TITLE TECHNICAL SPECIFICATION AND DRAWINGS

Ship Owner : TECHNOMAR SHIPPING INC

Shipyard : Hyundai Heavy Industries Co., Ltd.
Kind of Ship : 9,000 TEU Class Container Carrier
Hull Number : NCP0123~25
Equipment : Side Thruster, Bow, 3,000kW
Vendor Name : Hyundai Heavy Industries Co., Ltd.

Hull No. IMO No.

NCP0123 9710220
NCP0124 9710232
NCP0125 9710244

FOR FINAL
P.O. NO. EQUIP. NO. DOC. NO. HULL NO:NCP0123~25

K3212-AF0148

1 26-FEB-‘15 FOR FINAL C.Y.SHIN C.Y.SHIN S.H.LEE S.G.LEE

1 31-MAY-‘14 FOR WORKING H.B.JIN S.W.YE S.K.LEE J.S.HA

0 17-JAN.-‘14 FOR APPROVAL H.B.JIN S.W.YE S.K.LEE J.S.HA

REV DATE DESCRIPTION Prepared by Checked by Checked by Approved by

CONTENTS

A Technical specification and drawings 4

-1. Equipment list 5
-2. General specifications 6
-3. System overall configuration 13
-4. General arrangement of thruster unit 14
-5. Sectional assembly of propeller unit (VGP 2013 Application) 15
-6. Instruction manual for Thruster unit (VGP 2013 Application) 16
-7. Detail of coupling assembly 46
-8. Instruction for flexible coupling 47
-9. Detail of lip seal unit (VGP 2013 Application) 53
-10. Instruction manual for Propeller shaft seal 54
B Technical data for main motor 68
-1 Data sheet of main motor 69
-2 Outline of main motor 70
-3. Terminal Box Ass'y 71
-4. Acc'y T/B Ass’y 72
-5. Name Plate for Main T/Box 73
-6. Name Plate for WTD 74
-7. Name Plate 75
-8. General Assembly Drawing 76
-9. PTC Thermistor 77
-10. Painting Procedure for Motor 78
-11. Cable Gland Catalogue 82
-12. Instruction manual for Main motor 83
C Technical data for remote control system 134
-1. Components list 135
-2. Technical specifications 136
-3. Main Controller 149
-4. Aux. Controller 151
-5. Terminal Board 153
-6. Signal Converter Box 154
-7. No. 1 & 2 Schematic Diagram 155
-8. Arrangement of blade angle transmitter 158
-9. Instruction manual for Main controller 159
D Technical data for hydraulic system 222
-1 Arrangement of hydraulic pump unit 223
-2 Data sheet of hydraulic pump motor 224
-3 Gravity tank with air cooler 225
-4 Data sheet of air cooler motor 226
-5 Outline of Hydraulic pump motor starter 227
-6 Schematic diagram of hydraulic pump motor starter 228
-7 Terminal block 231
-8 Outline of air cooler starter 232
-9 Schematic diagram of air oil cooler 233
-10 Instruction manual for Hydraulic power package 234
E Spare parts and Special tool list 240
-1 Spare parts list 241
-2 Special tools list 250
A Technical specification and drawings 4
-1. Equipment list 5
-2. General specifications 6
-3. System overall configuration 13
-4. General arrangement of thruster unit 14
-5. Sectional assembly of propeller unit (VGP 2013 Application) 15
-6. Instruction manual for Thruster unit (VGP 2013 Application) 16
-7. Detail of coupling assembly 46
-8. Instruction for flexible coupling 47
-9. Detail of lip seal unit (VGP 2013 Application) 53
-10. Instruction manual for Propeller shaft seal 54
EQUIPMENT LIST
Doc. No. : K3213-AF0149
Rev. No. : 0
Date : 17-JAN.-14

Ship Owner TECHNOMAR SHIPPING INC

Ship Yard HANJIN SUBIC Shipyard Co., Ltd.

Kind of Ship 9,000 TEU Class Container Carrier

Hull Number NCP0123~25

Equipment Bow Thruster 3,000kW

Vendor Name Hyundai Heavy Industries Co., Ltd.

No. Equip. No. Descriptions Q’ty Remarks

1 NCP0123-AA Propeller unit 1 set with coupling

2 NCP0123-BB Main motor unit 1 set

3 NCP0123-CC Hyd. power unit 1 set

4 NCP0123-DD Gravity tank with air oil cooler 1 set

5 NCP0123-EE Electric equip. for hyd. power unit 1 set

6 NCP0123-FF Remote control panel 1 set

7 NCP0123-GG Spare part & tool 1 set

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CONTENTS

A. General
B. Scope of supply
C. Particulars
1. Propeller unit with tunnel
2. Flexible coupling
3. Prime mover
4. Motor control device
5. Hydraulic power unit
6. Gravity tank with air oil cooler
7. Remote control system
8. Blade angle transmitter
9. Weights
D. Inspection and test
E. Supervision and guarantee
F. Packing
G. Painting specifications

H.B.JIN S.W.YE J.S.HA

1 FOR WORKING
14.05.11 14.05.11 14.05.11

H.B.JIN S.W.YE J.S.HA

0 FOR APPROVAL
14.01.17 14.01.17 14.01.17

REV. PREPARED CHECKED APPROVED MODIFICATION

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A. General
1. Ship owner TECHNOMAR SHIPPING
2. Shipyard HANJIN SUBIC Shipyard Co., Ltd.
3. Kind of ship 9,000 TEU Class Container Carrier
4. Hull dimension, LBP / B / D / d, m 286/ 48.2 / 24.8 / 12.5
5. Classification Society GL, RINA
6. Quantity of ship 3 (Three)
7. Hull number NCP0123~25
8. Thruster, Type / Capacity / Quantity (/ship) Controllable pitch / 3,000 kW / 1 unit
9. Thruster, Install position Bow

B. Scope of supply
1. Propeller unit with tunnel ■ Maker □ Buyer
2. Coupling ■ Maker □ Buyer
3. Prime mover (Main motor) ■ Maker □ Buyer
4. Motor control device (Starter panel) ■ Maker □ Buyer
5. Hydraulic system with pump, motor and starter ■ Maker □ Buyer
6. Gravity tank with level switch ■ Maker □ Buyer
7. Remote control system ■ Maker □ Buyer
8. Blade angle transmitter ■ Maker □ Buyer
9. Hand pump with stop valve ■ Maker □ Buyer
10. Anodes ■ Maker □ Buyer
11. Special tools ■ Maker □ Buyer
12. Spare parts ■ Maker □ Buyer
13. Hydraulic pipes □ Maker ■ Buyer
14. Bolts and nuts for pipe fitting □ Maker ■ Buyer
15. Grid on tunnel ends □ Maker ■ Buyer
16. Installation on board □ Maker ■ Buyer
17. Commissioning ■ Maker □ Buyer
18. Onboard test ■ Maker □ Buyer

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C. Particulars
1. Propeller unit with tunnel
1.1 General
Manufacturer Hyundai Heavy Industries Co., Ltd.
Model or type number HSC-2950S
Number of units 1 (One)
Type Controllable pitch & skewed type
Propeller diameter, O.D, mm 2,950
Number of propeller blade 4 (Four)
Thrust, kN 415
Propeller speed, rpm 210
Input shaft speed, rpm 894
Input power, kW 3,000
Direction of input shaft rotation view from prime mover Clockwise
Position of propeller blade Port side

1.2 Materials for main parts

Propeller blade Ni-aluminum bronze casting
Propeller hub Ni-aluminum bronze casting
Propeller shaft Carbon steel forging
Bevel gear Alloy steel
Pinion shaft Alloy steel
Gear case Ductile iron casting
Tunnel Rolled steel plate and stainless steel
Plate lining in way of propeller tip(SUS316L)

1.3 Cathodic protection

Material □ Zinc anode ■ Aluminum anode
2
Mean current density, mA/m 35
Lifetime, years 5

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2. Flexible coupling
Manufacturer Hyundai Heavy Industries Co., Ltd.
Type Flexible grid type
Number of coupling 1 (One) / unit

3. Prime mover (Main motor)

Manufacturer Hyundai Heavy Industries Co., Ltd.
Frame number 800
Type HLA9 806-86Y
Number of units 1 (One) / unit
Output, kW 3,000
Voltage / phase / pole / frequency, V / Ф / P / Hz 6600 / 3 / 8 / 60
Rated speed, rpm 894
Enclosure-protection degree IP44
Insulation class F
Rating, minutes S2, 30
Starting method AUTO TR 65%
Cooling system Air cooling system, IC511

4. Hydraulic power unit

4.1 Hydraulic pump
Manufacturer MARZOCCHI or Eq.
Type Gear
Number of units 1 (One) / unit
Flow rate, liter/min. 26.6
Pressure (Max.), bar 110

4.2 Hydraulic pump motor

Manufacturer Hyundai Heavy Industries Co., Ltd.
Number of units 1 (One)
Output, kW 7.5
Voltage / phase / pole / frequency, V / Ф / P / Hz 440 / 3 / 4 / 60
Rated speed, rpm 1760

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Enclosure-protection degree IP44

Insulation class F
Rating, minutes Continuous
Starting method Direct
Cooling system Air cooling system
Space heater Winding type

5. Gravity tank with air oil cooler

5.1 Gravity tank
Manufacturer Hyundai Heavy Industries Co., Ltd.
Type Foot mounting type
Number of units 1 (One)
Volume, liter 140
Accessories -

5.2 Air oil cooler

Manufacturer Hyundai Oaler (Korea)
Number of units 1 (One)
Output, kW 1.1
Enclosure-protection degree IP44
Operating Temperature 405ºC

6. Remote control system

Manufacturer Hyundai heavy industries Co., Ltd.
Type Follow-up pitch control
Control position
Wheel house 1 (One)
Wings 2 (One)
Power supply
Voltage / phase / frequency, V / Ф / Hz 220 / 1 / 60

7. Blade angle transmitter

Manufacturer Hyundai heavy industries Co., Ltd.
Type Flange mounting, potentiometer
Number of units 1 (One)

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8. Weights
Thruster unit w/h tunnel (dry), kg Approx. 28,000
Main motor, kg Approx. 14,800
Hydraulic power unit, kg 152
Flexible coupling, kg 134
Gravity tank (dry) with air oil cooler, kg 235

D. Inspection and test

1. Material test Main part
2. Dimension check Propeller blade, tunnel, shafting part
3. Pressure leakage test Gear case, propeller hub part
4. Static balance test Propeller blade (individually)
5. Functional test Pitch control mechanism

E. Supervision & Guarantee

1. Free commissioning before/at sea trial, man-days 5 (Five)
2. Guarantee period
From ships delivery, months 12 (Twelve)
From equipment delivery, months 18 (Eighteen)

F. Packing
1. Propeller unit with tunnel □ Skid □ Base skid ■ enclosed wooden box
2. Coupling □ Skid □ Base skid ■ enclosed wooden box
3. Prime mover (Main motor) □ Skid □ Base skid ■ enclosed wooden box
4. Hydraulic power unit □ Skid □ Base skid ■ enclosed wooden box
5. Gravity tank □ Skid □ Base skid ■ enclosed wooden box
6. Remote control system □ Skid □ Base skid ■ enclosed wooden box
7. Spare parts and special tools □ Skid □ Base skid ■ enclosed wooden box

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G. Painting specifications

1. Tunnel inside &Thruster body, surface to exposed to seawater

Paint name Color D.F.T

1st EH2350 GREY 1128 125 μm
2nd EH2350 RED OXIDE 2260 100 μm
3rd EH2560 LIGHT ALUMINUM 75 μm
4th EGISPACIFIC(P) DARK BROWN 130 μm
5th EGISPACIFIC(P) RED BROWN 130 μm
6th EGISPACIFIC(P) RED BROWN 110 μm

2. Tunnel outside, inboard side

Paint name Color D.F.T

1st EH2350 RED OXIDE 2260 100 μm
2nd EH2350 GREY 1128 100 μm

3. Hydraulic pump unit (except motor) ET574 (M7.5BG7/2) 1 coat 40 D.F.T

4. Gravity tank, outside ET574 (M7.5BG7/2) 1 coat 40 D.F.T
5. Gravity tank, inside EH270 (N9.0, White) 1 coat 50 D.F.T

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CONTENTS
Page
1. General 1
1.1 Configuration 2
1.2 General specification 2
1.3 Notice for thruster operation 4
1.4 Guarantee 6
2. Assembly of the thruster 7
2.1 General 7
2.2 Propeller parts 7
2.3 Hydraulic power unit 9
2.4 Gravity tank 9
2.5 Pitch control device 9
2.6 Remote control system 9
3. Maintenance and checking 10
3.1 Maintenance and checking items 11
4. Inspection 14
4.1 Docking inspection (Pre-disassembly inspection) 15
4.2 Inspection of parts upon disassembly 18
4.3 Inspection after reassembly and restoration 19
4.4 Notification of inspection items to us 20
5. Disassembly and reassembly procedure 21
5.1 Disassembly of thruster proper 21
5.2 Reassembly of thruster unit 25
5.3 Locking procedure 26
6. Filling oil 27
6.1 Filling oil 27
6.2 Draining oil 27
6.3 Requirements for lubricant 27
6.4 Criterion of oil exchange 28
7. Initial start-up after installation 29
7.1 Checking the installation 29
7.2 Adjustment before main motor starting 29
7.3 Checking items after main motor starting 29

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1. General

1.1 Configuration
This manual describes important information concerning procedure, caution and provision for
operating, assembling and disassembling.
Therefore, please take time to understand all related instructions, and become thoroughly familiar
with it.
After reading this manual, if questions arise, please contact with HHI.

1.2 General specification

1.2.1 Propeller unit with tunnel

Type : HSC- 2950S

Propeller : DIA. 2950 mm (Skewed type) X 4 Blades
Thruster force : about 415 kN
Propeller speed : 210 rev./min
Input shaft speed : 894 rev./min
Rated blade angle : ± 23 °

1.2.2 Prime mover (Main motor)

Output : 3000 kW
Rated Speed : 894 rev./min (Synchronous speed)
Rating : S2,30 minutes
Voltage / Frequency : 6600 V / 60 HZ

1.2.3 Flexible Coupling

Type : Grid coupling, 1170 H

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1.2.4 Hydraulic system

1) Hydraulic pump unit

Hydraulic pump
Type : Vertical geared pump
Capacity : 26.6 liter/min x 10.0 Mpa(110kgf/㎠) × 1750 rev./min
Hyd.pump motor
Output : 7.5 kW × 1,730 rev./min × 3Ф
Voltage : 440V
Frequency : 60Hz
Solenoid valve
Type : 2 points × 1 sets
Relief valve
Type : DC Solenoid valve x 1 pc
Set pressure : 90 bar
Pressure S/W
Low pressure : 20 bar, Alarm
LowLow pressure : 10 bar, Interlock
Line filter
Capacity : 20 ㎛
Filter clogging : ΔP ≥ 5 bar, Alarm

2) Gravity tank

Capacity : 140 liter

Temp.S/W
High Temperature : 75 degree, Alarm
Level S/W : 2 point (Low / LowLow)
Low level : 30% of gravity tank capacity, Alarm
LowLow level : 25% of gravity tank capacity, Interlock
:

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1.2.5 Weight

Thruster unit : 29,100 kg

Main motor : 8,900 kg
Flexible coupling : 134 kg
Hydraulic pump unit : 152 kg
Gravity tank : 250 kg

1.3 Notice for thruster operation

The following notice should be noted for proper thruster operating.

1.3.1 Be sure to draft.

The draft should be kept shown in fig 1.at thruster running.
If the draft is insufficient, it not only interferes with the thruster exhibiting the specified
performance, but also causes cavitation or air inflow.
And the resultant vibration may possibly cause damage to the device.

Min. Draft for thruster running : A ≥ 1.0 D (D : Propeller diameter)

< Fig.1 Min.draft for thruster running>

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1.3.2 Operating speed

In case that the vessel is faster than 5 knots, the risk of air inflow is able to increase.
Then, it is advisable to avoid operation of the thruster.
In some cases, it is also possible that air inflow is caused when the vessel is below 5 knots.
If it is the case, the propeller pitch is to be so controlled that there is no risk of air inflow.

1.3.3 Line valve condition (See drawing ‘ System overall configuration, page ___)
For easy maintenance, several valves are equipped in each hyaraulic line.
Before operating the Hydraulic pump unit, all vales to be checked as follows.

Equipment Air cooler unit Remark

(8014)
Valve No. 8014-2 8014-3/4 All valves must be kept
open except “8014-2”
Below 10°C : Open Normal
Condition
Above 10°C : Close Open

! CAUTION
All valves except “8014-2” should be opened when hyd.pump is running.
When sea water temperature is below 10°C Valve “8014-2” should be open
until above 10°C to prevent excessive internal back pressure.

1.3.4 Oil Level

Following tanks should be filled with oil to standard level before thruster running.

Gravity tank : 2/3 of Gravity tank

Seal tank (If, installed) : 2/3 of Seal tank

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1.3.5 Temperature condition

Please observe the following step according to temperature condition before
thruster running to prevent excessive temperature rising.

Temperature HPU Main Motor

Condition Idle Running Idle & Load Running
Warm-up Continuous operating time < 4 hours
Cold Condition
above 1 hrs (at a time)
Minimized Continuous operating time < 2 hours
Tropical Condition
prior running (at a time)
Important! ; Total operating time per year : 500 hours

1.3.6 Possibility of Neutral Position Variation for Propeller Blade

* When thruster is transferred.
* When thruster is impacted for installation.

! CAUTION
Neutral position and pitch operation/control is performed under supervision of ship owner
when shop testing. Although neutral position is changed because of transfer or installation,
blade pitch value setting is done by HHI’s service engineer when sea trial. So, re-
adjustment of neutral position can’t be needed by hand.

1.4 Guarantee
The HHI, for the period of twelve(12) months from date of delivery of the vessel to the buyer,
guarantees the thruster against all defects which are followings.

1) Omissions
2) Non-conformities
3) Defective materials or equipment
4) Construction mis-calculation
5) Poor workmanship.

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2. Assembly of the thruster

2.1 General (See drawing ‘Sectional drawing’)

2.1.1 The propeller unit consist of a tunnel, propellers, power transmission, hydraulic actuating,
feed-back mechanism and shaft sealing.
For assembling the thruster, first of all, please assure and confirm the sectional, parts assembly,
and hydraulic scheme diagram and etc..

2.1.2 The power transmission flow from motor to propellers is as follows;

* Motor – Grid coupling(1630) – Pinion shaft(1252) – Bevel gear(1251) – Propeller Shaft(1231)
– Propeller Hub(1212) – Propeller Blade(1211)

2.1.3 The gear case is filled with oil and inside is pressured with the potential energy (from gravity
tank) in order to ensure against ingress of sea water into the case interior even in the event of
seal failure.

2.2 Propeller parts

2.2.1.Configuration.
*The propeller part is composed of blades, hub and pitch controlling mechanism.
*Propeller blade is connected by bolting to crank disk (1221).
*Propeller shaft such that the power is transmitted through reamer pins to the propeller part.
*Prop. shaft is covered with shaft guard for prevention form corrosion.
*Shaft guard has O-rings for sealing against sea water.

2.2.2. The propeller pitch control mechanism.

*The control mechanism is composed of cross head (1227), sliding shoe (1228), guide pin
(1235) and crank disc (1221).
*The linear motion of the hydraulic force converts into a rotary movement of the crank disc.
*The hydraulic force supplied in propeller cap(1213) and propeller shaft let crosshead(1227)
moves into left or right side. And the force delivers crank disk.
*The movement of crank dick fitted a guide pin(3) (1235) is changed into rotary movement.
So, this rotary movement is transmitted to the propeller blades pitch by two pins.

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2.2.3. Power transmission

* Power transmission is composed grid coupling(1630), pinion shaft(1252), bevel gear(1251),
gear hub(1241) and propeller shaft (1231).
- For the grid coupling ; See drawing ‘Detail of coupling assembly’,
* This gear set (bevel gear and pinion shaft) is manufactured with very high precision.
and is right angle reduction gear.
* The pinion shaft has arranged in spherical roller bearings, thrust bearing and taper roller
bearing.
* The Propeller shaft mounted with spherical roller bearing and thrust bearings.
* The gear set and bearings are to be lubricated by the gravity oil filling the gear case.
* This charge of gravity oil is sealed securely by the two radial shaft seals(1321) of the pinion
shaft and the Simplex-Compact seal.

2.2.4. Oil supplying and discharging mechanism

* The oil supplying mechanism is made up of oil distributor, oil dist pipe and oil pipes.
* The inside and out side of oil dist pipe(7051) mounted in the bore through the propeller shaft is
the oil passage of supplying and discharging oil.
The oil feed mechanism has a pair of bores and the hydraulic oil is supplied by either bore,
the other one is used for discharging it.

2.2.5. Feed back mechanism

* This mechanism is composed of the blade angle transmitter(4010), rod(4021), pipe(4038),
chain (4036) and swing plate(4034).
* This mechanism is for transmitting the blade angle signal to the blade angle transmitter and
remote control system.

2.2.6. Shaft sealing device (See drawing ‘Detail of shaft sealing device’)
* This mechanism is composed of liner, flange, intermediate rings, cover ring and sealing ring.
* This is for sealing the gravity oil in the gear case against sea water.

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2.3 Hydraulic power unit (See drawing ‘Arrangement of hydraulic pump unit’)
* The hydraulic unit consists of oil service pump(= hydraulic pump), shut off valve, relief valve,
check and throttle valve, pressure gauges, pressure switch, electrical motor(s) and etc.
* In case that the command to change the propeller pitch is given, the port of the valve is opened,
and the pressurized hydraulic oil is supplied through one of the hydraulic oil circuits.
- One side of the crosshead is delivered with the pressured oil.
- The oil in the crosshead on the opposite side is, meanwhile, returned to the gear case of the
thruster through the other hydraulic oil circuit and past the oil-discharging side of the valve.
- When the propeller pitch is held or upon completion of pitch-changing, the solenoid valve
port is closed, and the hydraulic oil is returned to the gear case interior through the valve.
- The oil supplied to the thruster during holding of the propeller pitch or during pitch-changing
fills the space in the gear case, and lubricates the bearings, gears etc. (Oil bath lubrication).
After that it circulates back to the gravity tank.
* For protection of the hydraulic oil circuit there is provided a relief valve

2.4 Gravity tank (See drawing ‘Detail of gravity tank’)

* The gravity tank which serves to apply the gravity oil pressure to the thruster unit.
* The lub. oil pressure in its interior is kept higher than the pressure of the ambient sea water.
and is also used as oil tank for the hydraulic unit.
* The float switch continuously monitors the system oil level and lights up the alarm lamp when
it has fallen below the specified level.

2.5 Pitch control device

* The device is composed of a remote control system for controlling the propeller pitch and
a hydraulic unit for regulating the blade angle.

2.6 Remote control system

* The remote control system serves to transmit the command to change propeller pitch given
through the control dial on the bridge.
* For the propeller blade angle to be adjusted accordingly, and also hold the propeller pitch.
* For further details of the remote control device refer to “User operation manual for controller”

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3. Maintenance and Checking

Please take countermeasures according to this manual, in case that user will meet of trouble or
failure.
But HHI cannot anticipate every circumstance which might involve hazardless.
So, For the long term of using the thruster, user should understand and execute the described below.

♦ The recommended practice of “Routine maintenance and checking”

* Every part is to be carried out periodically to be checked.

* The inspection intervals are given as rough guide or hint, so the proper interval is to be
determined with the frequency of thruster operation taken into due consideration.
* Fouling of the propeller blades or of the water path in the tunnel are bound to cause an undue
drop in thruster performance, so it is advisable to take every opportunity to clean them.
* For the items of docking maintenance and checking such as cleaning of water paths refer to
part “Docking inspection”.

Itemized records shall be kept of every maintenance checking, and such records with the
checking interval be reported to us together with the inspection findings on the items
enumerated in Part 4 “Inspection”.

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3.1 Maintenance/checking items

Checking Interval Description

- Abnormal noise Routine Checking of drive motor, grid

- Abnormal vibration checking coupling, thruster unity,
hydraulic (pitch control oil) pump.

- Oil level of gravity tank Monthly Checking by the oil level gauge of
the gravity tank.

* For routine level checking there is an “alarm lamp” provided on the bridge.
* Periodical checking by the said level gauge is, however, recommended.
* Checking by the “alarm lamp” on the bridge is to be done with the thruster operation
switch set to “Control source ON”.
* Checking over, the thruster operation switch is to be shifted back to “Stop”.

- Cleaning of hydraulic Monthly Check the differential pressure

unit line filter

- Ingress of sea water and Monthly Take a sample from the oil sump in
other material into the the bottom of the gear case using a
gear case interior hand pump, and check it.

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Checking Interval Description

Supplying grease Every 3 months 1. Grid coupling : grid element

2. Coupling of hyd.oil pump
3. Thruster unit : Two radial shaft seal
of pinion shaft.
4. Motor : See motor manual parts.

Frequency of shut-off valve Every 3 1. Blade angle : 0°

actuation and oil temperature months Measuring time : 3 min.
(With thruster in operation) * Actuation frequency to be measured
under this condition.
2. Oil temperature to be measured
with the thermometer attached to
the hydraulic unit.

Propeller pitch and Semi-annually Measure the working current of the

required input power drive motor (rack scale reading) under
the same conditions.

Note:
After long term laying-up
more than two (2) months,
input power might be
increased due to fouling by
marine growth on the tube
and propeller.
In case of that, to avoid such
case operate the thruster
periodically during laying-up.

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Checking Interval Description

Checking of remote control Semi-annually 1. Power source voltage

system 2. Checking for loosening of terminals,
relays and potentiometers.
3. Function of pilot lamps and buzzers
by lamp/buzzer test switch.

Confirmation of blade angle Semi-annually 1. Start the hydraulic (pitch control

indicator oil) pump, and adjust the control
dial to “0” .
2. At the same time confirm that the
indicating needle of the blade angle
indicator and blade angle
transmitter are at point “0”.

Oil leakage from the radial When leakage 1. Close the valve of radial shaft seal
shaft seal unit occurs unit.
2. Caution plate related with above is
attached at the radial shaft seal unit.
Refer to below caution plate.

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4. Inspection

For maintaining smooth thruster operation it is very important to carefully check every part of it
at each docking and also keep running records of thruster operating conditions, to say nothing of daily
maintenance/ checking (See part 3).

To be described and explained here are the procedure of inspecting the thruster as a whole including the
maintenance checking items requiring dry docking, with the inspections involved divided into the
following three.

(1) Dry dock inspection (pre-disassembly inspection)

(2) Disassembly (overhaul) inspection of parts
(3) Inspection after reassembly

Records should be kept of every inspection item involved.

Now described is the procedure of thruster overhaul.

Important !
Overhaul according to the schedule given below should be done for close inspection of its components
even if nothing wrong has been found in the routine maintenance/ checking etc.

NAME OF MACHINE INTERVAL DESCRIPTION

1. Thruster unit 5 years

Disassembly/ Checking
2. Flexible coupling 5 years

Measurement of Insulation
3. Drive motor 5 years resistance.
Disassembly/ Checking

4. Hydraulic power unit 5 years Disassembly/ Checking

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4.1 Dry dock inspection (pre-disassembly inspection)

If nothing abnormal is found in the routine maintenance/checking (See Part 3.), follow the
inspection interval given in the table below.

Inspection
interval
Inspection item Method/procedure Remedy
(year)
2~3 5
Cleaning of 1. Removal of deposits such as marine growths on of tunnel inside wall,
water paths, gear case and propeller, and cleaning of the same.
confirmation of 2. Check locking of bolts in thruster, and repair if any of them is fallen off.
locking and 3. Repair painting of water-contact parts where paint coat is stripped or
repair painting affected. (The water-contact parts are anti-corrosion painted except those
made of stainless steel).
4. The inside of the fairing cover, which comes into contact with the sea
water should be cleaned and repair painted with particular care.
Replacement of The anti-corrosive anode should be renewed each time the ship is docked.
anti-corrosive (The life of the anti-corrosive anode is taken to be more than 1 year.)
anode.
Check of Take a sample of the oil collecting on Each time
system oil the bottom of the gear case using a Replace the charge of system oil, the ship is
properties hand pump, and check its properties. if it is contaminated with sea water docked.
(This analysis is to be arranged for etc. of found badly deteriorated.
by the shipyard or the owner.)

Check of 1. Start the oil service pump of the

blade angle hydraulic unit. Do matching of scale readings with
indication 2. Change the propeller pitch by that of propeller hub as reference.
at pitch means of the control dial on the
transmitter bridge and check to confirm
matching of the scale reading
between the propeller hub and the
pitch transmitter.

