INSTRUCTION MANUAL Simrad RPU80/160/300 Reversible Pump
Note! 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. Warning! The equipment to which this manual applies must only be used for the purpose for which it was designed. Improper use or maintenance may cause damage to the equipment or injury to personnel.
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. Other documentation material that is provided with your system includes a warranty card.
Simrad Reversible Pump RPU80/160/300 Document revisions Rev Documentation department Date Sign Hardware/Software design Date Sign Project/Product Management Date Sign D 24/10-96 N.G. 24/10-96 I.K. 24/10-96 Th.H. E 20/2-97 N.G. 20/2-97 I.K. 20/2-97 Th.H. F 5/1-98 N.G. 5/1-98 I.K. 5/1-98 Th.H. G 20/1-99 N.G. 20/1-99 I.K. 20/1-99 Th.H. H 21/1-00 N.G. 21/1-00 I.K. 21/1-00 Th.H. I 17/10-00 N.G. 17/10-00 I.K. 17/10-00 Th.H. J 30.08.01 N.G. 30.08.01 I.K. 30.08.
Instruction Manual Contents 1 INTRODUCTION..................................................................................................5 1.1 General............................................................................................................5 1.2 Hydraulic steering gear suitable for the RPU80/RPU160/RPU300 ...............7 2 MEASUREMENTS AND CALCULATIONS FOR APPLYING THE RPU.12 2.1 Calculation of cylinder volume ....................................................................
Simrad Reversible Pump RPU80/160/300 7.8 When on automatic steering, the boat swings from side to side without stabilizing after course changes .............................................................................27 7.9 Small and sudden heading changes while on automatic steering .................27 7.10 Rudder moves only in one direction (with pump running) ..........................28 4 8 TECHNICAL SPECIFICATIONS ....................................................................29 8.
Introduction 1 INTRODUCTION Note ! This manual does not cover a previous model RPU80 with serial numbers 101-248. The model is covered by the RPU100 Reversible Pump Manual. Minor modifications where made to the RPU100 model and they are described in a separate "Technical Information" no. 01/94. 1.1 General Hydraulic steering systems are now being used in every category of small vessel. In many respects hydraulic steering is preferable to mechanical steering.
Simrad Reversible Pump RPU80/160/300 An automatic "Rudder test" function in these autopilots will also limit the output equivalent to a rudder speed of 8 degrees per second which is optimum for autopilots with proportional rudder control. (Equals to approx. 9 seconds for 35-0-35 degrees rudder travel).
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 volume cm3 (cu.in.
Simrad Reversible Pump RPU80/160/300 Steering gear Cylinder volume cm3 (cu.in.
Introduction Steering gear Cylinder volume cm3 (cu.in.
Simrad Reversible Pump RPU80/160/300 Steering gear Cylinder volume cm3 (cu.in.
Introduction Steering gear Cylinder volume cm3 (cu.in.
Simrad Reversible Pump RPU80/160/300 2 MEASUREMENTS AND CALCULATIONS FOR APPLYING THE RPU 2.1 Calculation of cylinder volume The RPU80 is recommended for cylinders between 80-250 cm3 (4,9-15,2 cu. in.), RPU160 for cylinders between 160-550 cm3 (9,8-33,5 cu.in.) and RPU300 for cylinders between 290 -960 cm3 (17,7-58,5 cu.in.). These figures will give for a rudder angle of 70 degrees (35°-0-35°) a hardover to hardover time of 6-20 seconds equivalent to a rudder speed of 11,6-3,5 deg./second.
Measurements and calculations for applying the RPU Recommended rudder time: 10-15 seconds is normal for a 70° (35°-0-35°) rudder angle. (The time will be shorter for smaller angles and longer for larger angles.) A longer rudder time (20 sec.) should be chosen if the boat has a quick response. Example: The stroke length is measured to be 20 cm, D = 5.0 cm and d = 1.
Simrad Reversible Pump RPU80/160/300 3 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. Outlet C is connected to either the expansion tank in the steering wheel pump or a separate expansion tank.
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. The pump unit has non-return valves on the outlets A and B.
Simrad Reversible Pump RPU80/160/300 3.3 Valve block This is an aluminum block with borings for non-return valves, suction valves, slide, gear pump, motor coupling and all necessary oil ways. The three outlets A, B and C are positioned on top of the valve block. 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.
