Kongsberg Simrad RPU80 Instruction Manual
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Kongsberg Simrad RPU80 Instruction Manual

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INSTRUCTION MANUAL
Simrad RPU80/160/300
Reversible Pump
20220422

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Summary of Contents for Kongsberg Simrad RPU80

  • Page 1 INSTRUCTION MANUAL Simrad RPU80/160/300 Reversible Pump 20220422...
  • Page 2 1RWH Simrad AS makes every effort to ensure that the information contained within this document is correct. However, our equipment is continuously being improved and updated, so we cannot assume liability for any errors which may occur. :DUQLQJ The equipment to which this manual applies must only be used for the purpose for which it was designed.
  • Page 3 Instruction Manual Instruction Manual This manual is intended as a reference guide for correctly installing and maintaining the RPU80, RPU160 and RPU300 reversible pumps. Please take time to read this manual to get a thorough understanding of the reversible pump and its relationship to a complete autopilot system.
  • Page 4 Robertson Reversible Pump RPU80/160/300 Document revisions Documentation Hardware/Software Project/Product department design Management Date Sign Date Sign Date Sign – 17/1-94 N.G. 17/1-94 I.K. 17/1-94 Th.H. 15/9-94 N.G. 15/9-94 I.K. 15/9-94 Th.H. 4/4-95 N.G. 4/4-95 I.K. 4/4-95 Th.H. 10/1-96 N.G. 10/1-96 I.K.

  • Page 5: Table Of Contents

    Instruction Manual Contents INTRODUCTION ................5 General ..................5 Hydraulic steering gear suitable for the RPU80/RPU160/RPU300 ............7 MEASUREMENTS AND CALCULATIONS FOR APPLYING THE RPU ....................12 Calculation of cylinder volume ........... 12 Minimum rudder time adjustment........12 DESCRIPTION OF RPU80/RPU160/RPU300........14 Construction ................
  • Page 6 Robertson Reversible Pump RPU80/160/300 The piston rod does not move with rudder commands .. 24 The rudder does not stay in off-midship position, but drifts towards midship due to water pressure on the rudder ..................24 Steering wheel is turning while pump unit is operated .. 25 The piston rod of the rudder cylinder does not move smoothly.................

  • Page 7: Introduction

    Introduction INTRODUCTION This manual does not cover a previous model RPU80 with serial numbers Note ! 101-248. The model is covered by the RPU100 Reversible Pump Manual. Minor modifications where made to the RPU100 model and they are described in a separate "Technical Information" no. 01/94. 1.1 General Hydraulic steering systems are now being used in every category of small vessel.
  • Page 8 Robertson Reversible Pump RPU80/160/300 buttons on the autopilot in manual mode, the rudder speed will be 8 degrees per second, whilst the rudder speed when in "Auto" mode normally is less and proportional to the heading error. If the pump unit is used with autopilot models like AP2500, AP200 or AP45, using J1000B, J101A or J45A junction units, the output level/flow rate is set by a potentiometer within the junction unit.

  • Page 9: Rpu80/Rpu160/Rpu300

    Introduction 1.2 Hydraulic steering gear suitable for the RPU80/RPU160/RPU300 All cylinders are single and balanced type unless otherwise specified. If the cylinder type in your boat is not listed, please refer to section 2. Steering gear Cylinder Estimated rudder time in seconds hard over volume cm to hard over (cu.in.)
  • Page 10 Robertson Reversible Pump RPU80/160/300 Steering gear Cylinder Estimated rudder time in seconds hard over volume cm to hard over (cu.in.) RPU80 RPU160 RPU300 HYNAUTIC (continued) K-18 115 (7,0) K-19 147 (9,0) K-22, K27 218 (13,3) K-28, K29 262 (16,0) K-31 418 (25,5) K-51 167 (10,2)
  • Page 11 Introduction Steering gear Cylinder Estimated rudder time in seconds hard over volume cm to hard over (cu.in.) RPU80 RPU160 RPU300 LECOMBLE & SCHMITT – Old models: VHM 32-DT 90 (5,5) VHM 35-DTP 152 (9,3) VHM 35-DT 129 (7,9) VHM 45-DT 240 (14,6) SEASTAR BA 125-7...
  • Page 12 Robertson Reversible Pump RPU80/160/300 Steering gear Cylinder Estimated rudder time in seconds hard over volume cm to hard over (cu.in.) RPU80 RPU160 RPU300 SERVI (Norwegian) MA 60 141 (8,6) MA 120 294 (17,9) MA 200 500 (30,5) MA 300 750 (45,8) SLEIPNER, HYDRIVE (Norwegian) LS 35 90 (5,5)
  • Page 13 Introduction Steering gear Cylinder Estimated rudder time in seconds hard over volume cm to hard over (cu.in.) RPU80 RPU160 RPU300 VETUS (continued) MT 225 500 (30,5) MT 340 750 (45,8) MT 450 1000 (61,0) Outboard engine cylinders: OB 35 106 (6,5) OB 85 170 (10,4) Old models:...