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Inspection
interval
Inspection item Method/procedure Remedy
(year)
2~3 5

Relief value set 1. Start the hydraulic pump of the The relief valve set pressure is
pressure hydraulic unit. P=90 bar.
confirmation 2. Confirm the NC(normal close)
test positional valve solenoid coil : O O
De-energized.
3. Confirm the relief valve set
pressure by means of the pressure
gauge on the pump discharge side.

Leakage test 1. Remove the inter cover(1120). 1. If oil leakage is detected,

of likely 2. Clean the gear case and propeller. disassembly the parts involved,
components 3. Confirm that the oil level in the and replace the seal packing,
gravity tank is as specified. if necessary.
1. Pinion shaft 4. Leave it to stand for 1 day after 2. Oil leakage through the oil seal
Radial shaft confirmation of the oil level to assembly …
seal check for oil leakage. > Replace the parts found bad or
Each time
2. Shaft sealing displace the lip contact part.
the ship is
device 3. Oil leakage through shaft water
docked.
3. Propeller seal…
blade – > Replace the part/s found bad or
Quad Ring re-machine the liner.
4. Other seals 4. Feed grease to the pinion shaft
radial seal, regardless of oil
leakage.

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Inspection
interval
Inspection item Method/procedure Remedy
(year)
2~3 5
1. Let out the system oil in the Contact us if there is any abnormal
Checking of thruster using a hand pump or indication such as pitching or
wear of gear through the drain hole in the scouring.
tooth face propeller hub. (▲) O
2. Open the checking cover and check
meshing of the gears inside.

Measurement 1. Completely drain the system oil,

of oil bush and remove the end cap.
(7053) & 2. Remove the manifold and swing
O
Oil Dist. pipe. lever from oil Dist. Pipe.
(7051) 3. Measure the dimensions to be
controlled.
Complete
O
overhaul

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Inspection of parts upon disassembly

Do inspection of the following parts when the thruster proper and grid coupling are disassembled.
If any of them is found damaged, please notify us without delay.

4.2.1 Thruster unit

Inspection item Inspection point Action to be taken

Measurement of 1. Oil bush – Oil Dist. pipe clearances Record the measured
clearance 2. Clearance between crank disc and crosshead. values.
3. Clearance between slide block, crank disc pin
and crosshead piston.
Color checking If any defect is discovered,
1. Rounded root of propeller shaft flange please notify us without
2. Keyway of Input shaft & Prop. shaft delay and do necessary
3. Entire gear tooth face preparation for replacement
4. Journal area of propeller blade of the part/s involved.

Wear of and damage to 1..Lip-contact part of the sleeve for pinion shaft Re-machine the liner.
rotary part (Radial shaft seal)
2. Lip-contact part of shaft sealing liner Re-machine the liner.

3. Contact surfaces of inner, outer race and roller Replace the parts affected.

Condition of gear Tooth bearing and tooth face condition of pinion Repair or replace.
tooth face gear and bevel gear
Damage to sliding part 1. Inside of propeller hub. Repair or replace.
2. Sliding surface of crosshead
3. Sliding surface of guide pin(3) and slide block.
4. Sliding surface of oil dist. pipe.

Packing for sealing 1. The packing for sealing (O- ring) should be replaced each time the assembly
and oil seal is disassembled.
2. Oil seal : Check the lip etc. and replace the seal if anything wrong is detected.
The standard replacement interval for oil seal is 4 years.

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4.3 Inspection after assembly and restoration

When any component of the thruster has been disassembled for checking and some part has been
replaced, do inspection on the following items and record the results or measured values.

Inspection item Method / procedure Action to be taken

1. Measurement of input shaft displacement Refer to 4.1 Record the measured values and
compare them with the values
2. Measurement of gear backlash Refer to 4.1 before assembly.
Less than 3 1r/day may be
3. Oil leakage test of shaft sealing Refer to 4.1
deemed negligible.

4. Matching of pitch scale reading Refer to 4.1

Trace for the cause and replace

5. Oil leakage test of thruster as a whole Refer to 4.1
seal packing.

6. Checking of contact pattern of gear tooth Refer to 4.14 Send the test record to us.

 Check the gear tooth bearing each time after replacement of the input shaft, bevel wheel as
well as after replacement of any of the bearings for the input and propeller shaftings.

4.3.1 Procedure for oil leakage test of shaft sealing

1) Feed oil from the gravity tank to the thruster unit, and keep the oil level in the tank
at the specified level.
2) With the oil in the tank kept at the specified level, leave it to stand for 8 hours and then check
for leakage through the drain hole in the flanged casing (2).
3) After the oil leakage test screw in the drain plug, remove the oil inlet plug and fill in the
lubricating oil between the seal rings #2 and #3.
4) Lock the oil inlet plug and drain plug. The oil leakage test is now over.

If the oil leakage out of the thruster (at various parts of it) in the step (1-3) of this test,
the “oil leakage test of the thruster as a whole” can also be done simultaneously.

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4.4 Notification of inspection items to us

After completion of the inspections 4.1, 4.2 and 4.3 mentioned above, notify us of the respective
inspection records.
4.4.1 Date and place of inspection
4.4.2 Kinds of inspection … Routine dry dock inspection (each time the ship is docked),
inspections after disassembly and reassembly.
4.4.3 Inspection items, actions taken and measure values
These should be notified to us without fail, the following in particular.
(1) Measured value of staring torque
(2) Measured value of backlash
(3) Measured displacement of input shaft
(4) Oil bush – oil dist. Pipe clearance
(5) Records of contact pattern of gear tooth
4.4.4 Details of routine maintenance/checking and checking interval
4.4.5 Special data
(1) Total running hours of the thruster
(2) Troubles experienced, if any, with description of each case
(3) Others

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5. Disassembly and reassembly procedure

5.1 Disassembly of thruster unit

5.1.1 Preparation for disassembly

1) Install a trolley
(The main components of the thruster are to be taken outboard in the way illustrated
in Fig.5-1, hence a trolley or a proper substitute should be provided.)

☞ Yard’s preparation tools; Chain block, trolley, beams and eye bolts.
The suspension tool is to be stored onboard as the special tool.

2) Prepare the required special disassembly tools and seal packing for the individual joints.

* Special tools -----See the annexed “List of special tools”

* Seal & packing --- See the annexed “List of spare parts”

3) Prepare an oil bucket for receiving the oil collecting inside which will flow out
as the thruster is disassembled.

4) Do pre-disassembly inspection (Part 4. 2) and record the result to itemize.

5) Arrange the propeller blade so that plug hole directs toward down side and let oil out using a
hand pump or through the drain hole in the propeller hub.

6) Confirm and check the match-marks before each part was disassembled.
* ID No. for Propeller hub - blades, Crank disk & Crosshead.
* Guide pins and Reamer bolts ; Prop. Hub, Crank disk, Prop. Shaft, Gear hub & bevel gear,
Bearing housings and etc.

7) Remove the gear case cap.

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5.1.2 Disassembly procedure

1. Drain oil in piping and gear case.

2. Remove the coupling cover and grid wire.
3. Pull out the main motor.
4. Pull out the propeller blade (1211, 4ea).
5. Remove the end cap (1121).

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6. Remove the inter cover (1122, 2 parts).

7. Remove the rod stopper (4031).
8. Remove bolts on the bearing retainer (1412).

9. Pull out the pinion shaft assembly.

10. Pull out the propeller shaft assembly.

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11. Disassemble the pinion shaft part.

12. Disassemble the propeller shaft part.

Approximately weight of thruster sub-assembly & Parts (kg)

MAIN INTER PINION PRO.SHAFT
MODEL PRO.BLADE END CAP
MOTOR COVER PART PART
HSE-18M 4050 660 120 85 450 1950
HSE-21M 4725 770 140 96 525 2275
HSE-24M 5400 880 160 110 600 2600
HSE-26M 7000 1140 320 130 800 3300
HSE-27M 8900 1250 320 130 850 3500

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5.2 Reassembly of thruster unit

5.2.1 Preparation for reassembly

1) Inspect the each disassembled parts in accordance with Part 4.

The parts saved for reuse after repair should be replaced at the next docking.
2) Be sure to clean all parts thoroughly before they are assembled.

5.2.2 Cautions and notices on reassembly work

For reassembly the described procedure for disassembly can be simply reversed.
To be observed are, however, the following.
1) Check the match-marks for each connection parts before assembling the individual parts.
2) In reassembling, be careful to ensure against ingress of dust etc. into the thruster interior.
3) Be sure to observe the specified fastening torque in fastening the bolts and nuts.
(For the fastening torques refer to the annexed “Technical data.”)
Every set of bolt and nut has stamped on it match-marks.
Which are to match when the nut is screwed up with the specified torque.

IMPORTANT : THE DEFINED FASTENING TORQUE IS TO BE STRICTLY OBSERVED.

4) The bolts and nuts set inside the thruster should be locked after fastening without fail before the
next step is proceeded with. (Refer to locking system)
5) Reassembly over, do inspection in accordance with Part 4.3 “Inspection after reassembly and
restoration” and record the result.
6) Lock the bolts on the outside of the thruster.
Reassembly is now over.

* Parts to be greased
(a) Compact seal of shaft / seal ring part
(b) Radial shaft seal (pinion shaft)

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5.2.3 Measurements to be taken during reassembly

During reassembly, measurement should be taken of the following and the result recorded
without fail.
1) Shaft sealing device ; Refer to “Installation and operation manual for shaft seal”
-1) Measurement of fitting dimensions
-2) Measurement to be taken while setting the liner.
2) Oil distributor.
Measurement of eccentricity of feed shaft (Tolerance: 5/100㎜)

5.3 Locking procedure

1) Dropping off of any bolts, nuts, pins or the like during thruster operation possibly causes
a serious accident.
These should, therefore, be locked securely by the respective methods recommended in the
table below.
To ensure perfect locking of all these, careful checking should be made in the course of
reassembly as well as at every dry dock inspection.

2) Locking method
See “Detail of screw locking”

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6. Filling oil and draining oil

The thruster proper as well as servo cylinder should be filled with the oil after reassembly.

6.1 Filling oil

6.1.1 Filling oil in the gear case and piping “T” & “L” line.
1) Fill the gravity tank with oil.
2) Start the hydraulic oil pump at low pressure (set the relief valve below 10 bar.)
3) Refilling oil in the gravity tank.

6.1.2 Filling oil in hydraulic pressure line, the servo cylinder and piping “A” & “B” line.
1) Fill the gravity tank with oil.
2) Start the hydraulic oil pump at low pressure (set the relief valve below 10 bar.) and operate
the solenoid valve manually to change pitch of propeller in full stroke several times.
3) Refilling oil in the gravity tank to normal level.

6.2 Draining oil

6.2.1 Case 1 : by using hand pump
8881) Open the valve below a hand pump
8882) Drain oil by using the hand pump.

6.2.1 Case 2 : by using air pump – Option (In case that ship owner has an air pump)
1) Disassemble a hand pump from “H” line.
2) Assemble an air pump to “H” line and drain oil by using the air pump.
* After draining oil, less than 1% oil may remain in the gear case.

6.3 Requirements for lubricant

6.3.1 Thruster proper (Including the gravity tank)
1) Oil used : Gear oil ISO VG 100 or equivalent
2) Oil amount
Thruster proper : liters.
Gravity tank : liters.
Total amount : liters.

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6.3.2 Grid coupling

1) Grease used : Grease NLGI Consistency #2 or equivalent
2) Grease amount
Grid coupling : kg

6.3.3 Recommended brands

1) Mineral oil
No. Maker Gear Oil Grease
1 BP ENERGOL GR-XP 100 ENERGREASE MP-MG 2
2 CASTROL ALPHA SP 100 SPHEEROL SX 2
3 CHEVRON MEROPA 100 MULTIFAK EP 2
4 TOTAL EPONA Z 100 CERAN WR2
5 SHELL OMALA S2G 100 GADUS S2 V220 2
- Grease is applied for the flexible coupling.
- If the vessel mainly will be voyaged in the lower temperature area, such as north sea
zone, low viscosity oil ISO VG 68 gear oil should be used.

2) EAL (Environmental Acceptable Lubricants)

No. Maker Gear Oil Grease
1 BP BIOSTAT 100 ENERGREASE MP-MG 2
2 CASTROL BIOSTAT 100 SPHEEROL SX 2
3 KLUBER KLUBERBIO EG 2-100 KLUBERLUB BE 41-1002
4 LUKOIL (FUCHS) PLANTOGEAR 100S NAVIGREASE CSX 2
5 SHELL Naturelle S4 Gear Fluid 100 GADUS S2 V220 2
- Before using EAL, all sealings (directly contact with sea water) have to be changed to
special material which is applicable to use EAL Please contact HHI to check above
contents.
- VGP 2013 rule is not applied to grid coupling. So, there is no need to use for EAL in
grid coupling.

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6.4 Criterion of oil exchange

No. Description Specification

1 Variation of viscosity (40℃) ±10%
2 Water contamination Max. 1%
3 Oxidation Max. +1 mgKOH/g
4 Contamination Max. 30mg/100ml

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7. Initial start-up after installation (Commissioning)

7.1 Checking the installation

The system properly filled with oil, be sure to check the followings.

1) Check to make sure that the oil level in the gravity tank is within the specified range, i.e.
between the green lines of the oil gauge.
2) Check every joint for oil leakage.
3) Checking for shaft sealing device (Lip seal unit)
4) Check all of the bolts for screw locking.
5) Check pressure switch actuation. (Set pressure 20 bar(Low Alarm ), 10bar (Inter lock )
6) Check movement of propeller blade. (Operate the solenoid valve manually.)
7) Check relief valve setting. (Set pressure 90 bar)
8) Check both scales of the blade angle between of the propeller blade and of the blade angle
transmitter to ensure matching each other.

7.2 Adjustment before main motor starting

1) Check for condition of hydraulic pump unit.

2) Check movement of propeller blade.
3) Check for oil pressure in the hydraulic pump unit.
4) Check for oil level and level switch of gravity tank.
5) Check for neutral position of propeller blade.
6) Check for working of alarm lamp on the controller.

7.3 Checking items after main motor starting

1) Adjustment of max. pitch port and starboard.

2) Check for oil pressure in the hydraulic pump unit.
3) Measurement of blade pitch and electric current.

For starting of the thruster, see “Instruction manual for remote control system”

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CONTENTS

1. Structure

2. Technical specification

3. Instruction for installation

4. Lubrication and handling

S.H.LEE S.K.LEE J.Y.AHN

0 FOR WORKING
2011. 07.06 2011. 07.06 2011. 07.06

REV. PREPARED CHECKED APPROVED MODIFICATION

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1. Structure
Table 1.

Part Number Part Name

1 Oil Seal

2 Cover

3 Hub

4 Grid

5 Gasket

6 Bolt

7 Lub. Plug

Figure 1.

2. Technical specification

Horizontal Split Cover type

Figure 2.

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Horizontal Split Cover type

Table 2.
Bore Dia.
HP per Max Basic Dimensions (mm) Gap (mm) Cplg Lub
(mm)
Size 100 Speed Torque Wt * Wt
rpm (rpm) (kg·cm) Min Max A B C D E Min Nor Max (kg) (kg)

1020 0.68 4,500 486 30 12.7 101.6 98.0 47.5 39.7 66.5 1.5 3 4.5 1.9 0.03

1030 1.93 4,500 1,383 36 12.7 110.0 98.0 47.5 49.2 68.3 1.5 3 4.5 2.6 0.03

1040 3.22 4,500 2,304 44 12.7 117.5 104.6 50.8 57.1 70.0 1.5 3 4.5 3.4 0.05

1050 5.63 4,500 4,033 50 12.7 138.0 123.6 60.3 66.7 79.5 1.5 3 4.5 5.4 0.05

1060 8.85 4,350 6,337 57 19.1 150.5 130.0 63.5 76.2 92.0 1.5 3 4.5 7.3 0.09

1070 13 4,125 9,217 65 19.1 161.9 155.4 76.2 87.3 95.0 1.5 3 4.5 10 0.11

1080 27 3,600 19,010 79 27.0 194.0 180.8 88.9 104.8 116.0 1.5 3 4.5 18 0.17

1090 48 3,600 34,564 95 27.0 213.0 199.8 98.4 123.8 122.0 1.5 3 6 25 0.25

1100 81 2,440 58,183 107 41.3 250.0 245.7 120.6 142.0 155.5 1.5 3 6 42 0.43

1110 121 2,250 86,411 117 41.3 270.0 258.5 127.0 160.3 161.5 1.5 4.5 9.5 54 0.51

1120 177 2,025 126,736 136 60.3 308.0 304.4 149.2 179.4 191.5 1.5 6 12.5 81 0.73

1130 257 1,800 184,343 165 66.7 346.0 329.8 161.9 217.5 195.0 1.5 6 12.5 121 0.91

1140 370 1,650 264,993 184 66.7 384.0 371.6 182.8 254.0 201.0 1.5 6 12.5 178 1.13

1150 515 1,500 368,686 203 108.0 453.1 371.8 182.9 269.2 271.3 1.5 6 12.5 234 1.95

1160 724 1,350 518,465 228 120.7 501.4 402.2 198.1 304.8 278.9 1.5 6 12.5 317 2.81

1170 965 1,225 691,286 279 133.4 566.4 437.8 215.9 355.6 304.3 1.5 6 12.5 448 3.49

1180 1,338 1,100 958,584 311 152.4 629.9 483.6 238.8 393.7 321.1 1.5 6 12.5 619 3.76

1190 1,770 1,050 1,267,358 339 152.4 675.6 524.2 259.1 436.9 325.1 1.5 6 12.5 776 4.40

1200 2,413 900 1,728,216 361 177.8 756.9 564.8 279.4 497.8 355.6 1.5 6 12.5 1,057 5.62

1210 3,217 820 2,304,288 386 177.8 844.5 622.3 304.8 533.4 431.8 3.0 12.7 24.0 1,424 10.50

1220 4,343 730 3,110,788 411 203.2 920.7 622.9 325.0 571.5 490.2 3.0 12.7 24.0 1,784 16.05

* Coupling Weight with unbore.

(korea Coupling Co., Ltd.)

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3. Instruction for Installation

1) Installation procedure

(1) Clean all metal parts using nonflammable solvent. Lightly coat

seals with grease and place on shaft before mounting hub.

Mount hubs on the shafts.

Figure 3.

(2) Using a spacer bar, equal in thickness to the normal gap. The

difference in maximum measurements must not be exceeded

over the angular limit.

Figure 4.

(3) Align so that straight edge rests squarely on both hubs as shown

fig. and also at 90˚ interval. The clearance with dial gauge must

not exceed the limit specified in table 2.

Figure 5.

(4) After greasing the tooth groove hub, fix the GRID in the same

direction.

Figure 6.

Figure 7.

5) Pack the spaces between and around the grid with as much lubricants as possible and position

gaskets on half assembled lower cover so that the match marks are on the same side.

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2) Coupling disassembly and grid removal

Whenever it is necessary to disconnect the coupling, remove the

cover halves and grid. A round rod or screw driver that will

conveniently fit into the open loop ends of the grid is required. Begin

at the open and of the grid section and insert the rod or screw driver

into the loop end. Use the teeth adjacent to each loop as a fulcrum

and pry the grid out radially in even, gradual stages, proceeding
Figure 8. alternately from side to side. Adequate lubrication is essential for

satisfactory operation and life of coupling.

3) Operating Misalignment Limit

The alignment of the center between the main motor shaft and the pinion shaft of the thruster should be adjusted
at the main motor installation work as follows.
Unit; mm

550kW 700kW 900kW 1400kW 1700kW 2000kW

Thruster Model 3000kW
600kW 800kW 1000kW 1600kW 1800kW 2500kW

Coupling Size 1100 1110 1120 1130 1140 1160 1170

Parallel
Target 0.10 0.10 0.12 0.12 0.12 0.13 0.13
Eccentricity
Shaft (P) Allow.
0.20 0.20 0.24 0.24 0.24 0.26 0.26
Misalignment (Sag/2) Limit
Allowance
Declination
Limit Allow.
(Y-X) 0.18 0.20 0.22 0.26 0.29 0.33 0.38
Limit
(Gap)

Max. 6 9.5 12.5 12.5 12.5 12.5 12.5

Coupling
Installation Normal 3 4.5 6 6 6 6 6
Gap
Min. 1.5 1.5 1.5 1.5 1.5 1.5 1.5

Shaft misalignment allowance limit Coupling installation gap

Parallel Eccentricity Declination

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4. Lubrication and Handling

You should choose the adequate lubricant for Grid Coupling to support good performance and long life.

1) Grease Lubrication
Pack the spaces between and around the grid. After Assemble the covers, fill up grease through the lube plugs.

2) Supplement and Replacement

Every 3(three) months, or 240-250 hours running, you should supply grease.

Every 3(three) years, or 4,000 hours running, you should replace after get rid of contaminated grease.

3) Selection
The usable temperature for grease is from - 17˚C to 70˚C. You choose grease according to the rpm and

circumstance in table 4.

Table 4.

Manufacturer Name
SHELL GADUS S2 V220 2

CHEVRON TEXACO Multifak EP2

EXXONMOBIL Mobilux EP2

BP Energrease MP-MG2

CASTROL Castrol spheerol sx2

GULF Gulf sea hyperbar super CS

※ Note: Lubricants listed in this manual are the typical products ONLY and should not
be limited as exclusive recommendations.

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PAGE NO. ; 1

CONTENTS

1. General …………………………………………………………... 2
1-1. Lip Seal Unit for Thruster….……………………………………. 2
1-2. Name of part……………………………………………………… 3
1-3. Height Calculation of Gravity Tank……………………………… 3
2. Installation…………………………………………………. 4
2-1. Installation……………………………………………………….. 4
2-2. Measures to be taken after Installation…………………………… 5
2-3. Tightening Torque for Bolt………………………………………. 6
3. Commissioning…………………………………………….. 7
3-1. Pressure Test…………………………………………………….. 7
3-2. Filling Oil Quantity of the Seal Chamber………………………. 9
4. Maintenance………………………………………………. 10
4-1. Exchanging of the Seal Ring by Bonding Device………………. 10
4-2. Skimming Allowance……………………………………………. 11
4-3. Trouble Shooting………………………………………………… 12
5. Appendix…………………………………………………… 13
5-1. Recommanded Lub.Oil………………………………………….. 13
5-2. Ring Anode………………………………………………………. 13

H.B.JIN S.W.YE H.S.GONG

0 FOR FINAL
2014.10.14 2014.10.14 2014.10.14

REV. PREPARED CHECKED APPROVED MODIFICATION

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1. General

1.1 Lip seal unit for thruster

The lip seal unit composed of three major parts, that is, (1) three rubber seal rings, (2) a metal housing with
the clamper for the rubber seal rings, and (3) a liner which rotates together with the propeller shaft. The metal
housing is made up, in the order from the gear case side, of a flange housing, an intermediate ring B, an
intermediate ring C and a split-type seal cover.
Rubber seal rings are fitted between these metal rings, and being bolted together. The clamp section of each
seal ring is securely fitted to the metal ring's inner circumferences and to the small grooves on the inner side of
the metal rings, so that the clamp part is made rigidly oil and water-tight.
The housing itself consists of individual rings which are bolted together between which the three seal rings
and fitted. They are arranged in a way that seal ring #1 and #2 facing against seawater and seal ring #3 facing
against the gear case. The metal of the liner is highly resistant to corrosion and wear.
We have strong technical abilities to make the lip seal unit different from other seals.
For seal material, we have a plenty experience in rubber recipe and therefore abrasion, thermal and oil
resistance fluorine rubber can be assured. Especially for abrasion resistance, our self-lubricant property is
essence.
For mounting(clamping) part of seal, This part has no load to elbow part due to uneven pressure and not
twisting seal ring during clamping.
For elbow(lever) part of seal, flexibility is most important in this part for the radial mobility and sealing
loading, operating like a swivel and lever.
For supporting of seal, the design of supporting ring is important to keep seal ring with static condition during
high pressure(draft) and fluctuation.

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1.2. Names of Parts

Fig. 1 Side Thruster Lip Seal Unit

1.3. Height Calculation of Gravity Tank

Specification for one Tank System

Generally, the oil pressure within the gear box at full loaded vessel(LW) is 0.15 to 0.3bar (Poil) above the
water pressure.
Height of Gravity Tank(1)
H(1)(m) = (HLW(m) x 1.025)/0.89 + (Poil(bar) x 10(m/bar))/0.89 (m)
HLW(m) : Height of Loaded Water Line(LW)
Poil(bar) : 0.15 to 0.3bar

Fig. 2. Installation Height for Gravity Tank

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2. Installation
2.1. Installation
• Clean and check for accuracy to size in way of the final position of the liner before pushing the seal unit into
the propeller shaft.
• Take out the seal unit from the packing box to check any damage happened during transport.

Fig. 3 Installation of seal unit at the thruster

• Hang the complete lip seal unit at its lifting bracket into a suitable lifting device. Be cautious of the mark of
"Top and Down" on the flange metal ring to avoid the miss-match.
• Remove the wood blocks from the housing flange.
• Coat the sealing surface of the flange ring and the gear box adapter which will be contact with the gasket with
grease.
• Put a gasket on the sealing surface of the flange ring.
• Put the O-rings into the seal lub. grooves of flange ring and the gasket matched correctly to avoid the blocking
the lub. groove with gasket.
• Place the O-ring and gasket on the sealing surface of the liner.
• Place seal unit assembly with gasket and the fitted liner on the shaft.
• Turn the seal unit in position, while ensuring that bores in the flange ring are matching with the oil supply
bores in the gear box adapter ring.
• Mount and fasten hexagon screws of flange ring and liner flange as follows :
- Insert the remaining hexagon screws
- Tighten the hexagon screws cross-wise with the tightening torque given on the seal unit drawing
Coat each screw with Loctite 243/245 and insert the screws cross-wise
Secure screws by using stainless wire
Remove the lifting bracket.
Remove screws with mounting strap and keep them on board.
Fasten the liner slightly at the propeller with screws.
Check the design length of the seal unit.

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PAGE NO. ; 5

2.2. Measures to be taken after Installation

Measuring Seal size

Div Measuring method Tool
Criteria #170∼#530 #560∼#750 #800∼

Measure gap at 4 Difference between

Thickness
A points on the max. 0.15 max. 0.25 max. 0.35
gauge maximum and
circumference
minimum values
Thickness
Measure gap at 4 Difference between
gauge/
B points on the max. 0.30 max. 0.50 max. 0.70
wooden maximum and
circumference
wedge minimum values
Confirm that the
Comparison with
spacing is as
C Scale ±3.0 ±3.0 ±3.0
indicated on the dimension on the
drawing drawing
Measure
circumferential Reading on dial
D Dial gauge max. 015 max. 0.20 max. 0.30
eccentricity of liner gauge
flange

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2.3. Tightening Torque for Bolt

Bolt for Liner Housing

Material SUS 304 SUS 304

Seal size Bolt size x number Torque(N.m) Bolt size x number Torque(N.m)

#170 M8 x 8 11.7 M12 x 8 39.5

#180 M12 x 8 39.5 M12 x 8 39.5
#220 M12 x 8 39.5 M12 x 8 39.5
#260 M12 x 8 39.5 M16 x 12 98.5
#280 M12 x 12 39.5 M16 x 12 98.5
#300 M12 x 12 39.5 M16 x 12 98.5
#330 M12 x 12 39.5 M16 x 12 98.5
#355 M16 x 12 98.5 M20 x 12 192.0
#380 M16 x 12 98.5 M20 x 12 192.0
#400 M16 x 12 98.5 M20 x 12 192.0
#420 M16 x 12 98.5 M20 x 12 192.0
#450 M16 x 12 98.5 M20 x 12 192.0
#480 M20 x 12 192.0 M20 x 12 192.0
#500 M20 x 12 192.0 M20 x 12 192.0
#560 M20 x 12 192.0 M24 x 12 330.8
#600 M20 x 12 192.0 M24 x 12 330.8
#630 M24 x 12 330.8 M24 x 12 330.8
#670 M24 x 12 330.8 M24 x 12 330.8
#710 M24 x 12 330.8 M24 x 16 330.8
#750 M24 x 16 330.8 M24 x 16 330.8
#800 M24 x 16 330.8 M24 x 20 330.8
#850 M24 x 16 330.8 M24 x 20 330.8
#900 M24 x 16 330.8 M24 x 20 330.8
#950 M24 x 16 330.8 M24 x 20 330.8
#1000 M24 x 20 330.8 M24 x 20 330.8
#1060 M24 x 20 330.8 M30 x 24 664.5
#1120 M30 x 20 664.5 M30 x 24 664.5
#1250 M30 x 24 664.5 M30 x 24 664.5

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PAGE NO. ; 7

3. Commissioning

3.1. Pressure Test

Fig. 4 Internal Arrangement of seal unit

Fig. 5 Pressure Test of seal unit

• Pressure Test of Seal Ring #3 and filling of Gear Box with oil
Fill the Gear Box with oil.
The Gear Box thus completely filled with oil should remain at the specified operating pressure for at least
one hour.
Check for oil leakage at outlet of plug No.7(chamber Ⅱ).
• Pressure Test of Seal Ring #2 and filling of chamber Ⅰ
Fill the chamber Ⅰ with oil with inserting socket pipe plug No.3.
Check again for oil leakages at outlet of plug No.7(chamberⅡ) and oil level through No.2 at least one hour.
Insert socket pipe plug No.2(chamber Ⅰ) oil tight with its sealing rings.
After the system has proven tight, insert the plug No.7(chamber Ⅱ) oil tight with its sealing ring.