Description of RPU80/RPU160/RPU300 3.8 Pipe connections The 3 outlets have fittings for 3/8" (US model) or 10 mm (EU model) outer diameter pipe. The two outer outlets A and B connect to the main pipes. The middle outlet C connects to the bottom of the expansion tank in the steering wheel pump or a separate expansion tank.
Simrad Reversible Pump RPU80/160/300 4 INSTALLATION 4.1 Mechanical Installation Siting The pump unit should be sited where it is most practical between rudder cylinder and helm pump, however, it should not be mounted in a wet area. If 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. This will disturb the oil flow as the air bubbles pass through.
Installation • Use the fingers and turn clockwise until a noticeable increase in torque is required. • Tighten further by 30 degrees (= 1/12 of a turn) using necessary force (25-30 Nm/230-260 In.Ibs). Pumps with new fittings have got new serial no. code and is valid from the following s.no’s; RPU80: s.n. 2460 H06, RPU160: s.n. 1560 H14, RPU300: s.n. 380 H28, RPU300, 24V: s.n. 180 H29 Installation of pipes Drain the oil from the steering gear by loosening the rudder cylinder couplings.
Simrad Reversible Pump RPU80/160/300 A clearly formed lip should be visible on the pipe in front of the cutting ring. If this is not present, the nut should be tightened by an additional ½ - 1 turn. Check once again as above. From the T-couplings run a pipe 10x1 mm (US model: 3/8"), to the pump unit. Avoid high points in the run that could allow air pockets to form. Sharp bends in the pipes (i.e. elbow bends) should be avoided as these restrict the oil flow.
Installation Figure 4-5 Connection to hand hydraulic steering gear Drw.no. 3-110101 Figure 4-6 Connection to Capilano steering gear Drw.no.
Simrad Reversible Pump RPU80/160/300 4.2 Electrical installation J3000X, J300X, J300X-40, J50, J50-40, AC10, AC20, AC40 The two leads from the motor are connected to the terminal block marked "MOTOR" in the Junction unit/Autopilot computer. There is no dedicated Port and Stbd output. The autopilot will automatically set the correct direction during "Rudder Test". Refer to Autopilot manual for further details.
Installation 5 PREPARATION AND TESTING 5.1 Oil filling and bleeding When installing a pump unit, it is recommended that the whole system be emptied and refilled. Use a well known oil of a viscosity meeting the specification of the steering gear manufacturer. Start by opening all stop cocks in the pipes leading to the pump unit. Simultaneously fill the steering wheel pump with oil whilst turning the wheel itself, back and forth.
Simrad Reversible Pump RPU80/160/300 6 MAINTENANCE 6.1 Dismantling After approximately 1000 operating hours, the pump unit should be removed for examination. Close the stop cocks to the pump unit, remove the nuts on the 3 couplings and all retaining nuts. Screw out the 2 fixing screws (24) located on each side of the pump cover which hold the valve block and motor together. (See figure 9-1). 6.2 Electric motor Examine the brushes for wear and replace if required. 6.
Fault tracing 7 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/autopilot computer. The following faults may be tested for: 7.1 Pump (motor) is not running/not responding to rudder command Probable reason: Brushes sticking or worn out. Remove the brushes and check.
Simrad Reversible Pump RPU80/160/300 7.4 The rudder does not stay in off-midship position, but drifts towards midship due to water pressure on the rudder Probable reason (Does not apply for the previous model of RPU80): 1. The non-return valves are leaking. Shut the stop cocks to the pump unit, and operate the steering gear by means of the steering wheel pump. If the steering is normal by hand operation, the fault must be in the non-return valves or the slide.
Fault tracing 7.7 Rudder movement stops as water pressure on the rudder increases. (J1000B, J101A, J45A only) Probable reasons: 1. Overload. Check whether the r.p.m. of the motor is too low. Eventually turn potentiometer RV1 in junction unit clockwise (CW) until rudder movement is recovered. 7.8 When on automatic steering, the boat swings from side to side without stabilizing after course changes (J1000B, J101A, J45A only) Probable reasons: 1. The rudder movement is too slow. Correct as in paragraph 7.
Simrad Reversible Pump RPU80/160/300 7.10 Rudder moves only in one direction (with pump running) Probable reason: Suction valve not working (pos. 20, 9, 21) on one side. This is most probably caused by metal fragments that have entered into the suction valve(s) through the tube fitting for the return line (C) during installation. Ref. figure 3-1.
