Operation and

Maintenance Manual −
Main System
MPP – Marine Propulsion Propeller
Important Safety Information
Most accidents that involve product installation, operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must be alert to potential
hazards, including human factors that can affect safety. This person must also have the necessary
training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and
could result in injury or death. Do not operate or perform any lubrication, maintenance, or
repair on this product, until you verify that you are authorized to perform this work, and have
read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and in some cases on the product. If
these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”.
The meaning of the “Safety Alert Symbol” is as follows: Attention! Become Alert! Your Safety is
Involved. The message that appears adjacent to the warning explains the hazard and can be either
written or pictorially presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
in this publication, and in certain cases on the product.
Berg Propulsion cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are, therefore, not all inclusive.
You must not use this product in any manner different from that considered by this manual
without first satisfying yourself that you have considered all safety rules and precautions
applicable to the operation of the product in the location of use, including site-specific rules
and precautions applicable to the worksite. If a tool, procedure, work method or operating
technique that is not specifically recommended by Berg Propulsion is used, you must satisfy
yourself that it is safe for you and for others. You should also ensure that you are authorized
to perform this work, and that the product will not be damaged or become unsafe by the
installation, operation, lubrication, maintenance, or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are based on information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete and most current information
before you start any job. Berg Propulsion can supply the most current information available.

WARNING! When replacement parts are required for this product, Berg
Propulsion recommends using original Berg Propulsion parts. Using
substandard parts may lead to premature failures, product damage, personal
injury or death.

© 2023 Berg Propulsion

REVISION LOG
Rev. Date Description Prep. By

A 13/09/2023 First issue JTO

MPP620 1 Introduction

2 Main Unit

Order No 7634M 3 Hydraulic System

Yard 189 SHIPYARD
NB No. SAR 631 4 Remote Control System

5 Accessories
Global Technical Support
24h Emergency Support Line:
+46 31 96 94 62 6 Alarm System
E-mail Support:
[email protected]
7 Spare Parts
Spare Parts
[email protected]

Service 8 Special Tools

[email protected]

9 Appendix – Drawings

10 Appendix – Oil Requirements

Document Version: 1 Date: September 13, 2023

TABLE OF CONTENTS
1. INTRODUCTION
1.1. ABOUT THIS MANUAL
1.2. SAFETY
1.3. GENERAL HAZARD INFORMATION
1.4. SAFETY FOCUS AREAS
1.4.1. ASBESTOS INFORMATION
1.4.2. PRESSURIZED AIR AND WATER
1.4.3. FLUID PENETRATION
1.4.4. CONTAINING FLUID SPILLAGE
1.4.5. LINES, TUBES AND HOSES
1.4.6. DISPOSE OF WASTE PROPERLY
1.4.7. BURN PREVENTION
1.4.8. OILS
1.4.9. BATTERIES
1.4.10. FIRE PREVENTION AND EXPLOSION PREVENTION
1.4.11. FIRE EXTINGUISHER
1.4.12. CRUSHING PREVENTION AND CUTTING PREVENTION
1.4.13. GAINING ACCESS TO THE PROPULSION EQUIPMENT
1.4.14. BEFORE STARTING THE PROPULSION EQUIPMENT
1.4.15. STARTING THE PROPULSION EQUIPMENT
1.4.16. STOPPING THE PROPULSION EQUIPMENT
1.4.17. ELECTRICAL SYSTEM
1.4.18. GROUNDING PRACTICES
1.5. TECHNICAL DATA
2. MPP MAIN UNIT
2.1. MPP PROPULSION SYSTEM OVERVIEW
2.2. PROPELLER HUB
2.2.1. GENERAL HUB DESCRIPTION
2.2.2. PROPELLER HUB CONDITION
2.3. HDX OD BOX
2.3.1. FUNCTIONAL DESCRIPTION
2.3.2. STARTUP
2.4. FEATHERING
2.4.1. OPERATION
2.5. EMERGENCY OPERATION
2.5.1. EMERGENCY CONTROL
2.5.2. MANUAL PITCH OPERATION – TAKE HOME FUNCTIONALITY
2.5.3. OPERATING THE BACKUP EQUIPMENT
2.6. MAINTENANCE
2.7. INITIAL MAINTENANCE
2.7.1. 100 HOURS AFTER COMMISIONING
2.7.2. AFTER 200 HOURS OF OPERATION
2.8. PERIODIC MAINTENANCE
2.8.1. DAILY − ENGINE NOT RUNNING
2.8.2. DAILY − ENGINE RUNNING
2.8.3. EVERY 3 MONTHS (IF USING EAL)
2.8.4. EVERY 6 MONTHS / 2000 HOURS OF OPERATION/
2.8.5. EVERY 12 MONTHS / 5000 HOURS OF OPERATION
2.8.6. EVERY 5 YEARS / 25000 HOURS OF OPERATION
2.8.7. FIVE-YEAR CLASS-RENEWAL SURVEY
2.9. MAINTENANCE JOB DESCRIPTIONS
2.9.1. CHECKING THE HPU FLUID LEVEL
2.9.2. FILLING OIL (TOP OFF)
2.9.3. PERFORMING A WALK-AROUND INSPECTION
2.9.4. CHECKING THE OIL TEMPERATURE
2.9.5. CHECKING THE OPERATING PRESSURE
2.9.6. CHECKING COOLING WATER TEMPERATURE (IF APPLICABLE)
 2.9.7. CHECKING THE OIL FILTER CONTAMINATION
2.9.8. CHECKING FOR VISUAL DEFECTS AND RUNNING NOISES
2.9.9. CHECKING HYDRAULIC HOSES
2.9.10. TAKING AN OIL SAMPLE
2.9.11. CHECKING THREADED CONNECTIONS
2.9.12. REPLACING OIL FILTER
2.9.13. CHANGING THE HYDRAULIC FLUID
2.9.14. MAINTENANCE OF VESSEL NOT IN OPERATION (LAY UP)
2.9.15. ACCESSORY MAINTENANCE
2.10. TROUBLESHOOTING
2.10.1. ALARMS
2.11. MOUNTING/DISMOUNTING PROPELLER BLADES
2.11.1. MOUNTING BLADES
2.11.2. DISMOUNTING A BLADE IN A NOZZLE
2.11.3. MOUNTING A BLADE IN A NOZZLE
2.11.4. CHECKING A USED BOLT
2.11.5. TIGHTENING BLADE AND HUB BOLTS
2.12. DISMOUNTING THE PROPELLER SHAFT
2.13. HUB OIL DRAINAGE
3. HYDRAULIC SYSTEM
3.1. INTRODUCTION
3.2. SYSTEM DESCRIPTION
3.2.1. HYDRAULIC POWER UNIT
3.2.2. PITCH CONTROL
3.2.3. OIL CIRCULATION IN THE HUB
3.3. SYSTEM CLEANLINESS AND FILTRATION
3.3.1. SYSTEM FILTRATION
3.3.2. CLEANLINESS LEVEL
3.4. FILLING SYSTEM
3.4.1. BEFORE FILLING
3.4.2. FIRST FILL
3.4.3. TOP OFF
3.5. HYDRAULIC SYSTEM ALARMS
3.6. HYDRAULIC STARTER PANEL
4. MPC800M REMOTE CONTROL SYSTEM
4.1. SYSTEM OVERVIEW
4.2. SYSTEM CONFIGURATION
4.3. SYSTEM UNITS
4.3.1. CENTRAL UNIT
4.3.2. LOCAL CONTROL UNIT
4.3.3. BRIDGE PANEL
4.3.4. ECR PANEL
4.4. MAIN CONTROL FUNCTIONS
4.4.1. PROPORTIONAL (FOLLOW-UP) PITCH CONTROL
4.4.2. ENGINE SPEED CONTROL
4.4.3. LOAD CONTROL SYSTEM
4.4.4. COMBINATOR CURVES
4.4.5. CLUTCH CONTROL
4.4.6. AUTOMATED FAULT HANDLING
4.4.7. FEATHERING
4.4.8. REDUNDANCY AND FAULTS INDICATION
4.4.9. LOCAL CONTROL FUNCTION
4.4.10. COMMAND TRANSFER FUNCTION
4.4.11. ZERO PITCH SYSTEM (IF INCLUDED)
4.5. ADDITIONAL FUNCTIONS
4.5.1. OVERLOAD
4.5.2. SLOWDOWN OR AUTO-LOAD REDUCTION
4.5.3. SHUTDOWN OR AUTO STOP
 4.5.4. OVERRIDE
4.5.5. PITCH INDICATION
4.5.6. SHAFT SPEED INDICATION
4.5.7. VOYAGE DATA RECORDER (VDR)
4.5.8. DYNAMIC POSITIONING (DP)
4.5.9. JOYSTICK (JS)
4.6. TECHNICAL DATA
4.6.1. MAIN DATA – MPC SYSTEM
4.6.2. ENVIRONMENTAL TESTS
4.6.3. EMC TESTS
4.7. USING THE SYSTEM
4.7.1. CONTROL PANEL OVERVIEW
4.7.2. THE MAIN PAGE
4.7.3. VARIABLES SECTION
4.7.4. THE LOAD CONTROL SECTION
4.7.5. ADJUSTING 0% / 100% PITCH, AND MAXIMUM MAIN ENGINE LOAD
4.7.6. PASSWORD
4.7.7. COMMAND TRANSFER PROCEDURES
4.7.8. ALARMS
4.8. QUICK GUIDE
4.8.1. BRIDGE
4.8.2. ENGINE CONTROL ROOM
4.9. MAINTENANCE – CONTROL SYSTEM
4.9.1. MAINTENANCE SCHEDULE
4.9.2. TROUBLESHOOTING
5. ACCESSORIES
6. ALARM SYSTEM
7. SPARE PARTS
7.1. SPARE PARTS LISTS
7.2. ORDERING SPARE PARTS
8. SPECIAL TOOLS
8.1. GENERAL
8.2. SHAFT NUT KEY
8.3. HYDRAULIC PUMP AND INJECTORS
8.4. IMPACT SOCKET
9. APPENDIX - DRAWINGS
9.1. MECHANICAL DRAWINGS
9.2. HYDRAULIC DRAWINGS
9.3. REMOTE CONTROL SYSTEM DRAWINGS
10. APPENDIX – MPP OIL REQUIREMENTS
10.1. GENERAL INFORMATION
10.2. OIL REQUIREMENTS – MINERAL OIL
1. INTRODUCTION
1.1. ABOUT THIS MANUAL
This publication is intended as a reference manual for personnel operating and performing
maintenance work on a Berg MPP Propulsion System. It is assumed that staff is familiar with
marine propulsion equipment and the propulsion controls of the vessel.
This manual covers operation and maintenance of a Berg MPP propulsion system equipped with an
HDX type Oil Distribution Box (OD Box).
This document contains safety, operation, lubrication, and maintenance information and should be
stored in or near the engine control room area in a literature holder, or other literature storage area.
Read, study, and keep it with other relevant documentation and vessel information.
Please note that the contents of this manual are not fully order-specific, which means that deviations
may exist as to text and images. Some images in this manual may show details or attachments that
are different from your specific product configuration. Guards and covers may have been removed for
illustrative purposes. Continuous improvements and advancement of product design may have
caused changes to your product which are not included in this manual.
Berg Propulsion endeavors to ensure that all information in this document is correct and fairly stated
but does not accept liability for any errors or omissions.
Addition of drawings and/or accessory manuals (if applicable) into this main document may cause the
document pagination to be broken.
The primary language of the Berg Propulsion product documentation is English. In case of ambiguous
information found in translated texts, the English version always takes precedence.

1.2. SAFETY
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 and/or injury to
personnel. The user must be familiar with the contents of the appropriate manual before attempting to
operate or work on the equipment.
The user is responsible for ensuring that proper actions, in accordance with the relevant statutory,
legal, and industry requirements, are taken to protect against risks to personal health and safety in
relation to the work described in this manual. Neither this manual, nor its use, in any way absolves the
users from their responsibility to ensure that such proper actions and precautions are taken.
Berg Propulsion disclaims any responsibility for damages or injury caused by improper
installation, use or maintenance of the equipment.

WARNING! Risk of personal injury. Do not install, operate, or perform

maintenance work on this equipment unless you have read and
understood the instructions and warnings in this manual as well as any
other relevant manuals. Failure to follow the instructions or heed the
warnings could result in serious injury or death.
1.3. GENERAL HAZARD INFORMATION
Attach a “Do Not Operate” warning tag to the controls before the propulsion system is serviced or
repaired. Attach the warning tags to the propulsion equipment and to each operator control station.
When appropriate, disconnect the starting controls.

Figure 1. Do not operate tag.

Do not allow unauthorized personnel on or around the propulsion equipment, when the equipment is
being serviced.
Cautiously remove the following parts:
 Filler caps
 Grease fittings (if applicable)
 Pressure taps
 Breathers
 Drain plugs
To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being
removed.
Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or
nuts that are at opposite ends of the cover plate or the device. Before removing the last two bolts or
nuts, pry the cover loose to relieve any spring pressure or other pressure.

Figure 2. Personal Protective Equipment (PPE).

 Wear a hard hat, protective glasses, and other protective equipment, as required.
 When work is performed around propulsion equipment that is operating, wear hearing protection.
 Do not wear loose clothing or jewelry that can snag on controls or on other parts of the propulsion
equipment.
 Ensure that all protective guards and all covers are secured in place on the propulsion equipment.
 Never put maintenance fluids into glass containers. Glass containers can break.
 Use all cleaning solutions with care.
 Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the following conditions:
 The engine is stopped. Ensure that the engine cannot be started.
 The protective locks or the controls are in the applied position.
 Disconnect the batteries (if applicable) and power supply, when maintenance is performed or
when the electrical system is serviced. Disconnect the battery ground leads (if applicable). Tape
the leads to help prevent sparks.
 Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment
that is damaged or repair the equipment.
 Power supplies switch off and locked.

1.4. SAFETY FOCUS AREAS

1.4.1. ASBESTOS INFORMATION

Berg Propulsion equipment and replacement parts that are shipped from Berg Propulsion are
asbestos free. Berg Propulsion recommends the use of only genuine Berg replacement parts.

1.4.2. PRESSURIZED AIR AND WATER

Pressurized air and/or water can cause debris and/or hot water to be blown out which could result in
personal injury.
The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective
equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
When pressurized air and/or pressurized water is used for cleaning, wear protective clothing,
protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.
Always wear eye protection for cleaning the hydraulic system.
Avoid direct spraying of water on electrical connectors, connections, and components. When using air
for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when
redeposited on hot surfaces.

1.4.3. FLUID PENETRATION

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak
can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek
treatment from a doctor that is familiar with this type of injury.

1.4.4. CONTAINING FLUID SPILLAGE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
1.4.5. LINES, TUBES AND HOSES
Do not bend or strike high-pressure lines. Do not install lines, tubes, or hoses that are damaged.
Repair or replace any hydraulic lines, tubes, or hoses that are loose or damaged. Leaks can cause
fires. Inspect all lines, tubes, and hoses carefully. Do not use bare hands to check for leaks. Always
use a board or cardboard for checking engine components for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
 End fittings that are damaged or leaking.
 Outer covering that is chafed or cut.
 Wire that is exposed in reinforced hose.
 Outer covering that is ballooning locally.
 Flexible part of the hose that is kinked or crushed.
 Armoring that is embedded in the outer covering.
Make sure that all clamps, guards, and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat.

1.4.6. DISPOSE OF WASTE PROPERLY

Figure 3. Proper waste disposal.

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be
disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do
not pour waste onto the ground, down a drain, or into any source of water.

1.4.7. BURN PREVENTION

Do not touch any part of an operating propulsion equipment. Allow the equipment to cool before any
maintenance is performed. Relieve all pressure in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related
items are disconnected.

1.4.8. OILS
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact the skin.

1.4.9. BATTERIES
Electrolyte is an acid which can cause personal injury. Protect the skin and the eyes. Always wear
protective glasses for servicing batteries. Wash hands after touching the batteries and connectors.
Use of gloves is recommended.
1.4.10. FIRE PREVENTION AND EXPLOSION PREVENTION
All fuels, most lubricants, and some coolant mixtures are flammable. Use of personal protection
equipment (PPE) may be needed. Always perform a Walk-Around Inspection, which may help you
identify a fire hazard. Do not operate a product when a fire hazard exists. Contact Berg Propulsion for
service. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components
can cause a fire. Fire may cause personal injury and property damage.
If the application involves the presence of combustible gases, consult Berg Propulsion for additional
information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and debris from the propulsion equipment. Do not
allow any flammable materials to accumulate on the propulsion equipment.
All fluids that are captured in fluid spill containment basins should be cleaned up immediately. Failure
to clean up spilled fluids can cause a fire. Fire may cause personal injury and property damage.
Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily
rags and any flammable materials in protective containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the propulsion equipment to any flame.
Do not weld on lines or tanks that contain flammable fluids. Do not use flame to cut lines or tanks that
contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route and attach all electrical wires. Check all
electrical wires daily. Repair any wires that are loose or frayed before you operate the propulsion
equipment. Clean all electrical connections and tighten all electrical connections.
Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller
than the recommended gauge. Do not bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing or sparking.
Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and hoses
must have adequate support and secure clamps. Tighten all connections to the recommended torque.
Leaks can cause fires. Properly install all oil filters. The filter housings must be tightened to the proper
torque.
Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery.
Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter
or a hydrometer.
Improper jumper cable connections can cause an explosion that can result in injury. Refer to your
battery manual for specific instructions.
Do not charge a frozen battery. Charging a frozen battery may result in an explosion.
The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box covers when the propulsion equipment or battery
is operated.

1.4.11. FIRE EXTINGUISHER

Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on
the instruction plate.
1.4.12. CRUSHING PREVENTION AND CUTTING PREVENTION
Support the component properly when work beneath the component is performed. Unless other
maintenance instructions are provided, never attempt adjustments while the propulsion equipment is
running.
Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is
performed. After the maintenance is performed, reinstall the guards.
Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.

1.4.13. GAINING ACCESS TO THE PROPULSION EQUIPMENT

Inspect the steps, the handholds, and the work area before gaining access to the propulsion
equipment. Keep these items clean and in good repair.
Gain access to the propulsion equipment only at locations that have steps and/or handholds. Do not
climb directly on the propulsion equipment.
Do not stand on components which cannot support your weight. Use an adequate ladder or use a
work platform.
Do not carry tools or supplies when you gain access to the propulsion equipment or when you
dismount the propulsion equipment. Use a hand line to raise and lower tools or supplies.

1.4.14. BEFORE STARTING THE PROPULSION EQUIPMENT

Inspect the propulsion equipment for potential hazards.
Do not start the engine and the propulsion equipment or move any of the controls if there is a “DO
NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.
Before starting the propulsion equipment, ensure that no one is on, underneath, or close to the
propulsion equipment. Ensure that the area is free of personnel.
All protective guards and all protective covers must be installed if the propulsion equipment must be
started in order to perform service procedures. To help prevent an accident that is caused by parts in
rotation, work around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal injury. The circuits are also provided in order to help
prevent propulsion equipment damage.
1.4.15. STARTING THE PROPULSION EQUIPMENT
If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine and
propulsion equipment, or move the controls. Consult with the person that attached the warning tag
before the engine is started.
All protective guards and all protective covers must be installed if the engine must be started in order
to perform service procedures. To help prevent an accident that is caused by parts in rotation, work
around the parts carefully.
Start the propulsion equipment from the engine control room panel or from other designated location.
Always start the propulsion equipment according to the procedure that is described in this manual
and/or other relevant vessel documentation.
Knowing the correct procedure will help to prevent major damage to the propulsion equipment
components. Knowing the procedure will also help to prevent personal injury. Ensure that the
electrical motor heaters (if equipped) are working properly.
Engine exhaust contains products of combustion that can be harmful to your health. Always start the
engine and operate the engine in a ventilated area. If the engine is started in an enclosed area, vent
the engine exhaust to the outside.

1.4.16. STOPPING THE PROPULSION EQUIPMENT

To avoid accelerated wear of propulsion equipment components, stop the propulsion equipment in
accordance with the specified procedures.
Use the Emergency Stop Button (if equipped) ONLY in an emergency. DO NOT use the Emergency
Stop Button for normal stopping.
After an emergency stop, DO NOT start the engine and propulsion equipment until the problem that
caused the emergency stop has been corrected.

1.4.17. ELECTRICAL SYSTEM

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging
unit is operating. A spark can cause the combustible gases that are produced by some batteries to
ignite.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires
before the propulsion equipment is operated. Repair all frayed electrical wires before the propulsion
equipment is started.

1.4.18. GROUNDING PRACTICES

Proper grounding is necessary for optimum propulsion equipment performance and reliability.
Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit
paths. Uncontrolled electrical circuit paths can result in damage to bearings, to bearing journal
surfaces, shaft surfaces and to aluminum components. Uncontrolled electrical circuit paths can also
cause electrical activity that may degrade the propulsion equipment electronics and communications.
Ensure that all grounds are secure and free of corrosion.
If rubber couplings connect the steel piping of the cooling system and the radiator, the piping and the
radiator can be electrically isolated. Ensure that the piping and the radiator are continuously
grounded. Use ground straps that bypass the rubber couplings.
Note: Additionally, a propeller shaft grounding system is indispensable for preventing galvanic
corrosion.
1.5. TECHNICAL DATA

Order No. 7634M

Propeller Data
Type: MPP
Propeller Quantity: Twin
Hub Type: MPP 620F
Propeller Diameter [mm]: 2150
Material: Bronze
No. of Blades: 4
Rotation (seen from aft): STB: CCW
PS: CW

General Vessel Data

Classification: ABS
Ice Class: No Ice
Rated Power [kW]: 2525

Hydraulic System
Pump Type: 55CC
Motor Type: 132M-4
Working Pressure [bar]: 50

Control System Configuration

Type: MPC800M
Central Units: 1
Local Control Units: 1
Bridge Control Panels: 1
Engine Control Room Panels: 1
Supply Voltage: 24V DC
Power Consumption: Max. 2x300W
2. MPP MAIN UNIT

2.1. MPP PROPULSION SYSTEM OVERVIEW

Figure 4. MPP propulsion system.

Pos. Name Description

1 Propeller Controllable pitch (CP) propeller.
2 Stern tube Sleeve containing shaft bearings and lubrication fluid.
3 Propeller shaft Hollow-bore shaft.
4 Intermediate shaft Hollow-bore intermediate shaft. (If applicable)
5 Shaft generator/PTO Eliminates need for external generators by using main engine rotation.
6 Hydraulic Power Unit/HPU The primary component of the hydraulic system, with pumps generating system
pressure, as well as filters, and sensors.
7 High speed shaft Connects the main engine and the gearbox when the gearbox is not installed
immediately behind the main engine. Rotates at main engine rpm.
8 Main engine A.k.a. prime mover.
9 Shaft seal Dynamic (rotating) seal. Seals between the hub flange cover and the stern tube.
There is water on the outside and lubrication oil (or water) on the inside.
10 Forward seal Dynamic seal. Seals between the engine room and the stern tube. There is air
on the outside and lubrication oil or water inside. If the propeller shaft is water-
lubricated, the system can include a forward seal only.
11 Oil Mounted Coupling (OMC) Hydraulically mounted flange coupling with a tapered inside diameter which is
mounted on the tapered shaft end. Attached to a flange on the intermediate
shaft or the gearbox.
12 Sleeve coupling Cylindrical sleeve coupling. Connects two straight shaft ends. No bolt
connection is required.
13 Gearbox Reduction gear. Gears down main engine rpm to propeller shaft rpm.
14 HDX gear mounted OD Box Distributes the hydraulic fluid, enabling rotating shaft pitch setting. It also works
as a pitch feedback unit.
2.2. PROPELLER HUB

2.2.1. GENERAL HUB DESCRIPTION

Figure 5. Hub overview.

The propeller hub consists of two main parts: the hydraulic cylinder (1 in Figure 5) and the hub body
(3). The cylinder and the hub are attached by stainless steel screws. The propeller unit is attached to
a forged flange (2) by stainless steel bolts on the aft end of the propeller shaft.
The hydraulic cylinder houses the piston (4), which is mounted on the aft end of the piston rod (5).
The hollow bored piston rod contains an oil pipe that allows pressure oil to flow either around or
through the pipe.
Oil flowing through the pipe (1 in Figure 6) is fed to the chamber on the aft side of the piston, while oil
flowing around the pipe (2) is ducted to the chamber on the forward side of the piston.

Figure 6. Hub details.

The movement of the piston and the piston rod is transferred to the mechanism in the hub body.
The moving parts of the hub body consist of a machined four-sided steel block (leading member, 3),
four smaller sliding blocks made of bronze (guide blocks, 4) and four rotating flanges (blade roots, 5).
The leading member is mounted on the forward end of the piston rod and is secured by a tension nut
(6). For assembly reasons and to allow for the fitting of the blade roots, the leading member is divided
into two halves at right angles to the centerline.
The propeller blades are attached by weld-locked stainless steel bolts (7).
Ingress of salt water at the blade mounts is prevented by a rubber sealing ring between the blade and
the hub body. Non-moving joints, such as the blade bolts, are sealed using rubber O-rings.

2.2.2. PROPELLER HUB CONDITION

The humidity in the oil is a measure of the condition of the propeller hub. Normally when the hub is in
good condition, humidity is low and a dependent pattern of the relation to temperature and air
humidity can be noted.
The blade seals are the only potential leaking points in an MPP hub, since they are the only dynamic
seals. All other seals are static. Should seals show significant wear, or if worn bearings cause leaking
seals, humidity will rise and must be addressed.
2.3. HDX OD BOX

2.3.1. FUNCTIONAL DESCRIPTION

The OD Box (hydraulic pitch control unit) type HDX is intended for use on vessels equipped with a
reduction gearbox.
The oil distributor is mounted on the forward end of the reduction gear. The oil distributor is required
to deliver pressure oil and receive return oil, respectively to and from the hub cylinder. It delivers oil
for lubrication of the hub while receiving return oil.
The OD Box consists of a distributor and a feedback housing. Oil is passed to the cylinder unit in the
hub in the required direction via intermediate pipes mounted in the hollow bored gearbox and
propeller shafts. The intermediate pipe is attached to the propeller hub piston rod which in turn
transmits longitudinal movement back to the oil distributor.
The OD Box also works as a feedback unit. The actual pitch position is sent to the control system but
is also visible on a mechanical scale on the OD Box, and on a feedback gauge located on the
Hydraulic Power Unit (HPU).

Information: Easy access to the OD Box must be provided to allow for

maintenance work.

2.3.2. STARTUP
When starting up the propulsion system, perform a full pitch sequence, from full ahead to full astern to
ensure that there is no air in the OD Box and the lubrication part of the hydraulic system.
2.4. FEATHERING

Figure 7. Ahead pitch (left) and feathered position (right).