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• Filling of Oil Chamber Ⅱ

Fill the chamber Ⅱ with oil by hand.
Insert the plugs No.4 and No.5 at chamber Ⅱ oil tight with their sealing rings.
• Field Pressure Test
Fill the chamber Ⅱ with oil by hand.
The Gear Box filled with oil should at the specified operating pressure.
After then, check oil leakage at outlet plug No. 6(chamber Ⅰ) for at least 20 minutes.
• Pressure Test of Ring #1
The seal ring #1 will not be tested as this one is working as a dirt filter only.

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3.2. Filling Oil Quantity of the Seal Chamber

Fig. 6 Seal Chamber Ⅰ, Ⅱ

unit : ℓ (liter) unit : ℓ (liter)

Seal Chamber Seal Chamber
Size Size
Ⅰ Ⅱ Ⅰ Ⅱ
#170 0.17 0.15 #560 0.87 0.81
#180 0.18 0.16 #600 0.93 0.86
#220 0.21 0.19 #630 0.98 0.90
#260 0.27 0.25 #670 1.04 0.96
#280 0.29 0.27 #710 1.19 1.24
#300 0.31 0.28 #750 1.34 1.31
#330 0.34 0.31 #800 1.78 1.63
#355 0.44 0.40 #850 1.89 1.73
#380 0.47 0.43 #900 2.15 2.06
#400 0.49 0.45 #950 2.27 2.17
#420 0.52 0.47 #1000 2.38 2.28
#450 0.64 0.60 #1060 2.78 2.88
#480 0.68 0.64 #1120 2.97 3.05
#500 0.71 0.67 #1250 3.44 3.50

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PAGE NO. ; 10

4. Maintenance

4.1. Exchanging of the Seal Ring by Bonding Device

Where the replace of seal ring is required prior to the expiry of survey as planned by requirements of the
classification society, this can be accomplished by using the HS MarinePlex Bonding Device, with the ship
being afloat or in dock, without having to dismount the propeller or to withdraw the shaft.

Fig. 7 Bonding by bonding device without any shaft work

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PAGE NO. ; 11

4.2. Skimming Allowance

In case of abnormal abrasion of the liner due to the external causes, such as entering of foreign objects etc.,
modification of the liner diameter by machining may become necessary.
The following figure table is the limit to which modification may be carried out to obtain desired effects.
Relating to machining accuracy,
• Roundness and cylindricalness to be within 3/100mm
• Surface roughness to be within 0.8 Ra

Liner Machining Liner Machining

Size Size
Diameter Allowance Diameter Allowance
#170 170 1.5 #560 560 1.5
#180 180 1.5 #600 600 1.5
#220 220 1.5 #630 630 1.5
#260 260 1.5 #670 670 1.5
#280 280 1.5 #710 710 2.0
#300 300 1.5 #750 750 2.0
#330 330 1.5 #800 800 2.5
#355 355 1.5 #850 850 2.5
#380 380 1.5 #900 900 2.5
#400 400 1.5 #950 950 2.5
#420 420 1.5 #1000 1000 2.5
#450 450 1.5 #1060 1060 2.5
#480 480 1.5 #1120 1120 2.5
#500 500 1.5 #1250 1250 2.5

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PAGE NO. ; 12

4.3. Trouble Shooting

No. Problem Possible cause Counter-measure Remark

Bearings or gears damaged • Need to check

• Replace of defective
Defects of thermometer
parts
Temperature of
1 bearing, gear or oil too Defects of piping or valves • Check pipe and valve
high
Deterioration of oil • Check oil for water
quality(mixed water) content

Heavy vibration due to • Repair propeller in dry

propeller damage dock

• Fill gravity tank with

higher viscosity oil
Oil level in gravity tank • Replace all seal rings in
2 is decreasing by several Oil loss at seal unit dry dock
liters • Check flange gasket
• Remachine liner if
necessary

• Check alignment of
Oil level in gravity tank Bad alignment of liner
liner during next
3 is increasing by several Leakage at CP-propeller
drydock
liters unit
• Check CP-propeller

• Observe water content in

Water penetration into the oil
gear box due to seal failure • Recover lub. oil if
necessary

Foreign particles as i.e. nets

• Remove nets or ropes
or ropes in seal
Oil/sea water emulsion By diver
4
in the gear box Hex-plug leaky • Check plug and cu ring

• Replace all seal rings

Seal ring damaged • Remachine liner if
necessary
In drydock
O-Ring between liner and
• Peplace O-Ring
propeller

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PAGE NO. ; 13

5. Appendix

5.1. Recommended Lub. Oil

- Mineral Oil
Maker
Product
Shell BP Total Castrol Chevron

EP Gear Oil OMALA ENERGOL EPONA ALPHA MEROPA

ISO VG100 S2G 100 GR-XP 100 Z 100 SP 100 100

- EAL (Environmental Acceptable Lubricants)

Maker
Product
BP CASTROL KLUBER LUKOIL SHELL
NATURELLE
EP Gear Oil BIOSTAT BIOSTAT KLUBERBIO PLANTOGEAR
S4 GEAR
ISO VG100 100 100 EG 2-100 100S
FLUID 100

5.2. Ring Anode

Fig. 8 Ring Anode

• Remove the mounting strap after lip seal unit has been installed.
• Place the ring anode segments in according to the above fig. using the bolts the threads of which have to
been wetted with Loctite 242/243.

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PAGE NO. ; 14

A a ØB sum
Size segment C
angle grade ∼max. weight(kg)
No.
#170 320 5.3
#180 362 6.1
#220 406 6.9
#260 454 8.5
#280 474 21 9.0
#300 2 180 491 9.5
#330 545 11.1
#355 578 12.7
#380 610 13.7
#400 620 15.0
26
#420 642 15.9
#450 666 18.3
#480 708 19.9
3 120 31
#500 718 20.2
#560 799 24.5
#600 824 31 25.1
#630 880 28.8
#670 942 31.8
37
#710 970 35.4
#750 1017 37.8
#800 1075 45.1
42
#850 3 120 1132 48.6
#900 1196 54.8
#950 1258 59.2
47
#1000 1298 60.8
#1060 1362 66.4
#1120 1426 52 73.1
#1250 1562 85.5

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

B Technical data for main motor 68
-1 Data sheet of main motor 69
-2 Outline of main motor 70
-3. Terminal Box Ass'y 71
-4. Acc'y T/B Ass’y 72
-5. Name Plate for Main T/Box 73
-6. Name Plate for WTD 74
-7. Name Plate 75
-8. General Assembly Drawing 76
-9. PTC Thermistor 77
-10. Painting Procedure for Motor 78
-11. Cable Gland Catalogue 82
-12. Instruction manual for Main motor 83
 AC INDUCTION MOTOR DATA SHEET
Model No.or RFQ No Item No. Rev. No. [ 0 ]
Project Name 엔진) 한진수빅조선소 PO123~125 Project No. 20140120RPH023~5 Quantity 1 set
GENERAL SPECIFICATION PERFORMANCE DATA
Frame Size 800 Rated Output 3000 kW
Type HLA9 806-86Y Number of Poles 8
Enclosure(Protection) TEAAC ( IP 44 ) Rotor Type Squirrel Cage
Method of Cooling IC511 Starting Method* AUTO TR 65%
Rated Frequency 60 Hz Rated Voltage 6600 V
Number of Phases 3 Current Full Load 321.6 A
Insulation Class F B H Locked-rotor** 650 %
Temp. Rise at full load (by resistance method) Efficiency
at 1.0 S.F 100 deg.C 50% Load 95.0 %
Motor Location Indoor Outdoor 75% Load 95.5 %
Altitude Less than 1000 meter 100% Load 96.0 %
Relative Humidity Less than 95 % Power Factor(p.u)
Ambient Temp. 45 deg.C (Max.) 50% Load 0.73
Duty Type S2-30 75% Load 0.82
Service Factor 1.0 100% Load 0.85
Mounting B3 B5 V1 V10 Speed at Full Load 894 r.p.m
Type Anti-friction Torque
Bearing DE/N-DE 6234C3 / 7332B Full Load 3,268.5 kg·m
Lubricant Grease(Shell,Gadus S2 V100 2) Locked-rotor** 90 %
External Thrust Not applicable Breakdown** 220 %
Coupling Method Direct V-Belt Moment of Inertia (J)
Shaft Extension Single Double Load -- kg·m²
Terminal Main Steel Cast Iron Motor 225 kg·m²
Box Aux. Yes No Sound Pressure Level (No-load & mean value at 1m from motor)
Rotation(Viewed
R i (Vi d ffrom DE) CW CCW BI
BI-Direction
Di i -- dB(A)
Application SIDE THRUSTER Vibration 2.3 mm/sec(r.m.s)
Area classification Non-Hazardous Permissible number of Cold 2 times
Type of Ex-Protection N/A consecutive starts Hot 1 time
Applicable Standard IEC,ISO,NEMA,ANSI,GL Paint Ral No. RAL 6019(Pastel Green)
ACCESSORIES SUBMITTAL DRAWING
1.Winding Temp. Detectors (Pt 100 Ω) : 2ea/Phase Outline Dimension Drawing \ Motor Weight(Approx.)
1.Winding Temp. Detectors (PTC Thermistor) : 2ea/Phase V10 HM-091684 8900 kg
: 1ea : For Alarm
: 1ea : For Trip
3.Space Heater : 1Phase, 220V, 1000W
4.Voltage Arrestor : 8ea/Motor
5.Jacking Bolt : 1set/Motor
6.Center Taper Pin : 4ea/Motor
7.Touch Up Paint : 10Liter/Motor REMARK
8.PCT Thermistor Relay Unit : 2ea/Motor *. Rr = 1.98 %, Rs = 0.67 %
Xm = 15.13 %, Xr = 3.32 %, Xs = 11.84 %
*. Starting time :
100% 전압 : 1.3sec
65% 전압 : 6.1sec

SPARE PARTS
1.Bearing (6234C3/7332B) : 1set/Ship
Date DSND CHKD CHKD APPD

2014.02.11 D.K.Hong -- -- J.K.Bae

Note: Others not mentioned in this data sheet shall be in accordance with maker standard.
Above technical data are only design values and shall be guaranteed with tolerance of applicable standard.
Inspection and performance test shall be maker standard, if not mentioned.
* In case of Inverter-Fed Motor, performance data is based on sine wave tests.
-38- of full load value.
** The data are based on rated voltage & frequency, and data are expressed as a percentage
HHI W230-131-1 A4(210mm X 297mm)
-39-
-40-
-41-
-42-
-43-
-44-
-45-
 PTC Thermistors

■ Dimension, mm

■ Specification
Operating Color of lead PTC thermistor Ordering Remark
Temperature Type Code (Application)
(℃)
60 White - Grey P331 - M135 PN2-06
70 White - Brown P341 - M135 PN2-07
80 White - White P351 - M135 PN2-08
90 Green - Green P361 - M135 PN2-09

100 Red - Red P371 - M135 PN2-10

110 Brown - Brown P381 - M135 PN2-11
120 Grey - Grey P391 - M135 PN2-12
130 Blue - Blue P401 - M135 PN2-13

140 White - Blue P411 - M135 PN2-14

150 Black - Black P421 - M135 PN2-15
155 Blue - Black P426 - M135 PN2-16 ☜ For Alarm
160 Blue - Red P431 - M135 PN2-17 ☜ For Trip
170 White - Green P441 - M135 PN2-18
180 White - Red P451 - M135 PN2-19

-46-
 PAINTING PROCEDURE FOR MOTOR
No. : P-20140120/Rev.0 1/4

1. SCOPE
This procedure defines the painting and rust prevention procedure at shop.
But non-ferrous metal will not be painted.

2. SURFACE PREPARATION
2.1 Oil,grease and crayon marks will be cleaned off with solvent solution.
2.2 Shot blast cleaning will be carried out in accordance with provision of
"The steel structure painting council's specification SSPC-SP10/NACE NO.2
blast cleaning(Near White)”.
2.3 The surface profile height is defined as distance between the tops of
the highest peak and lowest adjacent rough, measured in a direction
perpendicular to the mean surface height plane.
2.4 Surface to be coated will be cleaned and dried before coating is applied.
2.5 Rust, weld spatter, mill scale and other surface contaminants will be
removed by the power tools and shot blasting.
2.6 The compressed air used for nozzle blasting will be free from the liquid
water or oil. Adequate separators and driers will be used so as to get
rid of condensation.
2.7 In principle,shot or sand blasting will be done only when the weather
condition allow the surface to remain dry after blasting and coating
for several hours (Min.4 Hours).

3. PROCEDURE
3.1 Detail painting procedures refer to attached data sheet.
3.2 Painting conditions.
3.2.1 The metal temperature shall be minimum 3 deg. C above the dew point temperature.
Air temperature : 5 ~ 40 deg. C
Air relative humidity : less than 85%

3.3 Related conditions

No paintings shall be applied outdoor when it is foggy, rainy or excessive
wind. If chemical contamination occurs in paint it should be removed by
washing with water or solvent before painting.

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 PAINTING PROCEDURE FOR MOTOR
No. : P-20140120/Rev.0 2/4

4. APPLICATION DETAILS
4.1 Preparation of paintings
Paintings should be prepared for application according to the instructions.
Individual components of multi-component paintings must be stirred before
mixing. If the thinner is required, only designated thinner should be used
and thinning rate may be adjusted according to the job condition.
4.2 Application method
4.2.1 Airless spray may be most effective in obtaining specified thickness at once.
4.2.2 Keep the spray gun at constant distance and perpendicular to the surfaces.
4.2.3 Brush or roller should not be used. Required thickness shall be achieved by applying
several coats at indoor. No outdoor painting shall be allowed.
4.3 Application work
4.3.1 Welding seams, corners and edges should always receive a stripe coat
before full coating in order to obtain adequate film built.
4.3.2 Bolt jointing surroundings and flange matching faces should be blanked
off or otherwise protected from painting unless otherwise accepted.
4.3.3 Special care should be taken to gain uniform thickness.
4.3.4 Each coat should be allowed enough to dry and interval between coats.
4.4 Cleaning of tools
The application tools and equipments should be cleaned with the thinner
immediately after use.

5. INSPECTION
Before painting, the surfaces shall be inspected as following items.
- Surface cleaning as per SSPC SP1
- Surface preparations as per SSPC-SP10/NACE No.2
- Environmental condition (Air temperature, Air relative humidity)
After painting, the surfaces shall be inspected visually for wrinkle, swelling
and other harmful defects. Also the dry film thickness shall be measured according to SSPC PA2.
If repair coating is required, applicable surfaces shall be arranged by sand
paper and re coated with the same paint. Also repairing shall be in compliance with paint manufacturer
recommendation.

-48-
 PAINTING PROCEDURE FOR MOTOR
No. : P-20140120/Rev.0 3/4

6. COATING REPAIR
6.1 Defective paint work will be removed, and the surface re-prepared and
repainted according to the original specifications.
6.2 Damaged parts on the coated surface will be cleaned by power tool and
touch-up with the same coating system as applied initially.

7. STORAGE OF PAINT
The storage area should be well ventilated and protected from sparks, flame,
direct exposure to sun or excessive heat, preferably located in isolated room.
Storage place shall have a temperature ranging from 10 to 40 deg.C.

-49-
 PAINTING PROCEDURE FOR MOTOR
No. : P-20140120/Rev.0 4/4

8. PAINTING SYSTEM
8.1 Item : Motor
8.2 Painting schedule

POLYURETHANE
First or External and Brand : Korethan Primer UP171
Prime coat. internal Maker : KOREA CHEMICAL CO., LTD
surface of motor Dry film thickness : 35 micro-meter
Coating time : After preparation
surface
Coating method : spray and/or brush

POLYURETHANE
Finish coat. External surface Brand : Korethan Enamel UT 2578
of motor Maker : KOREA CHEMICAL CO., LTD
Color : RAL 6019(Pastel Green)
Dry film thickness : 40 micro-meter
Coating method : spray and/or brush
Curing method : Self Curing
Total Dry film thickness Min. 75 micro-meter

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-51-
HYUNDAI

INSTRUCTIONS FOR
THREE - PHASE INDUCTION
MOTORS
(Common items)

INSTRUCTION MANUAL

HYUNDAI HEAVY
INDUSTRIES CO., LTD.
 CONTENTS

page
1. Foreword ------------------------------------------------------------------------------ 1
2. Receiving, Handling and Storage ------------------------------------------------- 2
2.1 Receiving ---------------------------------------------------------------------- 2
2.2 Handling ----------------------------------------------------------------------- 2
2.3 Storage ------------------------------------------------------------------------- 2
3. Inspection and Test for initial start up ------------------------------------------ 4
3.1 Installation ------------------------------------------------------------------ 5
3.2 Inspection of installation ---------------------------------------------------- 6
3.3 Measurement of insulation resistance ------------------------------------ 6
3.4 Inspection of lub. oil --------------------------------------------------------- 7
3.5 Manual rotation -------------------------------------------------------------- 7
3.6 Connection to power and grounding -------------------------------------- 7
3.7 Solo run test ------------------------------------------------------------------- 7
3.8 Alignment ---------------------------------------------------------------------- 8
3.9 Test run of motor ------------------------------------------------------------- 10
4. Inspection and Maintenance schedule -------------------------------------------- 11
5. Maintenance of winding ------------------------------------------------------------- 17
5.1 General -------------------------------------------------------------------------- 17
5.2 Cleaning of coil ----------------------------------------------------------------- 17
5.3 Use of space heaters ------------------------------------------------------------ 18
5.4 Drying insulation --------------------------------------------------------------- 18
6. Maintenance of brush and brush holder ------------------------------------------ 20
6.1 Slip rings ------------------------------------------------------------------------- 20
6.2 Brush and brush holders ----------------------------------------------------- 21
7. Terminal box for high voltage supply ----------------------------------------------- 23
8. Terminal box for auxiliary circuits ------------------------------------------------- 26
9. Anti-condensation heating with heating tube ----------------------------------- 28
10. Maintenance of bearing ------------------------------------------------------------ 30
10.1 Flange type sleeve bearing (Ring lubrication system) ----------------- 30
10.2 Flange type sleeve bearing (Forced lubrication system) -------------- 33
10.3 Rolling contact bearing ----------------------------------------------------- 36
11. Air filter and cooler ----------------------------------------------------------------- 41
11.1 Air filter ----------------------------------------------------------------------- 41
11.2 Cooler -------------------------------------------------------------------------- 41
12. Protection (General) ---------------------------------------------------------------- 43
13. Failure and remedial treatment --------------------------------------------------- 44
1. FOREWORD

This instruction manual describes and provides instructions for installation, operation and
maintenance of induction motors.

These instructions do not purport to cover all details or variations in equipment nor to provide for
every possible contingency to be met in connection with installation, operation, or maintenance.
Should further information be desired or should particular problems arise which are not covered
sufficiently, the matter should be referred to the nearest HYUNDAI HEAVY INDUSTRIES'
business office.

NOTE

For service shop requirements, you are referred to ;

ELECTRIC MOTOR MANUFACTURE DEP'T

INDUSTRIAL & POWER SYSTEM DIVISION.
HYUNDAI HEAVEY INDUSTRIES CO., LTD

Postal office : 1, CHEONHA-DONG, DONG-KU, ULSAN, KOREA

Telephone : 82-52-230-6671,72
Fax : 82-52-230-6996

1
 2. RECEIVING, HANDLING AND STORAGE
2.1 RECEIVING
Each shipment should be carefully examined upon HHI for specific instruction to minimize damage, giving
arrival. If the packing should be found damaged, full particulars of the circumstance.
unpacking should be made immediately to check
whether or not the motor and its fitting are good
condition, and any damage to contents should be Storage Facility Requirements.
photographed and reported to the carrier and to the The storage facility must provide protection from
nearest HYUNDAI HEAVY INDUSTRIES' contact
business office. with rain, hail, snow blowing sand or dirt,
accumulations of ground water, corrosive fumes
All of large motors are equipped with a locking and infestation by vermin or insects.
device which functions to protect the bearing from There should not be continuous nor severe
damage due to the movement of the rotor in transit. intermittent floor vibration. There should be power
Do not remove this device until transport is service for the space heaters and illumination. There
complete and coupling is ready to be fitted. should be fire detection and fire-fighting plan. The
motors must not be stored where it is liable to
accidental damage, or exposed to weld spatter,
exhaust fumes or dirt and stones kicked up by
2.2 HANDLING
passing vehicles.
In order to handling after it is unpacked, the motors If necessary, guards or separating walls to provide
are always required the chain hoist, wire ropes and adequate protection. Avoid storage in an
other handling equipment. When hoisting the motor, atmosphere containing corrosive gases, particularly
the wire ropes should be attached to the lifting holes chlorine, sulphur dioxide and nitrous oxides.
on side of the motor frame, and should be put in a
hard rubber, thick cloth, etc. between the external
covers for protective purpose.
Temperature Control.
At that time, the motor is slowly and carefully
Whenever the motor temperature is equal to and
raised and moved to the intended position.
below room temperature, water vapor can condense
on and within it to promote rapid deterioration.
CAUTION: The unpacking works and handling
Prevent this by energizing the space heaters to keep
the motor should have been the attention
the motor temperature above room temperature by
during unpacking as following points.
at least 3 . However, during periods of extreme
-. Anti-corrosive agent which is applied to the
coupling shaft ends should be removed right cold or rapid temperature drops, the space heaters
before motor starting. may not be adequate to maintain this differential
-. The motors should be checked the coupling or and supplementary heating may be required.
shaft ends to ascertain whether or not they are in
abnormal condition.
CAUTION : If the motor is boxed or covered in
any way when the space heaters are energized,
there should be thermostatics control and
2.3 STORAGE sufficient surveillance to detect an over-
If the motors are not put into service at time of temperature condition quickly. Ensure that
delivery, it should be stored as follow conditions. temporary packaging does not contact the
space heaters.
When windings of motor are uninjured and
Outdoor Storage Is Not Recommended. their insulation resistance to ground is well
Because variations in temperature and humidity can above the minimum of rated voltage(KV) plus
cause condensation, resulting in corrosion of metal 1 megaohms when corrected to 40 C according
parts and possibly in insulation failure. Therefore, to IEEE 43 or as below Fig.1 , low temperature
the following covers the minimum acceptable is not a problem.
storage arrangements, in an unheated but protected However, if the resistance drops, the windings
environment. can be permanently damaged by freezing.
It is preferable to use a heated facility, which would Therefore, the motor temperature should be kept
simplify meeting these conditions. above the freezing point.
When outdoor storage can not be avoided, contact
2
Fig.1 Insulation Resistance Temperature Correction

3
3. INSPECTION & TEST for INITIAL START UP ON SITE

Generally, inspection and text of motors are performed as following chart for initial start up on site.

Inspection of installation

Confirmation of starting panel

Measurement of insulation resistance

Connection with
outgoing cables

Inspection of connection cables

High voltage test with outgoing cables

(If necessary)

Solo running test

Inspection of lub. oil

Connection with
outgoing cables

Inching operation

Hand turning (If possible)

Load running test

Inching operation

END

4
3.1 INSTALLATION

GENERAL
Ensure that the motor enclosure is suitable for its
environment, that the ambient temperature is less
than specification of operating the motor at all
times and that all bearings are lubricated before
operating the motor.

FOUNDATION
Motors should be mounted on a solid and rigid
foundations to ensure proper vibration and free
operation. The desirable foundation and anchor bolt
design will;
-. accommodate at least the maximum static and
dynamic foundation loads indicated on the
motor outline dimension drawings.
-. have sufficient rigidity to maintain acceptable
alignment after the application of load. Plate Type
-. be free of natural frequencies which are likely to
be excited during normal operation. ( This could
result in vibration problems on the motor.) Fig.2 Type of Foundation Bolt

In some cases where precision is required, a study

of these factors should be conducted to determine
the natural frequencies of the motor support. MOUNTING.
After remove the packaging from the skidding of
the motor; remove the polyethylene shroud; remove
FOUNDATION BOLT the motor from the skidding, the motors should be
There are some different methods of installing the mounted on a flat surface and packed out with
foundation bolt as shown in Fig.2. The methods shims (shim allowance generally 2 -3 mm thick).
depend on the capacity and construction of the The shims should support the maximum length of
motor. each motor foot. It is preferable to use corrosion
resistance shims such as brass or stainless steel,
otherwise "shims swell" due to corrosion resistance
may be detrimental to good alignment. Care should
be taken not to distort the frame during " bolting
down".

REMOVE THE LOCKING DEVICE OF

LARGE MOTORS.
All of large motors are equipped with the device for
preventing the shaft from movement in order to
protect the rolling face of bearing from damages
due to vibration in transit.

This locking device is fitted on the drive side or on

the non drive side. Before connecting motor to a
machine, the fitting bolts should be loosened, and
the fitting device should be taken off.
J-Type

5
3.2 INSPECTION OF INSTALLATION 3.3 MEASUREMENT OF
INSULATION RESISTANCE.
After installation, check should be made for
looseness of bolts and nuts on the terminal boxes,
cooler boxes and so on. At that time, the
foundation and centering of the motors should be
3.3.1 One Minute Test.
checked. These items are normally checked and
reviewed on the erection records. If the motors were stored in very damp
surroundings for a prolonged period, the insulation
resistance of windings to frame should be measured
Check list for inspection of installation at DC power for 1 minute with a low energy source
device (eg Megger).
In case of high voltage circuit, that is 600 V and
1. Outside view of machine above, is measured by 1000 V megger, and low
-. No rusted portions. voltage circuit, less than 600 V, is measured by 500
-. No damaged portions/parts. V megger. Insulation resistance of winding for the
-. Confirmation of caution, name plate. high voltage motor will be converted to 40 based
values by IEEE 43.
The criteria of its value are (kv + 1) Megaohm at
40 for winding, and 1 Megaohm for space heater
in accordance with international standard ( IEEE 43,
JEC 37 etc. ). If the insulation resistance has been
2. Removing of rotor locking device reduced as a result of extreme condition (eg
(If necessary) penetration of water) and has a value less than the
criteria value, the windings must be dried before
connection to supply voltage and operation.

3. Check of no looseness 3.3.2 Polarization Index.

-. End covers.
In case of high voltage circuit, that is 600 V and
-. Terminal boxes.
above, provided insulation resistance is within the
-. Cooler boxes.
acceptable limits, then a polarization index can be
performed.
On windings apply to DC power in accordance with
IEEE 43 between windings and ground; when the
stator coil is tested, the rotor coil and R.T.D leads
4. Check of around foundation are to be earthed.
-. Motor leveling. The insulation resistance at one (1) minutes should
-. Tightness of foundation bolts. be recorded and the insulation resistance at ten (10)
minutes should be recorded.
The polarization index is the insulation resistance
index at 10 minute divided by the insulation
resistance index at 1 minutes. This index should be
greater than 1.
If the polarization index is less than 1, the HHI's
5. Inspection of accessories
service center should be contacted. The windings
-. Thermometers.
may need to be dried before operation.
(Indication check at amb. Temp.)
-. Temperature detectors.
(Indication check at amb. Temp.)