Technical Specifications 8 TECHNICAL SPECIFICATIONS 8.1 Specifications Note ! RPU300 measurements at charging voltage RAM CAPACITY MODEL MOTOR VOLTS * JUNCTION UNIT/ AUTOPILOT COMPUTER ** MIN cm3 (cu. in.) MAX cm3 (cu. in.) FLOW RATE AT 10 bar cm3/min (cu.in/min) MAX PRESSURE bar PWR. BOAT CONSUM- LENGTH PTION *** RPU80 12 V J3000X/AC10 80 (4,9) 250 (15,2) 800 (49) 60 2,4-6 A <35 ft RPU160 12 V J300X/AC20 160 (9,8) 550 (33,5) 1600 (98) 60 3-10 A 35-50 ft.
Simrad Reversible Pump RPU80/160/300 8.2 Dimensions Figure 8-1 RPU80 Dimensions Drw.no. N3-111836 Figure 8-2 RPU160 Dimensions Drw.no.
Technical Specifications Figure 8-3 RPU300 Dimensions Drw.no. N3-111834 1.5 9 1.0 6 0.5 3 AMPS CAPACITY (l/min) 8.
Simrad Reversible Pump RPU80/160/300 2.0 23 1.5 17 1.0 11 0.5 0 AMPS CAPACITY (l/min) 8.4 RPU160 performance 5 10 20 30 40 50 60 PRESSURE (BAR) Capacity versus pressure Current versus pressure 3.5 30 3.0 25 2.5 20 2.0 15 1.5 V 12 AMPS CAPACITY (l/min) 8.5 RPU300 performance* 10 24V 1.0 0 5 10 20 30 40 50 60 PRESSURE (BAR) Capacity versus pressure Current versus pressure * Measured at charging voltage.
Spare Parts 9 SPARE PARTS 9.1 RPU80/RPU160/RPU300 Figur 9-1 Gear pump RPU80/RPU160/RPU300 Assembly drawing 20220422N Pos. 1 2 2 Qty. 1 3 3 5 1 6 7 8 9 10 12 2 2 2 2 1 2 Gear pump parts Valve block Fitting complete 7/16-20UNF Fitting US model complete: Nut 3/8” with 5/8”x18 SAE Fitting SAE 5/8”-18-7/16-20UNF Pump cover RPU80/160 Pump cover RPU300 Valve housing Plug Spring Spring Slide Steel ball Ø8 Part no.
Simrad Reversible Pump RPU80/160/300 13 14 15 16 17 18 20 21 23 24 25 2 2 1 1 2 1 2 2 4 2 4 1 1 1 1 44149649 44149706 44149722 21100185 44148146 44154656 44118552 44149904 44150050 44149912 44152775 21100169 21100227 21111926 21111034 2 Motor parts (LEMAC) RPU80 Lemac motor (Substitutes RPU80 Fracmo motor) RPU160 Lemac motor (Substitutes RPU160 Fracmo motor) Brush for RPU80/160 Lemac motor, C8386 9x6x18,2mm Brush cap for RPU80/160 Lemac motor RPU300 Lemac motor, 12V (Substitutes RPU300 Fracmo motor, 12
Spare Parts 9.2 RPU80 – Previous model gear pump RPU80 Reversible Pump with ser. no. 1317 H02 onwards (P/N 21116165) and 1805 H03 onwards (P/N 21116181 – US version) have identical gear pump with the RPU160 (see figure 9-1). Removed at installation Figur 9-2 Gear pump Previous model of RPU80 Assembly drawing Pos. Qty.
Simrad Reversible Pump RPU80/160/300 10 SALES AND SERVICE WORLDWIDE EUROPE AUSTRIA GREECE SWEDEN Aegean Electronics S.A. 1-3, Akti Miaouli Str. EL-185 35 Piraeus Tel.: +302 10 413 7269 Fax: +302 10 413 7270 Simrad AB Svalörtsgatan 14 42668 Västra Frölunda Tel.: +46 31 69 51 00 Fax: +46 31 69 51 20 www.simrad.se Allroundmarin-Alltechnik GesmbH Rheinboldtstrasse 11-13 A-2362 Biedermannsdorf b.Wien ICELAND Tel.: +43 2236 646 760 Fridrik A. Jonsson ehf Fax: +43 2236 63135 Eyjarslod 7 www.allroundmarin.