Feathering means changing the pitch angle to a position where a minimum water resistance is
obtained. This option is ideal for tankers with twin engines and for sailing yachts.
When sailing without cargo and running on one engine only, the idle propeller can be feathered to
save fuel.
A non-feathered propeller that is not currently being used will increase the resistance by 3%. Using
feathering, the extra resistance can be lowered to approximately 0.5%.
Feathering requires a shaft brake and a clutch.

2.4.1. OPERATION
Feathering can only be executed from the control panel in the engine room. The feathering position is
adjustable.
Feathering Sequence

Figure 8. Feathering sequence.

* If the Berg Propulsion MPC800 control system controls the shaft brake, it will be automatically engaged/disengaged.
Otherwise this must be done manually.

Automatically:
The brake will be activated automatically when the propeller has reached feathered position, and it
will be deactivated automatically just after it has started to move away from feathered position. (If the
brake has already been activated when the feathering sequence is started, it will be deactivated
before moving towards feathered position.)
Manually:
The brake will be blocked for activation when the propeller is out of zero pitch and automatically
deactivated if the propeller is moving away from zero pitch.
2.5. EMERGENCY OPERATION

2.5.1. EMERGENCY CONTROL

Emergency or back-up control is required in the event of a failure of the control system. Ahead and
Astern manual override valves are located on the hydraulic Control Valve, placed on the Hydraulic
Power Unit. The push override valves act directly on the Control Valve.
Pitch position is adjusted according to the feedback gauge on the HPU Connection Box. As a second
option, there is a mechanical feedback indicator on the OD Box. The actual appearance of the OD
Box depends on configuration. Please refer to the OD BOX ASSEMBLY drawing for detailed
information):

Figure 9. Mechanical indicator on the OD Box.

2.5.2. MANUAL PITCH OPERATION – TAKE HOME FUNCTIONALITY

Manual pitch operation is required in case of total loss of hydraulic power. The primary part of the
equipment is an emergency pump mounted on the Hydraulic Power Unit and connected to the
solenoid valve. Depending on configuration/size, the pump is either manual or electric.

2.5.3. OPERATING THE BACKUP EQUIPMENT

Procedure:
1. Push the Ahead or Astern manual override control on the solenoid valve.
2. Operate the emergency pump (manual or electric) until the required pitch is reached. The pitch
position is visible on the OD Box, and on a gauge located on the HPU.
3. Release the override valve.
2.6. MAINTENANCE
Regular maintenance is essential for safe and efficient operation of the propulsion equipment.
The customer is responsible for ensuring all recommended preventative maintenance is performed at
the specified service intervals as described in the Operation and Maintenance Manual, and any other
relevant documentation. Preventative maintenance includes, but is not limited to the servicing,
adjusting and/or replacing of certain components.
Maintenance of the hydraulic system requires a series of checks and measures to ensure proper
operation of the equipment. As a general rule, these actions involve using a quality hydraulic fluid,
checking its condition, regularly checking the level, and changing the filters periodically.
For maintenance information on specific accessories, please refer to any accessory manuals included
in this manual package.
Berg Propulsion can supply kits for typical periodic maintenance operations.

Information: For service/maintenance information on specific accessories,

please refer to the accessory manuals (if included).

2.7. INITIAL MAINTENANCE

2.7.1. 100 HOURS AFTER COMMISIONING

Perform the Following:

 Check fluid levels in all hydraulic tanks.
 Check hydraulic breathers for clogging.
 Visually inspect the hydraulic system for leaks.
 Check hydraulic connections for tightness.

Replace the Following:

 Hydraulic system filters.

Note: Spare filters for this purpose are included in the delivery.

2.7.2. AFTER 200 HOURS OF OPERATION

Perform the Following:

 Check flange connections to the engine and to the propeller. Check tightening of bolts/nuts.
 Visually inspect for external fluid leakage.
 Tighten threaded pipe connections in case of leakage.
2.8. PERIODIC MAINTENANCE

2.8.1. DAILY − ENGINE NOT RUNNING

Perform the Following:

 Carry out a walk-around inspection.
 Check HPU fluid level. Fill if needed.

2.8.2. DAILY − ENGINE RUNNING

Check the Following:

 Hydraulic working pressure
 Hydraulic fluid temperature
 Heat exchanger cooling water temperature (if applicable)
 Filter contamination indicator. Replace filter if needed.
 Visual defects and running noises.

The hydraulic/lubrication system is equipped with moisture sensors. Berg Propulsion recommends
that the oil temperature and moisture level are checked and logged regularly. If any deviations are
found, the log data may be sent to Berg Propulsion.

2.8.3. EVERY 3 MONTHS (IF USING EAL)

If using Environmentally Acceptable Lubrication (EAL) fluids, the change interval under Class-
Renewal Survey below applies under condition that samples are taken every 3 months.

Perform the Following:

 Take a sample and evaluate the hydraulic fluid condition. Change if needed.

2.8.4. EVERY 6 MONTHS / 2000 HOURS OF OPERATION/

Perform the Following:

 Take a sample and evaluate the hydraulic fluid condition. Change if needed.

Replace the Following Parts:

 Hydraulic system fluid filter elements
 Hydraulic tank breathers.

2.8.5. EVERY 12 MONTHS / 5000 HOURS OF OPERATION

Check the following:

 Flange connections, to the engine and to the propeller. Check tightening of bolts/nuts.
 External oil leakage – replace seals if needed.
2.8.6. EVERY 5 YEARS / 25000 HOURS OF OPERATION

Information This maintenance procedure should be performed by a Berg

Propulsion Service Engineer.

Check the Following. Replace/Repair if Necessary:

 Shafts for run-out
 Bearing seats for damage
 Blade Carriers
 OD Box
 Pressure gauge
 Radial/axial clearance for blade root/hub
 Blades/blade guide blocks
 Bearings.

Replace the Following Parts:

 O-rings
 OD Box screws
 Blade seals
 Oil filter elements and seals
 Inspection cover gaskets.

2.8.7. FIVE-YEAR CLASS-RENEWAL SURVEY

Information: This maintenance procedure should be performed by a Berg
Propulsion Service Engineer.

A vessel that has been designed and built to the appropriate rules of a recognized classification
society may apply for issuance of a Certificate of Classification from that society. Once in service, the
owner must submit the vessel to a clearly specified program of periodic class surveys to verify
compliance with class technical standards throughout the lifetime of the vessel.
Five years after issue of a Certificate of Classification from a recognised classification society, the
vessel should be docked for a special survey for class cycle renewal. The operations listed below
should normally be performed on the propulsion system.

Perform the Following:

 Overhaul the OD Box.
 Replace the blade seals.
 If EAL fluid is used: Change the fluid.
 If mineral fluid is used: Change the fluid if necessary. Note: It must be changed at least every 10
years.
 At shaft withdrawal, inspect the stern tube bearings and verify that measurements are within
tolerances. Replace if necessary.
 Inspect the shaft seals. Overhaul according to manufacturer recommendations.

Note: The listing above is limited to the propulsion components included in the Berg Propulsion scope
of delivery. It shall not be considered a complete listing of all steps included in a periodic class survey
(Class-Renewal Survey) of the vessel as required by the classification society. Please refer to the
stipulations of the relevant classification society for details.
2.9. MAINTENANCE JOB DESCRIPTIONS

2.9.1. CHECKING THE HPU FLUID LEVEL

Figure 10. Breather and sensor.

Pos. Description
1 Tank breather/Filling port
2 Level sensor

Procedure:
1. Check the oil level by visually inspecting the Level Sensor (2) on the Hydraulic Power Unit. The
filling level must be 80%.
2. Fill up if necessary. The Tank Breather must be removed for filling, see instruction below.

2.9.2. FILLING OIL (TOP OFF)

When filling, do NOT pour fluid directly into the filling hole. Instead, use a portable filter cart to ensure
that the oil is filtered and does not get in contact with ambient air.
Note: Top off of fluid must only be done in the HPU tank. When the system is running, any other tanks
in the system will be filled up from the HPU.

Procedure:
1. Switch off the system.
2. Remove the Breather (1).
3. Fill the HPU Tank until the Level Sensor (2) shows 80%.

NOTICE! Risk of product damage. Hydraulic fluid must be filtered before

filling. Most new fluids (straight from the drum) are unfit for use due to high
initial contamination. Contamination, both particulate and water, can be
added to a new fluid during processing, mixing, handling, and storage.

Information: Berg Propulsion recommends using portable filter carts

to prefilter and transfer fluids into the system. Use a filter rated at
10µm (Micron) or better. Note: A portable filter for this purpose is not
included in the Berg Propulsion scope of delivery.
In case of oil loss, determine the cause and solve the problem.
The water content of the oil is monitored continuously by the system. Should water ingress occur, an
alarm is triggered in the MPC800M Control System.

2.9.3. PERFORMING A WALK-AROUND INSPECTION

To obtain maximum service life for your propulsion equipment, perform a thorough walk-around
inspection before starting the engine and propulsion equipment.

Procedure:
 Check for any type of leak (lubrication oil, hydraulic oil, or grease).
 Clean up any fluids.
 If a leak is detected, find the source, and correct the leak.
 If leakage is suspected, check fluids more frequently until the leak is found or fixed, or until the
suspicion of a leak is proved to be unwarranted.
 Look for loose bolts.
 Look for trash build-up and remove any trash.
 Arrange for repairs, as needed.
 For safety reasons, make sure all fixed guards are in place. Repair any damaged guards or
replace missing guards.
 Make sure that the areas around the rotating parts are clear.

2.9.4. CHECKING THE OIL TEMPERATURE

The operating oil temperature is indicated on the HPU temp sensor. The normal operating oil
temperature should be 45- 55C.
Should the temperature rise above 60 C, a high temp alarm is triggered. If so, manually shut off the
overheating pump to determine if the temperature is lowered to normal level. Should the system temp
rise above 70°C, do not continue running the propulsion system.

2.9.5. CHECKING THE OPERATING PRESSURE

The operating pressure is indicated on the HPU pressure gauge. The normal operating pressure is 50
bar.

2.9.6. CHECKING COOLING WATER TEMPERATURE (IF APPLICABLE)

The normal temperature difference across the oil heat exchanger should be 3-5C. If the difference is
out of tolerance, it might indicate contamination on the water side of the heat exchanger, or that the
cooling water flow rate is insufficient. Note: An oil cooler is not always included in the system.

2.9.7. CHECKING THE OIL FILTER CONTAMINATION

Observe the contamination closely during the first 100 operating hours. If the filters get contaminated,
the differential pressure will increase.
Note: If the oil viscosity is relatively high and the fluid is cold during startup, the differential pressure
increases. If contamination is indicated during cold starts only, there is no need to replace the filter
elements.

2.9.8. CHECKING FOR VISUAL DEFECTS AND RUNNING NOISES

Check the pumps and the hydraulic system for leaks and loose parts. Also, ensure that the operation
noises are normal.
Deviations may indicate faults or malfunctions, for example, misalignment between the engine and
the propeller shaft. Take care of any problems immediately or after shutting down the engine.

2.9.9. CHECKING HYDRAULIC HOSES

The life span of hydraulic hoses is not unlimited. There are several factors that can affect the service
life of a hydraulic hose. Inspect all flexible hoses every month.
Check for cracks and any other anomalies such as weeping, swelling, cracks, blisters and bubbles. If
detected, it indicates that the hose is suffering from wear and should be replaced.
Note: Hose assemblies can fail relatively quickly if the minimum bend radius is not met. Adjust/replace
if deviations are found.

2.9.10. TAKING AN OIL SAMPLE

Berg Propulsion recommends implementing a systematic oil sample testing program. You can
perform a maintenance program on your own. You can also enlist the services of Berg Propulsion to
perform any level of preventive maintenance that will keep your equipment running at peak
performance. Please contact Berg Propulsion for more information.
Regular inspections, analysis of your equipment’s site conditions, electronic data, and service history
will enable you to evaluate your equipment’s health.
Note: If Environmentally Acceptable Lubrication (EAL) oil is used, the oil change interval under Five-
Year Classification applies under condition that oil samples are taken every 3 months.

Evaluate the Following:

 Additive levels and lubrication oil condition.
 Lubrication oil contamination.
 Oil deterioration.

Viscosity should remain at ISO grade +/- 10%. A gradual rise in viscosity would indicate either
hydrolysis (accelerated by water) or oxidation of the fluid, usually with rising acidity.
The water content MUST be below 1000 ppm, preferably below 500 ppm.
If you have changed from mineral oil to environmentally acceptable oil and the sample indicates a
high level of zinc, then there is most likely too much mineral oil left in the system. (Since most
environmentally acceptable oils are zinc-free.)

Taking an Oil Sample − Standard Method

To take an oil sample, you need the following:
 Equipment to pull and bottle the oil sample. Typical setup is a needle valve with a hose and
fittings connected.
 A clean standard sample bottle (500 ml).

Figure 11. Typical equipment to sample and bottle oil.

Sample Ports

Figure 12. HPU sample ports.

Procedure:
1. Make sure that the hydraulic unit is running and that the oil is warm.
2. Connect the sampling equipment to the HPU at the TP-CL, or the TP-L, Test Port.
3. Flush the bottling equipment clean. Collect the waste oil in a separate container.
4. Fill up the sample bottle with oil.
5. Close lid immediately.
6. Analyze the sample.

Note: Be consistent as to equipment used when taking a sample as well as to the location from which
the sample is taken.

Analyzing Oil Samples

As an alternative to the standard method of sampling oil and sending off the samples for analysis, an
electronic device designed for monitoring the solid particle loading of oils can be used, such as a
Hydac Fluid Control Unit.
The procedure below should be seen as a general example. Please refer to the corresponding
product documentation for full information.

Figure 13. Fluid Control Unit.

Procedure:
1. Place the device near the Hydraulic Power Unit at an appropriate height.
2. Connect the hoses.
3. Run the test according to the instructions in the manufacturer manual.
2.9.11. CHECKING THREADED CONNECTIONS
Make sure that the propulsion unit is cold when checking the tightening. Check the following
connections extra carefully:
 Reduction gear output shaft flange –- propeller shaft.
 The threaded pipe connections for the OD Box.
 If installed, check the rubber elements of the flexible coupling for porosity, cracking or other signs
of damage.
 If installed, check the heat exchanger for leakage and replace the seals if necessary.

2.9.12. REPLACING OIL FILTER

Figure 14. Oil filters.

Pos. Description
1 Filter bowl
2 Filter bowl
There are two pressure filters on the HPU, one of which is in service, the other one is standby.

WARNING! Risk of personal injury. If the main hydraulic pump is PTO

driven, the Main Engine must be shut down before replacing filters.

Procedure:
1. If the main hydraulic pump is PTO driven, shut down the Main Engine.
2. If the hydraulic pumps are electrically driven, switch off the pump by setting the pump Main Switch
to OFF in the corresponding Hydraulic Starter Cabinet.
3. Place a receptable under the Filter Unit.
4. Using a 30mm wrench, undo the Filter Bowl (1) or (2).
5. Fit the new filter.
6. Reinstall the Filter Bowl.
7. If the hydraulic pump is electrically driven, set the Main Switch to ON in the Starter Cabinet.
8. If the main hydraulic pump is PTO driven, start the Main Engine.
9. Visually ensure there is no leakage.
2.9.13. CHANGING THE HYDRAULIC FLUID
The hydraulic fluid must be changed in any of the following situations:
 The fluid has been overheated for an extended period of time.
 After a breakdown.
 Water ingress in the fluid.
Change the fluid after the engine has been shut down: The fluid should still be warm but not at
operating temperature. The HPU drain ports are located on the HPU front.
When changing fluid, unscrew and open the HPU emergency pump lid, and check that the tank is
clean inside. If not, open additional pump lids for access and clean the inside with a lint-free cloth.
Oil change intervals must be observed. The intervals may be extended only if regular and reliable oil
analyses are performed. In addition to ageing tests, lubricating capability must be checked.

2.9.14. MAINTENANCE OF VESSEL NOT IN OPERATION (LAY UP)

Berg Propulsion assumes that the temperature in the engine room is constant, in order to avoid
condensation when the vessel is out of operation for more than a month. The electronics for the
propeller system should not be turned off, as they generate some heat which can also reduce the risk
of condensation.
The equipment should be tested every month according to the procedure below, so that the oil in the
hub will circulate:
 Rotate the propeller using the main engine.
 Run the pumps for approximately 1 hour.
 Operate the pitch.
 Test run all the control panels (operate fully ahead and astern, about ten times).

Note: Periodic maintenance should be performed also when the vessel is not in operation.

2.9.15. ACCESSORY MAINTENANCE

For information on maintenance on specific accessories, please refer to the instructions in the
Accessories chapter.
Note: Pay attention to any grease/lubrication requirements and intervals specified in any third-party
manuals in the Accessories chapter (If applicable),
2.10. TROUBLESHOOTING

2.10.1. ALARMS

General
These alarms are sent to the vessel alarm system, NOT to the Berg PropulsionMPC800 remote
control system.

Alarm Description Cause Action

TEMPERATURE HIGH The temperature The most common Investigate why the oil is overheated.
- LUBE sensor mounted at the reason for
front of the hydraulic overheating is that
tank has detected high the overpressure
oil temperature. valve is open and a
lot of oil is passing it.
OIL LEVEL LOW - A side-mounted float Apart from oil leaks, Check for oil leaks
LUBE switch has detected this alarm may go off
low oil level (<2/3). because of variations
in oil temperature and
evaporation of water
in the oil (not very
likely, though).
PRESSURE LOW - Too low hydraulic oil Pump motor or starter Shut down the system and repair or replace
PITCH pressure for the pitch failure. the failed pump motor or starter.
system to be used.
The standby pump will
be activated after 5-10
seconds, which will
generate an Autostart
– pitch pump alarm
(see below).
PRESSURE HIGH - Too high hydraulic oil Failure of the Shut down the system and repair or replace
PITCH pressure. pressure relief valve the failed units.
in combination with
pump failure.
FILTER BLOCKED - The differential The pressure filter is Discard and replace the filter. Use the
PITCH pressure switches that clogged. switchover mechanism when replacing during
measure pressure operation.
in/out have detected
too big pressure
differences.
FILTER BLOCKED - See Filter blocked – The lubrication filter is Discard and replace the filter. Use the bypass
LUBRICATION Pitch. clogged. mechanism when replacing during operation.
STANDBY PUMP Pitch pump 1 has One pump (or the Repair or replace the failed pump or motor.
START P1 autostarted. electric motor for the
pump) has failed and
an oil pressure alarm
went off (high or low).
See above.
STANDBY PUMP Pitch pump 2 has One pump (or the Repair or replace the failed pump or motor.
START P2 autostarted. electric motor for the
pump) has failed and
an oil pressure alarm
went off (high or low).
See above.
OIL LEVEL LOW – Low oil level in the Most likely, the Investigate what is blocking the flow of oil to
LUBE gravity tank. continuous flow of oil the gravity tank. Note: if a hydraulic power
up to the gravity tank pack is switched off for an extended period of
is blocked. time, a low level alarm can appear at the
header tank. This is normal and will have no
negative effect on the system. When the
system is started up again, the level of the
tank will automatically go back to normal. The
header tank must not be topped up when
indicating low level.
LUBRICATION Output from the The saturation of the Investigate water leakage. Change the filters
SYSTEM FAULT saturation sensor. lubrication oil is too to attempt to remove the water from the oil.
high.
 Alarm Description Cause Action
LOCAL CONTROL The local control Can be the automatic Investigate reason and remedy.
POWER FAILURE system has failed. fuses or a number of
causes on the ship
side.
POWER SYSTEM A - The power supply for Can be a large Fault find and correct. The MPC system is
FAULT the remote control number of causes. redundant, which means that the B system
system A (MPC) has Short-circuit, for takes over automatically. However, the power
failed. example. supply failure must be fixed to ensure
redundancy and maneuver safety.
POWER SYSTEM B - The power supply for Can be a large The MPC system is redundant, which means
FAULT the remote control number of causes. that the A system takes over automatically.
system B (MPC) has Short-circuit, for However, the power supply failure must be
failed. example. fixed to ensure redundancy and maneuver
safety.
CONTROL SYSTEM A There is a fault in See the alarm list in See the alarm list in remote control system A.
- FAULT remote control system remote control
A (MPC). System B system A.
takes over
automatically.
CONTROL SYSTEM B There is a fault in See the alarm list in See the alarm list in remote control system B.
- FAULT remote control system remote control
B (MPC). System A system B.
takes over
automatically.

For detailed information on specific sensor levels etc, please refer to the vessel specific Alarms List.
2.11. MOUNTING/DISMOUNTING PROPELLER BLADES

2.11.1. MOUNTING BLADES

Procedure:
1. Make sure that the identifiers punched on the blades on the hub match. Correct component
location is essential.
Installation Identifier Description
Single Screw 1-4 Blade 1-4
Twin Screw P1-P4 Port propeller, blade 1-4
Twin Screw SB5-SB8 Starboard propeller, blade 5-8

Figure 15. Identifier locations.

Pos. Description
1 Punched blade identifier.
2 Punched hub identifier.
2. Check that the dowel (1 in Figure 16) is inserted into the unthreaded hole in the blade mount:

Figure 16.Installing the blades.

Pos. Description
1 Dowel
2 Blade seal
3 Bolts with O-rings

3. Make sure that the groove is clean and dry.

4. Apply a light and even coat of lubricant on the blade seal using multi-silicone grease OKS 11-10,
or equivalent. Make sure there is no excess grease in the groove UNDER the seal.

Figure 17. Blade seal in groove.

NOTICE! Risk of product damage. If the blade seal is lubricated incorrectly,

that is too much grease and/or unevenly applied, the seal may be damaged
thus requiring mandatory replacement.

5. Attach the blade seal (2 in Figure 16) in the groove in the hub body.
6. Fasten the blade to the blade mount. Ensure that each screw has an O-ring correctly positioned in
its groove (3 in Figure 16).
7. Tighten all bolts according to the main drawing. Use rotation measurement described in section
2.11.5 below.
8. Weld-lock the bolts (on each blade) on the side of the bolt head. The locks must be placed along
the periphery of the screws (not towards the bottom of the screw head):

NOTICE! Risk of product damage. When welding, be very careful not to

damage the O-ring under each bolt head.

Figure 18. Weld-lock the bolts.

NOTICE! Risk of product damage. After the final tightening of the blade
bolts, the hub must be tested, using low pressure air for example, to ensure
that there is no leakage at blade bolts, blade seals, and oil plugs.
2.11.2. DISMOUNTING A BLADE IN A NOZZLE

WARNING! Risk of serious personal injury/death. The main engine must be

shut down and all pumps must be shut off before dismounting a blade. Make
sure you follow standard lockout/tagout procedures to ensure that the
engine and pumps are not started before finishing the blade
dismounting/mounting.

Procedure:
1. Weld four lifting eyes to the hull.
2. Adjust the blades to zero pitch position.
3. Remove the weld locking on the blade bolts by grinding carefully.
4. Drain the hub.
5. Using a correct size Berg impact socket, loosen the blade bolts until the tightening torque is just
gone but keeps the bolts fixed in position.
6. Turn the blade to 6 o’clock position.
7. Insert a wedge under the blade and secure the blade so that it does not turn over without the
support of the lifting slings.
8. Remove the blade bolts using the power socket tool.
9. Apply four lifting slings around the blade flange and fasten them to the welded lifting eyes in the
hull:

Figure 19. Apply four lifting slings around the blade flange.
10. Lower the blade and take it out of the nozzle.
11. Ensure that the hole in the hub is covered.

Repeat the steps above for the remaining blades.

2.11.3. MOUNTING A BLADE IN A NOZZLE

WARNING! Risk of serious personal injury/death. The main engine must be shut
down and all pumps must be shut off before mounting a blade. Make absolutely
sure you follow standard lockout/tagout procedures. Lock controls and/or place
“Do not operate” signs where necessary to ensure that the engine and pumps
are not started before finishing the blade dismounting/mounting.

Procedure:
1. Weld four lifting eyes to the hull.
2. Adjust the blades to zero pitch position.
3. Turn the hub so that the opening for the blade flange points at 6 o’clock:

Figure 20. The opening for the blade points at 6 o’clock.

4. Apply four lifting slings around the blade flange and fasten them to the welded lifting eyes in the
hull.
5. From aft, position the blade just under the opening:
Figure 21. From aft, position the hoisted blade under the hub opening.

6. Insert a wedge under the blade and secure the blade so that it does not turn over when the lifting
slings are removed in the next step.
7. Remove the lifting slings.
8. Fasten the blade bolts according to section 2.11.1.

Repeat the steps above for the remaining blades.

2.11.4. CHECKING A USED BOLT

Procedure:
 Make sure that there are no visible damages.
 Make sure that the threads are undamaged and that the bolt threads easily into its hole. Minor
protruding burrs may be adjusted in a professional way.
 Examine the shaded area in Figure 22 for cracks using dye penetrant inspection. If any cracks are
found, the bolt MUST be discarded.

Figure 22. Checking a used bolt for cracks.

2.11.5. TIGHTENING BLADE AND HUB BOLTS

In the factory, OKS530 dry lubricant and OKS 250 all-round paste are applied to the bolts. This should
be done at the yard as well. However, to obtain a correct tightening that is not affected by such factors
the method described below should be used:

Figure 23. Tightening steps, example.

Note: Refer to the drawings for exact figures.

Procedure:
1. Pre-tighten one of the outer bolts (1 in Figure 24) just so that there is contact between the bolts
and the protective guard/blade flange.
2. To achieve a more well-defined starting angle, tighten the first bolt to 20% of the full tightening
torque (please refer to the PROPELLER HUB drawing). This way, grease, burr, hair and other
disturbing factors are eliminated or minimized.
3. Mark the position of the screw head at a suitable point (1 in Figure 23) on the outer diameter of
the screw.
4. Mark the tightening chord distance on the protective guard according to the PROPELLER HUB
ASSEMBLY drawing (2 in Figure 23) +- 5%.
5. Tighten the bolt to the prescribed torque in the PROPELLER HUB ASSEMBLY drawing.
6. Perform the steps above for the other outer bolts (1 in Figure 24) on each side of the blade. After
that, check that the two contact surfaces are perfectly tight using a 0.05 mm feeler gauge in the
remaining two center holes (2 in Figure 24).
Figure 24. Outer bolts (1) and holes for measuring tightness (2).