6. Confirmation of centering

6
3.3.3 High Voltage Test. 3.6 CONNECTING TO POWER
This test is intended for detecting the weak points AND GROUNDING
of winding for high voltage machine. The dielectric
test is carried out before the operating the motor, on
windings apply to specified voltage for one(1) Examine the nameplate data to make sure the
minute between the windings and ground. correct power supply. Also check the heater power
where applicable. Check all connections to ensure
that they have not come loose during transport.
Supply voltage : 2E+1000 for the line for Make certain that the correct cable size has been
above 1000 V selected and connect to phase rotation as shown in
E means rated voltage or secondary induction motor terminal box. The motor and control wiring,
voltage in case of the wound rotor ; AC power overload protection and grounding should be done
condition. in accordance with the National Electrical Code and
If AC power is not supplied, apply DC power local requirements.
instead of the power frequency voltage specified In case of the wound rotor, check brushes are "free"
above. The DC voltage level is at least 1.7times of in the holder and pressure of brush is working
AC high voltage test voltage. correctly. Ensure that slipring surface is clean and
free from contamination. Avoid "finger print" marks
on ring surface. To maintain the proper degree of
protection, make sure all gaskets and cover plates
CAUTION ; Cautions in testing as follows are properly fixed and sealed. Any unused entry
-. In case of the wound rotor type, the slip holes should be plugged.
ring and brush support part of the motor are
to be throughly cleaned; and dust and
moisture are to be completely removed
WARNING :
before the high voltage test is started.
-.Ensure that the motor starter (supplied by
-. When the stator coil is tested, the rotor coil
others) is open.
and RTD leads are to be earthed.
-.Make the connections as the required
-. Electricity is to be discharged without fail
rotation.
after the high voltage test has been finished.
-.Drill the cable entry plate (at bottom of box)
to suit your power cable and its fitting.
-.Connect the station ground to one of the
ground pads provided on the stator frame.
3.4 INSPECTION OF LUBRICATION OIL

Before the initial running test, inspection of

lubrication oil is very important, that is,
3.7 SOLO RUN TEST
confirmation of no oil leakage and proper oil level.
Refer to bearing maintenance manual. Before coupling with the load machine, the motor is
normally carried out solo running test.
At initial starting, the motor is inching operated for
approx. 1-2 sec.
3.5 MANUAL ROTATION At that time, inspection of rotation, abnormal noise,
and lubrication condition are checked during the
idling. If these items have any problem, the
If possible, rotate the rotor by manual means to supplied power shall be taken off and checked and
ensure that it is free to move without rubbing or reported in detail..
scraping and to lubricate the bearing surfaces. A The motor is then restarted. The motor is run during
minimum of 10 revolutions is recommended. 1 - 2 hrs. and vibration amplitude on the bearing
housing and bearing temperature are measured and
recorded.

7
3.8 ALIGNMENT Rigid Coupling
In case of the sleeve bearing, when both flanges are
The correct alignment of machinery is very connected to each other, the end play indicator is
important for reducing the stress and vibration of referred to install the flexible coupling in order to
the shaft and the wear of the bearing and coupling. determine the position of the motor.
In case that instructions are given by a coupling
maker, it is recommended that the instructions be Alignment
followed to. Alignment is made to bring the shaft centers of the
motor and machine combined with it into the same
Flexible Coupling line; the parallel and eccentricity are measured
The flexible coupling set forth herein means the one through the coupling. Generally a thickness gauge
which is driven through the rubber brush or the or a taper gauge is used in measuring the parallel,
leather brush, including the gear coupling. In and in measuring the eccentricity, a dial gauge is to
aligning the motor equipped with the sleeve bearing, be fitted to the coupling on one side; the both shafts
an attention is to be paid to the end play of the are to be turned by
motor bearing and to the position of the coupling. 0 deg, 90deg, 180deg and 270 deg; and the dial
Center of the motor bearing end play is indicated by gauge reading is to be taken at the four points as
the end play indicator. The bearing end play can shown Fig.4. The alignment accuracy is to be
be equally divided by setting the end play indicator generally 0.025mm or less(both plate and circle).
to the standard line of the shaft as shown in Fig.3.

Fig.4 Procedure for Alignment

Measurement of Eccentricity
Fig.3 End Play Indicator The both shafts are to be simultaneously turned; the
values shall be obtained from the measurement
made at four points by means of a dial gauge and
are to be recorded ; and the corrected value is to be
CAUTION : In the case that the coupling is used, obtained in the following manners.
it is liable to be considered that the rotor can be
easily moved in the axial direction. In actual fact, 90 degree
however, it hardly slides in the axial direction at
the coupling as torque grows greater. When by
some reason the rotor has undergone some axial 180 deg Circle 0 deg
movement, and the coupling does not provide
enough slip to allow the rotor to return to the
magnetic center of the motor, it will continue to 270 deg
operate with the bearing end in contact with the
shoulder of the journal. (Measuring Point)

8
 B F2

C Circle A G2 Circle E2

D H2

(Measured Value) (Measured Value)

A–C
Corrected value of left and right =
2 Corrected value of left and right =
( F1 + F2 ) - ( H1 + H2 )
=
B–D 2
Corrected value of top and bottem =
2 Corrected value of top and bottom =
(Corrected Value) ( E1 + E2 ) - ( G1 + G2 )
=
2
CAUTION ; The difference between the total
of the measured values at the left and right (Measured Value)
points (A-C) and the total of the measured
values at the top and bottom points (B- D)
should not exceed 0.03mm. Greater difference,
if any, may be caused by the improper fitting of
the dial gauge and the erection of the fitting Belt Connection.
arm. If it is intended that the motor will be direct coupled
through a flexible coupling to a machine, no check
for minimum sprocket diameter will be necessary.
Measurement of parallelism However, if a chain, gear, V-belt, or flat belt drive is
The values at the four points of E1, F1, G1 and H1 used on the output shaft a check should be made.
are to be corrected after measurement made by
means of a thickness gauge at the position where
the both shaft were connected to each other at the
time of eccentricity measurement; and Direction of belt tension.
measurements are to be made again at the points of In case of the motor with the roller bearing, the belt
E2,F2, tension may be applied in the horizontal or the
G2 and H2 after turning the both shafts. vertical direction. In case of the motor with the
sleeve bearing, the belt tension should be applied in
the horizontal direction only.
F1

Alignment of belted drives.

G1 Circle E1 Aligning a belted drive is much simpler than
aligning a direct coupling drive. To check alignment,
place a straight edge across the faces of the drive
and driven sheaves. If properly aligned, the straight
H1 edge will contact both sheave faces squarely.

(Measured Value)

9
 Coupling Balance
The coupling should be dynamically balanced to
G2.5 or better. The motor is dynamically balanced
with a half key fitted, therefore, the proposed
coupling should be balanced accordingly, and the
correct key profile fitted.

Fig.7 Coupling Balance

Fig.5 Alignment of Belt Drive

Frame Distortion Test.

Belt tension.
In addition to ensure the proper alignment of the
The V-belt is to be stretched in the following way. coupling, care should be taken to ensure that the
There is calculated deflection force to be applied motor frame is not distorted during alignment.
perpendicular to the belt at the center of the belt
span as shown in Fig. 6 To confirm that distortion has not occurred, we
recommend the following procedure be adopted ;
1) Align the motor within tolerances as required by
section "alignment".
2) Apply a dial gauge between the motor frame
adjacent to one mounting foot and the foundation,
and set indicator for zero.
3) Loosen hold down bolt and record movement of
dial gauge measurement.
4) Re-torque hold down bolt.
4) Repeat steps 1- 4 for all hold down bolts, one at a
time.

3.9 TEST RUN OF MOTOR.

Fig.6 Belt Tension After coupling with the load machine, the motor is
inching operated at first.
When both motor and load machine show no
abnormality, the motor is restarted with minimum
The drive is properly tensioned when the deflection load. At that time, the current, supplied voltage are
of the belt caused by the deflection force is equal to checked and recorded. While the motor is running
1.6mm for span length of 100mm. If the deflection continuously, the motor vibration on the bearing
forces higher than normal values, this will result in housing are controlled by the curve of Fig.8.
reduced belt life, reduced bearing life and could
cause shaft failure.

10
 4. INSPECTION AND MAINTENANCE SCHEDULE

The following maintenance and inspection recommended the intervals at which at least first
schedules cover the necessary steps for inspection inspection should be carried out if operating
of the motors. conditions are normal. On the basis of the
Since the conditions under which the motors is experience gained with the plant, the inspection
required to operate may differ considerably, the intervals should therefore be selected to meet such
maintenance and inspection schedules can only be conditions as contamination, frequency of start-ups
load etc.

Interval
Inspection and maintenance work Machine part
A B C

A : Daily Inspection
B : First Inspection ; Not later than 6 Months.
C : Following inspection ; Not later than two(2) years (when required, dismantling the machine)

Check the machine for irregular noise and excessive vibration (fig 8)

Where possible measure and record the bearing

temperature

Re-lubricant the grease lub. Bearing

Oil-lub bearing : Change the oil.
Clean and inspect the bearings.
For the intervals of maintenance work, see the
lubrication instruction plate on the machine.

Check the shaft sealing rubber ring for

deterioration

11
 Intervals
Inspection and maintenance work Machine parts
A B C

Where possible, measure the bearing temperature, oil pressure

O
and flow rate

O Check that the oil-rings are operating correctly.

O Check the oil flow, oil level and oil leak.

O O Check the contamination of lub. oil and change the lub. oil
Carry out the following oil change with (normal amb. temp.)
Sleeve(Whitemetal)
O O Self oil lub. : 5000-8000 operating hours
bearing
Forced feed oil lub. : 15000-20000 operating hours.
O Check the axial play

O O Check the shaft sealing for deterioration

O Inspect the bearing surface

Clean and inspect the bearing insulation and insulation of the

O O
pipe.

O O Check the system, connections and piping for leaks

Forced feed oil

O O Check the oil level
lub. System

O O Clean and inspect the oil filters and oil coolers

Check the enclosure is not clogging (blocking) the machine

O O
ventilation

O O Check the gaskets for deterioration.

O O Check the enclosure for deform and damage

O Check the noise-suppression material for damage.

O O Check and clean the external cooling air paths.

Enclosure
O Drain the drain plug, when provided.

O O Replace and clean the air filter, when provided

O O Check the clearances to rotating parts.

O O Check the enclosure for corrosion.

O Check earthing (grounding) terminals.

12
 Intervals
Inspection and maintenance work Machine parts
A B C

Check the enclosure including external cabling conduit

O O
connection for ingress of water or dust.

With loose leads: Check the cable connections are properly

O Junction(terminal) box,
insulated.
terminals
O Check connection for good contact.

O Check terminal insulators for damage.

Measure and record the winding temperature detectors, when

O
provided.

O O Check and record the insulation resistance of windings.

O O Clean the windings, as far as possible.

O For totally enclosed machines, clean the winding if required.

For the wound rotor machine with continuous sliding brushes Stator winding
and open enclosure machine;
O
Clean entire winding, cooling air paths including the
corepacks - airduct.

O Check the slot wedge for tight fit.

Check condition of winding insulation, including end

O
connections.

O Check winding, bracing for tightness.

O O Clean the winding, as far as possible.

O For totally enclosed machine, clean entire winding if required.

For the open enclosed machine:

O Clean entire winding, cooling air paths including the
corepacks-airduct.
Squirrel-cage rotor
Check cage bars and end rings for fractures and loose soldered
O
connection.

O Check cage for axial displacement.

Check end rings and support rings and the associated locking
O
elements for tightfit.

13
 Intervals
Inspection and maintenance work Machine parts
A B C

O O Check and record the insulation resistance of windings.

O O Clean the winding, as far as possible.

O For totally enclosed machines, clean the winding if required.

For the machine with continuous sliding

brushes or open enclosure machines;
O
Clean entire winding, cooling air paths including the
corepacks-airduct.
Wound rotor
Winding
O Check the slot wedge for tight fits.

O O Check the winding-end for deposits of oil and carbon dust.

Check the banding for tightness, and check for any loose
O
soldered joints.

Check bracings and wedges of winding end, and ring circuits

O
for tight.

Check leads of stator winding, slipring leads f wound rotor Leads on stator
O
machine and their locking lements for tight. and rotor

O Vent the cooler while in operation(monthly)

O Where possible, measure and record the water temperature.

Water air cooler
O O Check the cooler, connection and piping for leak. (heat exchanger)
O O Check and clean the cooler.

O O Inspect the corrosion protection (when provided)

Compare brush noise, sparking and contact marking with

O
conditions found in previous inspection(monthly)

O O Check the brush length and replace as necessary

O O Check the brushes can move freely in the brush holders. Slip ring, Brushes

Check the pigtail(connection) leads for discoloration and

O O
damage.

O O Take out and clean the air filter

14
 Intervals
Inspection and maintenance work Machine parts
A B C

Inspect contact surfaces; They should be bright, free from

O O
rubbing or threading and have a uniform skin.

Remove deposits of carbon dust from the slipring chamber, slip

O O
ring and brush holders.
Slip ring, Brushes
O Check the holder for damage. (cont'd)

Check the tight fitness of slip ring, including separators and

O
fixing studs.

O O For arm type brush holder, check brushes for tight screwed.

O Avoid continuously sliding the brushes.

O Avoid continuously rotate the thrust roller.

Check the mechanism, including the sliding surface of the
O O
shaft to short-circuit ring are free form dust.

O O Check the abnormality of thrust roller and limit switch.

O O Check the sliding surface of short-circuit ring for corrosion. Brush lifting
Mechanism
O Check setting of short-circuit ring to shaft.

O O For arm type brush holders, check brushers for tight screwed.

O O Re-lub. the reduction gear assembly.

O O Check the manually operated gear unit for damage.

Axial rotor placement should be kept by indication the shaft on

O
its magnetic center.

O O Check and adjust the belt tension.

O O Check the external and internal fan for damage or corrosion.

O Check rotor alignment.

Shaft and coupling
O Check the balancing weight for tight fit.

O Check all coupling bolts and locking element for tight fit

O Check the oil leakage of gear coupling.

O Check the shaft keys for tight fit.

15
 Intervals
Inspection and maintenance work Machine parts
A B C

Check the monitoring instruments and contact device for Monitoring

O
proper function. instruments.

O O Check the brush length and replace as necessary.

Ground brush
O Check the holder for damage.

Fig. Values of Vibration

16
 5. MAINTENANCE OF WINDINGS

5.1 GENERAL
be dry, especially if blowing with against insulation.
It is important in keeping the machines in good Moisture condenses and accumulates in air lines
conditions to perform periodical maintenance to and hoses.
prevent the insulation form being damaged by Care should be taken to assure this has been
moisture, dirt and other foreign matter. completely dried out before using the compressed
air on insulation.
If the machines has been operated under higher Compressed air should never be more than 3
humidity conditions, not used for a long time, or 4Kg/cm2 pressure. Higher pressures can damage
subjected to sudden changes of ambient insulation and force dirt under loosened tape.
temperature, the insulation may have absorbed Care should be taken not to blow loosened dirt into
considerable moisture, causing deterioration of the inner recesses where it will be difficult to remove
insulation. and where it might obstruct ventilating
ducts.
Other causes of insulation breakdown include
operation of the machines at an overcurrent
exceeding the rated current, use under an ambient
WARNING : Wear goggles when blowing dirt out
temperature exceeding the specified values as may
be possible with a heated air blower which directly with compressed air and be careful not to direct the
radiates heat over the machines, and overheated air jet toward others. Failure to heed this warning
windings resulting from dust accumulating on the
core packs and coil ends. All of the above items can be result in injury to the eyes.
impair insulation and reduce the life of the machine.

Cleaning by means of solvents.

5.2 CLEANING OF COILS Solvents are usually required to remove grease and
The method selected will depend on the type of oil dirt. A lint-free cloth wet with solvent may be
machines, type of insulation, kind of dirt, and other dipped in the fluid.
condition and circumstances. Petroleum distillates are the only solvents
recommended for cleaning electrical apparatus.
Cleaning by wiping with cloth. These solvents, classed as Safety-Type Solvents,
have a flash point above 37.8 deg and are available
Wiping cloths can be used for cleaning when the
from most oil companies and other supply sources
machine is small, the surfaces to be cleaned
under various trade names;
accessible, and the dirt to be removed is dry. -.Mineral spirits, cleaner's naphtha, and similar
Waste should not be used as lint will adhere to the
products with a flash point above 37.8 deg.
insulation and increase the collection of dirt,
-.Gasoline, naphtha, and similar grades must not be
moisture, and oil. This is particularly objectionable used for cleaning. They are highly volatile and
on high voltage insulation as it tends to cause
present a great fire hazard.
concentration of Corona.

Cleaning by means of compressed air.

Compressed air, blowing out dirt with a jet of air, is
usually effective especially where dirt has collected
in places that cannot be reached with a wiping cloth.
Cleaning can be done more quickly with
compressed air than a with wiping cloth. especially
on the large machines. If blowing with compressed
air results in simply transferring dirt from one place
to another on the machine, little is accomplished.

There are a number of precautions to be observed

when using compressed air; Air being blown should
17
 WARNING : Avoid prolonged or repeated Additional resistance heaters should be controlled
contact with petroleum distillates or breathing by a temperature controller with a probe adjacent to
their vapors. These solvents can cause severe the winding at the top of the motor. The temperature
skin irritation, are toxic, and are readily should be set for 100 deg to 120 deg. The drying
absorbed into the system. Failure to heed this process will take approximately 10 - 16 hours once
warning can cause severe personal injury or the correct temperature is achieved.
death.
Do not use carbon tetrachloride or mixtures < Key Points to Remember.>
containing carbon tetrachloride for cleaning
1. Heaters must be the "black heat" type otherwise
purposes. Carbon tetrachloride and its fumes
the insulation might be burnt.
are highly toxic. Failure to heed this warning
2. The motor may need to be covered by some
can result in serious illness or death.
thermal insulation to retain the heat.
Avoid excessive contact with cleaning solvents
3. A vent opening should be placed in the tip of the
and breathing of their vapors. Some solvents
thermal insulation tent for the evaporated moisture
are extremely toxic and readily absorbed into
to escape.
the system.
4. Sufficient space should be allowed between the
heaters and any winding insulation so as not to
generate local excess heating of the winding
insulation.
5.3 USE OF SPACE HEATERS
When the motor is operating, its interior is not 2) The internal heat method
humid, and in dry condition, but absorbs humidity With this method, the heat is applied by passing
at rest. current through the windings to generate heat.
In order to prevent absorption of humidity, the Extreme caution should be exercised using this
space heater installed inside frame is to be method so that you do not damage the internal
immediately energized after the motor comes to insulation before the windings are up to optimal
stop, and temperature.
the temperature inside of the motor is to be
controlled 3 to 5 deg higher than the ambient WARNING : This method should only be used
temperature.
If no space heater, it is considered that the 100 - 150 if all winding resistance is greater than 1 Meg
W incandescent lamp may be used. ohm.

5.4 DRYING INSULATION

Should the insulation resistance for the winding < Key Points to Remember.>
have poor insulation resistance due to the ingress of 1. Remove brushes and short the ring together with
moisture, then the windings must be dried to a copper link in case of a slip ring motor(wound
improve the insulation resistance to the minimum rotor)
specified value before the application of insulation 2. Connect an AC supply voltage to the stator
resistance. The preferred method of drying windings. The applied voltage should be
windings is the external heat method. The approximately 12 %. In this case that the stator
alternative is the internal heat method. nominal voltage is 3300 volts and since 415 V AC
represents 415/3300 x 100 = 12.5%, this will be a
convenient supply voltage, In this case that the
1) The external heat method. current taken from the supply would be typically
*. Temperature controlled oven. 70% of the full load rated current.
The best method is to dismantle the motor 3. The power supply should be controlled with a
(including bearing) and place the motor in a temperature controller operating from the internally
temperature controlled oven at between 110 deg connected RTDs supplied by the motor
max. for 8 - 10 hours depending on oven efficiency manufacturer.
to remove moisture. 4. The shaft should be locked tp prevent rotation.
*. The alternative external heat method is to remove 5. Set the temperature controller for 110 deg
endshields and covers, connect the anti- maximum.
condensation heaters, fit additional "black heat" 6. Drying will take approx. 8 -12 hours once the
resistance in and around the motor. windings have reached 100 deg. The windings
should take 6 -8 hours to heat up to 110 deg.

18
Determination of dried insulation Notes on drying insulation.
During the drying process the insulation resistance 1) A temperature controlled oven should be used if
should be checked with a 500 Volt(low voltage the windings have been completely immersed in
machine) or 1000 Volt(only high voltage machine) water.
DC low energy source meter(eg, megger) and then 2) Should the windings contain contamination, the
recorded after 1 minute. windings should be properly cleaned before
This process should be repeated every hour until the attempting to dry windings. Contact your factory
results show the winding is dry. representative for further advice.
3) All processes for drying of insulation are
Once the winding is completely dry, the insulation specified processes and should be performed under
resistance will stabilize. After the windings cool the supervision of qualified personnel. Failure to
down the insulation value should increase. observe proper procedures may result in permanent
damage to the insulation or winding system. For
further advice contact your factory representative.

Fig.9 Change in Insulation Resistance

19
 6. MAINTENANCE OF SLIPRINGS, BRUSHES
& BRUSH HOLDERS.

6.1 SLIPRINGS
the film build up on the rings.
Correction : The contamination should be removed
Good Conditions and a new set of brushes fitted and bedded in. It is
The slipring must run true to the centre of rotation. preferred that sliprings be cleaned with a dry lint-
The maximum permissible TIR(Total Indicator free cloth. If required, some "non residue/non-
Runout) must be no greater than 0.02mm. If the corrosive" electrical cleaning solvent could be used.
TIR is greater than this, the sliprings must be
machined true. The surface of the sliprings must be
WARNING ; Electrical solvent, if inhaled or
a smooth finish. The slipring will normally show a
running band under the brush contact area. This can absorbed through the skin, can be dangerous to
be from light straw in colour to dark brown (almost your health. Please refer to the manufacture
black). The most normal colour is "light brown" .
The surface should be consistent in colour around safety information for proper advice.
the periphery and across the brush track. Sparking
should not be evident during operation and the rings
should be dry with no signs of contamination. c) Corrosion of brush rings. This condition may
occur if the motor has been at standstill for a long
time (eg, after extended storage).
Correction ; This should be removed by using a fine
"commutator" stone available from most service
shops or brush suppliers. Rotate the motor either
with a small pony motor or run the motor on no
load and uncoupled with the sliprings short
circuited after accelerating to full speed (do not
start without rotor resistance starter).

WARNING ; Although no voltage is present

across the rings during this operation you
Fig.10 Examples of Good Condition
should ;
-. ensure the rings cannot open circuit, therwise
The Brush Running Band is a film on the ring basically
high voltages could be present.
consisting of copper oxide and carbon. This film occurs
-. follow electrical safety rules.
naturally during normal operating and it is essential for
-. this procedure only be performed by
good brush and ring condition. Do no try to remove it.
qualified and experienced personnel
The film is easily maintained by ensuring the area is free
from contamination and the machine is properly loaded.

d) Threading. If threading occurs, brush

Poor Conditions optimization should be corrected first.
Poor ring condition can be caused by several ➀ Light threading can be corrected the same
conditions. The common causes of poor ring way as "corrosion".
conditions are ; ➁ Heavy threading should be corrected by
a) Brush loading is not optimum.Correction : See machining the sliprings.
Section "Optimizing Brush Wear".
e) Out of round rings. This must be corrected by
b) Contamination : Such as oil, salt air, H2S or
machining the sliprings.
silicone vapours (even from silastic) may destroy

20
 6.2 BRUSH AND BRUSH HOLDERS

General.
The brushes must make good contact with the
slipring surface. To ensure this, they must move
freely within the brush holder and pressure lever
must apply the correct pressure. The brush holder
assembly is fixed. To replace brushes, unclip the
pressure level and undo the "pigtail" from the
holder assembly.

Fig,11 Examples of Poor Condition

Machining sliprings.

Method 1 - Preferred :
Dismantle the motor and remove bearings. Place
the rotor in a lathe, centre bearing journals true and
machine sliprings.

Method 2 - Alternative : Fig.12 Brush Holder Assembly

The rings be removed from the shaft with a puller
which can be attached to the hub of the slipring
assembly. Access to the rings can be gained by If satisfactory brush life has been obtained, replace
removing the drive end endshield and carefully the brushes with the same grade as the original.
disconnecting the rotor leads. After the rings have Always make sure brushes are bedded in after
been removed they can be machined in a lathe. replacement.

Method 3 - Alternative : It may be possible that brushes wear out quickly. A

Some motor repair shops offer on site machining. common cause for this is a light load or brushes not
This is not a preferred method, but may be required making proper contact with the rings. In this case
for emergency repair. If on site machining is consult Section " Brush Optimization" or your
performed, the following precautions should be carbon brush supplier.
adhered to ;
i) replace brushes after machining operation is If brush holders need replacing, the brush assembly
complete. may be removed by taking off the drive end
ii) all ring swarth to be removed from slipring endshield. The brushes are to be changed when they
enclosure. have work down to about 1/3 of their original
iii) this operation should only be performed by length. The wear is not the same for all brushes. It
experienced personnel. is important to keep the brush housing clean and
grease from excess carbon dust. Clean out housing
After machining, the rings should be kept clean and periodically, using vacuum cleaner and clean, dry
free from finger prints until ring film has developed compressed air(max. 4 bar) where possible.
during operation.

21
 `The brush surface contact area must not be less
WARNING ; Cleaning while operating is not
than 80% of the surface of each individual brush.
recommended, except in case of experienced During the initial run, if possible, it is desirable to
operators. High velocity compressed air can lift apply some bedding chalk to the rings before
entering under the brush surface, this will promote
brushes or short pigtails together. the final bedding in of the brush.

Bedding Brushes NOTE ; Bedding chalk is usually available from

When new brushes are fitted they should be bedded
in. If the sliprings wear, the diameter can vary, so most service shops or carbon brush suppliers.
the diameters of the brush face and the diameter of
the rings may not be exactly the same. So, in all
cases, brushes should be bedded in.

Fig. 13 'Bedding' Brushes In

Some abrasive sand paper should be placed around

the slipring and the brush fitted in the holder with
the tensator in place. The abrasive is drawn back
and forth until all of the brush is in contact with the
ring.

Fig.14 Example of Poor Surface Profile

22
 7. TERMINAL BOX for High-Voltage Supply

7.1 GENERAL
01 Terminal box body
Transport, Storage 02 Packing
Always keep the cover and the cable entries tightly 03 Cable holder
closed. 04 Cable grommet
05 Insulator
7.2 DESCRIPTION 06 Connector
07 Packing
1) Application 08 Terminal box cover
In the terminal box, the connection is made between 09 Gland plate
the stator winding and the supply cable from the 10 Packing
system. The terminal box is mounted on the 11 Terminal lug
machine frame at an easily accessible location. 12 Earthing terminal
Fig. 15 Construction of terminal box
2) Construction (Example, delivered design may deviate in details)
The typical construction is shown in Fig. 15
3) Degrees of protection
The terminal boxes comply at least with degree of
protection IP55 as per IEC 34-5.

4) Connection part for main

terminals
The connection part is suitable for connection with
cable lug depending on the equipment complement.

7.3 INSTALLATION

1) Termination

General
Ensure that the power supply agrees with the rating
plate data. The supply cables should be matched to
the rated current and plant-specific conditions(e.g
ambient temperature, method of cable installation
etc.). Connect the supply-cable conductors.

Connection by means of cable lugs

The size of cable lugs must be matched to the size
of the supply cable. Use appropriate units with
sufficient current-carrying capacity.

Direction of rotation
When the power supply phase conductors L1, L2,
L3 are connected to terminals U, V, W respectively,
the motor will rotate in a correct direction. If the
connections to any two terminals are reversed, i.e. if
lines L1, L2, L3 are connected to terminals V, U,
W(or U, W, V or W, V, U) respectively, the motor
will rotate in a reverse direction.

Installing and entering the cable

The following steps are recommended for split
entry :
- Cut the sealing insert so that its opening is some

23
millimeters smaller than the cable - Connection leads are not subject to strain and the
diameter. insulation cannot be damaged.

- Introduce the cable into the cable gland. In the - Unused entry openings are closed off by suitable
case of very small cable diameter the cable plugs.
diameter should be increased by applying insulation
tape at the securing point to ensure concentric - All seals and sealing surfaces are in perfect
positioning of the cable in the sealing insert. condition. If sealing of the joints is effected by
metal-to-metal joints only, the surfaces should be
- Provisionally attach the terminal box cover in cleaned and thinly regreased.
order to check whether perfect sealing is
achieved both at the flange surfaces and at the entry - Entry glands fulfill all requirements concerning
point with sufficient prestressing. If this is not the degree of protection, conditions of installation,
case enlarge the sealing insert cut out or adjust the permissible lead diameter.
cable diameter by means of insulation tape. The
securing bolts should then be tightened alternately
in steps. 7.4 OPERATION

- Unused entry openings always must be closed off Safety advice

by suitable plugs. Covers to prevent accidental contact with live or
These must rotating parts, and those required for proper air
guidance and thus effective cooling should not be
- be of permissible resistant material, opened during operation. During maintenance or
inspection work in the immediate vicinity of the
- conform to degree of protection IP55, terminal box or of the rotating machine suitable
measures should be taken to protect personnel
- be tightened so that they can be removed only by against hot gases escaping under short-circuit
means of a tool. conditions.

