electric motor and is complete with filters, control and safety valves; the rudder control is obtained by an a solenoid valve controlled by the electric transmitter on the bridge.
Actuator: Steering gear type CL……..
One power cylinder with double effect and identical chambers mounted on one frame or base connected with a clevis to the tiller arm keyed on to the rudder shaft.
A by-pass exclusion interception valve is supplied.
Manual hydraulic system “A”:
By turning the steering wheel the hydraulic pump/transmitter sends oil to the actuator/cylinder which moves the tiller arm, and thus the rudder shaft in the desired direction.
The power sent to the actuator is supplied by the operator and is amplified depending upon the ratio between the delivery per turn of the hydraulic transmitter and the displacement of the actuator (the number of turns is decided on by this ratio),and the diameter of the wheel as well as the tube dimensions for reasons of friction.
Hydraulic Servo-Assisted System (F.U.) :
By starting the pumping unit, piloting pressure is generated at the double selector valve that moves into work position, this puts into communication the hydraulic transmitter with the servo valve piloting chamber and feed-back cylinder; by turning the steering wheel the command of the servo-valve cursor is obtained that drives the power cylinder; thus obtaining the opening of the servo-valve according to the speed of rotation of the steering wheel.
With this system you can obtain a given angular movement of the rudder with a certain number of turns of the steering wheel.
In case of damage to the feedback cylinder, it can be excluded by opening the manual by-pass valve and manoeuvre with the (N.F.U.) system.
The changeover from the F.U. control system to the manual system, is done automatically by switching off the pumping units.
Electric Servo-Assisted System (N.F.U.):
The control device includes two solenoids (one for power cylinder and one for the feed-back by-pass ) electrically connected in parallel via a low voltage electric circuit; the Tiller (Joystick) and / or Autopilot are on the same circuit , these simultaneously drive the solenoid valve that feeds the power cylinders, and the by-pass valve solenoid of the feedback cylinder.
NB. In case of a total electrical blackout the change-over to manual operation takes place automatically without any manual operation in the hydraulic system, the manoeuvre can continue from the bridge but with an increase of the number of turns from hardover to hardover.
With Emergency Manual Tiller:
If provided, install the pulley block and fit the emergency manual tiller; from the by-pass valve the tubes are excluded and the power cylinder chambers are put into communication; the manoeuvre is possible with the pulley block by following the orders from the bridge.
AUTOMATIC FILLING OF SYSTEM:
After filling the power pack tank, switch on the electric motor, the compensation line “C” automatically fills the hydraulic transmitter.
Unscrew one of the air bleeder screws on the feedback cylinder and insert a transparent plastic tubing, with the other end into the tank; slowly turn the hydraulic transmitter steering wheel in the same direction as the removed air bleeder screw until clean oil comes out of the tube with no air bubbles.
Close the air bleeder screw, and repeat the same operation with the other air bleeder screw, turning the wheel in the opposite direction.
Now the command circuit is filled (feedback system line).
To fill the tubing line of the main cylinder, unplug the electrical connections on the selector Pos.9 Dwg. 3849 Rev.1and the bypass valve Pos.6 Dwg. 3849 Rev.1. Unscrew the air bleeder screw, on the main cylinder, and insert a transparent plastic tubing for the recovery of oil, and slowly turn the wheel in same the direction of the open bleeder screw until the total elimination of air from the cylinder and tubing. Repeat the same procedure on the other side.
It is a good idea to proceed with both pumps to eliminate the air in all branches of the tubing.
At this point all relevant tests can be effected by starting to check the oil level in the service tank, test with the pumping unit in operation, manoeuvre with the transmitter, and the electric Tiller if provided.
NB: The direction of manouevre, obtained by the hydraulic manual system, and the pumping unit switched off, is authentic and should correspond to the direction of manoeuvring the vessel, otherwise the connection of the main tubing to the interception valve must be reversed.
For system (FU) with the pumping unit switched on, the manouevre direction of the hydraulic transmitter , must correspond to that of the hydraulic manual manouevre, otherwise the tubing of the feedback cylinder must be reversed.
For the electric (NFU) it is sufficient to exchange the connectors on the solenoid valve control.
To sum up:
* By-pass: closed
* Tubing interception of pumping unit: open
* Tubing interception of compensation: open
* Bleeder screws actuator/cylinder : closed
* Oil level: okay
* Vented plug: on highest station or compensation tank if installed.
You may now test manoeuvre with the wheel, going from hard over to hard over by counting the number of turns that should result by dividing the actuator /cylinder displacement with the hydraulic transmitter / pump displacement,
Start the pumping unit and test the electric tiller/joystick and autopilot if provided.
OIL TO BE USED:
It is advisable to use an hydraulic oil the following characteristics:
Viscosity “Engler”2,5 – 3 °E a 50° C
||Energol HLP 20
||Hyspin AWS 25
||ESSO H 20
||Hydrus OIL 22
||Mobil DTE 24
||Tellus OIL 22
||Azolla ZS 20