7. Perform steps 1 - 5 for the remaining two center bolts in the empty holes.
2.12. DISMOUNTING THE PROPELLER SHAFT
The propeller shaft is delivered with the pipe assembly mounted to the piston rod. However, during
service the propeller shaft needs to be dismounted.
The propeller shaft is hollow bored and contains an assembly of pipes. If the propeller shaft needs to
be pulled away from the rest of the shaft line, the shaft pipes needs to be disengaged between the
propeller shaft and the next shaft.
The shaft pipes of an MPP system are fixed from rotating inside the shaft line. In the aft end the pipes
are locked by a square-shaped groove in the propeller hub (Figure 25).

Figure 25. Propeller hub and shaft arrangement.

The shaft pipes are fixed from rotating inside the shaft line by a square-shaped groove in the propeller
hub.
Information This pipe connection is not supposed to be disengaged! The
propeller hub and the propeller shaft are not supposed to be separated!
The illustrations are only intended to show how the shaft pipes are fixed.

To make service or disassembly of the shaft pipes possible, the first step is to disassemble the OD
Box. The pipe connection can then be disengaged.

Procedure:
1. Pull the propeller shaft from the rest of the shaft line to create a gap of about 100 mm.
Note: If the installation includes two or more intermediate shafts, it also includes a split spacer ring,
which must be removed before the shaft pipes are disengaged. The removed split spacer ring will
create a gap of 100 mm.
Figure 26. Create a gap between the propeller shaft and the rest of the shaft line.
2. To disengage the shaft pipe from the propeller shaft pipe, gently unscrew it without damaging the
outer pipes. When performing this step, use the mounting spanner tool for the specific OD Box.
Be sure that the OD Box with its steering sleeve is fully disassembled during this operation.

Figure 27. Disassemble the propeller shaft pipe.

3. When the pipe is fully disengaged from the propeller shaft pipe, the complete propeller hub and
propeller shaft can be pulled out from the stern tube.
2.13. HUB OIL DRAINAGE
The lubrication oil in the hub can be drained using the plugs seen below.

Figure 28. Oil plug.

Figure 29. The two oil plugs in the hub.

Locking Plug
The valve screw should only be lightly tightened. Final seal is achieved using the plug and the
washer. After fitting, the sealing plug is locked using a stainless-steel rod, spot welded at each end.
When welding, care must be taken not to damage the rubber seal.
When weld-locking the plugs, ensure that you weld the pin to the hub, not to the plug itself. This to
avoid melting the rubber-steel washer:

Figure 30. Weld-locking plugs.

Ref. Description
1 Weld
2 Pin
3 Hub
4 Plug
5 Washer

Information: Ensure that the plug, rod and sealing washer are made of
stainless steel.
3. HYDRAULIC SYSTEM
3.1. INTRODUCTION
The hydraulic system supplies hydraulic power for the pitch control of the propeller blades. The
system also circulates oil in the propeller hub and provides lubrication and cooling of the Oil
Distribution Box (OD Box).

3.2. SYSTEM DESCRIPTION

The primary component of the Hydraulic System is the Hydraulic Power Unit (HPU).

Figure 31. System overview.

Note: Actual system setup is configuration dependent. Please see the vessel specific drawings and
the technical specification for details. A Header Tank is not always included in the system setup.
3.2.1. HYDRAULIC POWER UNIT

Figure 32. Hydraulic Power Unit.

Pos. Component Description
1 Pump Two electric pumps, OR one electric and one PTO pump. For pitch
control, lubrication/cooling, and oil circulation.
2 Clogging indicator One clogging indicator on each filter unit.
3 Filter One oil filter for each pump.
4 Tank breather/Filler port The breather is fitted in the oil filler port. Remove to fill oil.
5 Lifting point 4 lifting points. (Note: 1 not visible in image.)
6 Temp sensor Oil temperature sensor with display and high temperature alarm.
7 Drain port 2 drain ports. One per tank section.
8 Main tank Main oil tank with two sections: pump suction, and reserve used in
case of emergency pitching.
9 Level sensor Oil level sensor with display and low-level alarm.
10 Connection box Electrical connection box with integrated pitch indicator.
11 Pitch indicator Pitch feedback indicator (electronic).
12 Emergency pump Emergency pump (manual or electric).
13 Manifold block Oil manifold block with multiple components. See specification below.
14 Pressure gauge Gauge for system pressure.
15 Control valve Hydraulic control valve.

Note: Additionally, an oil cooler (not shown in image.) can be included in the system.
The HPU Manifold Block Contains:
 Pump setting valves.
 Pressure relief valve.
 Pitch control valve.
 Pressure reducing valve and flow valves for lubrication/cooling and oil circulation.
 Pressure sensor for system pressure (4-20 mA output signal).
 Pressure gauge for system pressure.
 Water saturation sensor.
 Test ports.

For additional information, see drawing HPU AR-MPP.

3.2.2. PITCH CONTROL

The pump on the Hydraulic Power Unit (HPU) provides hydraulic power for pitching the propeller
blades. The pump is a variable displacement, axial piston pump with pressure control to limit the
maximum system pressure. Full pump displacement is achieved unless the system valve restricts the
output flow, or the load pressure reaches the maximum setting of the control. If pump flow is restricted
by the system valve, the pump will provide only the flow demanded, but at the maximum pressure
setting of the compensator control. If the outlet flow is completely blocked, the pump will destroke to
zero displacement and maintain the pressure at the setting of the compensator spring.
There are two or three pumps in the hydraulic system. Depending on configuration, the pumps can be
setup to function differently in the event of a pump failure.
After the pump, oil is filtered before it goes to the Control Valve, which is controlled by the MPC800
control system. The Control Valve lets the oil flow through the A or B channel to the hub, which
activates ahead or astern pitch angle respectively.
The return oil from the Control Valve goes directly into the reserve oil section of the tank. The
emergency pump suction is located in this section. It is separate from the pump suction area and
contains enough oil to perform one pitch stroke with the emergency pump.
The Control Valve has manual override to use in case of emergency. On the HPU there is an
emergency pump (manual or electric). There is also a pitch indicator that shows actual pitch angle.

3.2.3. OIL CIRCULATION IN THE HUB

Oil circulates in the propeller hub and is continuously monitored for water saturation to obtain an early
warning for damaged blade seals and any resulting water ingress.
The oil inlet in the hub is near the hub center, whereas the outlet is close to the outer perimeter.
Water, dirt, and any other particles are heavier than oil and therefore concentrate in the outer part of
the rotating hub. Oil flows back through the D-line to the HPU, where the oil is monitored for water
saturation before it ends up in the tank.
There are two ways to circulate oil in the hub: Pump Circulation (PC) and Tank Circulation (TC).
Pump Circulation (Standard)
Provides overpressure in the hub when the system is running. When the pitch pump is running, some
oil is bleeding off and goes directly to the L-line on the OD Box and then through the shaft line to the
hub. The flow, and indirectly the pressure, is set by using a valve on the HPU.
Tank Circulation (Optional)
When the pitch pump is running, some oil is bleeding off to fill the Header Tank. From the Header
tank oil flows through the L-line to the OD Box and through the shaft line to the hub.
3.3. SYSTEM CLEANLINESS AND FILTRATION

3.3.1. SYSTEM FILTRATION

On a standard system, there are two oil filters and an air breather on the HPU tank. If applicable,
there is one breather per additional tank. Other vessel specific filter configurations are possible. See
drawings.
 The pressure filters are mounted between the pump pressure connection and the control valve.
There is a differential pressure alarm to indicate when the in-service filter must be replaced.
 The HPU air breather is mounted on top of the tank. The unit contains a permanent filter, which
means the breather must be replaced at regular intervals. See the Maintenance Schedule for
specification.

NOTICE! New oils often contain impurities. For this reason, filters must be
checked and replaced (if necessary) at the first convenient opportunity
after an oil change or top-up.

3.3.2. CLEANLINESS LEVEL

To guarantee reliable function of the system, cleanliness must be in accordance with ISO 4406,
18/16/13 (equivalent to NAS grade 7) or higher.

3.4. FILLING SYSTEM

NOTICE! Risk of product damage. Failure to follow the oil requirements can
shorten the service life of the propulsion equipment. Before filling, make
sure oil has been filtered to at least 18/16/13 according to ISO 4406
(equivalent to NAS grade 7).

Information: Berg Propulsion recommends using portable filter carts to

prefilter and transfer fluids into the propulsion system. Use a filter rated at
10µm (Micron) or higher.

3.4.1. BEFORE FILLING

Most new fluids (straight from the drum) are unfit for use due to high initial contamination. During
filling, the oil MUST be filtered. Use a filter rated at 10µm (Micron) or better. Berg Propulsion
recommends using portable filter carts to prefilter and transfer fluids into the system.
Make sure oil has been filtered to at least 18/16/13 according to ISO 4406 (equivalent to NAS grade
7) before filling/topping up the system.
Note: The cleanliness level of hydraulic systems can dramatically affect the service life of various
system components. A hydraulic system can never be too clean!

3.4.2. FIRST FILL

Fill the system by adding fluid to all tanks: HPU, Header Tank (if present), and Circulation Tank (BCX
systems only).
Note: Use only fluid that meets the requirements for system fluid in Appendix – MPP Oil
Requirements.
Procedure:
1. Make sure the system is switched off.
2. Remove the Breather (1).
3. Fill the tank/tanks to the nominal oil level. See drawings for specifications.

3.4.3. TOP OFF

Figure 33. Breather and sensor.

Pos. Description
1 Breather
2 Level sensor

Procedure:
1. Switch off the system.
2. Remove the Air Breather (1).
3. Fill the HPU Tank until the Level Sensor (2) shows 80%.
Note: Top off of oil must only be done in the HPU tank. When the system is running, any other tanks
in the system will be filled up from the HPU.

3.5. HYDRAULIC SYSTEM ALARMS

Most alarms from the hydraulic system are displayed in the vessel alarm system, i.e not in the Berg
Propulsion MPC800 control system. However, the following alarms are presented in the MPC800
System:
 HUB LUBRICATION MOISTURE LEVEL
 HUB LUBRICATION OIL TEMPERATURE
Default Alarm Levels (Configurable)
 Saturation: >80% saturation detected for a time period exceeding 1 hour.
 High Oil Temp: Set temp level exceeded for 1 hour.
See the Alarms Page in the MPC800 system for further information. For a full listing of system alarms,
please refer to the vessel-specific System Alarms List.
3.6. HYDRAULIC STARTER PANEL

Figure 34. Typical hydraulic starter panel (Main Pump).

Pos. Description
1 Indicator light: Power ON, 24V
2 Indicator light: Alarm
3 Indicator light: Standby
4 Indicator light: Running
5 Indicator light: Heater
6 Run time meter
7 Amp gauge
8 Main switch
9 Selector: LOCAL/ ON-OFF-REMOTE
10 Selector: MAN-AUTO, AUTO=Pump start via Pressure Switch.

Operational Modes − Pumps

Settings Description Note
S1-LOCAL/ON + S2-MAN LOCAL/ON MAN MODE (Start) Set up as Main Pump.
S1-LOCAL/ON + S2-AUTO LOCAL/ON AUTO MODE (Auto Start/Stop) Set up as Backup Pump.
S1-OFF + S2-MAN OFF
S1-OFF + S2-AUTO OFF
S1-REMOTE + S2-MAN REMOTE START Manual remote pump control.
S1-REMOTE + S2-AUTO REMOTE AUTO START Automatic remote pump control.

To set a pump as backup, set Unit A to MAN MODE, and Unit B to AUTO MODE. (AUTO = Start via
Pressure Switch).

Information: To even out the running hours of the hydraulic pumps, the
setting for which pump is set up as Main and Stand By must be changed
weekly.
4. MPC800M REMOTE CONTROL SYSTEM
4.1. SYSTEM OVERVIEW
The Berg Propulsion MPC800M (Marine Propulsion Control) is a proprietary microprocessor-based
control system for the propulsion machinery of the vessel. The system provides proportional (follow
up) control of propeller pitch, engine speed and engine load.
The propulsion machinery is controlled from a number of control positions, with one control position
active at a time. Normally there is one control position in the ECR and one to five control positions on
the bridge. The MPC800M also provides an optional interface to higher level systems, such as DP
and Joystick.
For improved self-checking capabilities and reduced cabling, the MPC800M uses field bus (RS485)
communication between the central unit and control panels and interface units. The MPC800M has a
high level of redundancy and self-checking, which makes it single fault proof for most internal and
sensor faults.

4.2. SYSTEM CONFIGURATION

The detailed specific system configuration is shown in the MPC800M layout drawing. The figure
below shows the layout of a typical single-screw system.

Figure 35. Typical system layout.

This single-screw layout plan consists of three bridge control panels, one ECR Control Panel, one
Central Unit and one Local Control Unit. A twin-screw system works as two separate single systems.
Usually, a twin-screw system will have two double Bridge Control Panels and two single ECR panels,
which are designed to be operated in a similar fashion to a bridge double panel.
Most of the external connections are made to the Central Unit. The cabling between the Central Unit
and the control panels has just eight cores, containing the power supply and the field bus for the two
redundant branches.
The Central Unit is the heart of the system. It contains the electronic controllers for the redundant A
and B branches. These controllers contain the hardware and software for most of the functionality.
The Central Unit requires two separate 24V DC power supplies.
The control panels can be situated at different locations but are similar with only small differences.
The ECR panel, however, has a specific graphical user interface and a rotating selector instead of a
pushbutton in one position. The control panels consist of a lever unit, a pushbutton transfer unit, and a
GUI unit containing the display.
The Local Control Unit provides direct pitch control and pitch indication regardless of the state of the
rest of the control system.
4.3. SYSTEM UNITS

4.3.1. CENTRAL UNIT

Figure 36. Central Unit.

Pos. Component Description

1 Power Supply One power supply for each branch, A and B. On the output side, the
negative terminal is connected to the hull. The input side is potential
free.
2 Controller Unit One controller per branch. Each controller contains a processor that
runs the controller program.
3 Controller Unit Display Four-character alpha numeric display. Shows the following
information: SW version and unit address, Active/Standby Branch,
and Fault codes. Syntax: [F:NN].
4 Relay Unit Digital outputs to other equipment are connected through relays. The
contacts are potential free.
5 Diode Unit The supply to sensors and digital inputs are fed via the diode bridge.
This means that the inputs are supplied from either supply A or B,
whichever is present.
6 Circuit Breakers Main circuit breakers. A & B.
7 Terminals Spring clamp terminals. The power supplies are connected directly to
the fuses.

The Central Unit is normally fitted on a bulkhead in the engine control room or in the engine room.
The unit is tested for ambient temperatures up to 50 degrees Celsius but fitting the cabinet in a
temperature-controlled area is recommended. The cabinet should be fitted in an accessible position
where the door can be fully opened.
For central unit layout, please refer to the CENTRAL UNIT DIMENSIONS AND LAYOUT drawing.
CONTROLLER UNIT FAULT/STATUS INFORMATION
The following information is displayed:
1) Directly after power on: SW version number and unit address (shown in increments).
2) Continuously: RUN or STBY. Indicates Active/Standby branch.
3) Fault codes for internal use. Syntax: [F:NN].

Fault Codes – Fundamental Errors

F:00 – Bus communication fault
F:01 - Communication fault to the other system branch (A or B)
F:02 – Not used
F:03 - Open pitch valve output
F:04 - Open M/E RPM demand output
F:05 - Open pitch feedback input
F:07 - Pitch timeout
Note: Codes are also presented in the alarm log.
4.3.2. LOCAL CONTROL UNIT

Figure 37. Local Control Unit.

The Local Control Unit is used for controlling the propeller pitch from the engine room. The unit
displays shaft RPM and pitch. It is equipped with ahead/astern pushbuttons and a selector for Local
or Remote control. Activating the local control will disconnect the main system and cause a warning in
the fault handling of the control system.

Information: The local control unit is intended for service purposes and as
a back-up device in case of total electronic system failure. It is normally
fitted in the engine control room, adjacent to the local control unit of the
main engine.
4.3.3. BRIDGE PANEL

Figure 38. Bridge panel.

The system always contains one or more Bridge Panels. A Bridge Panel is used for controlling the
pitch and engine speed. For more information, please refer to section 4.7.1.
4.3.4. ECR PANEL

Figure 39. ECR panel.

The ECR Panel is used for controlling the pitch and engine speed by separate levers.
For more information, please refer to section 4.7.1.

4.4. MAIN CONTROL FUNCTIONS

4.4.1. PROPORTIONAL (FOLLOW-UP) PITCH CONTROL

Pitch is controlled from control levers on the Bridge and in the Engine Control Room (ECR). One
position of the lever corresponds to one pitch position. From the lever position, the desired pitch
position is calculated from a "pitch curve", and an internal regulator controls the propeller hydraulics to
achieve the desired propeller position.
The purpose of the pitch curve is to provide a specific relationship between the lever position and the
obtained pitch. The lever position can, for example, be made linear to the speed of the ship or linear
to the propeller thrust.
The propeller hydraulics is controlled by a proportional hydraulic valve. The actual pitch value
(feedback) to the control system is derived from a potentiometer or magnetic sensor on the hydraulic
pitch control unit.

4.4.2. ENGINE SPEED CONTROL

Engine speed is controlled from control levers on the Bridge and in the ECR. One position of the lever
normally corresponds to a specific engine speed. It is also possible to select a "Constant Rpm" mode,
which sets the engine speed to a selectable constant value.
The output from MPC800M for engine speed setting is a 4-20mA signal to an electronic governor.
4.4.3. LOAD CONTROL SYSTEM
The automatic Load Control System is designed to maintain a constant load on the Main Engine at a
level which is pre-set in the engine room. The level setting normally ranges from 60% to 100% of full
power. Both the upper and lower limits can be set in the system parameter setting program. The
maximum allowed load is also a factor of the engine speed when using the combinator curve.
The system compensates for variations in load by fine adjustment of pitch. Engine load is continually
calculated in the program controller by the measurement of the engine fuel rack position and the
propeller shaft speed. The load control program is chosen to suit the characteristics and requirements
of the particular vessel. The load curve is defined in the system parameter setting program.
The purpose of the load control subsystem is to protect the engine by keeping the engine load below
the load limit curve. It is also possible to restrict the engine load to less than 100% by a manual
setting, load limit.
The engine load is controlled by decreasing and increasing the propeller pitch. When the maximum
load of the engine is reached, the pitch will not increase further, even if the lever position (pitch order)
is higher. If the load decreases, the pitch will start to increase again.
For example, when accelerating the speed of the ship from zero to full speed, the pitch will only
increase at a rate where the engine load does not exceed the maximum allowed, defined by the load
limit curve and the load limit setting.
The load control system consists of sensors for monitoring the engine speed and engine fuel rack
position, and a load limit control for setting the maximum load.
The fuel rack position signal is either taken directly from the engines electronic governor or from an
inductive analogue sensor set to sense the rotation of the fuel rack shaft.
The load control input signals from the sensors and load limit setting are processed by the controller
and a comparison is made between the actual load and the permitted load. The results of the
comparison are converted into small pitch correction signals. The rate of pitch change depends on the
difference between actual and required load.
A small dead band is built into the system to prevent continual operation of the Pitch Control Unit
when the actual load is within a certain percentage of the required load. The range of the dead band
is a parameter set in the program.
Through the parameter setting system, the Load Control System can be tuned to suit individual
engines, hull designs and operational modes.
The load limit setting (%) is set at the ECR control panel.

4.4.4. COMBINATOR CURVES

The Combinator Curve defines the relationship between the lever position, the engine speed (rpm)
and the pitch. A propeller controlled from a single lever for both engine speed and propeller pitch, is
referred to as running in Combinator Mode.
The propeller pitch is not linear to the thrust or the speed of the ship. The propeller revolutions are not
linear to the thrust or the speed of the ship. Depending on what conditions the ship will be used in,
different relationships might be needed. The MPC system can utilize different combinator curves, both
standard and user defined ones.
Figure 40. Typical combinator curve.

4.4.5. CLUTCH CONTROL

It is possible to control up to three different clutches from the MPC800M system. Clutch status is
indicated at all control points. Manoeuvre of the clutches can be made from any control panel on the
Bridge or in the ECR.
Clutch control is provided with interlocks when engaging and automatic disengage upon certain faults.

4.4.6. AUTOMATED FAULT HANDLING

Functions for automatic load reduction and automatic clutch out are provided. For example, there is a
Slow Down function suitable for load reduction to a preset value if the Main Engine exhaust
temperature is too high. Further, there is a Shut Down or Auto Stop function that decreases the pitch
and clutches out, which may be required due to a gearbox oil pressure drop.

4.4.7. FEATHERING
Feathering means to pitch the blades to a position where a minimum water resistance is obtained.
Feathering is controlled from the ECR Main page.

4.4.8. REDUNDANCY AND FAULTS INDICATION

To achieve a single-fault-proof control system, all sensors and electronics are duplicated as two
identical branches. Each branch has its own sensors, electronics, power supply and field bus. Only
one branch is active at a time with the standby branch reading the data from the active branch, thus
enabling a rapid switchover upon an internal fault or a manual switch request.
 Information: When an automatic swap is caused by a failure of the active
power supply, a short transient voltage dip of approximately 0.5s will be
experienced, which can cause the output relays to set & reset. Signals to
external systems can be momentarily lost during this period.

An extensive self-checking protocol is running constantly, measuring the condition of supply voltages,
sensors, output valves, program execution, and total system response. Any detected errors will cause
an alarm or a warning. If the fault is internal, an automatic switch-over to the standby system will
occur.
All faults and warnings are displayed in plain text, readable from all control panels. There is also an
alarm log.
The alarm outputs consist of relay contacts, potential free, to be connected to the ship's alarm system.
There are two contacts indicating loss of supply and two contacts indicating fault/warning, in total four
contacts for faults and power supply indication.

4.4.9. LOCAL CONTROL FUNCTION

The Local Control Unit is used for controlling the propeller pitch from the engine room. The unit
displays shaft RPM and pitch. Activating local control will disconnect the main system and cause a
warning in the fault handling of the control system.

4.4.10. COMMAND TRANSFER FUNCTION

Only one control panel can be active at a time. Note: The ECR panel always takes precedence of the
control. That is, at all times the control can be transferred to the ECR panel without acknowledgement
from the Bridge.

4.4.11. ZERO PITCH SYSTEM (IF INCLUDED)

The zero pitch system brings the pitch to zero in an emergency situation, or when there is a failure in
either the electronic control system or the hydraulic system.
The system uses the emergency pump and a separate closed loop controller mounted in the local
unit. The system is operated via the zero pitch switch on the bridge or in the ECR:
Press the emergency zero pitch switch to start the electrically driven emergency hydraulic pump. The
zero pitch controller then takes control over the pitch servo valve to bring the pitch to zero from any
position.

4.5. ADDITIONAL FUNCTIONS

The MPC800M system incorporates a number of special functions which, depending on the
equipment specification, may or may not be included as a functional part of the equipment.

4.5.1. OVERLOAD
The overload signal consists of a micro-switch mounted on the engine fuel rack that is set to activate
at 103%. When activated, the overload lamp is illuminated at all control panels after a preset delay.
Because the load control system is already automatically reducing the pitch, the overload signal will
not cause any additional pitch reductions.
Should the lamp remain lit, manual intervention to reduce the pitch is required.

4.5.2. SLOWDOWN OR AUTO-LOAD REDUCTION

Slow Down or Auto-Load Reduction is a function that provides automatic reduction of the pitch at a
given signal from the alarm system or engine safety system. On activation, the maximum engine load
is automatically limited to a value set in the parameter table (normally 60%).
4.5.3. SHUTDOWN OR AUTO STOP
Shut Down or Auto Stop is a function that provides automatic shutdown of the propeller at a given
signal from the engine or gearbox safety systems, or when the engine is (emergency) stopped. The
function causes the pitch to be reduced to minimum and the clutch disengaged.

4.5.4. OVERRIDE
The Slowdown function has the possibility of Override during emergency situations. When a
Slowdown input becomes active, the Override function is available for selection using the ENTER
button.

4.5.5. PITCH INDICATION

The propeller pitch is indicated in the graphical display at all control positions.
If required, a galvanically isolated 4-20 mA signal can be provided for the use of an external pitch
indicator. Alignments for scaling of the indicator are part of the parameter settings.

4.5.6. SHAFT SPEED INDICATION

The propeller shaft speed is indicated in the graphical display at all control positions.
When required, a galvanically isolated 4-20 mA signal can be provided for the use of an external shaft
speed indicator. Alignments for scaling of the indicator are part of the parameter settings.

4.5.7. VOYAGE DATA RECORDER (VDR)

A serial VDR signal is available from all panels. The signals are compatible with NMEA0183, and use
a RS485 interface. It can be used both for VDR and Conning systems.

4.5.8. DYNAMIC POSITIONING (DP)

An external function for keeping the vessel in a fixed position. Requires handshaking.

4.5.9. JOYSTICK (JS)

An external function for controlling the main propeller, rudder, and thruster simultaneously.
4.6. TECHNICAL DATA

4.6.1. MAIN DATA – MPC SYSTEM

Central Unit Main Supplies (2 pcs): 24V DC +/- 10%, 300W, at least one supply UPS
Local Control Unit Supply: 24V DC +/- 10%, 50W, UPS
Operating Temperature: 0 – 50°C GL: Environment C

Ingress Protection
Control Panels: IP 54 (From top)
Central Unit: IP 54
Local Control Unit: IP 65 (Door closed)

4.6.2. ENVIRONMENTAL TESTS

Test Procedure Parameters
Power Supply 18 – 32V DC
Power Failure 3 interruptions of 30s each during 5 minutes
Dry Heat IEC60068-2-2 +50 °C, 2 Hours
Cold IEC 60068-2-1 +5 °C, 2 Hours
Damp Heat IEC60068-2-30 +55 °C, 2 x 12 Hours
Vibration IEC60068-2-6 2-13.2Hz ,+/- 1mm
13.2 – 100Hz, +/-0.7g
Inclination IEC60092-504 Static 22.5°
Insulation Resistance 48V on Power Supply
High Voltage 1 minute 548V AC between subsystems. Electronic
circuits disconnected.

4.6.3. EMC TESTS

Test Procedure Parameters
ESD 61000-4-2 6kV Contact, 8 kV Air
Electromagnetic Field 61000-4-3 10V/m, 80MHz – 2 GHz, 80% AM
Conducted Low Freq, Power IEC60945 50Hz – 10kHz, 10% of Supply Voltage, max 2W
Supply
Conducted Radio Freq IEC61000-4-6 3 Vrms, 150kHz – 80MHz, 80% AM
Burst, Supply Line IEC61000-4-4 2 kV
Burst, IO Line IEC61000-4-4 1 kV
Surge, Supply Line IEC61000-4-5 0.5 / 1.0 kV
Radiated Emission, Enclosure CISPR 16-1, 16-2 0.15-0.3 MHz: 80-50 dBuV/m
0.3-30MHz: 50-34 dBuV/m
30-2000MHz: 54 dBuV/m
156-165MHz: 24 dBuV/m
Conducted Emission, Power CISPR 16-1, 16-2 10-150kHz: 96-50 dBuV
Supply 150-350 kHz: 60-50 dBuV
350kHz-30MHz: 50 dBuV
4.7. USING THE SYSTEM
There are two types of control panels, one for the bridge (Bridge Panel) and one for the engine room
(ECR panel). The bridge panel is normally equipped with a combinator lever that controls both pitch
and engine speed simultaneously, or only pitch when running in constant speed mode. The ECR
panel normally has two separate levers, one for pitch and one for engine speed.
In general, the two panels work the same way. However, the user interface differs somewhat. Also,
the alarm information is more comprehensive on the ECR panel.