Earth connection 7.5 MAINTENANCE

A earth terminal for connecting the cable earth
conductor is provided in the terminal box. 1) Safety advice
Before any work is started on the machines,
The minimum connection cross-section of earth particularly before covers are removed from live
connections should be selected according to IEC parts, make sure that the machine/plant has been
34-1 with reference to live conductors. correctly disconnected from the power supply.
Make sure in any case of installation and Please adhere to the general "5 safety rules"
maintenance work that the equipotential bonding is
maintained. - Isolate the equipment from the power supply,

Final checks - Provide a safeguard to prevent unintentional

Before closing the terminal box, check the reclosing,
following :
- Verify safe isolation from the supply,
- Conductor connections and, if applicable, the
circuit connections have been made correctly. - Earth and short-circuit,

- Interior of the terminal box is clean and free from - Provide barriers or covers for adjacent live parts.
remainders of cable material.
2) Tightness, high-current loading
- All terminal screws and the appropriate cable The terminal boxes should be inspected regularly to
entry parts are firmly tightened. ensure that they are tight, that the insulation in
undamaged and that the connections are firmly
- Clearance in air of 8 mm at 500V, 10 mm at attached.
660V, 14 mm at 1kV, 60 mm at 6kV, If the terminal box is subject to extremely high
100 mm at 10kV are maintained. Remove any current loading it is recommended that the
projecting wire ends! insulators, connecting parts and cable connectors be
checked.
24
If any dust or moisture has penetrated the terminal
box, clean and dry out the terminal box. The seals
and sealing surfaces should also be checked and the
cause of faulty sealing should be remedied.

3) Tightening torques
Max. tightening torques for current-carrying bolted
joints is given in below table.

Screw M5 M6
Strength class 8.8 8.8

Tightening Torque
8.0 8.0
(Nm)

M8 M10 M12 M16

8.8 8.8 8.8 8.8

20 40 70 170

* The tolerance of tightening torques will be 10%.

25
 8. TERMINAL BOX for Auxiliary Circuits

8.1 GENERAL
01 Terminal box body
Transport, storage 02 Packing
Always keep the cover and the cable entries tightly 03 Support ring
closed. 04 Rail
05 Terminal block
8.2 DESCRIPTION 06 Cable grommet
07 Earthing terminal
1) Application 08 Packing
The terminal boxes are employed for connection of 09 Terminal box cover
auxiliary circuits. Fig. 16. Construction of terminal box
If specially ordered for anti-condensation heater, an (example, delivered design may deviate in details)
auxiliary terminal box for anti-condensation heater
may be supplied. 3) Degrees of protection
The terminal boxes comply at least with degree of
2) Construction protection IP55 as per IEC 34-5.
The typical construction is shown in Fig. 16.
8.3 INSTALLATION

1) Termination
When making the connections of auxiliary circuits
note wiring diagram for auxiliary circuits
documented in the approval specification.
The cross-section of a supply cable should be
selected on the basis of the rated current and plant-
specific conditions.
The connection terminals for auxiliary circuits are
suitable for conductor cross-sections of at least
2.5mm2.
The ends of the conductors should be stripped in
such a way that the remaining insulation reaches
almost up to the terminal.

2) Installing and entering the cable

In addition to the information given for cable
selection and preparation, the following specific
notes apply, depending on the type of entry fitting
used :
To maintain the degree of protection IP all screwed-
in glands must be firmly tightened and sealed by
suitable measure, e.g. by means of an adhesive or
by fitting sealing ring. The same measures are
required when fitting screwed-in plugs.
The center rings of screw glands included in the
scope of supply are always screwed in place, fixed
in position and sealed in accordance with degree of
protection IP55 by use of LOCTITE. These glands
also are fitted with blind washers for transport
protection.
For adapting the cable diameter to the gland
conditions it may be necessary to apply a layer of
insulation tape to the leads to enlarge its overall
diameter or to cut out some rings of the sealing
insert. With extreme lead diameter it may be

26
necessary to replace the glands by those of
appropriate dimensions.
Entry plates of terminal boxes may be supplied
undrilled in order to allow selection of cable entry
screw glands, whose design, number and size are
suitable for the cables employed.
The entry elements should be selected so that

- they are suitable for the cable diameter,

- they conform to the degree of protection,

- they are suitable for the installation conditions.

The supply leads-particularly the protective

conductor-should be laid loosely in the terminal box
with an extra length to protect the cable insulation
against splitting.
Unused entry openings always must be closed off
by suitable plugs.
These must

- be of permissible resistant material,

- conform to degree of protection IP55,

- be tightened so that they can be removed only by

means of a tool.

3) Earth connection
A earth terminal for connecting the cable earth
conductor is provided in the terminal box.

27
 9. ANTI-CONDENSATION HEATING with Heating Tube

9.1 DESCRIPTION

1) Application
Anti-condensation heaters fitted in electrical
machines warm the air inside the sstationary
machine to a temperature above that of the
surroundings, thus effectively preventing moisture
condensation.

2) Construction

The typical constructions are shown in Fig. 17, 18

and 19. 01 Insulation materials
02 Heating conductor
03 Heatomg pipe
04 Lead cable

Fig. 19 Strip type anti-condensation heater for

explosion-proof machines with "increased safety"
(example, delivered design may deviate in details)

The heating tube has a heating conductor which is

embedded in insulating material and arranged
inside a corrosion-resistant metal tube. The tube
ends are sealed to prevent the ingress of moisture.

3) Installation
01 Insulation materials The anti-condensation heater consists of one or
02 Heating conductor more tubular heating elements connected together.
03 Heatomg pipe These heating tubes are combined to form units and
04 Lead cable
are installed in the stator frame. The arrangement
constitutes the so-called "stabilized design", i.e. the
Fig. 17 O type anti-condensation heater heating temperature stabilizes itself at the rated
(example, delivered design may deviate in details) voltage thanks to the optimum balance of heater
rating and heat dissipation. Special temperature
monitoring devices are therefore not necessary. This
applies to explosion-proof versions as well.

9.2 INSTALLATION

1) Connecting the supply cable

The heater connections are brought to terminals
which are located in a separate terminal box and
may be made without cable lugs.
Connection must be made in accordance with
wiring diagram documented in the approval
specification. Examine the data plate to see that the
01 Insulation materials voltage and the power of the heating agree with the
02 Heating conductor
main supply. The supply connection of the heaters
03 Heatomg pipe
04 Lead cable
must be interlocked with the main breaker of the
machine to ensure that the heaters are switched off
when the machine is running and switched on once
Fig. 18 U type anti-condensation heater the machine has come to a standstill.
(example, delivered design may deviate in details) Through appropriate series connection of the

28
heating tubes, even the temperature of explosion
-proof machines can be limited such that these
machines meet the requirements of "stabilized
design" and do not require any additional
temperature monitoring measures. For this reason,
no changes may be made in the original heating-
tube connection!

2) Insulation testing
The heater may only be put into operation if the
specified minimum insulation value of 0.5
Mohm is obtained from measurement of the
insulation resistance with the heater connected.
For the period after commissioning of machines
equipped for anti-condensation heating, it is
assumed that either the machine itself is in
operation or the anti-condensation heater is heating
the stationary machine.

9.3 MAINTENANCE

1) Safety advice
The anti-condensation heater is switched on when
the machine has come to a standstill. Therefore, it
must be switched off before any protecting cover is
opened for maintenance work.

2) Cleaning
With respect to maintenance, occasional cleaning
performed during routine maintenance of the
machine and the replacement of any damaged parts
is sufficient.

3) Repairs
Should replacement of the heating tubes become
necessary use the same type of heaters. Install the
new tubes securely and lock the fixing elements.
The heating tube units in explosion-proof machines
may only be replaced as a whole and must be
purchased as whole preformed units to suit the
particular application. If repairs and modifications
to models covered by the certificate for these
machines are not performed in a HYUNDAI
workshop, an acceptance inspection by an
authorized engineer is necessary. If modifications
not covered by the certificate are made, the machine
must be newly certified.

29
 10. MAINTENANCE OF BEARING

10.1 FLANGE-TYPE SLEEVE BEARING If the bearings are fitted with thermometers for
(Ring Lubrication System) checking the bearing temperature, fill the
thermometer well in the upper bearing shell for
1) Mounting thermofeeler with oil to improve heat transfer and
The flange-type sleeve bearings of electrical top up with oil every time the lubricating oil is
machines are of the split type. They are ring- changed.
lubricated and are subject to the following
instructions supplementing and modifying the 3) Dismantling, Assembling
operating instructions of the machine: When dismantling the machine the lower part of the
Corresponding to the operating conditions the bearing housing need not be unscrewed from the
sleeve bearings of new machines have a favorable end shield, When opening the bearing housing,
bearing clearance which should not be changed. locate before, if on which side of the machine the
Also scraping (spot-grinding)is not allowed to do adjusting shims.(upper and lower parts)are installed.
not make worse the antifrictional qualities. These shims must be installed at the same place
It is recommended that the contour of the when assembling the machine. Exceptions are
transmission element remains within the hatched possible if the stator core was changed. Drain the
range (see Fig.19) to remove the upper part of the oil, take off the upper part of the bearing housing
bearing housing for maintenance without removing and the upper bearing shell, lift the shaft very
the transmission element. slightly and turn out the lower bearing shell and the
Before the machines are aligned and commissioned, sealing rings in peripheral direction. The oil ring
the bearings should be filled with lubricating oil, can be withdrawn by holding it at an inclined
because the machines are delivered without oil in position to the shaft.
the bearings. (Oil type is indicated on the name If only slight damage has occurred to the bearing
plate for bearing) surface, it may be re-conditioned by scraping as
long as the cylindrical shape of the bore is
2) Oil Change maintained, so that a good oil film can form. The
Check the bearing temperature regularly. The lining must be renewed if more serious damage is
governing factor is not the temperature rise itself, found. The oil pockets and grooves of the new
but the temperature variations over a period of time. lining or scraped shell should be cleaned and
If abrupt variations without apparent cause are finished with particular care
noticed., shut down the machine and renew the oil.
The lubrication oil indicated on the data plate is
used for starting up the machines at an ambient
temperature of above +5 .At lower temperatures
(to about -20 ), it is sufficient to preheat the oil. If
the ambient temperature are below -20 another
type of oil according to the special conditions is
used. Do not mix oils of different grades.
Recommended oil changing intervals are about
3000 and 6000 operating hours in the case of
intermittent and continuous duty. When cleaning,
first flush the bearings with kerosene and then with
oil. Pour in the kerosene and oil through the top
sightglass hole. Leave the drain open until all the
kerosene has been removed and clean oil runs out.
Now plug the drain and fill the bearing with oil up
to the centre of the lateral inspection glass.
When the machine has run up to speed, check the
oil ring through the top inspection glass to see that
it rotates correctly, and check the bearing
temperature, Should the bearing temperature not
drop to the normal value after the oil change, it
recommended that the surfaces of the bearing shells Fig. 20 Oil pockets and oil grooves
be inspected.
30
The replacement bearing shells are delivered by the
works with a finished inner diameter. Only if the
bearing shells were delivered unfinished, the inner
diameter is 1mm smaller than the finished diameter.
Oil rings which have become bent through careless
handling will not turn evenly. Straighten or replace
such rings. Replace any damaged sealing rings.

31
 1. Screw plug(thermometer mounting)
2. Inspection glass
3. Sealing ring for 2
4. Sealing ring for 1
5. Bearing housing, upper part drive end
6. Cylindrical pin
7. Sealing ring, upper half, drive end
8. Guide pin to prevent twisting
9. Upper bearing shell, drive end
10. Oil ring, drive end
11. Lower bearing shell, drive end
12. Bearing ring, lower half, drive end
13. Sealing ring, lower half, drive end
14. Taper pin
15. Guide pin to fix bolted parts
16. Sealing ring for 17
17. Drain plug
18. Bearing housing, upper part, non-drive end
19. Sealing ring, upper half, non-drive end
20. Upper bearing shell, non-drive end
21. Oil ring, non-drive end
22. Lower bearing shell, non-drive end
23. Bearing housing, lower part, non-drive end
24. Sealing ring, lower half non-drive end
25. Upper adjusting shim, drive end
26. Sealing cover drive end
27. Lower adjusting shim, drive end
28. Upper adjusting shim, non-drive end
29. Sealing cover, non-drive end
30. Lower adjusting shim, non-drive end
31. Protective cap
32. Pressure compensation opening

Fig. 21 Ring-lubricated flange-type sleeve bearings(examples, delivered design may deviate in details

32
10.2 FLANGE-TYPE SLEEVE BEARINGS glass.
(Forced Lubrication System) If the bearings are fitted with thermometers for
checking the bearing temperature, fill the
1) Mounting thermometer well in the upper bearing shell for the
These flange bearings of electrical machines are of thermofeeler with oil to improve heat transfer and
the split type. They are lubricated by and oil ring top up with oil every time the lubricating oil is
and are provided for additional forced lubrication. changed.
They are subject to the following instructions In the case of insulated bearings, make sure that the
supplementing and modifying the operation insulation is not bridged by the tubes; interrupt the
instructions of the machine: Corresponding to the electrical conductivity of the tubes near the bearings,
operating conditions the sleeve bearings of new e.g. by installing oil-resistant fittings of plastic
machines have a favorable bearing clearance which material or hoses of rubber or plastic material.
should not allowed to do not make worse the Switch on the oil pump before starting up the
antifrictional qualities. machine. The use of a pump driven from the shaft
of the main machine is permitted only in special
It is recommended that the contour of the cases, i. e. when the acceleration and coasting times
transmission element remains within the hatched are short.
range to remove the upper part of the bearing
housing for maintenance without removing the 2) Oil change
transmission element. Check the bearing temperature regularly. The
Before the machines are aligned, the bearings governing factor is not the temperature rise itself,
should be filled with lubricating oil (oil type is but the temperature variations over a period of time,
indicated on the name plate for bearing), because if abrupt variations without apparent cause are
the machines are delivered without oil in the noticed, shut down the machine and renew the oil.
bearings. Recommended oil changing intervals are about
Connect the bearings to the oil pump, oil tank and 20,000 operating hours. After the machine is
cooler before commissioning the machines. No come to a standstill and the old oil is drained out of
reducers must be fitted in the piping. Install a the bearings and oil tank operate the oil pump with
regulating orifice on the oil supply line to protect kerosene for a short time and then with oil to clean
the bearing from flooding. If the oil pump fails, the the bearings. the oil pump, the oil tank, the cooler
lubrication maintained by the oil ring is effective and the pipe lines. Pour in the kerosene and then the
for about 15 to 30 minutes, provided the oil oil through the filling opening of the oil tank.
contained in the bearing does not drain away. To Leave the drains open from time to time until all the
prevent this, connect the oil discharge tube on that kerosene has been removed and clean oil runs out
side where the oil rings moves downwards into the of the bearings and oil tank. Now, plug the drains
oil. In addition to this, install a non-return valve in and fill the tank with oil. Should the bearing
the oil supply line. As an alternative, the oil 100 temperature not drop to the normal value after the
mm high, to raise the level of the oil in the bearing. oil change, it is recommended that the surfaces of
Oil discharge tubes must terminate flush with the the bearing shells be inspected.
inside surface of the bearing housing to prevent the
oil rings from rubbing against the tubes. 3) Dismantling, Assembling
Fill the oil tank with lubricating oil indicated on the When dismantling the machine the lower part of the
data plate. This oil is used for starting up the bearing housing need not be unscrewed from the
machine at an ambient temperature of above +5 . end shield. When opening the bearing housing,
At lower temperatures preheat the oil. It is locate before, if and on which side of the machine
recommended to use a control system adjusted in the adjusting shims(upper and lower parts)are
such a manner to have an oil temperature of 15 to installed. These shims must be installed at the same
place when assembling the machine. Exceptions are
20 in the tank and to have a preheated oil flow
possible, if the stator core was changed. Drain the
through the cold bearings for 5 to 10 minutes before
oil, take off the upper part of the bearing housing
starting up the machine. Do not mix oils of
and the upper bearing shell, lift the shaft very
different grades.
slightly and turn out the lower bearing shell and the
The necessary pressure of the oil entered the
sealing rings in peripheral direction. The oil ring
bearings and the oil flow rate are indicated on the
can be withdrawn by holding it at an inclined
data plate. Adjust to these values when starting up
position to the shaft.
the machine for the first time and correct them
If only slight damage has occurred to the bearing
when the bearing has attained its normal running
surface, it may be re-conditioned by scraping as
temperature. The oil in the bearing housing must
long as the cylindrical shape of the bore is
not ascend over the center of the lateral inspection
33
maintained, so that a good oil film can form. The
lining must be renewed if more serious damage is
found. The oil pockets and grooves of the new
lining or scraped shell should be cleaned and
finished with particular care.
The replacement bearing shells are delivered by the
works with a finished inner diameter. Only the
bearing shells were delivered unfinished, the inner
diameter is 1mm smaller than the finished diameter.
Oil rings which have become bent through careless
handling will not turn evenly. Straighten or replace
such rings. Replace any damaged sealing rings.

34
 1. Screw plug(thermometer mounting)
2. Inspection glass
3. Sealing ring for 2
4. Sealing ring for 1
5. Bearing housing, upper part drive end
6. Cylindrical pin
7. Sealing ring, upper half, drive end
8. Guide pin to prevent twisting
9. Upper bearing shell, drive end
10. Oil ring, drive end
11. Lower bearing shell, drive end
12. Bearing ring, lower half, drive end
13. Sealing ring, lower half, drive end
14. Taper pin
15. Guide pin to fix bolted parts
16. Sealing ring for 17
17. Drain plug
18. Bearing housing, upper part, non-drive end
19. Sealing ring, upper half, non-drive end
20. Upper bearing shell, non-drive end
21. Oil ring, non-drive end
22. Lower bearing shell, non-drive end
23. Bearing housing, lower part, non-drive end
24. Sealing ring, lower half non-drive end
25. Upper adjusting shim, drive end
26. Sealing cover drive end
27. Lower adjusting shim, drive end
28. Upper adjusting shim, non-drive end
29. Sealing cover, non-drive end
30. Lower adjusting shim, non-drive end
31. Protective cap
32. Pressure compensation opening
33. Oil supply tube with orifice
34. Oil discharge tube with sight glass

Fig. 22 Flange-type sleeve bearing for forced-oil lubrication

(examples, delivered design may deviate in details)

35
10.3 ROLLING- CONTACT BEARING lubrication to special instructions, e.g. where there
is an extreme coolant temperature or aggressive
1) Mounting vapours. The old grease from several regreasing
Electrical machines fitted with rolling-contact operations gathers in the space inside the outer
bearings mentioned above are subject to the bearings caps. Remove the old grease when
following instructions supplementing and overhauling the machines.
modifying the operating instructions of the The model of bearing is favorably chosen as for
machine: direction and size of load (type of construction,
The locating bearings are deep-groove ball bearings forces acting on the shaft)and therefore it should
for horizontally mounted machines. These bearings not be changed.
may also be in pairs with cylindrical roller bearings The permissible values of axial and radial forces
in the case of bearings is not guide radially and is may be taken from the list of machine or may be
prevented from rotating by compression springs. inquired.
The locating bearings for vertically mounted The machines should operate in only one type of
machines are angular-contact ball bearings of type construction as shown the rating plate, because
range 72 or 73 (angular-contact ball bearings with another type of construction required perhaps
increased axial fixation see supplementary further measures in addition to a modification of the
operating instructions.) model of bearing. Always in this case an inquiry
The floating bearings are deep-groove ball bearings is necessary.
or cylindrical roller bearings. In case of deep-
groove ball bearings as floating bearings, the axial
play is compensated by means of compression
springs.

Deep-groove ball bearing

Cylindrical roller bearing

Angular contact ball bearing

Fig. 23 Examples for bearing combination

1) Regreasing
Initial lubrication of the bearings is normally
carried out in the works with a Alvania #2 grease
satisfying the conditions of running test at a test
temperature of 120 to DIN 51 806. If a different
type of grease is required, this is indicated on the
data plate, provided that the particular operating
conditions were given in the order.
Keep the new grease meticulously clean. Greases
having a different soap base should not be mixed
since this would reduce the grease quality.
For regreasing clean the lubricating nipple and
press in the grease quantity indicated on a data plate,
using a grease gun. The shaft should rotate during
regreasing, hence the machines need not be stopped.
After regreasing, the bearing temperature will rise
by a few degrees and will drop to the normal value
when the grease has reached its normal service
viscosity and the excess grease has been forced out
of the bearing.
It is recommended that the lubricating instructions
be strictly followed. Special cases may require
36
2) Lubrication
Regrease the bearings if the machines have been
stored unused for longer than 2 years.

3) Dismantling, Assembling
For working on the locating bearing in the vertical
position of the machine, support or discharge the
rotor.
It is recommended that new rolling bearings be
installed as follows: Heat the ball bearings or the
inner ring of the roller bearings in oil or air to a
temperature of approx. 80 and slip them onto the
shaft. Heavy blows may damage the bearings and
must be avoided.
When installing single angular-contact ball bearings,
make sure that the broad shoulder of the inner
ring(and the narrow shoulder of the outer ring) in
operating position points upwards, i.e.in a direction
opposite to that of the axial thrust.
When assembling the machines, avoid damage to
the sealing rings. Rubber sealing rings(V-rings)
should be carefully fitted over the shaft as shown
the illustration. New felt sealing rings should be so
dimensioned that the shaft can run easily while
proper sealing is still effected. Before fitting new
rings, soak them thoroughly in highly viscous
oil(normal lubricating oil N68 to DIN 51 501)
having a temperature of approx. 80 .

4) Locating Faults.
The trouble shooting table helps to trace and
remove the causes of faults. It is partly difficult to
be found the damages of bearings. In the case
doubt it is recommended to renew the bearings.

37
10.4 INSULATION TO PREVENT SHAFT A care should be taken that this insulation is not
shorted out. All lines (Lubrication oil pipes, B.T.D,
CURRENT Vibration sensors etc.) fitted at the workshop are
(High Voltage And Large Machines) insulated from the end shield, but it is necessary to
ascertain whether or not the insulation is required
for all lines which are connected at the time of the
To prevent the shaft current according to the motor installation at the site. The bearing cooling
unbalance of magnetic reluctance in magnetic pipe for forced-oil lubrication is insulated as shown
circuits, the insulator is provided at end shield side in Fig.25. The shaft voltage(Peak to peak) is high
as shown in Fig. 24. frequency voltage of usually 1 volt or less and
rarely several volt. When a shaft current by this
voltage flows, the shaft and journal part are
tarnished and in the worst case sparking can make
minute black spots on shaft and journal part. There
is a possibility that the oil film is broken locally,
developing a bum-out trouble. When disassembling
or assembling, be sure to measure the insulation
resistance. The value of 1 to 3k will be
satisfactory.

Fig. 24 Bearing insulation

With motors having one shaft extension, the bearing

at non-drive end is insulated. Motors with double
end shafts are insulated at drive & non-drive end
bearings. When double end shaft motor is coupled
with driven load, insulation must be supplied in the
coupling of one end to prevent bridging of bearing
insulation.

Fig. 25 Bearing cooling pipe system

for forced-oil lubrication

38
 Cylindrical roller bearing

Deep-groove ball bearing

with compensation of axial play

Deep-groove ball bearing with compensation

of axial play, with bearing housing bush
and intermediate ring
7. Cylindrical roller bearing 1)
1. V-ring 1) 8. Inner bearing cap with felt sealing rings1)
2. Outer bearing cap 1) 9. Deep groove ball bearing (floating-bearing)
3. Circlip 1) 10. Compression spring 1)
4. Grease slinger 1) 11. Bearing housing ring
5. Bearing housing 1) 12. Bearing housing bush
6. Lubricating nipple 13. Cylindrical pin

1) floating bearing side

Fig. 26 Floating bearings (examples, delivered design may deviate in details)

39
 Single bearing, shaft does not
pass through the outer bearing cap

Single bearing, shaft does not

pass through the outer bearing cap

Angular-contact ball Angular-contact ball

bearing placed below bearing placed above

Single bearing, shaft does not

14. Inner bearing cap with pass through the outer bearing cap
felt sealing rings 2)
15. Angular-contact ball bearing
16. Bearing slinger 2)
17. Grease slinger 2)
18. Circlip 2)
19. Outer bearing cap 2)
20. V-ring 2)
21. Deep-groove ball bearing Single bearing, shaft does not
(locating bearing ) pass through the outer bearing cap
or angular-contact ball bearing
22. Compression spring 2)
23. Compression spring 2) 1) floating bearing side
24. Cylindrical roller bearing 2) 2) locating bearing side
25. Oil seal for shaft 1) 2) 3) 3) special operating conditions only

Fig. 27 Locating bearings (examples, delivered design may deviate in details)

Fig. 28 Fitting instructions for V-ring and oil seal for shaft

40
 11. AIR FILTER AND COOLER

11.1 AIR FILTER 2) Cleaning

The frequency of cleaning operations depends
Air Filter Cleaning Period essentially on the purity of the water used. We
The cleaning period depends on the site conditions recommend a minimum of one inspection per year.
and can change. The cleaning of the filter is The life of zinc block for anti-corrosion is about a
requested if the record of the stator winding year. Therefore replace it with a new one every year.
temperature (using the stator winding sensors) Cut off the water supply by isolating the inlet and
indicates an abnormal increase in temperature. outlet lines and drain the water. Disconnect the leak
sensor(option with double-tube cooler) and make
Air Filter Cleaning Procedure sure that there are no leaks. Remove the water
The filter element (flat or cylindrical) is immersed boxes on each side of the machine. Rinse and brush
in a tank of cold or warm water (temperature less each water box.
than 50 ). Use water with detergent added.
Shake the filter gently to ensure that the water flows Note : Do not use a hard wire brush as this will
through the filter in both directions. remove the protective tar-epoxy layer which has
When the filter is clean, rinse it with clear water. formed on the surface of the water boxes. Clean
Drain the filter properly (there must be no more each tube with a metal scraper. Rinse in soft water.
formation of droplets). Keep the leakage chamber dry(double-tube water-
Refit the filter on the machine. cooler only)

3) Stop The Machine

CAUTION ; Do not clean the filter using Leak detection for a double-tube exchanger. If a
compressed air. This procedure would reduce leak is detected, cut off the power supply of the
filter efficiency. water in/outlet lines and change to emergency
operations, it is necessary to ascertain and repair it.
Remove the two water boxes, apply a slight positive
11.2 COOLER pressure in the leakage chamber and thus between
the two tubes (only concerns double-tube coolers).
1) General Points If a tube is damaged plug it at both ends. Use a
The purpose of the cooler is the remove machine tapered plug. The plug should preferably be made
heat losses (mechanical, ohmic etc). The exchanger of salt-water resistance aluminum bronze or of a
is located on the top of the machine. synthetic material.

Normal Operation 4) Leak Detection (Float System)

The air is pulsed by a fan fixed to the machine shaft. A magnet float activates a switch located in the
float guiding rod.
Description of air-water double tube exchanger
The double-tube technique keeps the cooling circuit
from being affected by possible water leakage. The
double tube provides a high safety level. In case of
leakage, the water goes from the inside of the
internal tube to the coaxial space between the two
tubes. The water is drained axially to a leakage
chamber where it may activate a sensor. An
exchanger comprises a fin-tube block containing :
-. a steen frame
-. a fin-tube block expanded mechanically to the
tubes.
The tube bundle is roll-expanded in the end plates.
The water distribution in the tubes is provided by
two removable water boxes. A water box is
equipped with collars for fitting the inlet and outlet
lines. Neoprene seals ensure water boxes and the Fig. 29 Leakage detector
end plates.

41
5) Cooler Removal
The cooler unit is slid into its housing. It is possible
to remove the cooler from the housing without
removing the water boxes. The cooler is fastened to
the housing via a series of screws on the housing.
Remove the supply and return pipes. Provide two
supports to hold the cooler when it comes out of its
housing. Remove the cooler using slings that can be
attached to the connecting flanges.

6) Cooler Re-Assembly

Carry out the operations of th "Cooler Removal"

in the reverse order. Be careful to push the cooler
completely into its housing before tightening the
fastening screws of the cooler to the casing.