  • Page 14: Measurements And Calculations For Applying The Rpu

    Robertson Reversible Pump RPU80/160/300 MEASUREMENTS AND CALCULATIONS FOR APPLYING THE RPU 2.1 Calculation of cylinder volume The RPU80 is recommended for cylinders between 80-250 cm (4,9- 15,2 cu. in.), RPU160 for cylinders between 160-550 cm (9,8-33,5 cu.in.) and RPU300 for cylinders between 290 -960 cm (17,7-58,5 cu.in.).
  • Page 15 Measurements and calculations for applying the RPU Example: The stroke length is measured to be 20 cm, D = 5.0 cm and d = 1.8 cm π − The cylinder volume is: = 340 cm From the nomogram we find that the estimated rudder time in seconds, hard over to hard over, will be 7 seconds for RPU300, 13 seconds for RPU160 and 25 seconds for RPU80.

  • Page 16: Description Of Rpu80/Rpu160/Rpu300

    Robertson Reversible Pump RPU80/160/300 DESCRIPTION OF RPU80/RPU160/RPU300 3.1 Construction The pump comprises an electric permanent magnet motor, valve block with reversible gear pump, non-return (check) valves on outlet A and B and suction valves from both sides of the gear pump to outlet C.

  • Page 17: Principle Of Operation (Ref. Figure 3-1 And Figure 9-1)

    Description of RPU80/RPU160/RPU300 3.2 Principle of operation (ref. figure 3-1 and figure 9-1) RPU80/160/300 is reversible: that is the motor changes direction of rotation and the gear pump delivers oil to that side of the rudder cylinder dictated by the signal from the autopilot. The pump runs until the signal from the autopilot ceases.

  • Page 18: Gear Pump

    Robertson Reversible Pump RPU80/160/300 3.4 Gear pump This comprises of the driving gear wheel, which is coupled to the motor shaft via a flexible shaft coupling, and meshed with the driven gear wheel supported by the valve block (1) at one end and by the pump cover (5) at the other.

  • Page 19: Installation

    Installation INSTALLATION 4.1 Mechanical Installation Siting The pump unit should be sited where it is most practical between rudder cylinder and helm pump, however, it should not be mounted in a wet area. If the pump unit is sited higher than the rudder cylinder, air bubbles in the oil coming from the rudder cylinder could pass through the pump unit on the way to the expansion tank in the steering wheel pump.
  • Page 20 Robertson Reversible Pump RPU80/160/300 • Tighten further by 30 degrees (= 1/12 of a turn) using excessive force (25-30 Nm/230-260 In.Ibs). Pumps with new fittings have got new serial no. code and is valid from the following s.no’s; RPU80: s.n. 2460 H06, RPU160: s.n. 1560 H14, RPU300: s.n.
  • Page 21 Installation Figure 4-4 Pipes should be bent cold. Attempts to use blowtorch and sand will lead to impurities entering the system, and should therefore be avoided. Stop cocks should be fitted to all pipes near the pump unit. Sluice cocks or similar should be used, and not cocks of the water supply type.
  • Page 22 Robertson Reversible Pump RPU80/160/300 Figure 4-1 Connection to hand hydraulic steering gear Drw.no. 3-110101 Figure 4-2 Connection to Capilano steering gear Drw.no. 3-110115 20220422K...

  • Page 23: Electrical Installation

    Installation 4.2 Electrical installation J3000X, J300X, J300X-40 The two leads from the motor are connected to the terminal block marked "MOTOR" in the Junction unit. There is no dedicated Port and Stbd output. The autopilot will automatically set the correct direction during "Rudder Test".

  • Page 24: Preparation And Testing

    Robertson Reversible Pump RPU80/160/300 PREPARATION AND TESTING 5.1 Oil filling and bleeding When installing a pump unit, it is recommended that the whole system be emptied and refilled. Use a well known oil of a viscosity meeting the specification of the steering gear manufacturer. Start by opening all stop cocks in the pipes leading to the pump unit.

  • Page 25: Maintenance

    Maintenance MAINTENANCE 6.1 Dismantling After approximately 1000 operating hours, the pump unit should be removed for examination. Close the stop cocks to the pump unit, remove the nuts on the 3 couplings and all retaining nuts. Screw out the 2 fixing screws (24) located on each side of the pump cover which hold the valve block and motor together.