4.7.1. CONTROL PANEL OVERVIEW

The Bridge Panel

Figure 41. Bridge single panel.

On the bridge panel, a lever for combined control of pitch and engine speed is provided to the top
right. The lever section, to the top right, holds the levers for pitch control and engine speed on the
ECR panel.
The transfer unit, to the bottom right, contains numerical values for pitch and shaft speed, a switch
and pushbutton for command transfer and an indicator for current control position and system status.
The GUI panel, to the left, contains the display, the jog wheel and the pushbuttons needed for
entering data.
The jog wheel is used for selecting a menu item, the ENTER button is used for entering the subpage
or activating a function, the ESCAPE button is for leaving a subpage or deactivating a function.
The ECR Panel

Ref. Description
A Graphical display
B RPM lever/knob
C Pitch lever/knob
D Jog wheel
E ESCAPE button, exit the current page
F ENTER button, select the current option or save
G Pitch/RPM numerical display
H Command transfer buttons / switch
I Command indicator

4.7.2. THE MAIN PAGE

The main page of the panel is divided into sections and is displayed when the system is started. The
pages shown here are examples. What is contained in the actual pages can differ.
BRIDGE MAIN PAGE
Typical Bridge main page:
Figure42. Bridge main page.
ECR MAIN PAGE
Typical ECR main page:
Figure 43. ECR main page.
THE SYSTEM SECTION
The sub-pages for the SYSTEM section are described in section 4.7.3.
SYSTEM A ACTIVE / SYSTEM B ACTIVE (grey/green)
Indicates which system is active, A or B. If, for some reason, the active system fails, the standby
system takes control automatically.
Only faults will cause a switch from SYSTEM A to SYSTEM B. If a warning occurs, the current system
will continue running. Examples of faults: lost pitch control, lost communication, lost RPM control, and
lost power supply.

SWAP
This function causes the standby system to assume control. Used for testing, setup and general
maintenance.

PROPELLER IN SERVICE (grey/green)

When highlighted, indicates that the clutch is engaged (if present), that there is hydraulic pressure in
the system and that the propeller is ready to be used.
CLUTCH ENGAGED
When highlighted, indicates that the main clutch is engaged
THE ALERTS SECTION
 OVERLOAD (grey/red) – indicates that the engine overload switch is engaged, for example in
rough weather conditions. Refer to the overload section under Error! Reference source not
found..
 WRONG WAY PITCH – alerts if the lever and actual pitch don’t have the same sign (+ or -).
Transient conditions are ignored, however.
 LOCAL PITCH CONTROL (grey/yellow) – indicates that the local/remote switch on the local unit
is switched to local. The pitch lever will have no effect on the pitch movement.
 LOCAL M/E CONTROL (grey/yellow) – indicates that the local/remote switch on the Main Engine
is switched to local. The RPM demand signal is no longer controlling the engine speed.
 LOAD CTRL OFF (grey/yellow) – indicates that the load control function is off.
 SYSTEM ALARM STANDBY (grey/yellow) – indicates there is a warning in the standby system.
Usually occurs after a fault has occurred.
 SYSTEM ALARM ACTIVE (grey/red) – indicates there is a fault affecting both systems.

THE CONTROL SOURCE SECTION

The control station currently in command is indicated in green. The current lever position is
represented by a value from -10 to 10. For ECR, the pitch lever position is indicated.

DP/Joystick Interface
If a DP/Joystick interface is connected, the DP/JS options appear in the Control Source frame.

THE AUTO LOAD REDUCTION SECTION

 OVERRIDE (grey/white) – indicates that the slowdown function can be overridden. Override
allows cancelling the pitch reduction. Refer to 5.3.4.
 SLOW DOWN – indicates that the SLOW DOWN function has been activated. Refer to section
5.3.2
 SHUT DOWN – indicates that the SHUT DOWN function has been activated. Please refer to
section about shutdown or autostop under Error! Reference source not found..

CONSTANT RPM (C RPM)

Activate/deactivate constant RPM. This section is always displayed on the ECR panel, while it is
optional on the Bridge panel. When constant RPM is active, the engine runs at 100% RPM and the
shaft generator may be engaged. Also, if the shaft generator is engaged, constant RPM is activated
automatically and can’t be deactivated.
On the ECR panel, you can adjust the constant RPM value. Select the SYS PAGE button according
to section 4.7.3.
THE CONTROL MODE SECTION
Indicates the active control mode, for example Shaft Brake, Feathering, Fire Fighting (FIFI)and Power
Take Home (PTH). Note: Other control modes can be configured.
FEATHERING
Can only be activated from the ECR panel. Select the MODES PAGE button in the CONTROL MODE
section. In the FEATHERING section, select the FEATHERING MODE button. The following happens:

Figure 44. The FEATHERING section.

1. The system attempts to clutch out and CLUTCH OUT is lit.

2. The shaft brake is engaged and ENGAGE SHAFT BRAKE is lit.
3. The blades are feathered and MOVE TO FEATHERING is lit. When the blades have reached
feathering position, FEATHERING MODE is lit (green), both in the FEATHERING section and in
the CONTROL MODE section.

To return to normal operation, perform the following steps.

Procedure:
1. Select the NORMAL OPERATION button.
2. Disengage the shaft brake.
3. Engage the main clutch.

Information: The propeller can only be in feathering state when the ECR
is in command. If the command is transferred to the bridge while in
feathering mode, the propeller will automatically move to normal operation.

SHAFT BRAKE
To engage/disengage the shaft brake, select the MODES PAGE button in the CONTROL MODE
section on the ECR Main page. The SHAFT BRAKE section appears:

Figure45. The MAIN CLUTCH and SHAFT BRAKE sections.

If the main clutch is engaged, the shaft brake is blocked, and the corresponding text is lit (red). If so,
disengage the main clutch using the OUT button in the MAIN CLUTCH section.
Then engage the SHAFT BRAKE using the IN button in the SHAFT BRAKE section. This will also
block the main clutch.
Disengaging the shaft brake works in a similar way.
FIRE FIGHTING
Indicates that the vessel is operating in FiFi mode.

The CLUTCH section (MAIN, PTO, and PTI)

MAIN CLUTCH
To clutch in/out, two requirements apply:
 Pitch must be 0.
 RPM must be limited.

Otherwise, MAIN CLUTCH BLOCKED is red in the CLUTCH section.

Procedure:
1. Reduce the pitch to 0.
2. Reduce the rpm to so that the MAIN CLUTCH BLOCKED text in the MAIN CLUTCH section is
grey.
3. In the CLUTCH section, select the IN button.

The MAIN CLUTCH ENGAGED text is displayed in green, both in the CLUTCH section and the
SYSTEM section on the main page.
Clutching out is always possible. However, caution is advised if clutching out when the engine is
running under heavy load.

PTO AND PTI CLUTCHES

To operate the PTO and PTI clutches, select the CLUTCH PAGE button in the CLUTCH section. The
following clutch sections appear:
Figure 46. The clutch sections.
Restrictions: If the PTO clutch is engaged, the PTI clutch is blocked (since the PTI clutch is used only
as an auxiliary engine).

CLUTCH RESTRICTION OVERVIEW

The restrictions apply only when clutching in.

Clutch 1 (Main Engine):

 Zero pitch (more or less)
 Limited engine RPM
 Shaft brake disengaged
 Hydraulic pressure OK
 PTI/PTH clutch is disengaged
 No external shutdown signal

Clutch 2 (PTI/PTH):
 Zero pitch (more or less)
 Shaft brake disengaged
 Hydraulic pressure OK
 Main engine and PTO clutches are disengaged
 No external shutdown signal
 PTH has a waiting time, or “cooling time”, defined that forces an adjustable waiting time between
moments for clutching in

Clutch 3 (PTO):
 PTI/PTH clutch is disengaged
 No external shutdown signal
THE DIMMER SECTION

Figure 47. The DIMMER section.

Use this section to adjust the brightness of the panel.
THE LOAD LIMIT SECTION

Figure 48. The LOAD LIMIT section.

In this section, you can adjust the load limit curve, which affects the load control. The curve is raised
or lowered in one piece by a percentage factor:

Figure 49. Raising/lowering the load limit curve.

The load limit can only be adjusted from the ECR panel. To adjust the curve, perform the following
steps.

Procedure:
1. Using the jog wheel, select the SET button in the LOAD LIMIT section and press the ENTER
pushbutton.
2. Adjust the value with the jog wheel.
3. Press the ENTER pushbutton to save the new load limit.
4.7.3. VARIABLES SECTION
To access the variables, select the SYS PAGE button in the SYSTEM section. The following page
appears:

Figure 50. The VARIABLES section.

The VARIABLES section displays the most important variable values.

Set Pitch
The desired pitch value, calculated from the DP/JS/ETA input, lever position, and combinator curve.

Actual Pitch
The pitch value that is measured from the potentiometers on the hydraulic Pitch Control Unit.

Engine Set Speed

The requested engine RPM value, calculated from the DP/JS/ETA input, active combinator curve, or
Constant RPM value if CRPM is active.

Engine Act. Speed

The actual RPM value that is received from the engine control system.
Shaft RPM
The RPM value of the propeller shaft.

Engine Max Load

Indicates the maximum load that is allowed. This value is calculated from the engine speed and the
manual Load Limit setting.

Engine Act. Load

The actual load value that is received from the engine control system.

4.7.4. THE LOAD CONTROL SECTION

Turn on/off the Load Control function.

Figure 51. The LOAD CONTROL section.

4.7.5. ADJUSTING 0% / 100% PITCH, AND MAXIMUM MAIN ENGINE LOAD
To be able to adjust the input values for 0% / 100% pitch and the maximum main engine load, you
must enter the crew password. Please refer to 4.7.6.
When you have entered the password, the following page is displayed:

Figure 52. The PITCH FEEDBACK and MAX MAIN ENGINE LOAD sections.
ADJUSTING 0% / 100% PITCH

0% PITCH
To adjust the input value for 0% pitch, perform the following steps:
1. Ensure that the lever is in 0 position so that the Save A + B field (#1 in the figure above) in the
PITCH FEEDBACK section is green. This requires that the set pitch is 0 and that the actual pitch
= set pitch +- 5%.
2. Using the jog wheel, place the cursor in the Zero field (#2 in the above figure) in the PITCH
FEEDBACK section and press the ENTER pushbutton.
3. Using the jog wheel, adjust the 0% pitch to the desired value – the Calculated Actual Pitch field
and the Pitch dial reflect the value instantaneously.
4. When the value is stable, place the cursor on the Save A + B field to the right of the Zero field and
press the ENTER pushbutton twice (to discard the new value, press the ESCAPE pushbutton).
The Calculated Actual Pitch field and the Pitch dial now display 0% pitch.

100% PITCH
To adjust the input value for 100% pitch, perform the following steps:
1. Ensure that the lever is in full ahead position so that the Save A + B field (#3 in the above figure)
in the PITCH FEEDBACK section is green (red in the above figure though).
2. Using the jog wheel, place the cursor in the Ahead field (#4) in the PITCH FEEDBACK section
and press the ENTER pushbutton.
3. Using the jog wheel, adjust the 100% pitch to the desired value – the Calculated Actual Pitch field
and the Pitch dial reflect the value instantaneously.
4. When the value is stable, place the cursor on the Save A + B field to the right of the Ahead field
and press the ENTER pushbutton twice (to discard the new value, press the ESCAPE
pushbutton).
The Calculated Actual Pitch field and the Pitch dial now display 100% pitch.

ADJUSTING THE MAXIMUM MAIN ENGINE LOAD

In the figure above, 5.56mA (#5) is the set input equivalent to 10% engine load (#6). To set a new mA
value (4-20 mA) for the maximum engine load, perform the following steps.

Procedure:
1. Find the actual maximum main engine load with the engine running. (The corresponding mA
value is displayed in the Act Load In field (#5 in the figure above).
2. Place the cursor in the Save A + B field (#7) to the right of the 100% Load field and press the
ENTER pushbutton.
4.7.6. PASSWORD

Information: The password is preset by Berg Propulsion and cannot be

changed by the user.

The password consists of three or four digits. Contact the crew member responsible for the control
system for information about the vessel-specific password.
To enter the password, perform the following steps.

Procedure:
1. Select the SYS PAGE button in the top right corner of the main page. The PASSWORD section
appears:

Figure 53. The PASSWORD section.

2. Place the cursor in the leftmost value field (#1 in Figure 53) and press the ENTER pushbutton.
3. Enter the first digit of the password using the jog wheel. The current digit is displayed in the field
to the left (#2).
4. Press the ENTER pushbutton to save the digit.
5. Perform the above steps for the remaining two digits of the password (#3 and #4 in Figure 53).
6. Select the Set button for Crew Settings (#5) and press the ENTER pushbutton. The PITCH
FEEDBACK and MAX M/E LOAD sections appear (refer to Figure 52).
4.7.7. COMMAND TRANSFER PROCEDURES

Only one control panel can be active at a time. The ECR panel always takes precedence of the
control. That is, at all times the control can be transferred to the ECR panel without acknowledgement
from the Bridge. To prevent this from happening accidentally, the ECR panel has a rotary selector
instead of a pushbutton for this transfer. In all other respects, the transfer controls are similar on all
panels.

Figure 54. ECR panel.

Pos. Description
1 Take Over button
3 Bridge / ECR control selector
4 Bridge Control indication
5 ECR indication
6 In Command indication
7 Transfer indication

Information: In addition to the controls above, there may be an optional

common Take Over button, which transfers the control of all connected
equipment in the system.
Figure 55. Bridge panel.

Pos. Description
1 Take Over button
2 Send Acknowledge button
4 Bridge Control indication
5 ECR indication
6 In Command indication
7 Transfer indication

Transfer of Command from ECR to Bridge − Initiated on an ECR Panel

1. On the ECR panel, set selector “3” to Bridge Control.
2. On the desired bridge panel, push the Take Over button “1”, or use the optional common take
over button.

The control is now transferred to the Bridge. Indicators "4" and "5" show bridge control and the In
Command indication “6” is lit on the active panel.

Information: The bridge levers are motorized. They automatically follow

the ECR pitch lever. This means that the lever positions correspond
without any further handling.
Transfer of Command from ECR to Bridge − Initiated on a Bridge Panel
1. Push the Take Over button “1” on the desired bridge panel. , or use the optional common take
over button.
The Transfer indication “7” starts blinking on the ECR panel.
2. On the ECR panel, set selector "3" to Bridge Control.
3. On the bridge panel, push Take Over “1” again. , or use the optional common take over button.

The control is now transferred to the bridge. Indicators "4" and "5" show bridge control and the In
Command indication (6) is lit on the active panel.

Information: The bridge levers are motorized. They automatically follow the
ECR pitch lever. This means that the lever positions correspond without any
further handling.

Transfer of Command from Bridge to ECR, initiated from ECR

1. On the ECR panel, set selector “3” to ECR.
2. Adjust the ECR pitch lever to the same position as the lever on the bridge. This must be done
manually, since the pitch lever in ECR is not motorized. The current lever position on the bridge is
shown on the main page of the graphical user interface.

The control is now transferred to the ECR.

3. To stop the Warning indication on bridge, the Send button “2” must be pushed.

Transfer of Command from Bridge to ECR, initiated from Bridge

1. On the bridge panel, push the Send button “2”.
Transfer indication "7" starts blinking.

2. On the ECR panel, set selector "3" to ECR position.

3. Put the ECR pitch lever to the same position as the lever on Bridge. This must be done manually
since the pitch lever in the ECR is not motorized. The current lever position on the bridge is
shown on the Main Page.

The control is now transferred to the ECR.

Transfer of Command − Bridge Panel to Bridge Panel

1. On the receiving bridge panel, push the Take Over button “1”.

The command is transferred.

Note: If a Common Take Over button is included in the system, you can press that button (for
transferring the command of all connected equipment in the system to this control station).

Information: The bridge levers are motorized. They automatically following

the lever in command. This means that the lever positions correspond
without any further handling.

4.7.8. ALARMS
ALARMS PAGE
The present alarms are displayed on the ALARMS PAGE which is entered from the MAIN PAGE. An
example page with some alarms active is shown below.

Figure 56. The ALARM page.

Grey text: Alarm OFF. Red text: Alarm ON. Yellow text: Warning ON.

ALARM LOG
The alarm log lists the previous 20 alarm conditions. The alarms are listed with the most recent first,
with the time in hours since the alarm noted to the left.
Information: When troubleshooting, do NOT reset both power supplies A
and B. Doing so will erase the alarm log.
Figure 57. The ALARM log.
4.8. QUICK GUIDE
Below you will find panel quick guides (bridge and engine control room) that you, as a suggestion, can
place on the command bridge and in the ECR.

4.8.1. BRIDGE
4.8.2. ENGINE CONTROL ROOM
4.9. MAINTENANCE – CONTROL SYSTEM

4.9.1. MAINTENANCE SCHEDULE

To ensure optimal operation of the control system, the following maintenance schedule is required.
These checks should be completed to both Port and Starboard systems.

Every week:
 Switch active systems by selecting SWAP from the SYSTEM field. Ensure that all functions are
still active and no alarms are present.

Every month:
The monthly test is preferably done with the main engine stopped and hydraulic pumps running.
 Check that all control functions from all control stations are in order: Zero position, Full Ahead,
Full Astern, Idle RPM, Max RPM.
 Check the function of the Local Control Unit, that is, the pitch indicator and the pushbuttons
operate correctly.

Every 6 months:
In addition to the above:
 Check the function of the load control sub-system, run the engine at 100% load (during voyage)
and check that the indication in the ECR control panel reads 100 +/- 10%.
 Check that it is possible to decrease and increase the load with the Load Limit function on the
ECR control panel (also during voyage).

Every 3 years:
During a planned maintenance period, the following should be completed:
 With both power suppliers off, check all cable connections in all cabinets and control panels.
 Replace the feedback potentiometers on the pitch control unit.
 Check-up and readjustment of all settings.
4.9.2. TROUBLESHOOTING

Information: Do NOT reset the power supplies when troubleshooting. Doing

so will erase the alarm log.

General
To troubleshoot the control system, a basic understanding of some system principles is essential:
 The system gets its values from potentiometers connected to levers and other mechanical
components. The potentiometers convert a mechanical position into an electric signal between 0
and 10 Volts.
 The system reads the voltage values and converts them into internal representation percentage
values that are either 0 to 100 or -100 to +100. These values can be read in the display.
 For correct operation, the conversion between the input voltages and the internal representation
must be correct. To ensure this, please follow the adjustment schedule.
 The system controls both the pitch and the engine speed by correction signals if the set values
and the actual values differ.
 The load control function measures the engine speed, and the fuel-rack position and decreases
the pitch if the engine load is above the power limit curve.

Check the following as a first action:

1. Use the display for fault finding. If there is an error indication in the system, the cause of the error
is written in plain text under the ALARMS section in the main page.
2. You can view the latest faults that have occurred even if they are no longer active. The fault log is
provided with a time stamp that shows when the fault was activated.
3. If there is no response from a lever, check the alarm page to see if the system reads the signal. If
not, you should check the signal voltage from the potentiometer.
4. If the pitch is working but not moving far enough, there is probably a problem with the Load
Control. Check the fuel rack and shaft speed values on the display and make any necessary
adjustments.

Information: Most faults occur due to incorrect adjustments. Check that all
values are within valid limits.
5. ACCESSORIES
5.1. FORWARD SEAL

5.2. STERN, STERNTUBE BEARINGS, AFT BRACKET BEARING &

ROPE GUARD

5.3. SHAFT BRAKE

5.4. BULKHEAD SEAL

5.5. SHAFT EARTHING DEVICE

5.6. SLEEVE COUPLING

5.7. GEARBOX PUMP STARTER

5.8. WATER QUALITY SYSTEM

5.9. GEARBOX (SEE SEPARATE MANUAL)

FORWARD SEAL
 STF-WL INSTALLATION AND MAINTENANCE MANUAL

Order number LS56543

Forward seal serial number X28517X - X28518X
Forward seal size 260
Forward seal assembly drawing(s) X81260AA245
P&ID drawing number(s) PID-STF-WL

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STF-WL INSTALLATION AND MAINTENANCE MANUAL

TABLE OF CONTENTS
STF-WL INSTALLATION AND MAINTENANCE MANUAL ............................................................................... 1
1. ABOUT THIS DOCUMENT ........................................................................................................................ 2
2. PIPING & INSTRUMENTATION DIAGRAM STF-WL ............................................................................... 3
3. SUPREME STF-WL SEAL ......................................................................................................................... 4
3.1. INSTALLATION PRECAUTIONS ............................................................................................................... 4
3.2. PLACEMENT FORWARD SEAL ................................................................................................................ 6
3.2.1. ALIGNMENT AND TIGHTENING ....................................................................................................... 9
4. HANDLING AND STORING OF THE PRODUCT .................................................................................... 12
5. LUBRICATION SPECIFICATIONS AND TANKS .................................................................................... 13
5.1. STF-WL CIRCULATION TANK ............................................................................................................... 13
6. START-UP PROCEDURE ........................................................................................................................ 16
7. PERIODIC MAINTENANCE ..................................................................................................................... 17
7.1. WEEKLY CHECKS ................................................................................................................................ 17
7.2. HALF YEARLY MAINTENANCE .............................................................................................................. 17
7.3. EACH DOCKING .................................................................................................................................. 17
7.4. POINTS OF INTEREST DURING OVERHAUL .......................................................................................... 18
7.5. OVERHAUL OF THE SUPREME FORWARD SEAL .................................................................................. 19
8. DISASSEMBLY AND REPAIR OF THE SEALS ...................................................................................... 21
8.1. DISASSEMBLY ..................................................................................................................................... 21
8.2. REPAIR ............................................................................................................................................... 21
9. APPENDIX: SERVICE AND SPARE PARTS ........................................................................................... 22
10. APPENDIX: WEAR-DOWN LOG SHEET .............................................................................................. 22

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STF-WL INSTALLATION AND MAINTENANCE MANUAL

Release date Version Comment Checked by

20-02-2018 1 Original issue Pepijn Swarte
-
-
-

Tab. 1: Document history

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

1. ABOUT THIS DOCUMENT

This manual provides guidelines for professional installation, maintenance and disassembly of the seals and
peripheral components where applicable.

The instructions in this manual are accompanied, where necessary, by special symbols indicating specific
hazards and risk levels:

Risk of personal injury or significant risk of damage to the product

and/or interfacing machines.

Moderate risk of damage to the product and/or interfacing

machines.

These hazardous situations can arise when:

Inadequately trained staff service the product

The product is inexpertly installed, maintained or disassembled
The product is used for purposes other than those for which it was originally designed

In addition to the above hazard symbols, extra information that the end-user is expected to take note of to
ensure proper product operation, is designated by the following symbol:

Extra information

All persons responsible for installation, maintenance or disassembly of the product must:

Be familiar with the contents of this manual

Possess adequate technical skills

Although the information in this manual has been composed and verified as accurately as possible and the
descriptions are as clear as possible, no liability can be accepted for errors and/or deficiencies in the work done
during maintenance, installation or startup procedures.

This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may
not be made public or disclosed, copied or otherwise reproduced or used in any form or by any means, without
prior permission in writing from Lagersmit.

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2. PIPING & INSTRUMENTATION DIAGRAM STF-WL

Below the P&ID is shown. Note that the image below is only for reference, actual situation might be different.

Fig. 1: P&ID for reference only

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

3. SUPREME STF-WL SEAL

The Supreme STF-WL seal consists of two lip seals which are clamped in bronze housing parts. The lip seals run
to a corrosion resistant liner. The liner is equipped with a hard metal layer preventing groove forming on the
running tracks. This liner is connected to the shaft with the aid of a split clamp ring. The purpose of the Supreme
STF-WL seal is to prevent water ingress into the machine room. Lip seal #2 is lubricated with fresh water from a
20 liter circulation tank. A combination of temperature difference and rotation of the propeller shaft, together
with the presence of a scraper in the seal, forces the water to circulate.

Fig. 2: The Supreme STF-WL seal (actual seal might differ slightly from this example)

3.1. INSTALLATION PRECAUTIONS

The following precautions must be taken before commencing the installation of every Supreme seal in general:

1. Check the shaft and stern tube, thruster, gearbox or fin stabilizer for damage and contamination
Clear the shaft and stern tube, thruster, gearbox or fin stabilizer of deficiencies such as dirt
and/or damage/burrs.
2. Check the goods for transit damage and for completeness;
If transport damage and/or shortages is/are noticed, please contact the supplier, see Appendix:
Service and spare parts for contact information.
3. Check the connection dimensions and tapped holes;
The connection must correspond with measures on the assembly drawing, for the sealing unit to
be fitted. If not, please consult please contact the supplier, see Appendix: Service and spare parts
for contact information.
The thread in the tapped holes must be the correct size and the holes must be undamaged.
4. Centring of the housing component:
Arrange the housing components as shown in the assembly drawing.

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3.2. PLACEMENT FORWARD SEAL

The Supreme STF-WL seal is delivered in a pre-assembled cartridge design, including brackets. In order to
prevent damage to the liner or the lip seals, the complete seal must slide onto the propeller shaft as a unit,
including the brackets.

Do not drive/rotate the shaft when work is done to the seal.

Do not use the mounting brackets for lifting purposes.

These steps only apply to standard executions. For each and every
deviating execution consult the applicable assembly drawing.

Fig. 3: Placement of the SUPREME forward seal (Actual seal might differ slightly from this example)

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Step Description Picture

Take the precautions outlined in Installation precautions

Install the inflatable seal housing (240) including the gasket
1
(243) on the stern tube using HSH screws (245);
Check the shaft to bore misallignment, in case there's no
2 centering edge and dowel pins are to be used. See Alignment
and tightening;
Lock the inflatable seal housing with the dowel pins as
3
indicated on the assembly drawing, if applicable;
Connect the filter reducer to the inflatable seal housing (240)
4
and to the compressed air pipe installation;
5 Test the inflatable seal on leakage.
6 Lubricate the shaft.
Slide the complete forward end of the seal, including the liner,
7
gasket (206), brackets (221) and O-ring (205) onto the shaft;

Fit the seal against the inflatable seal housing;

- Take heed of the correct positioning of the gasket and the
8 bleed plug.
- For the purpose of alignment do not yet fasten the HH screws
(207) of the flange ring (203).