1. Cover
2. Gasket for 1
3. Cooler housing
4. Gasket for 5
5. Air to water cooling element

Fig. 30 Cooler Removal

42
 12. PROTECTION(GENERAL)
It is our recommendation that all electric motors are
fitted with motor protection. The preferred type of 4) If installed bearing temperature indicator, alarm
motor protection should provided the following and trip setpoints separate.
protection features;
1) Current limit by a programmable thermal limit 5) Calculation of motor thermal capacity available.l
curve with thermal modeling based by winding
temperature. 6) Ground fault detection.

7) Current unbalance detection.

2) If installed RTD for winding temperature
detector, winding temperature detection by RTDs 8) Capacity for the protection system to learn motor
should be separated alarm and trip setpoints. cooling times.

3) Ambient temperature RTD located in the motor A motor protection system with these features
ambient air stream. should reward you with better reliability and will
allow you to optimize the motor to is maximum
performance

PROTECTION SETTING RECOMMENDED

Guide values for adjustment of tripping temperature.

Insulation Class ‘B’ Insulation Class ‘F’

Description
Permissible Permissible
Max. Alarm Trip Max. Alarm Trip
Temp.rise (T) Temp.rise (T)

Winding max. max.

125K 130K 145K 150K
Temperature 130 deg 150 deg

Bearing
max. max.
Temperature 85K 90K 85K 90K
90 deg 90 deg
(Anti-friction*)

Bearing
max max
Temperature 85K 90K 85K 90K
90 deg 90 deg
(Sleeve)

Current max. 6% 10% max. 6% 10%

unbalance 10% (10sec delay) (Inst.) 10% (10sec delay) (Inst.)

-. T means operation temperature including ambient temperature.

-. Max. permissible temp.rise includes ambient temperature.
✲ In the case when a suitable heatproof lubricant is used or a greasing interval is changed, the limit of
temperature rise shall be determined by agreement between manufacturer and purchaser

43
13. FAILURE AND REMEDIES OF INDUCTION MOTORS

Abnormality Probable cause Remedy

1. Drop in line voltage A check is to be made with a voltmeter.

a. A check is to be made on voltage at motor

Power 2. Great drop in voltage due to
terminal before and at time of starting.
source inadequate line capacity and
b. Similar change in voltage is to be checked
& line impedance drop.
at motor terminal.

3. Cut line or unbalanced Defective parts are to be repaired.

4. Erroneous wire connection. To be repaired

5. Cut line or unbalanced

To be reconditioned.
voltage.
Starter
6. Drop in line voltage Compensator tap connection is to be raised.

7. Cut line or unbalance in Resistance is to be measured; repairs are to be

starting resistor. made.

8. Cutting of stator coil or of Resistance and current are to be measured,

rotor coil. and repairs are to be made.
Motor fails
to start
9. Erroneous connection of stator
To be reconditioned
coil.

a. Squirrel cage motor; Rotor conductor is to

be checked for disconnection.
10. Defect of rotor. b. Wound motor; A check is to be made for
line cutting and unbalance.
c. Repairs or renewal is to be made.
Motor
11.Stator core is in contact with
a. A check is to be made by turning by hand.
rotor.

b. Bearing is to be disassembled and

12. Defective bearing
examined.

a. Squirrel cage motor; Motor is to be

replaced with the one having larger capacity
13. Insufficient starting torque and of the wound type.
b. Wound motor; Tap for starting resistor is to
be replaced.

Load 14. Load is to be reduced.

44
 Abnormality Probable cause Remedy

A check is to be made on voltage drop of power

1. Inadequately low voltage.
source and line.

a. Squirrel cage rotor; Rotor bar and end ring are

Length of time to be checked for contact.
required for 2. Defective rotor.
b, Wound motor; A check is to be made on coil for
acceleration unbalance and on brush for imperfect contact.
after starting

Load is to be checked; If load is normal, motor

3. Overload or inadequate torque
capacity is to be changed.

Rotation in Two phases of U.V.W(or R.S.T) at starter or motor

Phase reversal
reversal direction terminal are to be changed.

1. Overload Load is to be reduced(to rated current)

a. A check is to be made with a voltmeter Power

2. Overcurrent due to voltage
source voltage is to be raised..
drop.
b. Load is to be reduced.

3. Excessive iron loss due to A check is to be made with a voltmeter Power

overvoltage. source voltage is to be reduced.

Motor body
overheated 4. Cut line or imperfect contact in
To be reconditioned
one phase

5. Short-circuiting and grounding Resistance and current are to be checked, and

of coil reconditioned.

6. Contact between stator and Judgement can be made according to noise; Bent
rotor shaft, bearing, etc. are to be corrected.

7. Inadequate ventilation due to

Cleaning is to be carried out.
dust.

1. Unbalance of rotor
a. Bending of shaft To be repaired.
b. Loose joint To be tightened by bolts securely.
c. Residual unbalance To be readjusted.
Vibration
d. Critical speed of shafting
e. Dust attached to rotor To be cleaned.
f. Imperfect connection between To be reconditioned.
coupling and shaft

45
Abnormality Probable cause Remedy

2. Improper magnetic center To be reconditioned.

3. Defective bearing Refer to the section "Bearing"

4. Coupling deflection To be reconditioned.

5. Abnormal contact between shaft

a. To be checked by turning manually.
and stationary part, such as end
b. To be disassembled for detecting defects.
cover,etc.

6. Unsatisfactory contact of brush. Brush is to be checked for contact.

7. Improper alignment. To be reconditioned.

8. Sinking of foundation. To be reconditioned.

9. Transmission of vibration from

Insulation for vibration.
combined machine.

10. Unequal pitch of claw

Reconditioning of pitch.
coupling.
11. Improper bush of flexible
Reconditioning of pitch.
coupling.
Cause are to be detected; and repairs are to be
1. Disagreement of air gap.
made.

Causes of single phase operation such as line

2. Single phase operation. cutting and imperfect contact are to be detected;
and repairs are to be made.

3. Short-circuits of layer and

To be reconditioned.
phase of stator coil and rotor coil.
4. Abnormal contact between shaft
a. A check is to be made by turning manually.
and stationary part such as end
b. To be disassembled for inspection.
cover.
Noise
5. Unsatisfactory foundation and
readjustment of installation.
installation.

6. Loose bolts for foundation Foundation bolts are to be tightened.

7. Gap between foundation and

Reconditioning of installation
base.

8. Resonance with foundation Readjustment of foundation

9. Crackings at brazed joint rotor To be disassembled and defective parts are to be

bar and end ring. repaired.

Power source and lines are to be checked and

1. Voltage unbalance.
Unbalance of balanced.
phase current
Line cutting and improper contact are to be
2. Single phase operation.
reconditioned.

46
 Abnormality Probable cause Remedy

a. Rotor shaft coil resistance is to be measured and

reconditioned.
b.Contact of brush or shortcircuit ring is to be
3. Secondary circuit
checked.
c. A check is to be made on endring contact of a
squirrel cage motor.

Flaking
(a) Flaking of 1. A care should be taken of shaft at time of
rolling elements 1. Excess of tightening allowance. assembling and of bearing box at time of
matching.

2. Erroneous selection of
2. Clearance is to be reinspected.
clearance.

3. Minus operating clearance. 3. A care should be taken at time assembly.

4. Thermal expansion 4. Examination of working condition

1 Inclusion of dust and other

(b) Local foreign substances or rust, bruises
flaking of a race

1. Shaft or bearing box is distored Machining accuracy and tightening of bearing box
(c) Flaking all elliptically. are to be checked.
over a race

2. Improper tightening
(d) Flaking on
component parts
3. Inaccuracy due to improper
opposite to a
matching.
race

4. Deterioration with time

(e) Flaking all Abnormal thrust load Design of bearing system is to be checked
over around
track center
1. Shaft bending
(f) Flaking
across a race
2. Oblique fitting of outer and
inner rings

(g) Flaking
similar to pitting 1. Vibration during stoppage Examination of working condition.
on a race
2. Rust

47
 Abnormality Probable cause Remedy

1. Inadequate clearance. Proper clearance is to be provided.

Seizing
(a) Race ring
2. Inadequate lubrication Oil amount of lubricant is to be checked.
and rolling
discolored and
turned soft Reconsideration of working condition and
(b) Damage 3. Improper overload of lubricant
handling.

Breakage Careful handling

(total or partial) 1. Advancement of flaking
(a) Fracture caused by shock and below. Examination of tightening
2. Great tightening allowance &
(b) Cutting large round corner of fitted part. Examination of machining accuracy of shaft &
bearing housing

Breakage of
retainer
(a) Fracture 1. Moment load Careful handling and reconsideration of working
(b) Non-uniform 2. Rotation at shift speed condition.
abrasion 3. Inadequate lubrication Examination of oil supply and lubricant.
(c) Wear of 4. Inclusion of foreign substances
pocket section
(d) 'Biting-off'

1. Unsatisfactory condition of
Rust
storage.
(a) Rust formed Inspection of storage room.
2. Left alone
all over surface
3. Inadequate cleaning
Careful handling
4. rust preventive reagent
Examination of rust preventive reagent.
(b) Rust on local
1. Unsatisfactory packing
place Re-examination of machining of shaft & bearing
2. Sweet
housing.
(c) Contact Re-examination of working condition.
1. Inadequate allowance of
erosion on joint
tightening.
surface
2. Change in load

Wear
(a) Abnormal 1. Inclusion of foreign
wear of race and substances.
Examination of lubrication and oil supply
rolling element 2. Occurrences of wear.
(b) Abnormal Inadequate lubrication.
wear of retainer

Electrode
(a) Cratershaped
Passage of current Examination of design of bearing system
depression and
corrugated scars

48
 Abnormality Probable cause Remedy

Dent and
scratch
Examination of handling and assembling
(a) Indentation
Dust and foreign substances conditions.
(on a race, etc.)
pressed between race and body
(b) Aventurine
Careful handling
hardening
Careless handling
(c) Dents given
(dropping, etc.) Careful assembling
during handling
(d) Scratches
during assembly

Smearing
1. Inadequate lubrication
Biting-off on a Examination of lubricant and lubricating
2. Skewing of rolling element.
race and rolling condition.
3. Selection of lubricant.
element.

Creep
1. Inadequate tightening 1. Examination of tightening.
wear of outer and
allowance. 2. Examination of machining accuracy of shaft
inner surface,
2. Inadequate tightening of and bearing box.
sliking and
sleeve. 3. Examination of design.
discoloring.

49
C Technical data for remote control system 134
-1. Components list 135
-2. Technical specifications 136
-3. Main Controller 149
-4. Aux. Controller 151
-5. Terminal Board 153
-6. Signal Converter Box 154
-7. No. 1 & 2 Schematic Diagram 155
-8. Arrangement of blade angle transmitter 158
-9. Instruction manual for Main controller 159
 DOC. NO. K3211-AF0280
COMPONENT LIST
SHEET NO. 1 of 1

HULL NO. NCP0123~25

EQUIP. NAME REMOTE CONTROL SYSTEM
PROJECT NAME 3000kW THRUSTER

No. Component No. Descriptions Q’ty Part No. Remarks

1 NCP0123 - BB - 01 Main Controller 1 set 8011 Wheel House

Wing Side
2 NCP0123 - BB - 02 Aux. Controller 2 sets 8012
(Port & Stb’d)

3 NCP0123 - BB - 03 Terminal board unit 1 set 8013 Wheel House

Signal converter junction

4 NCP0123 - BB - 04 1 set 7022 Thruster Room
box

5 NCP0123 - BB - 05 Blade Angle Transmitter 1 set 4011 Thruster Room

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Contents

1. Introduction
2. Basic Specifications
2.1 Main Controller
2.2 Wing Controller
2.3 Terminal Board Unit
3. Main Functions
3.1 Change over of control station
3.2 Change over of control mode
3.3 OLP (Over Load Protector) for main motor
4. Operation
4.1 "CONTROL SOURCE (ON/OFF)" push button switch
4.2 "STOP" push button switch
4.3 "AUX RUN" push button switch
4.4 "THRUSTER REQUEST" push button switch
4.5 "THRUSTER RUN" push button switch
5. Trip reset
5.1 Trip reset of main motor
5.2 Trip reset of hydraulic pump motor
6. Composition
6.1 Control Board
6.2 Display Board
7. Communication and Analog output for VDR

H.B.JIN S.W.YE J.S.HA

1 FOR WORKING
2014.05.31 2014.05.31 2014.05.31
H.B.JIN S.H.LEE H.G.KIM
0 FOR APPROVAL
2013.09.12 2013.09.12 2013.09.12

REV. PREPARED CHECKED APPROVED MODIFICATION

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

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1. Introduction

This system is a remote controller for the side thruster which makes ship's maneuvering with
precise and safety when she arrives at and departs from a port.
The common functions of this system are to control input/output signals, analog values and blade
angle of the thruster with the most optimal condition by the control algorithm.
This side thruster (Controllable Pitch Propeller type) remote control system provides functions of
pitch setting and overload protections of main motor with microprocessor by operating the
maneuvering dials which is located on wheelhouse(main controller), port wing and starboard wing
stands.
In addition, display and alarm systems which are independent of control system are provided.
Furthermore, non follow up pitch control (manual mode) device is provided to control the
thruster in case of emergency such as failure of follow up pitch control (auto mode) system.

2. Basic Specifications

2.1 Main Controller

1) Mounting; Flush Mount Type
2) Type; 8-bit Microprocessor
3) Protection Degree; IP22
4) Operating Temperature; -25°C - +70°C
5) Communications; CAN (Main ↔ Terminal Board Unit)
6) Indication Lamp; 1 set
-For alarm; Max. 15
-For Status; Max. 10
-For Pitch; Round LED Indication
-For Current; Decimal (with pitch indicating by mode switch)
2.2 Wing Controller
1) Mounting; Flush Mount Type
2) Type; 8-bit Microprocessor
3) Protection Degree; IP56
4) Operating Temperature; -25°C - +70°C

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5) Communications; CAN (Wing ↔ Terminal Board Unit)

6) Indication Lamp; 1 set
-For alarm; Max. 5
-For Pitch; Round LED Indication
-For Current; Decimal (with pitch indicating by mode switch)
2.3 Terminal Board Unit - 1 set
1) Supply Voltage
-Main Source; AC220V, 60Hz
-Emergency Source (for Back-up); DC24V
2) Install Location; Bridge Console
3) Operating Temperature; -25°C - +70°C
4) Communications; CAN
(Main ↔ Terminal Board Unit, Wing ↔ Terminal Board Unit)
5) Input Specification
-Digital Input; 24 channel
-Analog Input; 4 channel
6) Output specification
-Contact output
- 2 channel for solenoid valve operation
- 14 channel for signal output
-VDR (Voyage Data Recorder)
- Pitch Feedback Signal; 4 - 20mA or ±1OV
- Pitch Order Signal; 4 - 20mA or ± 1OV
- Thruster Run Signal; "A" Contact
-INS (integrated Navigation System) – If necessary
- Pitch Feedback Signal; 4 - 20mA or ±1OV
- Pitch Order Signal; 4 - 20mA or ± 1OV
-ICMS
- Controller abnormal alarm signal; "B" contact
-Emergency Stop Signal; "B" contact (series)

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3. Main Functions

3.1 Change over of control station

This change over can be carried out by pushing the station change over button ("W/H" &
"WINGS" button) on wheelhouse or wing stations(PORT and STBD).
Then the change over should be performed after making the maneuvering dials correspond to
each other. If the maneuvering dial value is not equal to actual pitch value, control station is not
changed over. In other word, the change over should be not performed during pitch is controlling.
Note: Pitch indicators always show actual pitch at wheelhouse and both wings.

3.2 Change over of control mode

This change over can be carried out by pushing the control mode button ("AUTO" &
"MANUAL") wheelhouse or wing stations(PORT and STBD). Then, this change over from non
follow up control mode(manual mode) to follow up control mode(auto mode) should be
performed after making the maneuvering dial and actual pitch corresponded to each other.

1) Follow up pitch control (auto mode)

When operating the maneuvering dial, the difference of position between the potentiometer in
the maneuvering dial and that attached to blade angle transmitter results. The voltage resulted
from the difference of position is amplified and excites the solenoid valve in the hydraulic unit.
Therefore, the blade of CPP (Controllable Pitch Propeller) begins shifting in the direction
commanded by the maneuvering dial.
At the same time, the potentiometer connected to the blade by means of link and chain begins
turning, and when its position corresponds to the position of potentiometer in the maneuvering
dial, the voltage will disappear and the solenoid valve is de-energized.
Thus, the blade of CPP follows up the pitch commanded by the maneuvering dial.

2) Non-follow up pitch control (manual mode)

When pushing the push button ("PORT" or "STBD"), the solenoid valve in the hydraulic unit
is excited. Therefore, the blade of CPP begins shifting in the direction commanded.
When release the push button, the solenoid valve is de-energized and then the blade of CPP
stops shifting.

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3.3 OLP (Over Load Protector) for main motor

When the main motor load signal exceeds the predetermined load value which is set by OLP
setting tool, the blade of CPP will be automatically reduced to OLP(Over Load Protector) setting
level. Therefore, if the main motor load lightens, the blade of CPP will be automatically returned
to the pitch commanded by the maneuvering dial.
Please inform the following values for the design of OLP device.
a) Rating current of main motor, 321.6 Amp.
b) Input Signal for OLP, 4~20mA

4. Operation

4.1 "POWER" push button switch

By pushing this button, this system is supplied with electric source. Lamp "POWER" is turned
on. By pushing again, electric source is turned off.
Note: Before turning off electric source, you should stop the main motor and auxiliary
machineries by pushing the "STOP" button switch.

4.2 "STOP" push button switch

By pushing this button during main motor and hydraulic pump running condition, they can be
stopped.
When the main motor, oil pump are stopped, lamp "STOP" button is turned on.
If the main motor is stopped under not being neutral position, the oil pump will be continuously
running until the pitch feedback position corresponds to neutral position.
Then neutral LED will be flickering to indicate being operation.

4.3 "HYD.PUMP START" push button switch

By pushing this button, the output signal toward hyd. pump starter is sent to start hyd.pump and
lamp "HYD.PUMP RUN" begins flickering. When oil pump runs, lamp "HYD. PUMP RUN"
will be turned on.

4.4 "THRUSTER REQUEST" push button switch (Option)

By pushing this button, the main motor power supply request signal is sent to the power
management system and lamp "THRUSTER REQUEST" is turned on.
When the main motor stops after starting the main motor, lamp "THRUSTER REQUEST" is
turned off.

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4.5 "THRUSTER START" push button switch

By pushing this button after confirmation of the lighting of "READY TO START" lamp, the
start signal is sent to motor starter and also the lamp "THRUSTER RUN" button begins flickering.
When the main motor is started, this lamp is turned on. This lamp is continuously turned on by
the feedback of the main motor run signal.
Please note, it is impossible to control the pitch during the flickering of this lamp by the interlock
circuit even if the operations of the maneuvering dial.
Note: The start interlock circuit for the main motor and auxiliary machineries is supplied by a
starter maker.

4.6 “FAN START and FAN STOP” push button switch

By pushing “FAN START” button, the output signal toward fan starter is sent to start the fan
and lamp “FAN RUN" begins flickering. When fan runs, lamp "FAN RUN" will be turned on.
If operator wants to stop the fan, just push “FAN STOP” button.

5. Trip reset

5.1 Trip reset of main motor

If the main motor stops in spite of no stop operation (push the "STOP" button), the main motor
running signal will be released regarding the main motor as tripped.
In this case, the main motor will not start even if the "THRUSTER START" button is pressed; it
is necessary to reset the trip condition by pressing the "STOP" button before restart of the main
motor.
5.2 Trip reset of hydraulic pump motor
If the hydraulic pump motor stops in spite of no stop operation (push the "STOP" button), the
hydraulic pump motor running signal will be released regarding the hydraulic pump motor as
tripped. Simultaneously, the stop signal operates to release the main motor and fan running
signals.
In this case, the hydraulic pump motor will not start even if the "HYD.PUMP START" or
"THRUSTER START" button is pressed; it is necessary to reset the trip condition by pressing
the "STOP" button before restart of the hydraulic pump motor.

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<switch operation pattern>

<alarm pattern (normally closed)>

If Alarm factor signal enters, relevant alarm indication LED becomes on, and buzzer rings.
If Buzzer stop signal enters, buzzer stops sound.
While Lamp buzzer test signal enters, all lamp indication LED become on.

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<change-over of control position>

push button indicator lamp

W/H W/H WING WING W/H W/H WING WING Control Remark
/ / / / / / / / position

W/H WINGS W/H WINGS W/H WINGS W/H WINGS

Init. ○ ○ W/H

W/H ○ ○ W/H

↓ ┻ ◎ ◎ W/H

WINGS ┻ ○ ○ WING

WINGS ○ ○ WING

↓ ┻ ◎ ◎ WING

W/H ┻ ○ ○ W/H

┻ : Push button switch operation

○ : Indicator lamp continuous lighting

◎ : Indicator lamp flickering

* distinguish between PORT and STBD by each serial communication protocol.

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6. Composition

6.1 Control Board

1) Functions

① control and computation

- control and monitoring by the micro-processor
- embedded the control program for the starter
- embedded the control program for the pitch
- saved the setting parameter values
② external input/output signals
- control output signals and current input status about the main motor starter
- control output signals and current input status about the Hydraulic Motor Starter
- data communication with the wing side controller
- output signals to the VDR system
③ internal input/output signals
- serial data communication with internal display board
- serial data communication with internal key data
- input signal from the maneuvering dial
- input signal about the manual mode control key data
- adjustment the display LED dimmer
- output the buzzer signal
④ self diagnostic system
- self diagnostic function by the watch-dog timer
- automatic initialization when the system errors occurs
⑤ power input and conversion
- input power: 24VDC (max. @3A)
- power conversion: 24VDC -> 5VDC (for Digital Circuit)
24VDC -> +15VDC,-15VDC (for Analog Circuit)

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2) specification

① micro-processor
- Model name: ATmegaCAN128-16AI
- 11MIPS @11.0592MHz
- data width: 8 bit
- internal ROM: 128 Kbytes Flash, 4 Kbytes EEPROM
- internal RAM: 4 Kbytes SRAM

② external input/output

TYPE ITEMS CHANNEL

Thruster Motor Starter Status (10 Channel)

CONTACT
Hyd. Starter Status (6 Channel) 24
INPUT
Spare (8 Channel)
Thruster Motor Load(4~20mA) (1 Channel)
ANALOG
Blade Angle Status(4~20㎃) (1 Channel) 4
INPUT
Spare (2 Channel)
Thruster Motor Starter Control (6 Channel)
Hyd. Starter Control (4 Channel)
CONTACT VDR (1 Channel)
18
OUTPUT Buzzer (1 Channel)
Emergency (1 Channel)
Spare (5 Channel)
8
ANALOG VDR Data (4~20mA)
(Including
OUTPUT VDR Data (±10V)
Spare)

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③ internal input/output

TYPE ITEMS CHANNEL

Analog Input maneuvering dial (1 Channel) 1

Digital Input Emergency Switch (1 Channel) 1

Digital Output buzzer (1 Channel) 1

6.2 Display Board

1) function
① Alarm and Status
- Alarms: Power, Main Motor, Oil Alarm
- Status: Power, Main Motor, Fan, Hyd. Pump Status
② Operating Switch input
- Change-over the Auto/Manual Mode Switch
- Change-over the Control Station Switch
- Operation Mode Switch
- Lamp Dimmer Switch
- Lamp/Buzzer Test Switch
- Alarm Ack Switch
- Emergency Stop Switch
③ Main Motor and Pitch Data output
- Main Motor current value FND
- Main Motor % value FND
- Pitch angle feedback value Indicator Bar
- Pitch Control Command value
④ power input and conversion
- power input: 24VDC
- power conversion: 24VDC -> 5VDC (for Digital Circuit)

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2) specification

① microprocessor
- model name: ATmegaCAN128-16AI
- 11MIPS @11.0592MHz
- bus width: 8 bit
- internal ROM: 128 Kbytes Flash, 4 Kbytes EEPROM
- internal RAM: 4 Kbytes SRAM

② Alarm and Status

TYPE ITEMS CHANNEL

Oil Alarm
Integrated Main Motor Alarm
4
Alarm System Fail
Control Source Fail

Gravity Tank Level Low

Oil Low Press
Oil Alarm 3
Hyd. P/P Over Load

Main Motor Start Fail

Main Motor Over Load
Main Motor
Main Motor Trip 5
Alarm
Main Motor High Temperature
Main Motor Earth Fault

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Motor Overload Reduction

Main Source On
Fan Run
Status Auto Pitch Reduction 10
Hyd. P/P Run
Thruster Run
4 Spare

③ input switches

TYPE ITEMS CHANNEL

Change-over the Auto/Manual Mode (2 Channel)

Change-over the Control Station (3 Channel)
Operation Mode switch (7 Channel)
Operating input Lamp Dimmer switch (1 Channel) 18
switches Lamp/Buzzer Test switch (1 Channel)
Alarm Ack switch (1 Channel)
Emergency Stop switch (1 Channel)
Manual Mode Pitch Control Switch (2 Channel)

④ output Data
TYPE ITEMS CHANNEL

Output data for unit display for main motor value LED(2 Channel)
34
main motor display for main motor load FND (32 Channel)
output data for Pitch Indicator Bar LED (21 Channel)
42
blade pitch Pitch Control LED (21 Channel)

7. Signal output for VDR

There are 2 analog outputs, 1 digital output.
- Command Signal: 4 ~20mA or ±10V
- Feedback Signal: 4 ~20mA or ±10V
- Thruster run signal: ON/OFF Contact

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 1
4
2

! Caution
1.Do not use thruster at the ship
speed over 5 knots.
2.Set the control dial at the same

3
position as original to keep a
constant pitch when change
over the control station.
3.When change over, operator
should be matched on pitch
order and pitch feedback signal.

6 RIGHT VIEW

FRONT VIEW

- NOTES -
1. Quantity : 1 Set/Ship
2. Location : Wheel house
3. Color : Maker standard
"A" 4. Weight : Abt. 4.2Kg
5. IP Grade : IP22

BOTTOM VIEW
CUTTING DIMENSION

-67-
 ! Caution
1.Do not use thruster at the ship
speed over 5 knots.
2.Set the control dial at the same
position as original to keep a
constant pitch when change
over the control station.
3.When change over, operator
should be matched on pitch
order and pitch feedback signal.

-68-
 1 4

! Caution
1. Do not use thruster at the ship speed
over 5 knots.
2. Set the control dial at the same position
as original to keep a constant pitch
when change over the control station.
3. When change over, operator should be
3
should be matched on pitch order and
pitch feedback signal.

RIGHT VIEW

FRONT VIEW

- Notes -
1. Quantity : 2Sets (PORT and STBD)
2. Location : Wing Console
3. Color : Maker Standard
"A" 4. Weight : 3.6Kg
5. IP Grade : IP56
5

BOTTOM VIEW

CUTTING DIMENSION

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 ! Caution
1. Do not use thruster at the ship speed
over 5 knots.
2. Set the control dial at the same position
as original to keep a constant pitch
when change over the control station.
3. When change over, operator should be
should be matched on pitch order and
pitch feedback signal.