  • Page 26: Fault Tracing

    Robertson Reversible Pump RPU80/160/300 FAULT TRACING If fault develops, the source and location must be traced. Close all stop cocks to the pump unit and check whether the steering gear functions normally using only the steering wheel pump. If so, then the fault is most probably in the pump unit or junction unit.

  • Page 27: Steering Wheel Is Turning While Pump Unit Is Operated

    Fault tracing pressure on the ball is sufficient to keep the ball seated. The spring needs a certain pre-loading to bring the slide back to neutral position. 2. If the problem appears on an RPU80 installation, the reason may be oil contamination or worn ball seals in the suction valves. Remove the steel balls for inspection and check the seals for possible wear.

  • Page 28: Small And Sudden Heading Changes While On Automatic Steering

    Robertson Reversible Pump RPU80/160/300 2. Wrong setting of the autopilot. Refer to the set-up procedure for the autopilot. 7.8 Small and sudden heading changes while on automatic steering (J1000B, J101A, J45A only) Probable reasons: 1. The rudder movement is too fast. Turn potentiometer RV1 in junction unit counter-clockwise (CCW) until optimum rudder speed is achieved.
  • Page 29 Fault tracing 3. Make sure the grub screw (21) is screwed in until it is flush with the valve block (1). This will ensure correct spring tension in the suction valve. 20220422K...

  • Page 30: Technical Specifications

    Robertson Reversible Pump RPU80/160/300 TECHNICAL SPECIFICATIONS 8.1 Specifications RAM CAPACITY MODEL MOTOR JUNCTION FLOW PWR. BOAT VOLTS UNIT RATE AT PRESSURE CONSUM- LENGTH (cu. in.) (cu. in.) 10 bar PTION /min (cu.in/min) RPU80 12 V J3000X 80 (4,9) 250 (15,2) 800 (49) 2,4-6 A <35 ft...
  • Page 31 Technical Specifications Figure 8-2 RPU160 Dimensions Drw.no. N3-111835 Figure 8-3 RPU300 Dimensions Drw.no. N3-111834 20220422K...

  • Page 32: Rpu80 Performance

    Robertson Reversible Pump RPU80/160/300 8.3 RPU80 performance PRESSURE (BAR) Capacity versus Current versus pressure pressure 8.4 RPU160 performance PRESSURE (BAR) Capacity versus Current versus pressure pressure 8.5 RPU300 performance PRESSURE (BAR) Capacity versus Current versus pressure pressure 20220422K...
  • Page 33 Technical Specifications 20220422K...

  • Page 34: Spare Parts

    Robertson Reversible Pump RPU80/160/300 SPARE PARTS 9.1 RPU80/RPU160/RPU300 Figure 9-1 Gear pump RPU80/RPU160/RPU300 Assembly drawing Pos. Qty. Gear pump parts Part no. Valve block 21100250 Fitting complete 7/16-20UNF 44166767 Fitting US model complete: 21101399 Nut 3/8” with 5/8”x18 SAE 44155927 Fitting SAE 5/8”-18-7/16-20UNF 44166775 Pump cover RPU80/160...
  • Page 35 Spare Parts Plug 21100292 Spring 21100193 Spring 21100391 Slide 21100268 Steel ball Ø8 44149656 O-ring 9,25x1,78 Nitrile 44149649 Copper washer Ø10,2x14x1,5 44149706 Oil seal 8x22x7 44149722 Support ring 21100185 Copper washer Ø10,2x14x1 44148146 O-ring 9,25x1,78 Silicon, red 44154656 Steel ball Ø6,35 44118552 Grub.

  • Page 36: Rpu80 - Previous Model

    Robertson Reversible Pump RPU80/160/300 9.2 RPU80 – Previous model RPU80 Reversible Pump with ser. no. 1317 H02 onwards (P/N 21116165) and 1805 H03 onwards (P/N 21116181 – US version) have identical gear pump with the RPU160 (see figure 9-1). Removed at installation Figure 9-2 Gear pump...
  • Page 37 Spare Parts Gear wheel (1) RPU80/160 21100169 Gear wheel (2) RPU80/160 21100227 Motor parts (Ref. figures 8-2 and 8-3.) RPU80 Motor 44140713 Brushes for RPU80 motor 44161933 Brush holder cap RPU80/160 – Type I 44163228 Brush holder cap RPU80/160 – Type II 44163236 20220422K...

  • Page 38: Sales And Service Worldwide

    Fax: +358 9 692 7917 SPAIN AUSTRALIA CANADA FRANCE Simrad Spain, SL Quin Marine Pty. Ltd. Kongsberg Simrad Mesotech Ltd. Simrad S.A. Partida Torres N° 38 89 St Vincent Street (Maritime Dept.) Parc d’Activités Ragon Nave 8 Y 9 Port Adelaide, SA 5015...

This manual is also suitable for:

Simrad rpu160Simrad rpu300

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