9 Couple the propeller shaft

10 Remove the brackets (221)

If the mounting brackets are not removed, they will cause

damage when the seal is put into operation.

The mounting brackets do not determine the built-in length.

Adjust and mount the clamp ring (213) onto the propeller shaft
using the spring rings (231) and HSH screws (230);
11
- The adjustment value is given on the assembly drawing.
- Do not use excessive force when tightening the HSH screws

To allow for the possibility of shunting the liner aside to the

stern tube, the maximum adjustment value should be
achieved/ensured at new-build stage.

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

Step Description Picture

Fit the liner (204) against the clamp ring (213) using the HH
12 screws (211);
- Tighten the HH bolts evenly.

Check the run-out (dynamic eccentricity) of the liner (204). See

13
Alignment and tightening

Check the alignment (static eccentricity). See Alignment and

14
tightening

Connect the cooling water piping to the STF-WL. For connection

15
sizes, please refer to the correlating assembly drawing.
Connect the circulation tank to the STF-WL. For connection
16
sizes, please refer to the correlating assembly drawing.

At all times, the seals must be protected against grinding dust

and/or welding spatter. Wrapping of the seals, for example with
fibreglass cloths, is recommended by Lagersmit

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3.2.1. ALIGNMENT AND TIGHTENING

The maximum allowed deviations are given in Tab. 2. Minimising the misalignment will prevent uneven lip seal
wear and premature failure. The maximum run-out values are given in Tab. 3. The tightening torques for the
bolts are given in Tab. 4.

Measurements must be taken in horizontal and vertical direction.

The radial measurement must be taken on the running surface,
not on the flange edge!

Fig. 4: Radial alignment measurement aft seal (for reference only, actual situation may be different)

On assemblies without sand barrier (right on the reference

drawing above), the end-ring (pos. 101) must be removed;
exposing the end-support ring (pos.102) from which
measurements should be taken.

Please note that the given value is the difference in measurement

divided by 2

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

Max. allowable difference in measurements

Supreme size
divided by 2 (A1-B1)/2 and (A2-B2)/2
110 to 140 0.30 [mm] 0.012“ [inch]
155 to 355 0.35 [mm] 0.014” [inch]
380 to 530 0.40 [mm] 0.016“ [inch]
560 to 710 0.45 [mm] 0.018” [inch]
750 to 850 0.50 [mm] 0.020“ [inch]
900 to 950 0.60 [mm] 0.024” [inch]

Tab. 2: Alignment measurements

Supreme size Max. allowable clock gauge deflection

110 to 200 0.10 [mm] 0.0040“ [inch]
220 to 450 0.15 [mm] 0.0060” [inch]
480 to 710 0.20 [mm] 0.0080“ [inch]
750 to 950 0.25 [mm] 0.010” [inch]

Tab. 3: Maximum allowable clock gauge deflections

Bolt Tightening torque collar bolts (A4-70) Tightening torque (steel)

Location Mainly aft seal bolts Mainly forward seal bolts
M6 7 [Nm] 7 [Nm]
M8 20 [Nm] 20 [Nm]
M10 45 [Nm] 40 [Nm]
M12 75 [Nm] 70 [Nm]
M16 120 [Nm] 110 [Nm]
M20 205 [Nm] 160 [Nm]
M24 350 [Nm] 250 [Nm]

Tab. 4: Tightening torques

Tightening order seal

Tab. 5: Tightening order

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

4. HANDLING AND STORING OF THE PRODUCT

The products have to be stored in a clean and dry place. All components must be protected against any kind of
damage. Store the products in the original packaging. The lip seals are sensitive to sharp parts, sunlight and
dust.

Special care must be taken with components containing electronic parts. During handling vibration of these
components must be prevented.

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5. LUBRICATION SPECIFICATIONS AND TANKS

5.1. STF-WL CIRCULATION TANK

The aerated circulation tank containing 20 liter W.Q.S. LUBE™ or fresh water is used for cooling and lubricating
the forward seal.

Install the circulation tank in the location given in Tab. 6. Install corrosion resistant flexible hoses between tank
unit and the SUPREME STF-WL seal, in accordance with the piping & instrumentation diagram. Fill the forward
seal circulation tank up to just below the upper sight glass. Rising and falling lubricant / water levels will then be
clearly visible through the sight glass.

STF-WL circulations tanks with level switches are available upon request.

Fig. 5: Forward seal circulation tank

Equip. name Location Height

A suitable position above the forward 300-600 [mm] above the forward
Forward circulation tank
seal seal

Tab. 6: Equipment location

The wiring of the high/low level switch in the forward tank is as shown in Fig. 6.

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

Fig. 6: Wiring level switch

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

6. START-UP PROCEDURE

To put the propulsion installation into operation, see the relevant manuals from the supplier(s) of the
propulsion installation. With regard to the STF-WL seal, the following steps must be taken:

The following actions can only take place when afloat.

1. Check that the SUPREME STF-WL seals are correctly fitted, placed and vented;
1. For the correct fitting and placement, see the installation & placement chapters and the assembly
drawing.
2. Fill the FWD circulation tank with fresh water;
1. Check the contamination in the tank before filling. Any contamination will damage the lip seals.

Make sure the inflatable seal is deflated.

During start-up, keep well clear of the shaft!

Fig. 7: Piping & instrumentation example diagram

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STF-WL INSTALLATION AND MAINTENANCE MANUAL

7. PERIODIC MAINTENANCE
Periodical Act
Weekly Check the water level in the circulation tank and refill when necessary.
Half-yearly Check the static eccentricity (misallignment).
Check the static eccentricity (misallignment), wear down and dynamic
Each docking
eccentricity (run-out).
Points of interest at overhaul Test the inflatable seal and renew every 5 years.

7.1. WEEKLY CHECKS

Check the water level on a weekly basis for clarity and colour. Refresh if necessary.

At normal operating conditions, seals will consume little water. This consumption depends on a large number of
factors. For instance the size, peripheral velocity, misalignment, temperature and conditions of the lip seals/liner
all have a great influence. As a rule of thumb, a maximum water consumption of 0.5% of seal size in litres per
day should be allowed for. For example, a seal type 200 can use 1 [L/day].

7.2. HALF YEARLY MAINTENANCE

Check the static eccentricity and compare the measured value with the tolerable limits as indicated in this
manual.

7.3. EACH DOCKING

Measure the static eccentricity and wear down:

Before overhauling the seal; the wear-down on the bearing bush needs to be measured. This can be
done in the same way as the static eccentricity is measured; When comparing the measurements taken
at top position of the lock-up-ring, the bearing wear-down can be calculated.
For the maximum allowable bearing wear, contact the bearing supplier.

Measure the run-out as illustrated in this manual.

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

7.4. POINTS OF INTEREST DURING OVERHAUL

In most situations the lip seals can be replaced without removing the propeller or withdrawing the propeller
shaft.

Bonding the lip seals in situ can only be done if the inflatable seal
is inflated and the forward end of the seal is free of water.

In the event of repairs, Lagersmit recommends renewing, the lip

seals and other “soft” materials such as O-rings and gaskets.

Overhauling Supreme seals demands specialist skills / tools and as

such needs to be done by a service engineer from Lagersmit or by
a service engineer from a service station recognized by Lagersmit.

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STF-WL INSTALLATION AND MAINTENANCE MANUAL

7.5. OVERHAUL OF THE SUPREME FORWARD SEAL

It is advisable to put the ship into dock in order to overhaul the seal. If desired lip seal bonding can take place
afloat, using the inflatable seal. Before such an overhaul can take place, be sure that the inflatable seal is
watertight. When inflating the safety seal, the applied air pressure must be at least 4 bar higher than the
draught pressure (min. pressure difference is 4 bar). To check if the inflatable seal is water tight the bottom plug
on the outside ring can be loosened, when the safety seal is inflated.

It is prohibited to have the shaft running, whilst the safety seal is

inflated.

The maximum air pressure difference over the inflatable seal is 10

[bar].

The liner of the STF-WL is equipped with a hard metal layer, which will prevent groove-forming. However if
desired the liner position can be adjusted. After removing the clamping ring, the liner can be shunted aside to
the stern tube. This way, the lip seals will run on a new running surface. After adjusting the liner, fit the liner
back against the clamp ring. See Fig. 8.

Fig. 8: Adjusting the liner

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STF-WL INSTALLATION AND MAINTENANCE MANUAL

8. DISASSEMBLY AND REPAIR OF THE SEALS

This chapter describes the actions that may be necessary during disassembly and/ or repair of the seals.

While work is being done on the seal unit, the shaft must not be
powered up.

8.1. DISASSEMBLY

To disassemble the Supreme seal(s), the instructions set out in assembly of the after seal should be followed in
reverse order.

8.2. REPAIR

Depending on the nature of the fault, the Supreme seal unit may be repairable. This will primarily be the case
with replacement of those parts that are subject to wear.

In the event of repairs, It is recommended to renew the lip seals

and other “soft” materials such as rubber O-rings and gaskets.

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 STF-WL INSTALLATION AND MAINTENANCE MANUAL

9. APPENDIX: SERVICE AND SPARE PARTS

Lagersmit offers an excellent spare parts service. We recommend that a spare parts order gets placed several
weeks before the dry dock/service (if possible). This way, we can guarantee that spare parts will be delivered on
schedule. If necessary, the Lagersmit Service Engineers are available to deliver service where needed worldwide.

To ensure that the correct parts are supplied, the following information must be provided on the order:

The information on the data sheet of this manual

Description of the required parts
Part number and/or code number of the required parts
Quantity, desired delivery time and delivery details for the parts required

In addition to the required information for ordering spare parts, the following information should be provided
when ordering a service engineer:

Place of docking/service;
Desired starting date.

Orders for spare parts and/or a service engineer should be addressed to:

Lagersmit
P.O. Box 176
Address
2950 AD Alblasserdam
The Netherlands
Telephone +31 (0)88 0216 200
Service telephone +31 (0)88 0216 300 (available 24/7)
Fax +31 (0)88 0216 249
E-mail [email protected]
Website http://www.lagersmit.com

10. APPENDIX: WEAR-DOWN LOG SHEET

Propeller blade #1 at TOP
— Date — Single screw Twin screw — Date — Single screw Twin screw
— PS — — SB — — PS — — SB —

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STF-WL INSTALLATION AND MAINTENANCE MANUAL

Propeller blade #1 at TOP

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 REV DESCRIPTION NAME DATE
SECTION A-A (1:1) View "P" (1:2) E A Original issue NDHARTOG 09-nov-2022

219 217 B
A
206 240 218 206 216 203 223 202 201 204 213
+3
234 0

155

101 View "R" (1:5)

19 Place serial number 15° 30
D ° (1
2x
)

...
G3/8 (3x) x. 30° 3 0°

R P
5
12 40
212
E
A
PCD. 410

242 241 205

214 C

215

245 12 HSH Screw M16x80 - D912 A4-70 -

SECTION E-E (1:1) 244 8 HH Screw M8x20 D933 A4-70 00135188
A

242 1 Inflatable Seal 245 NBR70 36265245

Liner O 245 F7

245 C 241 1 Inflatable Seal Lock-Up Ring 260 Bronze HB081260-245

61
O 365 g6

240 1 Inflatable Seal Housing 260 Bronze HB280260-245

B
O 445

O 320
223 1 Scraper NBR 75 46261951
222 2 HH Screw M10x16 D933 Steel 8.8 00141722
22 165 SECTION B-B (1:2)
221 2 Bracket STF 220-355 S235JR MC220-355F
DETAIL D (2:1) 207 210 220 2 Nut M12 D934 Steel 8 00185162
A Stern tube hole tolerance H7
Inflatable seal connection 219 3 Sealing Ring 17x22 D7603-A Copper 02150225
B Shaft diameter tolerance h7 O 24 218 3 HHS Plug G-3/8 D910 A4 00625043
G3/8
217 1 Sealing Ring 10x14 D7603-A Copper 02150207
216 1 HHS Plug G-1/8 D910 A4 00625041
(PCD. 410 )

215 2 Lip seal spring 260 AISI316 36261607

15

214 2 Lip Seal 260 NBR80 36261407

213 1 Clamp Ring 260 EN-GJL-250 46251157-245
212 1 Name Plate Bronze 46255006
SECTION C-C (1:1) 211 6 HH Screw M12x40 D933 Steel 8.8 00141772
210 12 HH Screw M8x25 D933 Steel 8.8 00141686
209 12 Spring ring M8 D127-B Steel 00353009
Bracket View (1:1) 208 12 HSH Screw M8x35 - D912 Steel 8.8 ELVZ 00251235
Remove after installation 207 12 HH Screw M16x40 D933 Steel 8.8 00141852
206 2 Gasket 260 AFCF 46261357
222 221 220 205 1 O-Ring 227.97x7 NBR70 10027191
204 1 Liner WLC-260 Stainless steel LB100260-245
203 1 Flange Ring STF-260 Bronze HB200260C
202 1 Support Ring STF-260 Bronze HB210260M
201 1 Lock Up Ring STF-260 Bronze HB220260M
218 POS QTY Description Material Art. / DRAWING No REMARKS
This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any form or by
any means, including but not limited to use hereof for the design and manufacturing of identical or similar parts or products, without prior permission in writing from Lagersmit.
219 DRAWN NDHARTOG General tolerances acc. ISO 2768-mK
Shape and position tolerances acc. ISO 1101
DRAWN DATE

APPR.
09-nov-2022
cboer LAGERSMIT Roughness Ra according ISO 1302
REF. DR:
THE ORIGIN OF SEALING SOLUTIONS
10-Nov-2022 15:00 -
218 APPR. DATE

208 REF. - TITLE: DRAWING NO.: REV.

MATERIAL: SUPREME STF WL-260 X81260AA245 A

219 MASS: 110 kg
244 209 STATUS:
Forward seal assembly PROJ.: SCALE: UOM:

1:5 (1:2; 1:1; 2:1) mm

60 Shaft dia 245 A1
 REV DESCRIPTION NAME DATE
TYPICAL DRAWING - LAY-OUT AND VALUES FOR GUIDANCE ONLY. CBOER 09-dec-2020
C Changed pressure air inlet

Air inlet (5-10 bar) HEADER TK 20L

(Optional )

O.D.10
G 1/4" (inner thread) connection available FILL

No connection needed FRESH

WATER
LS20
Cooling water
connection
De-aeration plug LS21
O.D.10 O.D.15

O.D.15
O.D.15

300-600mm
#1 #2

NOTE:
1. Interconnectiong piping & cabling is not included in LS delivery.
WATER PIPE
2. Cooling water inlet min. 0,15 l/min/mm shaft diameter
3. Water filtration unit required conform specs. bearing supplier
AIR PIPE
This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any form
or by any means, including but not limited to use hereof for the design and manufacturing of identical or similar parts or products, without prior permission in writing from Lagersmit.
PRESSURE REDUCING VALVE DRAWN NDHARTOG General tolerances acc. ISO 2768-mK
Shape and position tolerances acc. ISO 1101
DRAWN DATE
APPR.
23-jan-2018
rdbruin
LAGERSMIT Roughness Ra according ISO 1302

LEVEL SWITCH THE ORIGIN OF SEALING SOLUTIONS REF.:

APPR. DATE 10-Dec-2020 09:34 -
DRAWING NO.: REV.
Cooling water MATERIAL: TITLE:

BALL VALVE WEIGHT: SUPREME STF-WL PID-STF-WL C

connection STATUS: PIPING DIAGRAM
PROJ.: SCALE: UOM:
60 - Final - -:- A2
mm
STERNTUBE, STERNTUBE
BEARINGS, AFT BRACKET
BEARING & ROPE GUARD
 SVENSKA BEARING
STERN TUBE BUSH IN BUSHES
AND STERN TUBE
INSTALLATION GUIDELINES
WITH
PART LIST & ASSEMBLY DRAWINGS
 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 2 of 1 6

Table of Contents
General and Safety ................................................................................................................................... 3
Intended use............................................................................................................................................. 3
Information regarding the Installation Guidelines ............................................................................. 3
Special notation used ....................................................................................................................... 3
Liability and warranty ...................................................................................................................... 3
Copyright protection ........................................................................................................................ 4
Delivery .......................................................................................................................................... 4
Disposal .......................................................................................................................................... 4
Safety .............................................................................................................................................. 4
Contents of the Installation Guidelines ............................................................................................. 5
Changes and conversions to the equipment ....................................................................................... 5
Responsibility of the customer ......................................................................................................... 5
Requirements of the personnel ......................................................................................................... 5
Work Safety .................................................................................................................................... 6
Personal protective gear ................................................................................................................... 6
Order Specification .................................................................................................................................. 7
Preparation before the installation of the Stern Tube and the Stern Tube Bush in Bush .............................. 8
Unpacking ....................................................................................................................................... 8
Visual check .................................................................................................................................... 9
Disassembly of the Stern Tube ......................................................................................................... 9
Cleaning ........................................................................................................................................ 10
Installation ............................................................................................................................................. 11
Mounting of the Stern Tube ........................................................................................................... 11
Mounting of the Adapter Ring........................................................................................................ 11
Mounting of the AFT Stern Tube Bush in Bush .............................................................................. 11
Final alignment of the Stern Tube ........................................................................................................... 12
Fixing of the Welding and mounting of the Cover Ring .................................................................. 13
Pressure test before the epoxy resin filling ...................................................................................... 13
Filling of the epoxy resin........................................................................................................................ 13
Final assembly ....................................................................................................................................... 14
Bolts at the AFT Flange of the Stern Tube Bushes and the Stern Tube ............................................ 14
Installation of the Rope Guard........................................................................................................ 14
Protection of the installed Stern Tube Bushes and the Stern Tube ................................................... 14
Screw tightening torque table ................................................................................................................. 14
Stern Tube Bush handling for avoiding problems during operation ..................................................... 15

POLIGONO INDUSTRIAL SETE PIAS

Existing law protects Svenska Bearing's right of possession to this document.
PARCELA 34
The design or the document must not, without permission of the company, be
36634- CAMBADOS
published, copied, reproduced, manufactured or exploited in any other
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 3 of 1 6

General and Safety

Explanation of symbols
Important safety-related notes in this Installation Guidelines are identified by symbols.
The notes stated regarding work safety must definitely be adhered to and complied with. Conduct yourself with
particular care in these cases to avoid accidents, personal injury and property damage.

WARNING! Danger of injury or mortal danger!

This symbol identifies notes that, if not complied with, can lead to health impairment,
injuries, permanent bodily damage or to death.
ATTENTION! Danger to material assets!
This symbol identifies notes that, if not complied with, can lead to damage, malfunctions
and/or breakdown of the equipment.
NOTE!
This symbol labels tips and information that must be observed to ensure efficient and
trouble-free handling of the equipment.

Intended use
The Svenska Bearing Stern Tube and the AFT and MID1 Stern Tube Bearing Bushes in bush in bush design
supplied (also referred to as "Stern Tube" and “Stern Tube Bush(es)” in the following) are to be used
exclusively for the bearing of a rotating ship tail shaft in a tube housing between the AFT boss and the bulkhead
and in A-brackets outside the hull structure.

Information regarding the Installation Guidelines

This Installation Guidelines describes how to handle and install the equipment safely and correctly.
The safety notes and instructions stated, as well as the local accident prevention guidelines applicable for the
area of use and general safety conditions must be observed.
Before starting any work on the equipment, read through the Installation Guidelines completely, in particular the
chapter on Safety and the corresponding safety notes. You must have understood what you have read.
The Installation Guidelines is a component of the equipment. It must be kept accessible at all times in close
proximity to the equipment (e.g. in the machine control room, general control rooms). The Installation
Guidelines must always be passed on to third parties with the equipment.

Special notation used

The numbers in brackets ( ) mark the position numbers of the relevant drawings.

Liability and warranty

All information and notes in this Installation Guidelines were collated while taking into consideration the
applicable regulations, the status of technology and our many years of discoveries and experiences.
The Installation Guidelines must always be kept accessible in direct proximity to the equipment for all persons
who are working on or with the equipment.

ATTENTION! Danger to material assets!

Read through this Installation Guidelines carefully before starting any work on or with the
equipment! The manufacturer assumes no liability for damages and disruptions that arise
from non-compliance with the Installation Guidelines.

The texts and illustrations do not necessarily correspond to the scope of delivery. The drawings and graphics do
not correspond to a ratio of 1:1

POLIGONO INDUSTRIAL SETE PIAS

Existing law protects Svenska Bearing's right of possession to this document.
PARCELA 34
The design or the document must not, without permission of the company, be
36634- CAMBADOS
published, copied, reproduced, manufactured or exploited in any other
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 4 of 1 6

Copyright protection
The Installation Guidelines must be treated as confidential. It is determined exclusively for those persons
working on and with the equipment.
All content-related information, texts, drawings, pictures and other representations are protected as defined by
copyright protection law and are subject to other industrial property rights. Any improper utilization is liable to
prosecution.
It is not permitted to pass on the Installation Guidelines to third parties, to make reproductions in whatever type
or form - even extracts - or to recycle and/or communicate the contents without written permission by
SVENSKA BEARING (manufacturer). Violations incur the obligation to pay compensation. All other rights
reserved.
We reserve the right to exercise industrial property rights.

Delivery
Examine the delivery on receipt for transport damage.
Report any damage immediately to the carrier and make a note of it on the delivery note.
Check the scope of delivery immediately for completeness.
Contact the manufacturer as soon as possible if any parts are missing.

ATTENTION! Danger to material assets!

Only operate the equipment with parts that belong to the scope of delivery.

Disposal
If no agreement has been made regarding return or disposal, dismantled components are to be recycled
following appropriate dismantling:
• Scrap metal material remains
• Take plastic elements to plastics recycling
• Dispose of remaining components that are sorted according to material composition

ATTENTION! Danger to material assets!

Electrical scrap, electronic components, lubricants and other auxiliary substances as well as
some metals (e.g. cadmium) are subject to hazardous waste treatment and may only be
disposed of by permitted specialist companies!

Safety
At the time of its development and manufacture, the equipment was built according to applicable, recognized
rules of technology and is considered to be safe to operate.
However, risks can arise from this equipment if it is not used by appropriately trained personnel, or if it is
operated incorrectly or not according to the intended use.
The Chapter "Safety" gives an overview of all-important safety aspects for the optimum protection of persons
and the safe, trouble-free operation of the equipment.
In addition to this, the other chapters in this Installation Guidelines contain concrete safety notes identified by
symbols to avert danger. Furthermore, pictogram, signs and labels located on the equipment must be observed.
This means that they may not be removed and must be kept in a good, legible condition.

Operational safety is only guaranteed if the equipment is used according to the intended use.

ATTENTION! Danger to material assets!

Any use that goes beyond the intended use and/or any other use of the equipment is
prohibited and is not considered intended use. Claims of any kind against the manufacturer
and/or his representatives that arise from damage due to non-intended use of the equipment
are excluded. The customer is solely liable for any damage arising from non-intended use.

POLIGONO INDUSTRIAL SETE PIAS

Existing law protects Svenska Bearing's right of possession to this document.
PARCELA 34
The design or the document must not, without permission of the company, be
36634- CAMBADOS
published, copied, reproduced, manufactured or exploited in any other
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 5 of 1 6

Intended use also includes correct adherence to the operating conditions as well as the information and
instructions of this Installation Guidelines.
The equipment may only be operated with the parts listed in the scope of delivery.

Contents of the Installation Guidelines

Each person authorized to carry out work on or with the equipment must have read and understood the
Installation Guidelines before starting work on the equipment. This also applies if the relevant person has
already worked with this kind of equipment or similar equipment or if that person was trained by the
manufacturer.
Knowledge of the contents of the Installation Guidelines is one of the prerequisites to protect personnel against
danger, and to avoid errors so that the equipment is operated safely and trouble-free.
The customer is recommended to get confirmation proving that personnel have acknowledged the contents of
the operational manual.

Changes and conversions to the equipment

To avoid danger and to ensure optimum performance, no changes or attachments and conversions can be carried
out on the equipment which have not been explicitly authorized by the manufacturer.
All pictogram, signs and labels located on the equipment must be kept in a good, legible condition and may not
be removed. Pictogram, signs and labels that have been damaged or become illegible are to be replaced as soon
as possible.

Responsibility of the customer

This Installation Guidelines must be kept in direct proximity to the equipment (e.g. in the machine control room)
and must be accessible at all time to persons working on and with the equipment. Observe the information in the
Installation Guidelines completely and without limitation! Together with the safety notes and instructions stated
in this Installation Guidelines, the local accident prevention guidelines applicable for the area in which the
equipment is used and the general safety guidelines as well as the applicable environmental protection
conditions must be adhered to and complied with. The customer and the personnel authorized by him are
responsible for the trouble-free operation of the equipment and for clear allocation of responsibilities with
regard to installation, operation, servicing and cleaning the equipment.

Requirements of the personnel

Only authorized and trained expert personnel may work on and with the equipment. Personnel must have
received instruction regarding potential dangers.

Expert personnel are defined as whoever can assess the work allocated to him and recognize potential dangers
based on his expert training, knowledge and experience, as well as his knowledge of pertinent conditions.
If personnel do not have the necessary knowledge, they must be trained.
Responsibilities for work on and with the equipment (installation, operation, servicing and maintenance) must
be clearly determined and adhered to, so that there is no unclear distribution of competency with regard to
safety.
Only those persons who can be expected to work reliably may work on and with the equipment. Avoid any
mode of operation that impairs the safety of persons, the environment or the equipment.
Persons who are under the influence of drugs, alcohol or reaction-impairing medication must never work on or
with the equipment.
When selecting personnel, the age- and profession-related regulations applicable at the place where the
equipment is being used are to be observed.
The customer must also make sure that non-authorized persons are kept a sufficiently safe distance away from
the equipment.
Personnel are obliged to report to the customer immediately about any changes to the equipment that impair
safety.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 6 of 1 6

Work Safety
Personal injuries and material damage during work with and on the equipment can be avoided by following the
safety notes and instructions stated in this Installation Guidelines.
Non-compliance with these notes can lead to persons being endangered and damage to or destruction of the
equipment.
If the safety notes and instructions stated in this Installation Guidelines and the accident prevention guidelines
applicable for the place of use and general safety conditions are not complied with, then all liability obligations
and claims for damage compensation against the manufacturer or his representatives are excluded.