-70-
 JP3 JP4

B1 A1
POWER AVAIL
B2 A2
MAIN SOURCE ON
B3 A3
READY TO START

TB-1 THRUSTER RUN

B4 A4

B5 A5
JP1 MOTOR START FAIL
B6 A6
1 MOTOR TRIP
P2 (DC 24V) B7 A7
MOTOR OVER LOAD
2
N2 (DC 0V) B8 A8
3 MOTOR HIGH TEMP
FG B9 A9
MOTOR EARTH FAULT
BLANK B10 A10
AC POWER FAIL

POWER DIODE
BLANK

BLANK
FAN RUN
B11

B19
A11

A19

SUPPLY
HYD.P/P RUN
7
EX DIAL IN - A

MODULE 8 JP5 JP6

UNIT 9
EX DIAL IN - B

EX DIAL OUT - A
OIL LOW PRESS
B20 A20
10
EX DIAL OUT - B B21 A21
GRAVITY TANK LV LOW
B55 A55
JP2 GRAVITY TANK LV L.LOW
B23 A23
11 HYD.P/P OVERLOAD
CAN HIGH (MAIN)
B24 A24
12 OIL TEMP HIGH

NOISE FILTER 13
CAN LOW (MAIN)

CAN GND (MAIN)

LOCAL CONTROL
B27

B28
A27

A28
14 HYD.P/P SOURCE ON
CAN HIGH (PORT) B34 A34
15 DC POWER FAIL
CAN LOW (PORT)
B47 A47
16 IN EX ENABLE
CAN GND (PORT)
B49 A49
17 D/G OVER LOAD
CAN HIGH (STBD)
B50 A50
18 SPARE
CAN LOW (STBD) B51 A51
19 SPARE
CAN GND (STBD)

RX TX
BLANK JP7 JP8
TB-4
B12 A12
MOTOR LOAD
AXX A29
+24VDC
AXX A30
BLADE CON
BXX B29
GND
PITCH ORDER - A B36 A36
( 4~20mA )
PITCH FEEDBACK - A B37 A37
( 4~20mA )
PITCH ORDER - S B38 A38
( 4~20mA )
EXTERNAL SIGNAL PITCH FEEDBACK -
( 4~20mA )
PITCH ORDER - A
S B39

B40
A39

A40

I/O CONTROL BOARD ( -10 ~ +10 VDC )

PITCH FEEDBACK -
( -10 ~ +10 VDC )
A B41 A41

PITCH ORDER - S B42 A42

( -10 ~ +10 VDC )
PITCH FEEDBACK - S B43 A43

(ELB1) (ELB2) (RY1) (RY2) ( -10 ~ +10 VDC )

TB-4 N.C
JP15
N.O
JP9
COM
JP10

B13 B13 A13

THRUSTER START
EM'CY STOP -A EM'CY STOP -B B14 B14 A14
A31 B31 THRUSTER STOP
(MAIN) (MAIN)
B15 B15 A15

EXTERNAL POWER TERMINAL(TB-5)

EM'CY STOP -A EM'CY STOP -B
A32 B32 THRUSTER REQUEST
(PORT - AUX) (PORT - AUX)
EM'CY STOP -A EM'CY STOP -B B16 B16 A16
A33 B33 PITCH NEUTRAL
(STBD - AUX) (STBD - AUX)
B17 B17 A17
FAN START
B18 B18 A18
FAN STOP
B25 B25 A25
HYD.P/P START
B26 B26 A26

! Caution HYD.P/P STOP

B35 B35 A35
VDR THRUSTER START
1. Attention to the wirings B48 B48 A48
- POWER(AC, DC) ABNORMAL
B46 B46 A46
- EM'CY OUT EX ENABLE
2. Wrong connection causes AUTO PITCH REDUCTION
B52 B52 A52

damage to the controller. B53 B53 A53

SPARE
3. When main power is fed,
B54 B54 A54
check the input voltages. SPARE
B44 B44 A44
(AC and DC) SOL V/V (PORT)
B45 B45 A45
SOL V/V (STBD)

- Notes -
1. Weight : Abt. 5.0Kg
2. Quantity : 1 Set/Thruster
3. Location : Wheel house
4. Painting color : 7.5 BG 7/2

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TERMINAL BOARD UNIT TB4 SIGNAL CONVERTER JUNCTION BOX BLADE ANGLE TRANSMITTER

CONVERTER
TB
+24VDC_B A29 5 +24V 1
1 1
BLD_CON A30 6 4~20mA 2
2 2 POTENTIOMETER
DGND_B B29 7 0V 3
3 3

YARD WIRING YARD WIRING

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-73-
-74-
 20 +10
16 +5
12 0
8 -5
4 -10

< PITCH ORDER & FEEDBACK SIGNAL RANGE >

SYSTEM FAIL

SOURCE FAIL

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 DEV. 2013. REV. A

User Manual
for
Side Thruster Controller

MODEL : DSTC- N

HYUNDAI DAEYANG
 CONTENTS

1. SYSTEM
- INTRODUCE / SYSTEM DIAGRAM --------- 4
- SCOPE OF SUPPLY LIST --------- 6

2. NAME & FUNCTIONS

--------- 8
- MAIN CONTROLLER --------- 16
- WING CONTROLLER

3. OPERATION
- GENERAL OPERATING --------- 23
- CHANGE OVER THE STATION FOR W/H & WINGS --------- 27
- CHANGE OVER THE MODE FOR AUTO & MANUAL --------- 31
- PITCH TO ZERO --------- 32
- MAIN MOTOR LOAD --------- 34
- PROTECTION FUNCTION --------- 35
- THRUSTER STOP & TERMINATION --------- 38
- OPERATING ERROR MESSAGE --------- 39

4. PDA --------- 41

5. NOTICE --------- 57

6. TROUBLESHOOTING --------- 59

7. APPENDIX --------- 62

HYUNDAI DAEYANG
 1 SYSTEM

SUMMARY / SYSTEM DIAGRAM

HYUNDAI DAEYANG
 INTRODUCE

INTRODUCE
1
DAEYANG SIDE THRUSTER CONTROLLER(DSTC) is a product to control the tunnel thruster or other
equivalent thrusters when docking and steering vessel towards a which is direction.
The DSTC generates pitch control signals to manage a pitch actuator connected to the propeller.
The DSTC is responsive to the pitch feedback signal to change the pitch of the blade on the propeller

SYSTEM
in order to operate the lateral thrust at a desired level.
The DSTC is normally installed in the ship’s wheel house and wing sides. The main controller is
installed in the wheel house while wing controllers are installed in wing sides.
The DSTC has many functions such as providing a set pitch, protecting the main motor from
overloading, indicating relevant alarms, showing the current operation status, and controlling the
thruster remotely by the sue of the jog-dial.
The DSTC operator can simply change over the control authority between main controller and wing
controllers.
In addition, the DSTC operator can manually change the pitch setting mode if the auto pitch setting
fails or if any emergency situation occurs.
Contents of the DSTC manual are divided into the Alarm Indicating Section, the Operation Procedure
Section, and the Remote Control Section.

Contents of this manual have been divided into several parts including the name and function of each
controller, operations, which will cover how to properly use the thrusters, and troubleshooting which will
cover how to overcome certain problems.

HYUNDAI DAEYANG
 SYSTEM DIAGRAM

SYSTEM DIAGRAM
1

SYSTEM
WING Controller Main Controller WING Controller
(PORT) (Wheel House) (ST’BD)

Terminal Board Unit Ship’s Power (AC220V/60Hz)

Emergency (DC24V)

V D R Signal Converter
(Voyage Data Junction Box
Recoder) (Thruster Room)

AMS Blade Angle Local Push

(Alarm Monitoring Transmitter Button Box
System) (Thruster Room) (Thruster Room)

HYD.Pump & Thruster

Motor Starter
(Engine Room)

※ Main controller is communicate with wing controllers (PORT and ST’BD) by CAN communication

HYUNDAI DAEYANG
 SCOPE OF SUPPLY LIST

SCOPE OF SUPPLY LIST 1

SYSTEM
List QTY Contents Remarks

Main controller 1 EA Wheelhouse

Aux. controller 2 EA Wing bridge (PORT & STBD)

Terminal board 1 EA Wheelhouse

Junction Box 1 EA Thruster room

HYUNDAI DAEYANG
 2 NAME & FUNCTIONS

MAIN CONTROLLER

WING CONTROLLER

HYUNDAI DAEYANG
 MAIN CONTROLLER

PART NAME

① ②
2

NAME/FUNCTIONS
③ ⑧

⑤ ⑨

⑩
⑥

NO NAME NO NAME
① Alarm ⑥ Operation
② Status ⑦ Lamp/Buzzer
③ Integrated Alarm ⑧ Main Motor
④ Emergency Switch ⑨ Pitch
⑤ Control & Mode ⑩ Pitch Dial

HYUNDAI DAEYANG
 ※ Alarm lamps will flicker when alarms are occurred.
The lamp keeps “ON” after acknowledgement.
※ The buzzer will ring as soon as alarms are occurred.

MAIN MOTOR ALARM

ALARM CONTENTS

• “M.MOTOR START FAIL” indicates a start up failure in the main

motor

2
• “M.MOTOR TRIP” indicates a trip in the main motor

NAME/FUNCTIONS
• “M.MOTOR OVERLOAD” indicates an overloaded status in the
main motor

• “M.MOTOR HIGH TEMP” indicates when there is a high

temperature status in the main motor

• “MOTOR LOW INSULATION” indicates when there is a low

insulation in the main motor

OIL PRESSURE ALARM

ALARM CONTENTS

• “OIL LOW PRESS” indicates a low level of hydraulic oil

• “GRAVITY TANK LEVEL LOW” indicates low level of hydraulic oil in

the gravity tank

• “GRAVITY TANK LEVEL LOW” indicates low low level of hydraulic

oil in the gravity tank

• “HYD. P/P OVERLOAD” indicates an overloaded status in the

hydraulic pump

• SPARE

HYUNDAI DAEYANG
 ※ Status lamps are “ON” when relevant functions have completed.
※ Status lamps are “FLICKERING” while relevant functions are waiting
for response.

STATUS

STATUS Contents

• “POWER AVAIL” indicates that the generator is ready to the

start-up the main motor

• “MAIN SOURCE ON” indicates that the main source 2

is supplied to the motor start-up panel

NAME/FUNCTIONS
• “READY TO START” indicates the status for the thruster to
start up

• “FAN RUN” indicates the status of the fan in the thruster room

• “HYD. P/P RUN” indicates that the hydraulic oil pump is running

• “THRUSTER RUN” indicates that the main motor is running

• “NEUTRAL” indicates of pitch feedback is on the neutral position

• HYD.P/P SOURCE ON” Indicates of the Hydraulic oil pump

source is supplied the start panel condition

• SPARE

• “AUTO PITCH REDUCTION” indicates that the main motor’s load

is over the limit value

10

HYUNDAI DAEYANG
 EMERGENCY SWITCH

Button Contents

• In case of being occurred an emergency on running

thruster, operator push this emergency switch for
stopping whole thruster operation.
2

NAME/FUNCTIONS
※ All emergency switch are connected close loop between
main controller and both wing controller.

ENABLE

11

HYUNDAI DAEYANG
 INTEGRATED ALARM

INTEGRATED
CONTENTS
ALARM

• “OIL ALARM” lamp is illuminated when one of the following

2
alarms is occurred

NAME/FUNCTIONS
- oil low press
- gravity tank level low
- gravity tank level low low
- hyd. p/p overload

• “MOTOR ALARM” lamp is illuminated when one of the

following alarms is occurred
- main motor start fail
- main motor trip
- main motor over load
- main motor high temperature
- main motor low insulation
• “SYSTEM FAIL” lamp is illuminated when one of the following
alarms is occurred
- communication error
- out of pitch feedback range
- initial condition failure after “Power ON”
• “SOURCE FAIL” lamp is illuminated when the
electric power source is not supplied for the controller
- main source (AC 220V) is not supplied
- emergency source (DC 24V) is not supplied

12

HYUNDAI DAEYANG
 CONTROL

BUTTON Contents
• Control the pitch using the jog-dial
• Gives automatic protection against the main motor
overload. Prevent the main motor from
mode overloading automatically

• Commands the pitch using “PORT”, “ST’BD” button 2

• Doesn’t supply the automatic protection function

NAME/FUNCTIONS
• Indicates the control authority on the main
controller
• Push the button (change over the control station)
• Indicates the control authority on the wing
station controller. (PORT, ST’BD)
• Push the button, change over the control station

• Indicates the control authority belongs to the local

position at E.C.R.

OPERATION

BUTTON Contents

•Side thruster controller Power on/off

• The main motor and hydraulic pump motors stop

• When the auxiliary system runs

- The hyd. Pump starts

• Requests that the generator system for the thruster be

available before running the thruster

• Thruster start

13

HYUNDAI DAEYANG
 FAN

BUTTON Contents

• Fan Stop
2
• Fan Start

NAME/FUNCTIONS
LAMP / BUZZER

BUTTON Contents

• “SIGNAL DIMMER” dims down all LEDs in 5 steps

• “PITCH TO ZERO” function

• “ALARM ACK” acknowledges the alarm

• “LAMP BUZZER TEST” tests the lamp and buzzer

14

HYUNDAI DAEYANG
 MAIN MOTOR

FORMATION Contents
• The LED display indicates the load value of the main
motor
• The LED display indicates the “Err” message in case of
the operation failure

• It makes the LED display indicate the load rate of the 2

main motor

NAME/FUNCTIONS
• It makes the LED display indicate the load ampere of
the main motor

• Change over the display unit(“%” or “A”)

PITCH

FORMATION Contents
• The slider bar indicator displays the feedback pitch
of the blade angle

• The rounded bar indicator displays the command

pitch of the blade angle

• The jog-dial maneuvers the command pitch of the

blade angle in auto mode

• “PORT” and “ST’BD” maneuvers the command pitch

of the blade angle in manual mode

15

HYUNDAI DAEYANG
 WING CONTROLLER

PART NAME

2
① ②

NAME/FUNCTIONS
③

④ ⑦

⑤ ⑧

NO NAME NO NAME
① Integrated alarm ⑤ Operation
② Main Motor ⑥ Lamp/Buzzer
③ Emergency switch ⑦ Pitch
④ Control ⑧ Pitch Dial

16

HYUNDAI DAEYANG
 EMERGENCY SWITCH

Button Contents

• In case of being occurred an emergency on running

thruster, operator push this emergency switch for
stopping whole thruster operation.
2

NAME/FUNCTIONS
※ All emergency switch are connected close loop between
main controller and both wing controller.

ENABLE

17

HYUNDAI DAEYANG
 INTEGRATED ALARM

INTEGRATED
CONTENTS
ALARM

• “OIL ALARM” lamp is illuminated when one of the following

alarms occurs
- oil low pressure
- gravity tank level low
2
- gravity tank level low low

NAME/FUNCTIONS
- hyd. p/p overload

• “M.MOTOR ALARM” lamp is illuminated when one of the

following alarms occurs
- main motor starter fails
- main motor trips
- main motor over loads
- high temp on main motor
- main motor low insulation
• “SYSTEM FAIL” lamp is indicated when one of the following
alarms occurs
- communication error
- pitch feedback is out of range
- initial condition failure after “Power ON”
• “SOURCE FAIL” lamp is illuminated when the
electric power source is not supplied to the controller
- main source (AC 220V) is not supplied
- emergency source (DC 24V) is not supplied

18

HYUNDAI DAEYANG
 CONTROL

BUTTON Contents
• Control the pitch using the jog-dial
• Gives automatic protection against the main motor
overload. Prevent the main motor from
mode overloading automatically

• Commands the pitch using “PORT”, “ST’BD” button 2

• Doesn’t supply the automatic protection function

NAME/FUNCTIONS
• Indicates the control authority on the main
controller
• Push the button (change over the control station)
•Indicates the control authority on the wing
station controller. (PORT, ST’BD)
• Push the button, change over the control station

• Indicates the control authority belongs to the local

position at E.C.R.

OPERATION

BUTTON Contents

•Side thruster controller Power on/off

• The main motor and hydraulic pump motors stop

• When the auxiliary system runs

- The hyd. Pump starts

• Requests that the generator system for the thruster be

available before running the thruster

• Thruster runs

19

HYUNDAI DAEYANG
 FAN

BUTTON Contents

• Fan Stop
2
• Fan Start

NAME/FUNCTIONS
LAMP / BUZZER

BUTTON Contents

• “SIGNAL DIMMER” dims down all LEDs in 5 steps

• “PITCH TO ZERO” function

• “ALARM ACK” acknowledges the alarm

• “LAMP BUZZER TEST” tests the lamp and buzzer

20

HYUNDAI DAEYANG
 MAIN MOTOR

FORMATION Contents
• The LED display indicates the load value of the main
motor
• The LED display indicates the “Err” message in case of
the operation failure

• It makes the LED display indicate the load rate of the 2

main motor

NAME/FUNCTIONS
• It makes the LED display indicate the load ampere of
the main motor

• Change over the display unit(“%” or “A”)

PITCH

FORMATION Contents
• The slider bar indicator displays the feedback pitch
of the blade angle

• The rounded bar indicator displays the command

pitch of the blade angle

• The jog-dial maneuvers the command pitch of the

blade angle in auto mode

• “PORT” and “ST’BD” maneuvers the command pitch

of the blade angle in manual mode

21

HYUNDAI DAEYANG
 3 OPERATONS

GENERAL OPERATING
CHANGE OVER THE STATION FOR
W/H & WINGS
CHANGE OVER THE MODE FOR
AUTO & MANUAL
PITCH TO ZERO
MAIN MOTOR LOAD
OVERLOAD PROTECTION
THRUSTER STOP & TERMINATION
OPERATING ERROR MESSAGE

HYUNDAI DAEYANG
 GENERAL OPERATING

GENERAL OPERATING

⑤ ⑥ ⑤ ③ ④

⑥ 3

Operating
② ④ ⑤ ⑥ ③
⑦

23

HYUNDAI DAEYANG
 GENERAL OPERATING

GENERAL OPERATING

STEP FUNCTION KEY Contents

• Push the “POWER” button
• If “POWER” button led is on,
and then controller power
will be supplied
1
• “W/H”, indicating current
control station, led is on
• “AUTO”, indicating mode, led
is on
• Go on 2nd step

• Push the “STOP” button 3

2 • “STOP” Led will be on

Operating
• Go on 3rd step

• Push the “FAN START”

button
• “FAN START” button led
will be on

• “FAN RUN”, monitoring fan

status, will be on
• Go on 4th step

• Push the “HYD.PUMP

START” button
• “HYD.PUMP START” button
led will be on

4
• “HYD.P/P RUN”&“HYD.P/P
PWR ON”, monitoring HYD
P/P status, led will is on
• Go on 5th step

24

HYUNDAI DAEYANG
 GENERAL OPERATING

GENERAL OPERATING

STEP FUNCTION KEY Contents

• Push the “THRUSTER

REQUEST” button
• “THRUSTER REQUEST”
button led will be on

• “POWER AVAIL” &

“READY TO START”,
• Go on 6th step

Operating
• Push the “THRUSTER
START” button
• “THRUSTER START” button
led will be on

6
• “MAIN SOURCE ON” &
“THRUSTER RUN”,
monitoring main motor
status, led will be on
• Go on 7th step

25

HYUNDAI DAEYANG
 GENERAL OPERATING

GENERAL OPERATING

STEP FUNCTION KEY Contents

• When the dial order is

maneuvered at the PORT,
the “PORT” led will be on
• When the dial order is
maneuvered at the STBD,
“STBD” led will be on

7
3

Operating
• When the dial order is
equal to the pitch feedback,
the arrow “PORT” or
“STBD”
led under the dial will be off

26

HYUNDAI DAEYANG
 CHANGE OVER THE STATION
FOR W/H & WINGS
W/H -> WINGS MODE CHANGE STEP

①
②
3

Operating
③
④

27

HYUNDAI DAEYANG
 CHANGE OVER THE STATION
FOR W/H & WINGS
W/H -> WINGS MODE CHANGE STEP

STEP FUNCTION KEY Contents

• Check the Dial order is

equal to the pitch feedback
1 of No.2 main controller.

•Go on 2nd step.

3
• Push the “WINGS” button

Operating
of
main controller.
• “WING” button led of
2
main controller will be
flickered.

• Go on 3th step.

• Check the dial order is

matched on the pitch
3 feedback of aux. controller.

• Go on 4th step

• Push the “WINGS” button

of
4 aux. controller
• “WING” button led of
aux. controller will be on

28

HYUNDAI DAEYANG
 CHANGE OVER THE STATION
FOR W/H & WINGS
WINGS -> W/H MODE CHANGE STEP

② ①

Operating
③
④

29

HYUNDAI DAEYANG
 CHANGE OVER THE STATION
FOR W/H & WINGS
W/H -> WINGS MODE CHANGE STEP

STEP FUNCTION KEY Contents

• Check the dial order is

matched on the pitch
1 feedback of aux. controller.

• Go on 2nd step

3
• Push the “W/H” button of

Operating
no.1 aux. controller.
• “W/H” button led of aux.
2
controller will be flickered.

• Go on 3rd step.

• Check the Dial order is

equal to the pitch feedback
3 of main controller.

•Go on 4th step.

• Push the “W/H” button of

main controller
4
• “W/H” button led of main
controller will be on

30

HYUNDAI DAEYANG
 CHANGE OVER THE MODE
FOR AUTO & MANUAL
AUTO -> MANUAL
※ Operator should follow next step after General operating.
※ When a power is supplied, each controller is set the “AUTO” mode.

①
②

Operating
③

STEP FUNCTION KEY Contents

• Check the dial order is

1 matched on the pitch
feedback of controller.

• Push “MANUAL” button

2
• “MANUAL” led will be on

• Dial indicating leds will be

all off, when control mode
3
has changed

31

HYUNDAI DAEYANG
 PITCH TO ZERO

PITCH TO ZERO

④ Some times, pitch feedback is not on the neutral

position when a power is supplied on the controller.

Operator should use the “PITCH TO ZERO” button for

return to neutral position before operating.

It is important for safety.

When operator pushes “PITCH TO ZERO”, HYD P/P start

& stop is operated automatically by controller.
②
When operator uses this function, dial should be at the
neutral position.

④
⑤

① 3
③

Operating
STEP FUNCTION KEY Contents
• Push the “POWER” button
• If “POWER” button led is on,
and then controller power
will be supplied
1
• “W/H”, indicating current
control station, led is on
• “AUTO”, indicating mode, led
is on
• Go on 2nd step

• Check the pitch feedback is

on the neutral position when
2 power is supplied.
• Go on 3rd step

• Push “PITCH TO ZERO”

• “PITCH TO ZERO” led will
3
be on
• Go on 4th step.

32

HYUNDAI DAEYANG
 PITCH TO ZERO

PITCH TO ZERO

STEP FUNCTION KEY Contents

•“HYD.PUMP START” button

led is on

• “HYD.P/P RUN” indicators

of status is on

Operating
• Pitch feedback is returned
on the neutral position with
regarding the dial position.
• When pitch feedback is on
5
the neutral position, arrow
“PORT” or “STBD” led under
the dial is off.
•Go on 6th step.

• “STOP” led is on.

6 • HYD.P/P is stopped.
• Go on 7th step.

• Push “PITCH TO ZERO”

button.
7
• “PITCH TO ZERO” button
will be off.

33

HYUNDAI DAEYANG
 MAIN MOTOR LOAD

Main Motor Load

Real Current Value [A] Percentage Value [%]

STATUS LED Contents

• When the load of the main motor or Diesel generator are over the
specified value (95% of maximum load of the main motor), “AUTO
PITCH REDUCTION” will be "ON" 3
※ If the load of the main motor is over or under the specified
value during 3 seconds, “AUTO PITCH REDUCTION” or “MOTOR

Operating
OVERLOAD REDUCTION” button is “ON” or “OFF”

34

HYUNDAI DAEYANG
 OVERLOAD PROTECTION(OLP)

Protect against overload

OLP (Overload Protection)

• It’s able to store the maximum load rate the internal

memory of the side thruster controller

• If the main motor has overload, the OLP function

starts running and try to keep it under the maximum
overload setting value

• Also, the pitch command values are dropping

towards the neutral point
• The maximum step down point is the neutral
point
• The step down count is 3 seconds
3

Operating
Maximum load rate

Maximum load rate of running

If the motor overloads over 3 seconds the “AUTO PITCH REDUCTION” LED is "ON"

35

HYUNDAI DAEYANG
 Protect against overload

Overload protection is running and

the “AUTO PITCH REDUCTION” lamp of the
STATUS LED is "ON"

Operating
Pitch order values are lowered by 10 % every 3
Seconds while under the maximum load rate

Pitch command values are lowered under maximum rate

“AUTO PITCH REDUCTION” is "OFF"

when motor load is under the limit load rate

36

HYUNDAI DAEYANG
 Protect against overload

Pitch order will slowly recover automatically.

Operating
If motor load is continually exceeded, it will repeat.

37

HYUNDAI DAEYANG
 THRUSTER STOP & TERMINATION
※ Operating termination should be performed
as normal terminating procedure

Normal terminating procedure

Thruster is running

Push the “STOP” button

“STOP” button will be on but “THRUSTER START”
button LED is flickering fast
Check “MAIN SOURCE ON” & “THRUSTER RUN”
indicators of status are off.
And then “THRUSTER START” &
“THRUSTER REQUEST” button LED is "OFF“
3

Operating
The “HYD.PUMP START ” button LED is flickering fast.
The operator should set the pitch order at neutral
position.
Check “HYD P/P RUN” & “HYD P/P POWER ON”
indicators of status are off.
The “HYD.P/P” will stop and the “HYD.PUMP START ”
button LED will be "OFF“

Push the “FAN STOP” button.

“FAN STOP” button LED is “ON“
Check “FAN RUN” indicator of status is off.
“FAN START” button LED is "OFF“

Termination completed.

38

HYUNDAI DAEYANG
 OPERATING ERROR MESSAGE
※ This message is not controller error, Be operating after checking
the below table and recognizing the contents.

Operating Error Message

MESSAGE Contents
• When operating the controls without controller authority, this
Err0
message will be displayed on the panel

Err11 • When is displayed CAN communication error at main controller

• When is displayed CAN communication error at the PORT side

Err12
of wing controller

Err13
• When is displayed CAN communication error at the STBD side 3
of wing controller

Operating
• When is displayed CAN communication error at the remote I/O
Err14
on the terminal block

• When changing the operating mode or controller authority,

Err2
to show that pitch order is not matched on the pitch feedback

• When executing the “AUTO MODE” command on “MANUAL

Err3 MODE” or “MANUAL MODE” command on “AUTO MODE”
this error is displayed

• Initial information has not been loaded accurately when power

Err4
turning the power on

• This error message is displayed to indicate that the pitch

Err5
feedback fail or operation range is out of the limit

• When is displayed pushing the irrelevant button on current

Err6
operating procedure

39

HYUNDAI DAEYANG
 4 P D A

INITIAL VIEW / EXECUTION

MAIN VIEW FUNCTION

BLADE ANGLE SET

MOTOR LOAD SET

DIAL VALUE SET

HYUNDAI DAEYANG
 INITIAL VIEW / EXECUTION

Initial View and Execution

Initial PDA Display

Execute Icon

If you want to start a program,

select and click the execute
Icon on the main screen.

PDA Power On Button

If the execute icon is not displayed on the desktop,

click “My Device” on the left-top in Windows.
After executing the explorer, go to the Nand folder in the root.
Execute “SMART STC.exe”.
“SMART STC.exe” is the side thruster controller’s setting program.

41

HYUNDAI DAEYANG
 MAIN VIEW FUNCTION

Main View Function

① ②

⑦ ⑧

NO Name Contents
① Operator Mode Select Operator Mode (Data Write Only)
4
Select Engineer Mode Need Password Input

P D A
② Engineer Mode
(Default password : dy)
③ Ship Name Input the relevant ship name
Blade Angle This function for setup the Blade Angle
④
Set Transmitter feedback signal value
Motor Load
⑤ Input the maximum rating of Main Motor load
Set
Dial Rotation
⑥ This function for setup control dial value
Set
⑦ Program Exit Terminating the program and exit
This function for checking the status of
⑧ Com
communicate with main controller

42

HYUNDAI DAEYANG
PASSWORD INPUT

④
①
⑤
③ ②
⑥

NO Name Contents
① Input Password Input the relevant password 4
② PwdChg Change Password Dialog Display

P D A
③ Button Select Check Password Ok or Cancel
④ Old Password Input Old Password (default password: dy)
⑤ New Password Input New Password (Max. 8 Char)
⑥ Confirm Password Input Confirm Password
⑦ Button Select Change Password Ok or Cancel

43

HYUNDAI DAEYANG
 BLADE ANGLE PROCESS

Composition and Function

④ ⑦

⑥ ③

NO Name Contents
① Input Windows Input the position of Blade Angle value
② REQ Button Load the position value of Blade Angle
When changeover Detail View, load the previous
③ ReLoad Button
data
④ Clear Button Clear the current input windows
Blade Angle
⑤ Return to main screen
Value Button
⑥ All Req Load all position value of Blade Angle
Changeover the Detail View with a rule-of-three
⑦ ReCalc Button
sum

44

HYUNDAI DAEYANG
Composition and Function

④ ⑦

⑥ ③

① ②

4
NO Name Contents

P D A
① Input Windows Input the position of Blade Angle value
② REQ Button Load the position value of Blade Angle
③ WRT Button Save the input data
④ Clear Button Clear the input windows
Blade Angle
⑤ Return to main screen
Value Button
⑥ All Req Load All position value of Blade Angle
⑦ Simple Change simple view

45

HYUNDAI DAEYANG
Operating (Engineer Mode)

Select the input window the current Load all position value when click the “All
blade angle position. Req button”.
Load each position value when click the
“REQ” button.

Save current loaded values when

push the “WRT” button.

P D A

46

HYUNDAI DAEYANG
Operating (Operator Mode)

Save current loaded values when push

the “WRT” button.

P D A

47

HYUNDAI DAEYANG
Error Message

◎ Trouble and Solution

◆ If input windows are not full of data.
→ Should be fill the appropriate value
into the blank.
◆ If values are wrong input such as below
example.
→ Check and change the appropriate
value.

ex) If values are PORT 100% : 80, PORT 90% : 98, you’ll have to change
PORT 100% : 100, PORT 90% : 98.

P D A

48

HYUNDAI DAEYANG
 MOTOR LOAD PROCESS

Composition and Function

① ④

② ⑤

NO Name Contents 4
Motor Load
① Input maximum value of main motor

P D A
Input Windows
Motor Load True
② Input limit rate for motor full load
Value Response
Motor Load Over Input percentage value of main motor over load
③
Percentage reduction

④ REQ Button Loading the initial data from main controller

⑤ WRT Button Save manual input values

⑥ Clear Button Clear manual input windows

Motor Load
⑦ Return to main screen
Value Button

49

HYUNDAI DAEYANG
 Operating

Input maximum value of main

motor load.
Input the limit rate of overload
rate for main motor.

Save data when click the “WRT”

button.

P D A
Error Message

◎ Trouble and Solution

◆ When communication is failed.
→ Retry it after checking the communication
wire connecting.

50

HYUNDAI DAEYANG
 DIAL VALUE PROCESS

Composition and Function

4
NO Name Contents

P D A
Dial Rotate
① Return to main screen
Value Button

② MAIN Button Main Ctrl. Detail View

③ PORT Button Port Ctrl. Detail View

④ ST’BD Button Starboard Ctrl. Detail View

51

HYUNDAI DAEYANG
Composition and Function

④ ⑥

⑤ ③

① ②

4
NO Name Contents

P D A
① Input Windows Display the value of control dial for each position

② REQ Button Load of position value of control dial

③ Write Button Save input value

④ Clear Button Clear input windows

⑤ All Req Button Load all position value of control dial

⑥ Back Button Return to back screen

Dial Rotate
⑦ Return to main screen
Value Button

52

HYUNDAI DAEYANG
Operating (Engineer Mode)

Select the input window the current Load each position value when you click
blade angle position. the “REQ” button.

Save current loaded values when

push the “WRT” button.

4
Click “OK”.

P D A

53

HYUNDAI DAEYANG
Operating (Operator Mode)

Save current values when push the

“WRT” button.

P D A

54

HYUNDAI DAEYANG
 Error Message

◎ Trouble and Solution

◆ If input windows are not full of data.
→ Should be fill the appropriate value
into the blank.
◆ If values are wrong input such as below
example.
→ Check and change the appropriate
value.

ex) If values are PORT 100% : 720, PORT 90% : 724, you’ll have to change
PORT 100% : 753, PORT 90% : 724.

P D A

55

HYUNDAI DAEYANG
 5 NOTICE

HYUNDAI DAEYANG
 Notice

1. When changing over the operating mode or control authority, the dial of pitch
should be at the neutral position.

2. If PORT(ST’BD) side wing controller has the control authority, do not directly give
the control authority to the ST’BD(PORT) side wing controller.

3. After thruster controller has begun operating, the thruster run command is
restricted to 3 times.

4. Most operations are proceeded step by step, if you do not execute step by step,
there is an operating error message displayed on the load of main motor.
Check the message and follow the operating procedure that is recommended.

5. In the case of a motor alarm such as m.motor start fail and m.motor trip, push the
stop button. The thruster will stop.

6. If you want to terminate the thruster controller, the normal termination procedure
should be followed.

7. Operating error messages are not the error of the controller, check the error
message table and search for the proper course of action.

5
NOTICE

57

HYUNDAI DAEYANG
 6 TROUBLESHOOTING

HYUNDAI DAEYANG
 No. Symptom Cause and Check point
Power supply is out of order, or power
Cause
connection is incorrectly connected
A power source
is not supplied to Check if power supply is operating or not
1 Check if power source is stable
the side thruster Check
controller - Refer to the connection list
point
: Main Source(15th, 16th) and EM'CY source
(17th, 18th) in the terminal board unit, TB-5
Cause An oil system is abnormal has malfunctioned.

Check the hydraulic oil system and signal

The Oil alarm is connection
2 displayed on the - Refer to the connection list.
Check
LED panel * Oil Low pressure(A20,B20), Gravity Tank
point
Level Low(A21,B21), Hyd. P/P Filter
Clog’g(A22, B22), Hyd. P/P overload(A23,
B23), Oil Temp. High(A24,B24)
Cause M.Motor system is abnormal status
Check the M.Motor system and signal connection.
A M.Motor alarm - Check the connection list
3 is displayed on Check * M. Motor Start Fail(A5,B5), M. Motor Trip
the LED panel point (A6,B6), M. Motor Overload(A7, B7),
M. Motor High Temp.(A8,B8), M. Motor Earth
Fault(A9,B9)
The controller doesn’t have controller authority to
Cause
operate

“Err0” is Check the controller authority

4 displayed on the - Step1 : Check the station mode either WHEEL
LED panel Check HOUSE or WINGS
point - Step2 : Run exactly as according to the
controller authority sequence for the
station changeover

Main controller is not aware of CAN

“Err11“ is Cause
communication interface
5 displayed on the
LED panel Check Check CAN communication cable lines and CAN
point interface IC of main controller.

Wing controller of PORT side is not aware of CAN

Cause
“Err12” is communication interface
6 displayed on the Check CAN communication cable lines and CAN
LED panel Check
interface IC of wing controller or check the load
point
resistance value.

Wing controller of STBD side is not aware of CAN

Cause
“Err13” is communication interface
7 displayed on the Check CAN communication cable lines and CAN
LED panel Check
interface IC of wing controller or check the load
point
resistance value.

59

HYUNDAI DAEYANG
 No. Status Cause and Check point

Remote I/O PCB on the terminal board is not aware of

Cause
“Err14” is CAN communication interface
8 displayed on Check CAN communication cable lines and CAN
the LED panel Check
interface IC of remote I/O PCB or check the load
point
resistance value.
The mode change is not allowed because the pitch
Cause indicator and status of the control are not matched on
each other
“Err2” is
9 displayed on Check the indicator value to see if its equal to the
the LED panel control value on the pitch section
Check
- Step1 : Turn the pitch command dial and then
point
fit it until it meets with the pitch
feedback value

“Err3” is Cause Mode status is not correct

10 displayed on Check Check the current control operation mode
the LED panel point - Operator should adjust AUTO/MANUAL mode
When power is ON, the initial information cannot read
Cause
accurately
1. Enter the value of the blade angle transmitter again
Err4” is * Step1
11 displayed on - The previous value of the blade angle transmitter
the LED panel Check
store at the PDA
point
- Adjust the value of the dial by using the PDA
2. Remember that this can be operated only on manual
mode.
Cause The pitch value is over the operating range
“Err5” is
12 displayed on The range of limit of the Port or ST’BD is at its limit.
Check
the LED panel - Operate it within the range (At least, a 10 %
point
reduction)

The button is not exactly pressed according to

“Err6” is Cause the operating sequence operated using an illegal
13 displayed on sequence
the LED panel Check
Check operating sequence in the manual
point

This error message is displayed to indicate that the

“Err7” is Cause
main source (AC 220V) has failed
14 displayed on
the LED panel Check Check main source(AC220V) or main source
point connection status or relay1 of terminal board

This error message is displayed to indicate that

“Err8” is Cause
emergency source (DC 24V) has failed
15 displayed on
the LED panel Check Check emergency source(DC24 V) or emergency
point source connection status or relay2 of terminal board

60

HYUNDAI DAEYANG
 7 APPENDIX

HYUNDAI DAEYANG
 Dial Setting parameter & Value

Range Unit Remark

Dial full Scale 0 ~ 1023 A/D
PORT 100 923 A/D *

PORT 90 898 A/D *

PORT 80 874 A/D *

PORT 70 850 A/D *

PORT 60 827 A/D *

PORT 50 802 A/D *

PORT 40 778 A/D *

PORT 30 755 A/D *

PORT 20 731 A/D *

PORT 10 707 A/D *

Neutral 684 A/D *

ST’BD 10 659 A/D *

ST’BD 20 635 A/D *

ST’BD 30 612 A/D *

ST’BD 40 588 A/D *

ST’BD 50 564 A/D *

ST’BD 60 540 A/D *

ST’BD 70 517 A/D *

ST’BD 80 493 A/D *

ST’BD 90 469 A/D *

ST’BD 100 445 A/D *

* The side thruster engineer makes it possible to control precisely.

62

HYUNDAI DAEYANG
 Blade Angle Setting parameter & Value

Range Unit Remark

Dial full Scale 0 ~ 1023 A/D
PORT 100 923 A/D *

PORT 90 898 A/D *

PORT 80 874 A/D *

PORT 70 850 A/D *

PORT 60 827 A/D *

PORT 50 802 A/D *

PORT 40 778 A/D *

PORT 30 755 A/D *

PORT 20 731 A/D *

PORT 10 707 A/D *

Neutral 684 A/D *

ST’BD 10 659 A/D *

ST’BD 20 635 A/D *

ST’BD 30 612 A/D *

ST’BD 40 588 A/D *

ST’BD 50 564 A/D *

ST’BD 60 540 A/D *

ST’BD 70 517 A/D *

ST’BD 80 493 A/D *

ST’BD 90 469 A/D *

ST’BD 100 445 A/D *

* The side thruster engineer makes it possible to control precisely.

63

HYUNDAI DAEYANG
D Technical data for hydraulic system 222
-1 Arrangement of hydraulic pump unit 223
-2 Data sheet of hydraulic pump motor 224
-3 Gravity tank with air cooler 225
-4 Data sheet of air cooler motor 226
-5 Outline of Hydraulic pump motor starter 227
-6 Schematic diagram of hydraulic pump motor starter 228
-7 Terminal block 231
-8 Outline of air cooler starter 232
-9 Schematic diagram of air oil cooler 233
-10 Instruction manual for Hydraulic power package 234
-78-
 DATA SHEET 10 HP - 4P
of TE
AC INDUCTION MOTOR DESIGN NO :
Model No.or RFQ No. Item No. Rev. No. [ 0 ]
Project Name Project No. Quantity :
GENERAL SPECIFICATION PERFORMANCE DATA
Frame No. 132M Output 10 HP 7.5 KW
Type HL-SD Poles 4P
Enclosure(Protection) Totally Enclosed (IP 44 ) Rotor Type Squirrel Cage
Cooling Method IC411(FC) Starting Method(*) D.O.L. Y-
Frequency 60 Hz Rated Voltage 440 V V V
Phase 3Φ Rated Load 14.1 A A A
Current
Insulation Class F B H Start'g-D.O.L 88.8 A A A
Temp. Rise at full load (by resistance method) Efficiency
at 1.0 S.F 105 ℃ 50% Load 86.5 %
Location Indoor Outdoor 75% Load 88.0 %
Altitude Less than 1000 meter 100% Load 87.0 %
Humidity Less than 80 % Power Factor
Ambient Temp. 40 ℃ (Max.) 50% Load 66.0 %
Duty Continuous(S1) 75% Load 76.0 %
Service Factor 1.15 100% Load 80.5 %
Electric Design NEMA Design B Speed at Rated Load 1760 RPM / SLIP 2.2 %
Construction B3 B5 V1 Torque (D.O.L)
Type Anti-friction Rated 4.1 Kg.m 100 %
Bearing DE/ODE 6208ZZC3 \ 6208ZZC3 Starting 8.7 Kg.m 210 %
Lubricant Grease(POLYREX-EM) Break down 10.4 Kg.m 250 %
External Thrust Not applicable Allowable Load GD 2 referred to motor shaft
Coupling Method Direct V-Belt 25.0 Kg.m 2
Shaft Extension Single Double Motor GD² 0.120 Kg.m 2
Main Steel Cast Iron Noise Level (dB(A)) 77 dB(A) at 1m from motor(No-load)
Terminal Aux. Yes No Vibration(Velocity) 3.8 mm/sec.(peak)
Box Location Left Right Starting Duty Cold 2 times \ Hot 1 time
(Viewed from Drive End) Paint Munsell No. 7.5BG 7/2
Application SUBMITTAL DRAWING
Area Classification Not applicable Outline Dimension Drawing \ Motor Weight(Approx.)
Applicable Standard KS,IEC B3 Kg
Inspection and Performance Test B5 Kg
HHI Stand. Maker Test Report V1 JL132TV001 70 Kg
ACCESSORIES(OPTION ITEM)
Main T-Box Ass'y 227B8003CB2
* SPACE HEATER (WIDING TYPE)

SPARE PARTS REMARK

Note: Others not mentioned in this specification shall be in accordance with Date DSND CHKD CHKD APPD
HHI standard.
Above technical data are only design values and shall be guaranteed 2004.06.01 BAEK.W.H CHOI.H.E KIM.Y.S
with tolerance of applicable standard. -79-
HHI W440-E017-1 * In case of Inverter or V.V.V.F Motor:Performance data is based on sine wave tests. A4(210mm X 297mm)
-80-
 AC INDUCTION MOTOR DATA SHEET
Model No.or RFQ No. Item No. Rev. No. [ 0 ]
Project Name Project No. Quantity sets
GENERAL SPECIFICATION PERFORMANCE DATA
Frame Size 90L Rated Output 1.1 kW 1.5 HP
Type HM Number of Poles 4 sin
Enclosure(Protection) Totally Enclosed ( IP44 ) Rotor Type Squirrel Cage
Method of Cooling IC411(FC) Starting Method* D.O.L Y-
Rated Frequency 60 Hz Rated Voltage 440 V
Number of Phases 3 Current Full Load 2.45 A
Insulation Class F B H Locked-rotor** 600 %
Temp. Rise at full load (by resistance method) Efficiency
at 1.0 S.F 105 deg. C 50% Load 74.0 % sin
Motor Location Indoor Outdoor 75% Load 76.5 % sin
Altitude Less than 1000 meter 100% Load 77.0 % sin
Relative Humidity Less than 95 % Power Factor(p.u)
Ambient Temp. 45 deg. C (Max.) 50% Load 0.605 sin
Duty Type Continuos ( S1 ) 75% Load 0.730 sin
Service Factor 1.0 100% Load 0.765 sin
Mounting B3 B5 V1 B3/B5 Speed at Full Load 1700 r.p.m sin
Type Anti-Friction Torque
Bearing DE/N-DE 6205ZZ / 6204ZZ Full Load 0.63 kg·m sin
Lubricant Grease(SML4) Locked-rotor** 270 % sin
External Thrust Not applicable Breakdown** 280 % sin
Coupling Method Direct V-Belt Moment of Inertia (J)
Shaft Extension Single Double Load(Max.) 3.500 kg·m2
Terminal Main Steel Cast Iron Motor 0.014 kg·m2
Box Aux. Yes No Sound Pressure Level (No-load & mean value at 1m from motor)
Location Refer to Outline Drawing 65 dB(A)
Application Vibration 1.6 mm/sec (r.m.s)
Area classification Non-Hazardous Permissible number of Cold 2 times
Type of Ex-Protection Not applicable consecutive starts Hot 1 times
Applicable Standard KS,IEC Paint Munsell No. 7.5BG7/2
ACCESSORIES SUBMITTAL DRAWING
Outline Dimension Drawing \ Motor Weight(Approx.)
Winding Heater type : 38V 0.6A , 1Phase B3 227B5010AB03 20 kg
B5 kg
V1 kg
B3/B5 kg
Main T-Box Ass'y 227B1535AB

SPARE PARTS REMARK

Date DSND CHKD CHKD APPD

2011.07.18 C.S.KO J.S.JEONG S.W.SEO B.M.YOO

Note: Others not mentioned in this data sheet shall be in accordance with maker standard.
Above technical data are only design values and shall be guaranteed with tolerance of applicable standard.
Inspection and performance test shal
-81-

HHI W230-131-1 A4(210mm X 297mm)

-82-
-83-
-84-
-86-
-87-
-88-
 DOC.NO ; K3205-AF3581

Instruction Manual for hydraulic power package REV. NO. ; 0

PAGE NO. ; 1

CONTENTS

PAGE
1. SYSTEM OUTLINE ................................................................................................. 2

2. FUNCTION OF THE MAIN COMPONENTS…………......................................... 2 - 3

2.1 HYDRAULIC PUMP UNIT(7011)
2.2 GRAVITY TANK(7012)
2.3 AIR OIL COOLER(8014)

3. MANUAL OPERATION PROCEDURE………….................................................... 4

4. MAINTENANCE AND INSPECTION..................................................................... 5 – 7

4.1 PREPARATION FOR OPERATION
4.2 TROUBLE SHOOTING TABLE

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

 DOC.NO ; K3205-AF3581

Instruction Manual for hydraulic power package REV. NO. ; 0

PAGE NO. ; 2

1. SYSTEM OUTLINE
The hydraulic oil pump unit is an equipment to control propeller pitch of the thruster by pitch
directional order (command signal) from Remote Controller installed on wheel house or wing side.
Before starting the thruster, the hydraulic oil pump should be kept in a run.
At this time, the discharged working oil by the pump flows down to inside of the gear casing of
the thruster through the relief valve(7011-6) without changing propeller pitch.
In case pitch control is necessary, the pressurized oil rush into the sliding block of the thruster until
reaching the spot corresponds to pitch order signal shut off valve(7011-12).
The unit can be mainly divided into three parts. Namely, driving parts (hydraulic oil pump & motor),
manifold block for pitch control (shut off valve, etc)and system protection parts (pressure switch,filter,
etc).
Note : Prior to operating thruster, the operator should confirm whether the condition of the hydraulic
system is normal or not. If an alarm might occur, the following trouble shooting table will be
helpful to solve the problem.

2. FUNCTION OF THE MAIN COMPONENTS

2.1 Hydraulic Pump Unit (7011)
(1) Hydraulic Pump ( 7011-1)
The hydraulic pump generates a flow of fluid and keep the preset pressure to the thruster for
pitch control and holds it until getting pitch order signal from remote controller.
The hydraulic pump which is applied to this system is gear type which has same torque
characteristics all through the range.

(2) Pressure Switch (7011-7,8)

This switch is used to know system pressure drop under normal condition which might
occur by oil leakage from connection pipe.
This alarm signal is used not only for alarm remote indication but also for starting interlock of
the thruster motor.

(3) Solenoid Valve (Shut off Valve, 7011-12)

The role of this valve make a flow of fluid or block into sliding shoe of the thruster in order to
control propeller pitch by remote order signal.
Our system has one(1) solenoid valve (normally closed) and guides the pressure oil via pipes
to the required chamber.

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

 DOC.NO ; K3205-AF3581

Instruction Manual for hydraulic power package REV. NO. ; 0

PAGE NO. ; 3

(4) Line Filter (7011-11)

(1) In order to ensure a long service life, a cleanliness of working oil is very important. This
filter is located in the front of manifold block and prevents to clog by foreign matters which
can cause severe malfunction.
If being clogged, the alarm signal will be sent to the remote controller and alarm monitoring
system for warning.
(5) Suction Filter (7011-13)
(1)This filter is used to clean up on working oil to detect and screen oil contamination on the
suction line of the gravity tank. It has also check valve for clogging.
Please make sure the bolt for check valve to be securely closed during operation of the
thruster.

2.2 Gravity Tank (7012)

(1) Level Switch (7012-1)
This switch is used to transmit the alarm signal to remote for warning when the oil level drops
below the preset value. It has also a test lever by which activation of the switch contact can be
identified without disassembling from gravity tank body.

2.3 Air oil cooler (8014)

This cooler will start when L.O temperature is over 45°C. Please open ‘bypass valve’
(8014-2) when L.O temperature is below 10°C to avoid excessive back pressure.
Inlet and Outlet valves(8014-3,4) should be continuously open except cooler maintenance.

3. Manual operation procedure

Manual operation is used for emergency situation without remote control.

Two worker are needed. One worker control hyd.power unit during the other one looking at blade
angle transmitter to check blade postion.

3.1 Change the control Position (W/H →Local) on the bow thruster control panel in E.C.R
3.2 Start Hyd.pump unit at local side. (“Start” on push button box in the thruster room)
3.3 Remove 4 plastic caps on the solenoid valve.
3.4 Pitch Control
i. push the right side of Sol v/v by L-wrench.

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

 DOC.NO ; K3205-AF3581

Instruction Manual for hydraulic power package REV. NO. ; 0

PAGE NO. ; 4

ii. push the left side of Sol v/v by L-wrench.

CAUTION! Handle with care!

Do not operate blade angle position over 100%.

4. MAINTENANCE AND INSPECTION

It is necessary to carry out proper maintenance and inspection in order to keep this system work
satisfactorily. Proceed the maintenance and inspection by the following table.
4.1 Preparation for Operation
The following check articles shall be carried out before (a few hours) starting the thruster.

No. Articles Judgement

It shall be over high level mark on the
1 Check for oil level of the gravity tank
gravity tank.

2 Check for contamination status of working oil Sampling

Check for pressure gauge of hyd. pump in an

3 Atmospheric pressure (1bar)
idle condition
Check if discharge pressure of hyd. pump is
4 operating pressure : 90 bar
running or not during operation.

5 Check for abnormal sound during operation

Check if oil temperature is in a normal condition

6 proper oil temperature: 10 ~70℃
or not

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

 DOC.NO ; K3205-AF3581

Instruction Manual for hydraulic power package REV. NO. ; 0

PAGE NO. ; 5

Check if the suction filter and check valve in the

7 Clogging indicator : RED color
HPU is blocked or not
Check if the line filter in the hyd. pump unit is If clogged, on the remote controller :
8
clogged or not. “Filter Clogging” Lamp flickering
Check if there is any leakage from oil pipe joints Visual check or the drop of system
9
or not. pressure

4.2 Trouble Shooting Table

Trouble Cause Remedy

After checking the rotation

Rotation direction of the pump is
direction plate on the pump body,
reversed.
reconnect motor power cable.

Oil level of the gravity tank is too Filling oil over high level mark on the
Pump not low. gravity tank.
delivering
After removing filter element from
Suction filer on the HPU is clogged by
suction filter, clean it by air or replace it
foreign matter.
with new one.

Viscosity of operating oil is too high. Change it to proper oil.

Air can be contained in the suction

Bleeding of air from the suction oil.
Abnormal oil of the pump.
Sound Bearing part of the pump can be worn After disassembling of the pump, replace
away. it with new one.
After disassembling spool of the solenoid
Opening hole of solenoid valve spool is
valve, clean the spool and remove foreign
Pitch control clogged by foreign matters.
matters from it.
does not operate
Adjust operating pressure by turning the
smoothly.
bolt screw of Relief Valve to
Operating pressure is wrongly set.
setting value described on the
drawing.

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

 DOC.NO ; K3205-AF3581

Instruction Manual for hydraulic power package REV. NO. ; 0

PAGE NO. ; 6

Throttle valve for adjusting flow

Open the setting point slowly..
quantity can be closed.
Operating voltage for solenoid
Check electric circuit.
valve is unstable.

Oil leakage can be found on the pipe

Replace it or tighten the joints.
and coupling joints.

Abnormal Adjust operating pressure by turning the

Pressure bolt screw of Relief Valve to
Operating pressure is wrongly set.
Drop or Raise setting value described on the
drawing.
Oil pipe and connection parts on the
After disassembling the pipe, remove
discharge side of the pump are
it.
blocked by foreign matters.

HSEF-K320-C041(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)

E Spare parts and Special tool list 240
-1 Spare parts list 241
-2 Special tools list 250
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 1

HULL NO. NCP0123~25

EQUIP. NAME PROPELLER UNIT
PROJECT NAME 3000kW THRUSTER

SUPPLY
PER UNIT DRAWING NO.
NO. DESCRIPTION SPECIFICATION MATERIAL REMARKS
/ PART NO.
WORK SPARE

1 O - RING NBR 1 1

A = 960, B = 10.0

2 O - RING NBR 1 1

A = 800, B = 8.0

3 O - RING NBR 1 1

A = 1142, B = 7.0

4 O - RING NBR 1 1

A = 215, B =5.0

5 O - RING FPM 1 1

A = 33.5, B = 3.00

6 O - RING FPM 24 24

A=52.0 B=3.5

7 QUAD RING FPM 4 4

A = 430.66, B = 7.0

8 O - RING NBR 1 1

A = 724 B = 7.0

9 ROD SEAL PTFE+ETC 1 1

A = 340

10 WEAR RING PTFE+ETC 1 1

A=340, B=19.5

-90-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 2

HULL NO. NC0123~25

EQUIP. NAME PROPELLER UNIT
1800KW THRUSTER 3000kW THRUSTER

SUPPLY
PER UNIT DRAWING NO.
NO. DESCRIPTION SPECIFICATION MATERIAL REMARKS
/ PART NO.
WORK SPARE

11 O - RING NBR 1 1

A = 450, B = 7.0

12 O - RING FPM 1 1

A = 17.7, B = 3.0

13 ROD SEAL PTFE+ETC 1 1

A = 340

14 WEAR RING PTFE+ETC 1 1

A=340, B=19.5

15 O - RING FPM 12 12

A = 64.0, B = 4.0

16 O - RING NBR 1 1

A = 164.0, B = 4.0

17 O - RING NBR 1 1

A = 429, B = 6.0

18 O - RING NBR 1 1

A = 358, B = 6.0

19 O - RING NBR+PTFE 1 1

A = 32 B = 3.0

SINGLE LIP
20 NBR 1 1
WIPER

A = 20, B =28, C=6

-91-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 3

HULL NO. NCP0123~25

EQUIP. NAME PROPELLER UNIT
PROJECT NAME 3000kW THRUSTER

SUPPLY
PER UNIT DRAWING NO.
NO. DESCRIPTION SPECIFICATION MATERIAL REMARKS
/ PART NO.
WORK SPARE

ROD SEAL
21 (DOUBLE NBR+PTFE 1 1
ACTING) A = 20

RUBBER
22 NBR 1 1
GASKET
A=130, B=69

23 O - RING NBR+PTFE 1 1

A = 53 B = 5

24 O - RING NBR 2 2

G 30

Non
25 GASKET Asbestos 1 1 15A x 10K

A = 15, B = 10

Non
26 GASKET Asbestos 1 1 25A x 5K

A = 25, B = 10

27 O - RING NBR 1 1

G 35

Non
28 GASKET Asbestos 1 1 20A x 5K

Non
29 GASKET Asbestos 1 1 65A x 5K

-92-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 4

HULL NO. NCP0123~25

EQUIP. NAME PROPELLER UNIT
PROJECT NAME 3000kW THRUSTER

SUPPLY
PER UNIT DRAWING NO.
NO. DESCRIPTION SPECIFICATION MATERIAL REMARKS
/ PART NO.
WORK SPARE

RUBBER
30 GASKET FOR NBR 1 1
HYD.

RADIAL SHAFT
31 FPM 2 2
SEAL

A = 230 B=200 C=10

32 V - RING NBR 1 1

33 OIL SEAL NBR 2 2 1170H

Non
34 GASKET Asbestos 2 2 1170H

-93-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 5

HULL NO. NCP0123~25

EQUIP. NAME HPU & Gravity Tank
PROJECT NAME 3000kW THRUSTER

SUPPLY
PER UNIT DRAWING NO.
C DESCRIPTION SPECIFICATION MATERIAL REMARKS
/ PART NO.
WORK SPARE

LINE FILTER
1 1 1 DF BN/HC140MA
ELEMENT

PRESSURE
2 1 1 Ø 63x160K("A", OIL)
GAUGE

3 TEST HOSE 0 1 1M

-94-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 6

HULL NO. NCP0123~25

EQUIP. NAME HYD.PUMP MOTOR STARTER
PROJECT NAME 3000kW THRUSTER

-95-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 7

HULL NO. NCP0123~25

EQUIP. NAME HYD.PUMP MOTOR STARTER
PROJECT NAME 3000kW THRUSTER

-96-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 8

HULL NO. NCP0123~25

EQUIP. NAME MAIN MOTOR
PROJECT NAME 3000kW THRUSTER

-97-
 DOC. NO. K3212-AF0190
SPARE PART LIST
SHEET NO. 9

HULL NO. NCP0123~25

EQUIP. NAME CONTROLLER
PROJECT NAME 3000kW THRUSTER

-98-
 DOC. NO. K3212-AF0190
SPECIAL TOOL LIST
SHEET NO. 10

HULL NO. NCP0123~25

EQUIP. NAME PROPELLER UNIT
PROJECT NAME 3000kW THRUSTER

SUPPLY DRAWING NO.

NO. DESCRIPTION SPECIFICATION MATERIAL REMARKS
PER UNIT / PART NO.

MOUNTING
1 - 4
STRAP

TRANSPORT
2 - 1
CLAMP

SPARE PARTS
3 AND TOOLS - 1
A =400
BOX
B = 500
C = 300

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