Personal protective gear

The following should be worn when working on and with the equipment, in line with the work at hand:

Protective work clothing

Close-fitting work clothing (low tear-resistance, no wide sleeves, no rings or other jewelry,
etc.)
Safety shoes
To protect against heavy, falling parts and slipping on slippery floors.
Protective gloves
To protect the skin against friction, abrasions, piercing and deeper injuries to the hands and to
protect against contact with health-harming substances.
Safety helmet
To protect against falling and flying parts and materials.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 7 of 1 6

Order Specification

CUSTOMER: Berg Propulsion

BUILDING YARD: TBA
NEW BUILDING NUMBER: TBA
CLASSIFICAION SOCIETY: ABS

DRAWING NUMBER: 3-100-2109-000

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 8 of 1 6

Preparation before the installation of the Stern Tube and the Stern
Tube Bush in Bush

Unpacking
T
After the Factory Acceptance Test (FAT) the Stern Tube and the Stern Tube Bush in Bush are packed and
delivered in packed condition. If or when the packing is broken the customer must ensure that the corrosion
protection and the cleanliness of the Stern tube is guaranteed.
All single part materials are packed in named bags and boxes.

For storage of the Stern Tube the following requirements must be followed:

• Store the parts in dry and moderately heated rooms only.

• Make sure that the parts are stored on the packing foundation.
• Make sure that the parts are resting immovably.

The end covers of the Stern Tube and the Stern Tube Bushes packing are
equipped with inspection holes for enabling the yard to do inspections
during the storage time.

Close the inspection hole immediately afterwards!

Unpack the Stern Tube and the Stern Tube Bush in Bush nearby to the assembly place to avoid damage during
internal transport. For lifting use only textile straps, no steel ropes, to avoid damage to the Stern Tube and the
Stern Tube Bushes.

ATTENTION! Danger to material assets!

DO NOT USE FORK LIFTS in the Stern Tube or the Stern Tube bush openings for lifting
the parts. As damage of the bearing surface will happen, and the bearings have to be
renewed.
WARNING! Danger of injury or mortal danger!
All to be moved parts are heavy and may cause health impairment, injuries, permanent
bodily damage or to death in case of accident.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 9 of 1 6

Lift, transport and unpack the Stern Tube as shown in the lifting note on the packing.

Marked on the Stern Tube are the prescribed lifting points, as indicated on the above picture. The Stern Tube
must be lifted with two (2) approved and adequate textile stripes/slings one at each indicated lifting area.

When lifting the Stern Tube and the Stern Tube Bushes, make sure that the handling element do not cause
damaged to the goods.

Visual check
Check the received Stern Tube and Stern Tube Bushes items against the delivery notes to ensure that nothing
has been damaged during transport and that no items are missing.

Disassembly of the Stern Tube

The Adapter Ring (5) must be disassembled from the Stern Tube:

Loosen the Screws (34) and dismount the Adapter Ring (5).

NOTE!
There are numbers of O-Rings (11) and (35) which are used to seal off the Adapter Ring.
These sealing must be handled with care.
NOTE!
Take care that none of the O-Rings (35) gets lost. A missing O-Ring will cause leakages.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 10 o f 1 6

Stern Tube FWD end

Cleaning

The anti-corrosion preservation on all mechanically machined surfaces must be removed carefully and all
surfaces must be cleaned.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 11 o f 1 6

Installation
General mounting sequence:
The Stern Tube itself consist of two main parts, the Stern Tube (1) including the AFT (2) and the FWD Stern
Tube Bush (3) and the Adapter Ring (5). All further parts are used for fixing these parts, to ensure the function
of the internal Stern Tube Bushes.
The Stern Tube can be installed using different methods. The shipyard can choose the method most suitable for
them. The commonly used method used is to insert the Stern Tube from the AFT side using chain blocks or
pushing it in a short distance and then pulling it from the inside of the ship, also using chain blocks.

The AFT Stern Tube Bush (70) in Bush in Bush design are complete pre mounted and ready for installation.

NOTE!
All parts are marked with “TOP”. Make sure that these marks are in “TOP” position, to
avoid problems during the installation

Mounting of the Stern Tube

Mounting sequence:
Insert the Stern Tube (1) through the AFT boss until the Adjustment Screws (33) are getting into contact with
the AFT boss and the forward end is coming out at the engine room side.

Mounting of the Adapter Ring

Mounting sequence:
Prior to the installation of the Adapter Ring (5) the Welding Ring (6), the O-Ring (12) and the Cover Ring (7)
have to be put on the FWD Stern Tube end.
Insert the O-Ring (11) into the Adapter Ring (5). Put the six O-Rings (35) into their grooves and fix them with
grease.
Lift the Adapter Ring and push it on the forward end of the Stern Tube.

NOTE!
Check that the O-Ring (11) is in position. A damage can cause leakages.
NOTE!
Check that the O-Rings (35) are in position and that no O-Ring gets lost. A damage can
cause leakages. A missing O-Ring will cause leakages.

Insert and tighten the Screws (34) and secure them with LOCTITE.

NOTE!
The O-Rings (11) and (35) are used to seal off the Adapter Ring. These sealing must be
handled with care.

Mounting of the AFT Stern Tube Bush in Bush

Mounting sequence:
Put the AFT Stern Tube bushes into the AFT A-bracket of the ship until the Adjustment Screws (33) are getting
into contact with the AFT A-bracket.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 12 o f 1 6

Final alignment of the Stern Tube

The final alignment of the AFT Stern Tube in Tube Bush in Bush and the Stern Tube including its installed
Stern Tube bushes to the given neutral axis of the shaft line must be done by the building yard.

Our recommendation for the alignment procedure is as follows:

- Take the recesses of the AFT Stern Tube Bush as reference.
- Bring it in position, align it and fix it to the AFT A-bracket.
- Use the AFT Stern Tube Bush centre line as zero line for the other bearing bushes.
- Bring the Stern Tubes AFT Stern Tube bush in position, align it and fix it to the AFT boss.
- Bring the Stern Tubes FWD Stern Tube bush in position, align it and fix it to the bulkhead.

For helping the yard during the alignment work the Stern Tube Bushes and the Stern Tube are equipped with
several alignment aids. These are mainly the Adjustment Screws (33) in the flanges and the Alignment Screws
(41) and (47) which are shown in View Z and the Section X-X.
In general, the Stern Tube Bush in Bush and the Stern Tube are aligned with these eight screws at the AFT end
of the parts.

The Adjustment Screws (33) are pre-installed with a nominal resin thickness of 20 mm for the AFT Stern Tube
Bush in Bush and the Stern Tube.

Move the AFT Stern Tube Bush into the AFT A-bracket until the Adjustment Screws (33) get in contact with
the AFT A-Bracket.
Move the Stern Tube into the stern boss until the Adjustment Screws (33) gets in contact with the stern boss.

Before the final alignment can start the length of the four Holders (40) at each flange of the Stern Tube Bush in
Bush and the Stern Tube have to be cut according to locality and the holders have to be welded under an angle
of approximately 35° from the horizontal centre line

NOTE!
Make sure that the holders (40) do not cover the Adjustment Screws (33).

The following alignment procedure is valid for each AFT flange end of the parts:
Press the AFT flange of the Stern Tube Bush in Bush or the Stern Tube with the horizontal Alignment Screws
(41) against the A-bracket /stern boss. Move the Stern Tube with the radial Alignment Screws (47) to the given
centre line.
The combination of the Adjustment Screws (33) and the Alignment Screws (41) allows to move the Stern Tube
Bushes and the Stern Tube FWD end into position.
Loosening the Adjustment Screws on one side and tightening the Alignment Screws at the same side will move
the Stern Tube to the other side. Similarly, the alignment works in vertical direction.

For helping to align the Stern Tube FWD end additionally two Holders (40) and Alignment Screws (41) and
(47) at the FWD end, see View Y. These are keeping the Stern Tube FWD in position or can move it radially.

The Stern Tube is machined with a high level of accuracy. See also the transmitted dimension sheets. The yards
target during the installation should be to reach this level.

The recommended alignment deviance, when using laser equipment, is, due to the high accurate pre-alignment,
0.02 mm / m i.e. 0.1 mm / 5 m. The shipyard must approve the alignment in writing!
After the Stern Tube is aligned to its final position it must be fixed until the epoxy resin filling is completed.

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 13 o f 1 6

Fixing of the Welding and mounting of the Cover Ring

Mounting sequence:
After the Stern Tube is aligned the Welding Ring (6) must be welded to the bulkhead according to yard´s
standard. A small welding seam with a throat depth of 5 to 8 mm is totally sufficient.

NOTE!
Make sure that the O-Ring (12) gets no heat during the welding.
A damage can cause leakages.

Move the O-Rings (12) and the Covering Ring towards the Welding Ring (6). Insert and tighten the Screws (27)
and secure them with LOCTITE.

Pressure test before the epoxy resin filling

This sequence is to be used at the aft flange of the Stern Tube bushes (70,71) and the Stern Tube (1) and at the
welding ring (6).
The pressure test sequence.
Fit a pressure gauge to the air vent connection at the top of the flange or the ring.
Connect compressed air with a pressure of 0.3- 0.5 bars to the epoxy resin connection at the bottom of the flange
or the ring.
Turn the compressed air off with a valve. Wait a few minutes and check the pressure gauge for drop of pressure.
If there has been none or only a small drop of pressure you can go further with filling of the epoxy resin. The
skill to judge the pressure drop can only be achieved through experience gained during actual installations. If
there has been a substantial pressure drop you must check with soap water to find the air leakage.

Filling of the epoxy resin

The epoxy resin filling must be done by a company which is class approved in presence of the local class
surveyor.
The epoxy resin filling has to be done by a company which is class approved and in presence of the local class
surveyor.
The filling sequence is similar for both the aft and the forward end.
The filling of the epoxy resin should be done through the hole at the bottom of the aft flange of the Stern Tube
(1) or the Welding Ring (6). Check the arrangement drawings to find out the thread size that is used.

NOTE!
The app. resin filling amounts are shown on the order cover page. When the resin filling
amount comes close to these values the pumping speed should be reduced. In case the resin
reaches the venting opening, the inner pressure increases immediately, and resin leakages
may occur at the resin space seals

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 14 o f 1 6

Final assembly

Bolts at the AFT Flange of the Stern Tube Bushes and the Stern Tube

The AFT Flanges of the Stern Tube Bushes and the Stern Tube are pre-drilled with a remaining wall thickness
of app. 3mm for avoiding a resin leakage during the filling process.
After the resin is hardened the yard must drill through the remaining wall thickness and the resin. Then the
threads for the fixing bolts (22) must be drilled and cut into the A-brackets and the AFT boss.

NOTE!
Svenska Bearing recommends the use of high-speed steel tools for this installation step.

I. Drill and tap the holes for the screws M16x80 (22) at the AFT Stern Tube Flange.
II. Insert the screws M16x80 (22), including the rubber-steel washer (23), tighten them and secure them
with LOCTITE.

NOTE!
The rubber-steel washers do have sealing function!
Make sure that all rubber -steel washers are in position. The loss of one rubber-steel washer
may cause leakages.

Installation of the Rope Guard

Screw the Rope Guard (53) with the screws M12x35 (54) to the aft flange of the AFT Stern Tube Bush. Tighten
the screws and secure them with a weld spot or Loctite

Protection of the installed Stern Tube Bushes and the Stern Tube

After the Stern Tube bushes and the Stern Tube are completely mounted it is very important to protect the
surface of the Stern Tube bushes. A useful protection would be for example plywood covers at both ends of the
Stern Tube Bushes and the Stern Tube.

Screw tightening torque table

Tightening torque [Nm]
Standard: ISO 898-1:2013 ISO 3506-1

Bolt size Material steel 8.8 Material A2/A4-70

M10 47 33
M12 81 57
M16 197 140
M20 385 273
M24 665 472

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 15 o f 1 6

Stern Tube Bush handling for avoiding problems during operation

For avoiding any problems during the operation of the Stern Tube the following instruction of the bearing maker
Thordon have to be achieved. (The original of the Thordon paper can be found in the enclosure)

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 SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2109-000 Pa ge : 16 o f 1 6

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 PART LIST
&
ASSEMBLY DRAWINGS
 PARTS LIST
DRAWING-No.: PAGE 1 OF 2
STERN TUBE 3-100-2109-000-F 2022-12-08

POS. NO. PART NAME DRAWING-No./ DIN MATERIAL

1 1 STERN TUBE 3-100-2109-010 STEEL

AFT BEARING, THORDON

2 1 TG-37645 THORDON SUPPLY
COMPAC
FWD BEARING, THORDON
3 1 TG-37648 THORDON SUPPLY
COMPAC

5 1 ADAPTER RING 3-100-2109-040 STEEL

6 1 WELDING RING 3-100-2109-050 STEEL

7 1 COVER RING 3-100-2109-051 STEEL

8 1 SEALING L= 1398 mm 4-100-1000-025 NITRILE

9 1 SEALING L= 1414 mm 4-100-1000-025 NITRILE

10 1 SEALING L= 1517 mm 4-100-1000-026 NITRILE

11 1 O-RING Ø353x8 NITRILE

12 1 O-RING Ø355x15 NITRILE

MC6S M16x80
22 18 SCREW
A4-70 ISO 4762
23 18 WASHER GBR M16 RUBBER/ STEEL

M10x50
27 8 SCREW
8.8 ISO 4017

32 12 O-RING Ø19x2 NITRILE

33 12 ADJUSTMENT SCREW 4-100-1000-037

M10x55
34 8 SCREW
A4-70 ISO 4762
35 8 O-RING Ø11x3 NITRILE

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 PARTS LIST
DRAWING-No.: PAGE 2 OF 2
STERN TUBE 3-100-2109-000-F 2022-12-08

POS. NO. PART NAME DRAWING-No./ DIN MATERIAL

40 10 HOLDER M16 4-100-1000-039

M16x80
41 10 ALIGNMENT SCREW
8.8 ISO 4017

45 2 ENDLESS STEEL BAND 8mm

46 2 TURN BUCKLE

M16x80
47 10 ALIGNMENT SCREW
8.8 ISO4017

50 1 AFT RETAINING RING 3-100-2109-052 CC333G

51 1 FWD RETAINING RING 3-100-2109-054 CC333G

M8X30
52 8 SCREW
A2-70 ISO 4762

53 1 ROPE GUARD 3-100-2060-053 STEEL

M12X35
54 12 SCREW
A4-70 ISO4017

70 1 AFT BUSH IN BUSH, COMPL. 3-100-2109-200

72 1 PLAIN KEY TG-37645 THORDON SUPPLY

CAPSCREW. LOW PROFILE, M12x50 ISO 6912
73 5 THORDON SUPPLY
SOCKET HEAD TG-37645

74 1 PLAIN KEY TG-37648 THORDON SUPPLY

CAPSCREW. LOW PROFILE, M12x50 ISO 6912
75 3 THORDON SUPPLY
SOCKET HEAD TG-37648

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 STERN TUBE LENGTH =4070
BETWEEN BOSSES = 3840

MIN Ø 570

MIN Ø 525
MIN Ø 553
MIN 226
70 MIN 655 D B 170

Ø 410
Ø 370
Ø 260 h7

Ø 395
Ø 365

Ø 405

Ø 355
SHAFT DIA

60 MIN 395
20 X A FWD SEAL
LAGERSMIT
20 STF WL-260

Z Y

SHAFT DIA
Ø 255 h7
SHAFT DIA

Ø 245 h7
Ø 550

35 245 130
X 25 383
725

G1/2 RESIN VENTING

B AFT STERN TUBE BUSH SIMILAR ON BOTTOM
60 MIN 395
A FWD STERN TUBE BUSH TO BE WELDED FOR RESIN FILLING
BY YARD
35 FOR BOTH STERN TUBE
20 MIN 226 170 VENTING AND FILLING
CONNECTIONS
ON TOP AND BOTTOM

35

10

SHAFT DIA
MIN Ø 553

MIN Ø 525
SHAFT DIA
( Ø 255 h7 )

( Ø 245 h7 )

Ø 365 H7
Ø 365

Ø 405

Ø 395
Ø 355

Ø 485
Ø 445
MOVED INTO
35 CUTTING
SECTION
383 ( 40 ) 130

ISO 128 DRAWING No.

CONTRACT No.
 Y
(FWD END)

Ø255,97 (RUNNING CLEARANCE)

G1 STERN TUBE G1/2 RESIN
X-X G1/2 RESIN WATER VENTING VENTING
VENTING CONNECTION CONNECTION
E CONNECTION
M16
DEPTH 40/50
)
6x
°(

x)
60

12
°(
30

Ø245,94 (RUNNING CLEARANCE)

35°

E
Y)

15°
R

Ø410 ±0,5
DD

( Ø 365 H7 )
LE

Ø445 ±0,5
STB STB TAL
S
43 (IN
PS 246, PS
Ø
F
35°

)
(4x
45°
F

L G1/2 RESIN
FILLING
Ø256,48 (INSTALLED DRY) CONNECTION G1/2 RESIN
FILLING
CONNECTION
G1STERN TUBE
WATER FILLING
CONNECTION

E-E L-L
(6x) (8x)
F-F
M16, DEPTH 36-46 (4x)
TO BE CUT BY YARD
AFTER STERN TUBE CONNECTION TO SHIP
ALIGNMENT AND RESIN TO BE SECURED SRUCTURE TO BE DONE
HARDENING ACCORDING WITH LOCTITE BY YARD. TO BE CUT
TO CHAPTER 8 OF THE AFTER RESIN
INSTALLATION HARDENING.
GUIDELINES.

MOVED INTO
CUTTING
SECTION ISO 128 DRAWING No.

CONTRACT No.
 D AFT BRACKET BEARING
Z G1/2 RESIN
70 MIN 655 (AFT END) VENTING
BEFORE INSTALLATION CONNECTION
20 OF POS.53
255 -3 Ø260,98 (RUNNING CLEARANCE)

I J

)
6x

30°
°(
60

(12
x)
SHAFT DIA
Ø 285 -0,5

35°
Ø 260 h7
Ø 550

10°
( Ø 574 +5 )

( Ø 550 +5 )

Ø 285 -0,5
Ø 370
Ø 410
Ø 570
PS STB

20°
35°
Z

)
(4x
45°
K

35
650 Ø261,5 (INSTALLED DRY) G1/2 RESIN
FILLING
725 CONNECTION
Ø480 ±0,5

K-K
(4x)
I-I J-J BEFORE INSTALLATION
(6x) (12x) OF POS.53

CONNECTION TO SHIP
SRUCTURE TO BE DONE
35 BY YARD. TO BE CUT
AFTER RESIN
HARDENING.

M16, DEPTH 36-46

TO BE CUT BY YARD
AFTER STERN TUBE
ALIGNMENT AND RESIN
HARDENING ACCORDING
TO CHAPTER 8 OF THE
INSTALLATION MOVED INTO
GUIDELINES. TO BE SECURED BY YARD CUTTING ISO 128 DRAWING No.

BY WELD SPOT AND LOCTITE SECTION CONTRACT No.

 PARTS LIST
DRAWING-No.:
AFT BUSH IN BUSH 3-100-2109-200-A PAGE 1 OF 1
COMPL. 2022-12-08

POS. NO. PART NAME DRAWING-No./ DIN MATERIAL

1 1 AFT HOUSING 3-100-2109-201 CC333G

2 1 AFT FLANGE 3-100-2109-202 CC333G

3 1 AFT RETAINING RING 3-100-2109-203 CC333G

AFT BEARING, THORDON
4 1 TG-37642 THORDON SUPPLY
COMPAC
M12x70 A2-70
5 6 SCREW STAINLESS STEEL
ISO 4017
M12x40 A2-70
6 12 SCREW STAINLESS STEEL
ISO 4762
Ø 10x60 ST
7 2 PARALLEL PIN STEEL
ISO 8735
8 1 SEALING L= 1131 mm 3-100-1000-053 NITRILE

9 1 ENDLESS STEEL BAND 8 mm

10 1 TURN BUCKLE

11 1 SEALING L= 1690 mm 3-100-1000-026 NITRILE

12 1 PLAIN KEY TG-37642 THORDON SUPPLY

CAPSCREW. LOW PROFILE, M12x25 ISO 6912
13 8 THORDON SUPPLY
SOCKET HEAD TG-37642

Existing law protects Svenska Bearing's right of possession to this

document. The design or the document must not, without
permission of the company , be published, copied, reproduced,
POLIGONO DE TRAGOVE manufactured or exploited in any other unauthorized way.
36634- CAMBADOS
PONTREVEDRA / SPAIN
TEL.: +34 986520909
 Ø260,98 (RUNNING CLEARANCE)
70 MIN 655
A
(AFT END) Ø261,5 (INSTALLED DRY)
20
G1/2 RESIN
VENTING
CONNECTION
D
C

)
6x
°(

30°
60

(12
x
SHAFT DIA

)
30°
D
Ø 260 h7

Ø 410
C

10°
Ø 285 -0,5

Ø 285 -0,5
E

Ø 370

Ø 570
Ø 410
STB
Ø 550

PS
F
A

15°

x)
20°
30° ( 2
B
B E

)
(2x
30

45°
°(
12
F

x)
35
Ø330 ±0,5
650 G1/2 RESIN
Ø480 ±0,5 FILLING
CONNECTION
725

B-B F-F C-C D-D PARTING LINES E-E

SEALED WITH
(12x) (4x) (6x) (12x) PERMATEX 2 (2x)

TO BE SECURED
WITH LOCTITE TO BE SECURED M 12
WITH LOCTITE
38
30

35

ISO 128 DRAWING No.

CONTRACT No.
 SAW CUT 2-4 SUFFICIENT
Ø550 TO BE MACHNED

STBD
BEFORE SAW CUT.

30°
(12
x)
45°

Ø 14

10°
20°
4x TYPE I
45°

NET CUTTER

MATERIAL 1.4571
X

SVENSKA BEARING
X

PS

( Ø 574 )
Ø 550 +5
46,6
(4x)
X-X

74

12
255 -3

CONTRACT No.
ISO 128
DRAWING No.
65

35

Ø 542 +3 (AFTER WELDING) 16

Ø 550 +2 (AFTER MACHINING)
( Ø 574 )
SHAFT BRAKE
 IOM Manual
M0479

Installation, Operation & Maintenance of

Stopping system 324216
Consisting of two Stopping units, two Brake discs (split) and
one Compactus unit

Customer: Berg Propulsion Production AB

Customer order no: 7634M.74
Order no: O2221691
Project: 7634M

DELLNER BUBENZER AB
Teknikergatan 1 SE-781 70 BORLÄNGE SWEDEN
Phone: +46 (0)23-78 30 50 [email protected] www.dellnerbubenzer.com
 Abbreviations
Abbreviations
C unit Compactus unit
DBAB Dellner Bubenzer AB
IOM manual Installation, Operation and Maintenance manual
PHPP Pneumatic Hydraulic Power Pack
S, T, L Stopping, Turning, Locking
SKD 65 Direct acting disc brake model 65
S system Stopping system
S unit Stopping unit

Record of changes
Issue Issuer Date Description
0 OMa 2022-11-29 Draft issue
1 OMa 2023-02-10 First issue

Disclaimer
© All rights reserved. Both the content and form of this document are the property
of Dellner Bubenzer AB. It is formally prohibited to use, copy, modify, disclose, or
perform all or part of this document without obtaining Dellner Bubenzer AB's prior
written authorization.

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Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 2 Stopping system 324216.
 Table of contents
Table of contents
1. INTRODUCTION .................................................................................................................................. 4
READING THIS MANUAL ................................................................................................................................... 4
THE DELLNER BUBENZER STOPPING, TURNING AND LOCKING SYSTEM ...................................................... 4
OVERALL SYSTEM GUIDE AND TECHNICAL DATA ............................................................................................ 5
2. SAFETY ................................................................................................................................................. 6
3. HANDLING, TRANSPORT AND STORAGE ...................................................................................... 7
HANDLING ......................................................................................................................................................... 7
TRANSPORT ................................................................................................................................................. 7
STORAGE ......................................................................................................................................................7
4. INSTALLATION ................................................................................................................................... 9
LIFTING ............................................................................................................................................................. 9
MECHANICAL ............................................................................................................................................ 10
HYDRAULIC ................................................................................................................................................ 11
ELECTRICAL................................................................................................................................................ 13
5. COMMISSIONING ............................................................................................................................. 14
BEFORE COMMISSIONING...............................................................................................................................14
DURING COMMISSIONING ......................................................................................................................... 15
6. OPERATION ....................................................................................................................................... 16
CONTROL SYSTEMS ........................................................................................................................................16
REMOTE CONTROL ....................................................................................................................................16
7. MAINTENANCE ................................................................................................................................. 17
GENERAL ......................................................................................................................................................... 17
MAINTENANCE SCHEDULE ........................................................................................................................ 17
PREVENTIVE MAINTENANCE ......................................................................................................................18
CORRECTIVE MAINTENANCE .....................................................................................................................19
8. SUB SYSTEMS.................................................................................................................................... 21
DISC BRAKE ..................................................................................................................................................... 21
COMPACTUS UNIT .................................................................................................................................... 23
9. HANDLING OF USED PARTS AND MATERIAL ............................................................................. 24
STEEL PARTS AND BRAKE PADS ..................................................................................................................... 24
SEALS AND PLASTICS ................................................................................................................................ 24
HYDRAULIC FLUID ..................................................................................................................................... 24
10. RECOMMENDED SPARE PARTS ................................................................................................25
STOPPING UNIT ......................................................................................................................................... 25
COMPACTUS UNIT .................................................................................................................................... 25
11. APPENDIX ......................................................................................................................................... 26

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 Introduction

1. Introduction
Reading this manual
In addition to this Installation, Operation and Maintenance (IOM) manual there are
several reference documents which are listed as appendices (see chapter 11). In case
of differences between documents, this manual shall prevail followed by the
documents in the appendix list in the order from up to down.

Operation and Maintenance instructions are intended for personnel with

experience of similar activities. The manual doesn’t contain detailed instructions to
guide inexperienced personnel through the operation and maintenance procedures.
Please consult Dellner Bubzener AB before proceeding if personnel are uncertain in
how to follow the instructions.

The Dellner Bubenzer Stopping, Turning and Locking system

The Stopping, Turning and Locking system is a multi-modular system with
requested functions contained in one physical unit (only one customer interface).

Dellner Bubenzer disc brakes handle the Stopping operation.

We offer an indexing Turning system (hydraulically or manually
operated) or a solution with a continuous Turning system (electrically
or manually operated). The brake disc is positioned manually or with a
PLC based control system.

The Turning system is used to positioning one of the brake discs slots to
align with the Locking device (manually, hydraulically, or electrically) to
mechanically lock the shaft in place.

The STL- systems are modular which means that they are based on modules that
allow the user to choose the function(s) and capacity needed. All from single S, T or
L functions, combined dual functions in terms of SL, ST or TL to a complete STL-
system can be selected.

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 Introduction
Overall system guide and technical data
Items delivered from Dellner Bubenzer AB are listed in Table 1.1 and shown in
Stopping system drawing (drawing number 3242161). It is defined that one Stopping
system consists of two Stopping units (one disc brake type SKD 65 with support
structure), two 25 mm thick Ø740 split brake discs, and one Compactus unit.

Table 1.1 (Scoop of supply per system)

Description No. of Weight per Art. & drawing
items unit [kg] no.
Stopping unit SKD 65 2 38,2 3234612
ON/OFF indicator SKD 65 2 0,2 2184653
Brake disc (split) 2 69,1 324200
Compactus unit 1 40,94 319596-05
C unit electrical terminal box 1 6,1 3218516
S unit electrical terminal box 2 0,7 3218507

Table 1.2 (Stopping performance per shaft)

Disc brake No. of Brake disc Ø Operating pressure Braking force Braking torque
type brakes [mm] [bar] [N/bar] [kNm]
SKD 65 1 740 100 273 8,88

Braking torque is calculated with a coefficient of friction,  = 0.42

(valid for clean and dry brake disc and bedded in friction material).
Note: External losses not accounted for.

1
See appendix 1
2
See appendix 1.1
3
See appendix 1.2
4
Dry weight. Max. 7 hydraulic fluid.
5
See appendix 1.3
6
See appendix 1.4
7
See appendix 1.4
8
Braking torque calculated with braking radius 370 – 45 = 325 mm.

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 Safety

2. Safety
Safety precautions concerns Your safety as well as safety of others and undertaking
could also result in serious damage to the equipment if, for example, the warning
text is ignored. The manual describes which safety precautions to take when
working with the system in general.

The warning sign indicates that there is great risk of personal injury as
Warning: well as serious damage to product if the warning text is ignored.
The caution sign indicates that minor personal injury as well as
Caution: damage to the product or major operating faults can occur if the
caution text is ignored.

The note text draws attention to important information which

Note: facilitates the reading of the instruction.

Properly warning and/or caution and/or note texts are mentioned in associated
description and shall be read very carefully.

Undertaking work may either directly, or indirectly, create risks to safety and health.
It is the user’s responsibility to ensure that appropriate controls and precautions are
identified and applied as well as making all relevant hazard identifications and risk
assessments of all activities associated with the use of this manual. It is also the
user’s responsibility to design and implement safety systems of work and to supply
safety equipment and training to anyone using this manual to work on products to
which it relates.

Neither this manual or its use in any way absolves the user from their
responsibility to identify controls, precautions, hazards and risks of
Note: all activates described in this manual are implemented.

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 Handling, transport and storage

3. Handling, transport and storage

Handling
Each part of the system must be handled with extreme care and in accordance with
the provided lifting instructions.

3.1.1 Lifting instructions

Each package containing details for the system are suited for handling by forklift/
pallet jack. Gross weight is noted on the packaging and should be considered, and
risk assessed prior to any operation.

Transport
All parts of the system will be packed and secured in a manner that minimizes the
risk of damage and/or deterioration to the condition of the parts upon
transportation and storage dependent on duration and location.

All parts will be delivered in suitable trade packs, which will provide adequate
protection and preservation of the articles during transportation and at storage.

For storage recommendation see chapter 3.3.

3.2.1 Inspections during loading and unloading

3.2.1.1 Loading
Authorized personnel from DBAB will be present during the loading procedure of
the packed parts of the system. They will make sure that the required protection is
used and that the products are properly packed. They will also make sure the
products are securely fastened before loaded. The packaging and loading procedure
will be documented.

3.2.1.2 Unloading
Authorized personnel shall be present during the unloading procedure of the
system. The unloading procedure is recommended to be documented. All parts of
the system are recommended to be immediately inspected at delivery.

Storage
3.3.1 General storage recommendations
Storage conditions must be such that condensation does not occur.

 Until assembly, store the parts in a dry and clean place that protects the parts
from moisture, sunlight, mechanical damages, dust and dirt
 Do not use storage areas with ozone generating equipment
 Do not use forced circulated air in the storage area

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 Handling, transport and storage
All parts of the system, spare parts included, is recommended to be stored in a
warehouse with a temperature around +20°C and a humidity between 30-70%.
Note that temperatures above +35°C will accelerate aging of rubber materials and
temperatures below +10°C might result in condensation and oxidation which is not
acceptable.

3.3.2 Equipment protection

All wooden elements in transport and storage casings meet the ISPM 15
requirements and internally lined with waterproof cover. The details within the
casings are wrapped in corrosion protection (Cortec 126 VpCI Blue or equal).

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 Installation

4. Installation
Lifting

Warning: Always be very careful when handling equipment over head.

4.1.1 Stopping unit

Guideline weight: 45 kg
The S unit is equipped with one hole for eye bolt (M10, preferably RUD VRS‐M10,
not supplied by Dellner Bubenzer AB), which are located on the top of the support
of the S unit (drawing number 3234619). The S unit can be lifted by connecting the
eye bolt to a lifting device e.g. a crane, by using one or more lifting straps

Be careful when lifting the Stopping unit and make sure not to
Caution: damage hydraulic fittings, hoses or other components.

4.1.2 Brake disc

Guideline weight: 87 kg
The brake disc is equipped with four holes for eye bolts (M12, preferably RUD VRS‐
M12, not supplied by DBAB), which are located on the side of the brake disc. The
brake disc can be lifted by assembling eye bolts in one of the eye bolt holes and then
connecting the eye bolt to a lifting device e.g. a crane, by using lifting straps. Since
the brake disc is of split type it can be taken apart in two halves (see chapter 4.2.2).
When this has been done each half can be equipped with one of the eye bolts and
can then be lifted in the same way as described above.

It is important that if the brake disc is taken apart the two screws
(M16x50) are secured with Loctite 243, or similar, and tightened
Warning: according to appendix 4. For more information, see chapter 4.2.2.

4.1.3 Compactus unit

Guideline weight: 60 kg
The C unit is equipped with two eye bolts (M12), which are located on top of the C
unit (drawing number 319596-010). The C unit can be lifted by connecting both eye
bolts to a lifting device e.g. a crane, by using one or more lifting straps.

9
See appendix 1.1
10
See appendix 1.3

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 Installation
Mechanical
Exposed mounting surfaces are corrosion protected11 at delivery. Assure to clean
these surfaces with a suitable solvent12 prior to installation.

4.2.1 Stopping unit

To be fastened according to S unit drawing (drawing number 32346113) with six M16
screws (min. strength class 8.8, not in DBAB supply). At correct tightening torque
this will contribute to approximately 450 kN in pre-load.

4.2.2 Brake disc

To be fastened according to S system drawing (drawing number 32421614) using
twelve thru holes Ø37H7 according to separate instructions from the manufacturer
of the shaft, coupling, flange etc.

Since the brake disc is of split type it can, if required, be taken apart in two halves
during installation. This is done by removing the two M16x50 screws located on the
periphery side on the brake disc. Ensure to collect these screws and the four guide
pins (Ø16m6x50) that are located in the section between the halves, since they shall
be used to align the disc halves to each other when installing them on the shaft
flange.

It is important that if the brake disc is taken apart the two screws
(M16x50) are secured with Loctite 243, or similar, and tightened
Warning: according to appendix 4.

Since oil or grease on the brake disc will lower the friction coefficient, the brake disk
must be cleaned with a suitable solvent15 after installation.

4.2.3 Compactus unit

To be fastened according to C unit drawing (drawing number 319596-016) with four
M8 screws (min. strength class 8.8, not in DBAB supply).
The back side of the cabinet shall be considered as primary mounting surface.
The C unit shall be mounted in the vicinity of the disc brake. If not possible, please
contact DBAB if the height difference is more than 10 meters.

11
DINITROL 77B, or equal
12
DINITROL 7450, or equal
13
See appendix 1.1
14
See appendix 1
15
DINITROL 7450, or equal
16
See appendix 1.3

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Page: 10 Stopping system 324216.
 Installation
Hydraulic

The friction material on the brake pads will lose friction when it gets
in touch with oil and it is therefore important to carefully keep it clean
and free from oil and grease. Mild oil or grease contamination of the
Note:
friction material may be removed with a suitable solvent17 prior to the
first actuation of the disc brake. Material that has become saturated
must be replaced with new brake pads.

4.3.1 Hydraulic tubing

The hydraulic tubes between S unit and C unit which is to be used in the hydraulic
tube assembly, is recommended to be seamless steel tubes according to DIN 2391/C,
dim. Ø12x1,5. The tubes and fittings have to be carefully cleaned internally and
blown through with compressed air. All tubes are also recommended to be “flushed”
with hydraulic fluid before assembly. Observe to avoid restrictions smaller than Ø5
mm in the hydraulic tube assembly.

The hydraulic tubing shall be connected according to the hydraulic circuit diagram
(drawing number 319596-0C18). All connections points are of type 12L and fits with
the above hydraulic tube recommendation. External hydraulic tubing is not included
in DBAB supply.

It is very important to keep the hydraulic assembly in cleanest

Note: possible manner to avoid dirt in the hydraulic system.

4.3.2 Hydraulic fluid filling

The utmost possible cleanliness must be maintained when filling fluid into a
hydraulic system. In order to secure the purity degree of the fluid also new fluid must
be filtrated before it is filled into the system. This should be done by pumping the
fluid to the tank of the system via the filling cap by means of a filling unit provided
with a filter.

• Use hydraulic fluid according to recommendations in chapter 5.1.2.

• Observe the level gauge on the fluid tank during filling so that the right quantity
is filled into the tank. The fluid level shall be seen at the upper marking of the
level gauge.
• During commissioning of the hydraulic system, the fluid level will most likely
decrease so that one or more refills are necessary.

17
DINITROL 7450, or equivalent
18
See appendix 1.3.2

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 Installation
4.3.3 Deaeration procedure
1. Pressurize the brake(s).
2. Mount a draining hose on the air bleeder nipple and open it carefully and keep it
open until all air is exhausted.
3. Close the deaeration nipple.
4. Repeat 1-3 on all brake cylinders.

The brake pads will lose friction if they are contaminated with oil or
grease. The brake pads should be replaced if the friction material has
Note: absorbed oil or grease.

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 Installation
Electrical
The S system and its separate units have electrical interfaces that will need
connections between themselves, and towards the ship. All units are prepared with
internal and external (when needed) connection points that hereafter will be
described.

For electrical circuit diagram see drawing 145219.

External electrical wiring is not included in DBAB supply.

Table 4.1 (Electrical connections)

Interface Description Cable entry Supply and/or
index dimension no. of cores
I/O signals to main control system
Power supply Internal power supply 11-17 mm 24 VDC

Brake ON Engages valve 1V1

PORT 4 cores +
11-17 mm
Brake ON Engages valve 1V2 spares
STBD
Brake status Brake status signal
PORT (Brake ON / OFF indication) 8 cores +
11-17 mm
Brake status Brake status signal spares
STBD (Brake ON / OFF indication)
I/O signals between C unit and S units
Cable 5 Cable between C unit electrical 8 cores +
PORT terminal box and S unit electrical 14-20 mm spares
terminal box
Cable 6 Cable between C unit electrical 8 cores +
STBD terminal box and S unit electrical 14-20 mm spares
terminal box

4.4.1 Compactus unit electrical terminal box

The C unit electrical terminal box is the primary electric interface towards the main
control system and is the systems internal power distributor. The C unit electrical
terminal box shall be connected to the main control system according to the
electrical circuit diagram20 using three cables acc. to Table 4.1.

4.4.2 Stopping units electrical terminal box

The S units electrical terminal box shall be connected to the C unit electrical
terminal box according to the electrical circuit diagram21 using two cables, one to
each S unit, acc. to Table 4.1.

19
See appendix 1.4
20
See appendix 1.4, page 8 & 10
21
See appendix 1.4, page 9

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 Commissioning

5. Commissioning
Before commissioning
5.1.1 Recommended actions before commissioning
• Check that mechanical, hydraulic and electrical installation has been carried
out according to chapter 4.
• Check that the friction surfaces on the brake discs have been degreased, see
chapter 4.2.

5.1.2 Hydraulic fluid recommendation

Figure 5.1 shows the average viscosity versus temperature curves for the most
commonly used fluids subdivided in three groups, each one with a different
viscosity. Manufacturers of hydraulic pumps and motors find their best operating
conditions with fluid having a viscosity around 30 cSt at operating temperature.
Since the average operational temperature of hydraulic circuits is about 50C, the
fluid often used is the fluid corresponding to curve B.

Table 5.1 (ISO VG standards)

Curve ISO VG standard
A 32
B 46
C 68

Figure 5.1 (Viscosity diagram)

We, Dellner Bubenzer AB, recommend a conventional hydraulic fluid based on

mineral fluid, which shall be compatible with nitrile rubber and polyurethane and
PTFE-Bronze compound (used materials in seals). The fluid shall at least fulfil
”Vickers M-2950-S (mobile hydraulic systems)” and at least have a purity 20/17
according to ISO 4406. Hydraulic fluid shall be chosen so that viscosity at working
temperature in your system is 30 cSt.

Table 5.2 (Example of suitable fluids)

Manufacturer Type (ISO VG 32) Type (ISO VG 46)
BP Bartran 32 Bartran 46
TEXACO Rando HD 32 Rando HD 46
SHELL Tellus oil 32 Tellus oil 46

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 Commissioning
During commissioning
Operation and preparations before the first operation shall be carried out according
to instructions below.

It is very important to follow the directives to avoid operation

Caution: malfunction and equipment breakdown.

5.2.1 Before first operation

5.2.1.1 Compactus unit

Prior to the first actuation of C unit, i.e. solenoid valve(s) energized and hydraulic
outlet port(s) pressurized, the following shall be checked:

1. Fluid has been filled into the tank. If not, see chapter 4.3.2.
2. The shut of valve (included in the air processing unit22) is in open position. If not,
open it.
3. The pressure gauge (included in the air processing unit23) shows a permissible
value valid for your installation. If not, correct the pressure with the regulator.

5.2.2 Recommended actions during commissioning of the Stopping system:

• Inspect the hydraulic system for leakage.
• Inspect proximity switches and verify that correct signals are received.
• Test all Stopping functions and adjust proximity switches if necessary.
• Deaerate the disc brake cylinders24.
• Inspect fluid level in the C unit after deaeration and after first and each
operation. Refill if needed, see chapter 4.3.2 for more information.
• Perform dynamic bedding in procedure of the brake pads25.

22
Included in pos. 4 in appendix 1.3
23
Included in pos. 4 in appendix 1.3
24
See chapter 4.3.3
25
See appendix 3

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 Maintenance

6. Operation
For more information regarding signals related to the S system see the electrical
circuit diagram (drawing number 141226).

Control systems
The C unit electrical terminal box27 is the primary electric interface towards the main
control system for the S system. The disc brake is controlled via signals through the
C unit electrical terminal box. Indication of the disc brake (ON / OFF) is received
from the C unit electrical terminal box.

Proximity switches (2S1 & 2S2, & 3S1 & 3S2), which indicates on the brake pad
movement, is used as Brake ON / OFF indicator.

Remote control
During remote control “Brake ON” and “Brake OFF” operation is available.

6.2.1 Disc brake

6.2.1.1 Engagement
PORT:
To engage the disc brake, circuits between terminals X1: 3 & 4 are to be closed
according to the electrical circuit diagram.

STBD:
To engage the disc brake, circuits between terminals X1: 5 & 6 are to be closed
according to the electrical circuit diagram.

6.2.1.2 Disengagement
PORT:
To engage the disc brake, circuits between terminals X1: 3 & 4 are to be opened
according to the electrical circuit diagram.

STBD:
To engage the disc brake, circuits between terminals X1: 5 & 6 are to be opened
according to the electrical circuit diagram.

26
See appendix 1.4
27
Pos. 5 in appendix 1, and appendix 1.4

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 Maintenance

7. Maintenance
It is recommended to turn the shut off valve (included in the air
Caution: processing unit28) into closed/vented position prior any major
maintenance tasks (for example removing system components), but
do NOT forget to restore its position afterwards.

General
Ensure to have the vicinity of the S system clean and free from dirt and the hydraulic
system depressurized prior to removal of any hydraulic system component. Protect
the C unit and the electrical items by keeping the cabinet doors closed. Be extra
careful at fluid filling since dirt in the fluid will damage the hydraulic system.

Maintenance schedule
Table 7.1 (Maintenance schedule)
When Every Every Every Every
I = Inspection, O = Operation, R = Replacement needed month 6 months year 10 years
Stopping unit – 323461
Exercise the brake units O29
Brake pads R30 I29 R31
Sliding surfaces I29
Seals R32
Compactus unit – 319596-0
Exercise the Compactus unit O29
Fluid R33 I29 R33
Air filter R34 R34
Air processing unit R35
Pneumatic Hydraulic power pack R36
Replacement when needed = Corrective maintenance. Otherwise Preventive maintenance

The Compactus unit is recommended to be used every month or as a

Caution: minimum exercised once a year. When in storage the Compactus unit
must be exercised with lubricated air once a year in order to avoid
dried out seals (substantial replacement procedure).

28
Included in pos. 4 in appendix 1.3
29
See chapter 6.3
30
See chapter 7.4.1.1 - Brake pads to be replaced when there is 2 mm friction material left
31
See chapter 7.4.1.1
32
See chapter 7.4.1.2
33
See chapter 4.3.2
34
See chapter 7.4.2.1
35
Contact DBAB
36
Contact DBAB

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Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 17 Stopping system 324216.
 Maintenance
Preventive maintenance
The preventive maintenance recommended in Table 7.1 ensures reliability and
function of the S system throughout its service life.

It is important to inspect and exercise the S system monthly in order to:

 Verify the function.

 Identify any problems (broken or damaged switches, leakage etc.).
 Re-lubricate all internal seals to prevent leakage.
 Check the brake pads for wear and damage.

We strongly recommend that the function of the Stopping system is

Note: verified as a bare minimum once a year.

At normal circumstances, Dellner Bubenzer AB recommends replacing the air filter

twice per year. If your air is much polluted, more frequently replacements are
recommended.

We recommend to once a year:

 Inspect the fluid quality and level in tank according to chapter 4.3.2. If the fluid
has turned black, change it. Use new clean fluid according to chapter 5.1.2. For
drawing reference see appendix 1.3.

1. Ensure that the solenoid valve is de energized (hydraulic system

depressurized).
2. Locate drainage port (DR1) and use an empty container to avoid fluid spillage.
3. Remove the plug and drain the fluid (self-pressure) into the container.
4. Reassemble the plug, remove the filling cap (position 1Z2) and fill the tank
with new fluid according to chapter 4.3.2.
5. Reassemble the filling cap.

Fluid level inspection shall be done when hydraulic system is

depressurized. It is recommended to deaerate the hydraulic system
Note: after fluid change

 Inspect sliding surfaces and unprotected surfaces and lubricate if needed.

 Inspect friction surfaces of the brake disc and clean if needed.

Every ten years we recommend a major overhaul of the S system as described in

Table 7.1.

The brake disc is recommended to be inspected and degreased

Caution: according to chapter 4.2 before operating the Stopping system.

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 18 Stopping system 324216.
 Maintenance
Corrective maintenance
Corrective maintenance is needed if problems are identified during inspection.
Minor corrective maintenance such as replacement of brake pads etc. is done with
support from assembly drawings. The most common procedures for major
corrective maintenance are described in chapter 7.4.1.1, 7.4.1.2, and 7.4.2.1.

Use test connectors and measure the pressure with a pressure gauge
Caution: to ensure that the hydraulic system is depressurized prior to removal
of any hydraulic system component.

7.4.1 Corrective maintenance of Disc brake

7.4.1.1 Replacement of brake pads procedure

The brake pads are to be replaced when 2 mm friction material is left. For drawing
reference see appendix 1.1.1.

1. Depressurize the brake.

2. Remove the guide pins and the return spring screws.
3. Slide brake pad up and out.
4. Slide new brake pad in.
5. Install guide pins and return spring screws.
6. Tighten screws acc. to tightening torque stated in appendix 4.

New brake pads have to be bedded in before full friction is achieved

Note: (see appendix 3).

7.4.1.2 Replacement of seals procedure

Seal change should be made if the Disc brake shows any sign of leakage. We
recommend changing all seals in the procedure (seal kit, see Table 10.1). For drawing
reference see appendix 1.1.1.1.

1. Release the Disc brake unit (atmospheric pressure in the cylinders) and ensure
that the working area is clean.
2. Remove all hydraulic connections from the Disc brake.
3. Remove the Disc brake from its support.
4. Remove the brake pads according to the procedure in chapter 7.4.1.1.
5. Pull out the piston (detail number 4).
6. Remove the u-ring (detail number 9) and the wiper (detail number 8) from the
cylinder in the housing.
7. Use white spirit or other equivalent solvent to clean the cylinder and the piston
that is to be remounted into the cylinder.
8. Lubricate the new seals (u-ring and wiper), the sealing grooves and the inside of
the cylinder with suitable cylinder grease37.

37
Mobil Mobilgrease 28, or equivalent

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 19 Stopping system 324216.
 Maintenance
9. Assemble the new seals into the sealing grooves in the cylinder.

Make sure to assemble the seals correctly regarding direction. The

seals shall be assembled as shown in section A-A on the general
Note: drawing.

10. Re-assemble the piston into the cylinder.

11. To protect the exposed surface (with the threaded hole) on the piston it is
recommended to apply a suitable corrosion protection38 to the surface in
question.
12. Re-assemble the brake pads according to the procedure in chapter 7.4.1.1.
13. Re-assemble the disc brake to its support.

7.4.2 Corrective maintenance of Air processing unit

7.4.2.1 Replacement of air filter procedure

Turn the shut off valve (included in the air processing unit 39) into
Caution: closed/vented position prior replacement of air filter. Do NOT forget
to restore its position afterwards.

1. Remove the bowl assembly40 by affecting the lock button.

2. Remove the old air filter.
3. Insert new air filter and assemble the bowl assembly back on the air
processing unit.
4. Ensure correct function and check for leakage.

38
DINITROL 77B, or equal
39
Included in pos. 4 in appendix 1.3
40
Included in pos. 4 in appendix 1.3

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 20 Stopping system 324216.
 Sub systems

8. Sub systems
Disc brake
For reference drawing, see appendix 1.1.1.

8.1.1 General description

Disc brakes of type SKD are direct acting and are activated by hydraulic pressure.
The braking power achieved is directly proportional to the applied pressure, see
Table 8.1.

The brake consists of two symmetrical brake halves. Each brake half is supplied with
two cylindrical guiding pins which transmit the tangential braking force from the
brake pads to the brakes. This means that the brake piston is not subjected to any
radial energy and as a result, contributes to a longer life for the brakes. Each brake
half is supplied with retracting springs, which pull the brake pad back at brake
release. The brake pad wear is automatically compensated through increased stroke
by the piston.

8.1.2 Technical data

Table 8.1 (Braking force)
Disc brake type Braking force41 Max. working pressure Air gap42
[N/bar] [bar] [mm]
SKD 65 273 100 Min. 2 x 2,0

8.1.3 Cylinder volume

Table 8.2 (Cylinder volume)
Type Volume 143 Volume 244 Volume 345 Volume 446
[cm3] [cm3] [cm3] [cm3]
SKD 65 96,1 43 13,3 53,1
Make sure that used fluid is applicable with nitrile rubber and
thermoplastic polyurethane.

8.1.4 Sealsp
Nitrile / polyurethane is used as material in seals. If chosen hydraulically fluid is not
suitable together with nitrile / polyurethane, other materials are available. For
example, if the operational fluid temperature is over 100 °C, viton is recommended
and available.

41
Ftan = F x p, Ftanmax = 273 x 100 = 27,3 kN (Calculated with coefficient of friction µ = 0,42. Valid for
bedded in friction material (see appendix 3) and clean brake disc (see chapter 4.2.2).
42
Air gap between brake pad and brake disc. Valid for symmetrical installed disc brake.
43
Max. volume in the brake with worn out brake pads (Brake pads to be replaced when there is 2 mm
friction material left, 6 mm max. permissible wear of brake pad).
44
Volume in released brake.
45
Min. working volume in applied brake (new brake pads, air gap 2mm).
46
Max. working volume (= Volume 1 – Volume 2) in applied brake (6 mm wear of brake pads, air gap 2
mm).

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 21 Stopping system 324216.
 Sub systems

8.1.5 Brake OFF indication

For reference drawing, see appendix 1.2.

The proximity switches on the disc brake (used for Brake disengaged indication) is
indicating on the movement of the brake pad. The recommended setting for the
switch is shown in appendix 1.2. The setting might however need to be finally
adjusted at commissioning.

8.1.6 Friction material

The friction material used on the brake pads is a non-asbestos rubber-bonded
material with no steel components, but some brass. The friction material has a
medium-high dynamic friction coefficient and especially a high static friction
coefficient. Max. continuous rubbing speed is 30 m/s and max. continuous
temperature is 250 ºC.

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 22 Stopping system 324216.
 Sub systems
Compactus unit
8.2.1 General description
For reference drawing, see appendix 1.3.

Figure 8.1 (Closed Compactus unit) Figure 8.2 (Open Compactus unit)
The C unit is a hydraulic unit consisting of a PHPP (valve-controlled, two-way
plunger pump type), Air processing unit (which consists of a shut off valve, a
pressure regulator with filter and pressure gauge, and a safety valve), tubing and
external inlet and outlet ports. All which are assembled inside a cabinet which keeps
the equipment clean and free from dirt.

The C unit shall be continuously supplied with pneumatic pressure through the
Pneumatic inlet port into the Air processing unit. When activated, the PHPP
converts the pneumatic pressure into hydraulic pressure through the hydraulic
outlet port which, if connected to a disc brake, engages the disc brake. When the
requested hydraulic pressure is received, the PHPP will stop and hold pressure. If the
hydraulic pressure decreases the PHPP will automatically restart to maintain a
constant hydraulic outlet pressure.

The C unit electrical terminal box, which is assembled on the right side of the
cabinet, shall be considered as interface between the hydraulic system and the
external main control system.

8.2.2 Technical data

Table 8.3 (Techinical data for PHPP)
Pump type Step-up Max. pneumatic Adjustment- Operating Control
ratio supply pressure [bar] pressure [bar] Pressure [bar] power
LP 80-12 1:44 10 Max. 4,547 Max. 20048 24 V DC

8.2.3 Seals
Seal material in the PHPP is nitrile.

47
Adjustment pressure is adjusted with the pressure regulator (secondary pneumatic supply
pressure).
48
Hydraulic operating pressure is calculated by multiplying secondary pneumatic supply pressure
with the step-up ratio (no losses considered).

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 23 Stopping system 324216.
 Handling of used parts and material

9. Handling of used parts and material

When changing wear parts (such as brake pads, seals and hydraulic fluid), and when
system has reached the end of their lifespan and is considered used, it is important
to recycle each component in a correct manner.

Please note that below information is to be considered as a guideline

for recycling, and a thorough check is necessary for each component
Note: how to be recycled.

Steel parts and brake pads

Steel parts, such as brake halves and supports, and brake pads are to be sorted as
mixed metal scrap and recycled accordingly.

Seals and plastics

Plastic and rubber parts, such as wipers and cover to the air processing unit, are to
be sorted as plastics and recycled accordingly.

Hydraulic fluid
The hydraulic fluid is to be sorted as hazard material and recycled accordingly.

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 24 Stopping system 324216.
 Recommended spare parts

10. Recommended spare parts

Below is a list of recommended spare parts for the S system. See chapter 7 for more
information regarding maintenance.

Stopping unit
Table 10.1 (Recommended spare parts for Stopping unit)
Description Appendix no. Drawing no./ Article no. Quantity needed
Detail no. per S system
Brake pad 321802 / 2 215527-A 4 pcs
1.1.1
Seal kit 321802 / 8, 9 216865-1 2 set
Proximity switch 1.2 218465 / 2 319206 4 pcs

Compactus unit
Table 10.2 (Recommended spare parts for Compactus unit)
Description Appendix no. Drawing no. / Article no. Quantity needed
Detail no. per S system
Solenoid valve 1.3.1 319597 / 200-35-140 2 pcs
1V1-1V2
Replacement filter49 1.3 319596-0 / AF30P-060S 1 pcs
4
Relay 1.4 1452 / E4025018 8 pcs
K101-K108

49
Included in pos. 4 in appendix 1.3

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 25 Stopping system 324216.
 Appendix

11. Appendix
Table 11.1 (Appendix list)
Appendix no. Document ID. Type Name Pages
1 324216 rev. 0 Drawing Stopping system 1

1.1 323461 rev. 0 Drawing Stopping unit SKD 65 1

1.1.1 321802 rev. 2 Drawing Disc brake SKD 65 1

1.2 218465 rev. 3 Drawing ON/OFF indicator 1

SKD 65
1.3 319596-0 rev. 2 Drawing Compactus unit 1

1.3.1 319597 rev. 2 Drawing Pneumatic / Hydraulic 1

Power Pack
1.3.2 319596-0C rev. 1 Hydraulic Compactus unit 1
circuit diagram
1.3.3 319596-0- Product Compactus unit 1
O2221691 rev. 0 specification
1.4 1452 rev. 221206 Electrical Stopping system 10
circuit diagram
2 B 7280 Manual Pneumatically operated 6
hydraulic pump type LP
3 AI04-011E-04 Instruction Bedding in procedure 2

4 908128-13-863 Information Tightening torques 4

issue 2

Document ID: M0479 Dellner Bubenzer AB, 2022. © All rights reserved.
Issue: 1 The manufacturer reserves the right to modification without special notice.
Page: 26 Stopping system 324216.
 4 5
755

155
400 4x M12 (for eye bolt)

PI (Pneumatic pressure inlet port)

Connection: 12L

400
Min. pneumatic pressure: 2,3 bar
Max. pneumatic pressure: 10 bar
600

B1 (Hydraulic outlet port)

Connection: 12L
Hydraulic pressure: 100 bar
Electrical connections DR1 (Drainage port)
B2 (Hydraulic outlet port) Connection: 8L
Cable glands:
Connection: 12L
2x M25 (11-16mm)
Hydraulic pressure: 100 bar
3x M20 (7-13mm)

25
PORT STARBOARD Represents hydraulic tubing (customer supply).
Recommended hydraulic tube dimension: n12x1,5 according to DIN 2391/C.
n740 ~191
Connections: 12L .
Max. flange n510 Represents electrical wiring (customer supply).
For more information, see electrical circuit diagram (dwg. 1452).
n270

For installation interfaces, dimensions and

~423

tolerances, see sub assembly drawings.

315
157,5

n350 157,5

12x n37 H7
j n0,05

6 2 1 6 2 321850 S-unit electrical terminal box 125x80x57 0,8

315 449 5 1 321851 Compactus electrical terminal box 400x300x155 6,1
449 4 1 319596-0 Compactus unit 40,9
3 3 2 324200 Brake disc, split Ø740, t=25 69,1
2 2 218465 ON/OFF indicator SKD 65 0,2
1 2 323461 Stopping unit SKD 65 38,2
Position Quantity Article number Name Material Dimension Weight
[kg / item]
Format Design by Drawn by Approved by Scale Weight Replaces Replaced by
A2 OMa OMa PMi 1 : 10 263,5 kg

STAND 324216-1-20221208 Stopping system E

Date
Project: 7634M
2022-11-29

File: 324216.idw
Painting system: TB 218527 - Class C3 according to EN-ISO 12944-2 © All rights reserved. Both the content and form of this document Drawing number
are the property of Dellner Bubenzer AB. It is formally prohibited to
Sheet 1 / 1
Top coat color: RAL 9005 - Black, Cabinets: RAL 7035 - Light Gray
use, copy, modify, disclose, or perform all or part of this document
without obtaining Dellner Bubenzer AB's prior written authorization. 324216 Revision 0
 Tightened acc. to Tightened acc. to
TB 323272
TB 323272 Disc diameter
6x n17 (for fastening screws) ****
6x v n33 (for washers) Max flange = Dia - 230
1 2 3 10 12

Dim. C = 157,5 `0,5

140
(315)

315
4
Max.
11 8
flang
e ra
dius
+ 13
***

140
7

Dim. A = 140 `0,5 Disc radius + 10 **

5 6 9
280 Dim. B = Disc radius + 79 `0,5
Hydraulic inlet port (315)
Connection: 12L
2x M10 (for eye bolts)
b = 25
b+8*

12 6 000125105000 Washer BRB 8.8 FZB 10,5x20x2 0

~193

11 1 000912006030 Screw MC6S 8.8 FZB M6x30 0

315

10 6 100912010025 Screw MC6S 12.9 M10x25 0

9 0,6m 7284012015 Hydraulic tube Ø12x1,5 0,1
8 1 5390-01-12 Tube clamp Ø12 0
7 2 6050-12-12 Fitting EVW 12L 0,1
*) 4 mm air gap between brake housing/pad and brake disc 6 2 6042-12-12 Fitting W 12L 0,1
(on both sides of the disc) if the S unit is installed 5 1 6070-12-12 Fitting EVL 12L 0,2
according to nominal axial installing dimension (see dim. A). 4 2 6009-12-04 Fitting GE 12L, G/ED 1/4" 0,1
3 1 217629-17 Spacer SKD 65 t=17 1,6
**) 10 mm air gap between support and brake disc 2 1 321802-5 Disc brake SKD 65 17,3
if the S unit is installed according to nominal 1 1 324136 Support 18,1
Position Quantity Article number Name Material Dimension Weight
axial installing dimension (see dim. B & C). [kg / item]
Format Design by Drawn by Approved by Scale Weight Replaces Replaced by
24 A2 OMa OMa PMi 1:3 38.2 kg
***) Min. 13 mm air gap between brake housing and max. recommended
~191 flange periphery if the S unit is installed according to nominal Stopping unit SKD 65 E

axial installing dimension (see dim. B & C).

Date

****) The S unit shall be assembled with 6x M16 screws, 0° support, T=25 (AG 4)
2022-12-08

File: 323461.idw
minimum strength class 8,8. At correct tightening torque this © All rights reserved. Both the content and form of this document Drawing number
are the property of Dellner Bubenzer AB. It is formally prohibited to
Sheet 1 / 1
will contribute to approximate 450 kN in pre-load. use, copy, modify, disclose, or perform all or part of this document
without obtaining Dellner Bubenzer AB's prior written authorization. 323461 Revision 0
 No. Change. Date. Intr. Appr.
1 Pos. 1 updated, now 6x M10 threads, ÄO 2014-11-11 TL MA
39343
2 Drawing updated. CO 91237 2023-02-10 OMa PMi

b = Brake disc thickness

A-A
b+4
2x Hydraulic inlet port
Connection: Internal thread G 1/4" b 2 8 9 4 1

43
15 6 14 7

~154

40
141
10 5

95
Outer diameter
Tightened acc. to 3 of brake disc
TB 323272

13 12 11
A 104 + b
Tightened acc. to
TB 323272

143

163

6x M10 x 15
B (for fastening screws,
min strengt class 8.8)

1 2
15 2 215543 Plastic plug 0
14 2 215334 Nipple G 1/4" 0
13 6 000125170000 Washer BRB 8.8 FZB 17x30x3 0
12 3 006924016000 Nut M6M locking 8.8 FZB M16 0
11 3 000931016140 Screw M6S 8.8 FZB M16x140 0,3
10 4 218384 Return spring 0
~164 + b

9 2 5773065007 U-ring T20 0

38 + b

8 2 5755065000 Wiper DK 65 0
7 2 5703014000 Bonded seal G 1/4" 0
Warning! 6 2 216290 Bleeder 0
Manual for this brake must be read 5 4 215531 Return spring screw 0
before installation. For installation, 4 2 204548 Piston 0,9
operation and maintenance, request 3 4 215530 Guide pin 0,1
manual from Dellner Bubenzer AB. 2 2 215527-A Brake pad 1,5
1 2 215271 Brake housing 5,5
Position Quantity Article number Name Material Dimension Weight
Assembly instruction: [kg / item]
All parts to be cleaned thoroughly before Format Design by Drawn by Approved by Scale Weight Replaces Replaced by

assembly. Sliding surfaces and seals to A2 TL TL PMi 1:2 17,3 kg

115
be greased with cylinder lubricant,
Mecman order no. 435-1 or equal. Disc brake SKD 65 E

Date
Max working pressure: 10 MPa with return springs (1 bar)
2014-03-03

File: 321802.idw
© All rights reserved. Both the content and form of this document Drawing number
Test pressure for the brake: 13,5 MPa are the property of Dellner Bubenzer AB. It is formally prohibited to
Sheet 1 / 1
use, copy, modify, disclose, or perform all or part of this document
without obtaining Dellner Bubenzer AB's prior written authorization. 321802 Revision 2
 No. Change. Date. Intr. Appr.
1 Pos. 1 & 2 was 218466 & 218467 05-04-20 PMi PM
2 Text corrected 08-10-30 PMi PM
1,5 Drawing updated. Drawing number changed.
3 2021-12-14 OMa PMi
CO 85777

1 2 85

A (2:1)

155
Detail view A shows recommended air gap 3
between proximity switch and brake pad
back plate at released condition. The air
gap might need to be finally adjusted at
commissioning.
Proximity switch shall indicate (lose
signal) when the disc brake is applied
(before 2 mm back plate travel from
released condition).

Wiring diagram (PNP)

3 4 000912006012 Screw MC6S 8.8 FZB M6x12

2 2 319206 Proximity switch NO, Sn 2 mm 2 m cable 10-30 VDC, 200mA
1 1 2 319203 Switch bracket
+U b Last Position Quantity Article number Name Material Dimension Weight
charge Format Design by Drawn by Approved by Scale Weight Replaces Replaced by
[kg / item]

4 load A3 JB JB 1:2 0,2 kg 23-18465

A
RL ON/OFF indicator SKD 65 E

3
0V Date

2001-10-12

File: 218465.idw
1: Brown 4: Black 3: Blue © All rights reserved. Both the content and form of this document Drawing number
Sheet 1 / 1
are the property of Dellner Bubenzer AB. It is formally prohibited to
use, copy, modify, disclose, or perform all or part of this document
without obtaining Dellner Bubenzer AB's prior written authorization. 218465 Revision 3
 No. Change. Date. Intr. Appr.
Pos. 26 was 000931006014. Pos 27 was
25 Pneumatic inlet port 1 2017-03-13 OK PMi
006924006000. CO 54824
24 Max. supply pressure: 10 bar 2 Drawing updated. CO 84274 2021-09-09 OKa PMi
600 Max. regulated pressure: See below *)
23
400 560 20
28 1 13 22 14 12
27

20
1 26
4

1V3
1V4 PI
1Z6

15
16
17 B1 B2

600

560
16 2

17
1P1
1V1
1V2
22 1Z1
1Z2 DR1
1Z3
1Z4
1Z5
9 4x n8,5
10 10 5 21 29 30 31 6 7 8 Hydraulic outlet ports Drainage port
Max. oulet pressure: See below *)
11 Product specification: 319596-0
31 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5 0
1V5 12 18 19 20 30 4 006924008000 Nut M6M locking 8.8 FZB M8 0
(to be sealed at assembly) 29 2 319287 Threaded bar 8.8 FZB M8x270 0,1
M1 28 4 00012564000 Washer BRB 8.8 FZB 6.4x12x1.5 0
M2 27 4 322910 Blind rivet nut FZB 6PO30 0
26 4 000931006016 Screw M6S 8.8 FZB M6x16 0
Note: 25 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3 0
Cabinet door not shown in upper left view. 24 2 006924012000 Nut M6M locking 8.8 FZB M12 0
Trap door / 10x Mounting screws, 23 2 319183 Eye bolt FZB M12 0,2
22 0,9 m 7284012015 Hydraulic tubes GK 12x1,5 0,3
could be opened at service *) Pressure step up ratio: 44.
21 0,45 m 7284008010 Hydraulic tubes GK 8x1 0,1
Max. hydraulic outlet pressure is specific for Your installation,
20 2 8303-00-12 Test connector DKLO 12L, M16x2 0,1
see product specification or contact Dellner Bubenzer AB. 19 2 6035-12-12 Fitting DKLO 12L 0,1
18 2 6043-12-12 Fitting T 12L 0,2
**) Plus max. 5 l hydraulic fluid. 17 3 5601-02-18 Bonded seal M18 0
16 3 6045-12-12 Fitting SV 12L 0,1
15 1 6089-12-06 Fitting EVGE 12L, G/ED 3/8" 0,1
14 1 6042-12-12 Fitting W 12L 0,1
13 1 6009-12-06 Fitting GE 12L, G/ED 3/8" 0,1
12 3 6009-12-04 Fitting GE 12L, G/ED 1/4" 0,1
11 1 6130-00-08 Plug 8L 0
10 2 5703014000 Bonded seal G 1/4" 0
9 1 6045-08-08 Fitting SV 8L 0,1
8 1 5703012000 Bonded seal G 1/8" 0
7 1 6050-08-08 Fitting EVW 8L 0,1
6 1 6003-08-02 Fitting GE 8L, GB 1/8" 0
5 1 534-421-003-0 Safety valve G 1/4" (2-6 bar) 0,2
4 1 319275 Air processing unit 0,9
2 1 319597 Pneumatic/Hydraulic Power Pack 9,7
1 1 AS06064 Cabinet 600x600x400 27,2
Position Quantity Article number Name Material Dimension Weight
[kg / item]
Format Design by Drawn by Approved by Scale Weight Replaces Replaced by
Cabinet door - Left hanged A2 PMi PMi MO 1:5 41 kg **)
Compactus unit E
Machinery plate
Date
LP80-12/B4 K1, BWN 1 L-NN-1-1-G24

File: 319596-0.idw
2013-02-12
© All rights reserved. Both the content and form of this document Drawing number
are the property of Dellner Bubenzer AB. It is formally prohibited to
Sheet 1 / 1
use, copy, modify, disclose, or perform all or part of this document
without obtaining Dellner Bubenzer AB's prior written authorization. 319596-0 Revision 2
 No. Change. Date. Intr. Appr.
1 Text updated 08-01-11 PMi PM
2 Drawing updated. CO 84277 2021-09-09 OKa PMi
~201

1P1 1V1 1V2

1Z2
A

~364
1Z3
1Z1

242,5
200 200
Drainage port DR (G 1/8")
255

B (1:2)
225
A (1:2)

1Z4 1Z5
B
4x n9

130
Pneumatic inlet port (G 1/4") Hydraulic outlet port Hydraulic outlet port
PH1 (G 1/4") PH2 (G 1/4")

1 Product specification: 319596-X, i.e. 319596 or 319596-1 or 319596-2 a.s.o.

Position Quantity Article number Name Material Dimension Weight
[kg / item]
Format Design by Drawn by Approved by Scale Weight Replaces Replaced by
A3 PMi PMi PM 1:5
Pneumatic/Hydraulic Power Pack E

Date
LP 80-12/B4 K1 (BWN 1 L-NN-1-1-G24)
2006-12-07

File: 319597.idw
© All rights reserved. Both the content and form of this document Drawing number
are the property of Dellner Bubenzer AB. It is formally prohibited to
Sheet 1 / 1
use, copy, modify, disclose, or perform all or part of this document
without obtaining Dellner Bubenzer AB's prior written authorization. 319597 Revision 2
 Document name Head line Date Page no.
COMPACTUS UNIT
PRODUCT SPECIFICATION LP80-12/B4 K1 (BWN 1 L-NN-1-1-G24) 2023-02-10 1 (of 1)
Issuer Approved by Contract / Order no. Contract name Document ID Revision
Olle Mases Pär Mikaelsson - / O2221691 7634 319596-0 -
Product no. Assembly drawing Assembly drawing, PHPP Hydraulic circuit diagram Assemly / test instruction
319596-0 319596-0 319597 319596-0C -

No. Pos. Qty. Art. no. Description Remarks

2 1 319597 Pneumatic Hydraulic Power Pack LP80-12/B4 K1 (BWN 1 L-NN-1-1-G24) Acc. to doc. ID. D 7280 H & E 7282 B
2 1P1 1 321157 Pump unit Acc. to doc. ID. D 7280 & E 7282
2 1Z1 1 - Oil tank 7 litre (usable 5 litre) Acc. to documet ID. E 7282 B
2 1Z2 1 - Filling cap Acc. to documet ID. E 7282 B
2 1Z3 1 402-50-005 Level gauge
2 1Z4 1 - Manifold sub plate Acc. to documet ID. D 7470 B/1
2 1Z5 1 - Manifold sub plate Acc. to documet ID. D 7470 B/1
2 1V1 1 200-35-140 Solenoid valve WN 1 N-G24 24 V DC
2 1V2 1 200-35-140 Solenoid valve WN 1 N-G24 24 V DC
4 1 319275 Air processing unit Max. supply: 10 bar (145 PSI)
4 1Z6 1 Silencer
VHS30-F03B-S
4 1V3 1 Shut off valve
4 1V4 1 AW30K-F03DE-B Pressure regulator with filter and gauge Setting: 2,3 bar (33 PSI)
5 1V5 1 534-421-003-0 Safety valve (2-6 bar) Setting: 3 bar (43,5 PSI)
20 M1 1 8303-00-12 Test connector DKLO 12L (M16X2)
20 M2 1 8303-00-12 Test connector DKLO 12L (M16X2)

319596-0.xls, page 319596-0-O2221691, rev. 0

 0 1 2 3 4 5 6 7 8 9

WUPE001E 01.03.1994

Dellner Bubenzer AB
Phone: +46 23-78 30 50
E-mail: [email protected]
www.dellnerbubenzer.com

Customer : BERG PROPULSION

Plant designation : S-SYSTEM
Drawing number : 1452
Commission : DELLNER BUBENZER

Electrical Drawings
Highest 0-number :
Not used 0-number :
Remarks:

Created on : 08.Maj.2014 by : FNE Highest Page No. : 10

Processed on : 06.Dec.2022 by : FNE No. of pages : 10

2
Date 08.Maj.2014 =
BERG PROPULSION
Desig. FNE 1452 +

Rev.date 06.Dec.2022 Verif. p. 1

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

Table of content Column x: created autom. but modified manually WUPJ005 22.04.96

Page Page designation Supplementary field Date Editor X

1 23.Okt.2013 FNE

2 TABLE OF CONTENT 23.Okt.2013 FNE X

3 LAYOUT COMPACTUS 23.Okt.2013 FNE

4 LAYOUT S-UNITS 23.Okt.2013 FNE

5 BRAKE VALVES 23.Okt.2013 FNE

6 S-UNITS PORT & STBD SIDE 23.Okt.2013 FNE

7 CUSTOMER SIGNALS 23.Okt.2013 FNE

8 FIELD WIRING COMPACTUS 23.Okt.2013 FNE

9 FIELD WIRING 23.Okt.2013 FNE

10 FIELD WIRING CUSTOMER SIGNALS 23.Okt.2013 FNE

1 3
Date 08.Maj.2014 =
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Desig. FNE
TABLE OF CONTENT 1452 +

Rev.date 06.Dec.2022 Verif. p. 2

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

MOUNTING PLATE CONNECTION BOX

400x300x155MM

QTY. POS. DESCRIPTION MANUFACTURE

1 CABINET MAS0403015 ELDON

TERMINAL WDU 2,5 WEIDMULLER

22 X1
K101

K102

K103

K104

2919602

CONDUIT M25 RUTAB

2
1476114

CONDUIT M20 RUTAB

3
1476113

K101 RELAY 24VDC 2CO LD/PB WEIDMULLER

4 -
X1 4025018
K104

CONDUITS
2xM25
3xM20

2 4
Date 08.Maj.2014 =
BERG PROPULSION
Desig. FNE
LAYOUT 1452 +

Rev.date 06.Dec.2022 Verif. COMPACTUS p. 3

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

CONNECTION BOX
80x125x57MM

S-UNIT
PORT SIDE
QTY. POS. DESCRIPTION MANUFACTURE
X2
2 CABINET KLIPPON 9529150000 WEIDMULLER

TERMINAL WDU 1,5 WEIDMULLER

8 X2+
X3 2919602

CONDUIT M25 RUTAB

2
CONDUITS 1476114

1xM25
CONDUIT M16 RUTAB
2xM16 4
1476112

CONNECTION BOX
80x125x57MM

S-UNIT
STBD SIDE
X3

CONDUITS
1xM25
2xM16

3 5
Date 08.Maj.2014 =
BERG PROPULSION
Desig. FNE
LAYOUT 1452 +

Rev.date 06.Dec.2022 Verif. S-UNITS p. 4

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

+24VDC /6.0
0V /6.0

X1 3 5

CUSTOMER

X1 4 6

X1 7 9

1 1

1V1 1V2
BRAKE 2 BRAKE 2
VALVE VALVE

X1 8 10

X1 1 2

PORT BRAKE STBD BRAKE

+24VDC

ON/OFF ON/OFF
0V

4 6
Date 08.Maj.2014 =
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Desig. FNE
BRAKE VALVES 1452 +

Rev.date 06.Dec.2022 Verif. p. 5

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

5.9/ +24VDC +24VDC /7.0

5.9/ 0V 0V /7.0

X1 11 12 15 16

S-UNIT S-UNIT
PORT SIDE STBD SIDE
X2 1 2 X3 1 2

2S1 2S2 3S1 3S2

BRAKE BRAKE BRAKE BRAKE
OFF OFF OFF OFF

X2 3 4 X3 3 4

X1 13 14 17 18

A1 A1 A1 A1

K101 K102 K103 K104

A2 A2 A2 A2

11 14 11 14 11 14 11 14
7.1 7.2 6.2 6.3
11 12 11 12 11 12 11 12
7.2 7.2 7.6 7.6

5 7
Date 08.Maj.2014 =
BERG PROPULSION
Desig. FNE
S-UNITS 1452 +

Rev.date 06.Dec.2022 Verif. PORT & STBD SIDE p. 6

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

11 11
K103 K104
11 11
K101 K102 6.6
12
6.6
12
6.1 6.2
12 12

21 22

X1 19 20

PORT BRAKE NOT OFF STBD BRAKE NOT OFF

(=SIGNAL) (=SIGNAL)

6 8
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BERG PROPULSION
Desig. FNE
CUSTOMER SIGNALS 1452 +

Rev.date 06.Dec.2022 Verif. p. 7

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

X1 1 2 3 4 5 6 7 8 9 10
+24VDC

BLACK

BLACK
0V

REMOTE ACTIVATE
PORT BRAKES

REMOTE ACTIVATE
STBD BRAKES

BLUE

BLUE
POWER
SUPPLY

1 2

1 2 1 2

VALVE VALVE
Pos.1V1 Pos.1V2

7 9
Date 08.Maj.2014 =
BERG PROPULSION
Desig. FNE
FIELD WIRING 1452 +

Rev.date 06.Dec.2022 Verif. COMPACTUS p. 8

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

X1 11 12 13 14 15 16 17 18 X2 1 2 3 1 2 4 X3 1 2 3 1 2 4

1 2 3 4 1 2 3 4 1 2 3 1 2 3 1 2 3 1 2 3

5 6 7 8 9 10

1 2 3 1 2 3 1 2 3 1 2 3

1 2 3 4 1 2 3 4

+ - N0 + - N0 + - N0 + - N0

X2 1 2 3 4 X3 1 2 3 4

CABLE BETWEEN CABLE BETWEEN

COMPACTUS AND S-UNIT COMPACTUS AND S-UNIT
PROXIMITY SWITCH PROXIMITY SWITCH PROXIMITY SWITCH PROXIMITY SWITCH
PORT SIDE STBD SIDE
2S1 2S2 3S1 3S2

8 10
Date 08.Maj.2014 =
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Desig. FNE
FIELD WIRING 1452 +

Rev.date 06.Dec.2022 Verif. p. 9

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S-SYSTEM DELLNER BUBENZER 10 p.
 0 1 2 3 4 5 6 7 8 9

X1 19 20 21 22

PORT BRAKE STBD BRAKE

STATUS STATUS
(SEE PAGE 7) (SEE PAGE 7)

9
Date 08.Maj.2014 =
BERG PROPULSION
Desig. FNE
FIELD WIRING 1452 +

Rev.date 06.Dec.2022 Verif. CUSTOMER SIGNALS p. 10

Revision Norm
S-SYSTEM DELLNER BUBENZER 10 p.
Brief operation manual
for pneumatically operated hydraulic pump type LP
acc to D 7280 and D 7280 H

1. Pneumatic and hydraulic connection

Pressure medium Driving component Compressed air prepared with usual commercial maintenance devices;
and pressure (air side) Operating pressure pL = 1.5 ... 10 bar
Water content in the air conforming ISO 8573-1 class 2 (3)
Pump component Hydraulic oil 10 ... 68 mm²/s (ISO VG 10 to VG 68 as per DIN 51 519)
(hydraulic side) Viscosity range appr. 4 ... 1500 mm²/s, opt. operat. appr. 10 ... 500 mm²/s
For perm. hydraulic pressure phydr. see D 7280 (H)

Maintenance unit Commercially available maintenance devices, consisting of air filter (filter cartridge approx. 5[m) with
water separator, pressure control valve (press, reducer), oiler and manometer are required for perfect
preparation of compressed air and safe functioning of the pumps (see sect. 4)

Recommended size of Type LP 80 LP 125 LP 160

the maintenance unit Norm. flow % lpm 800 1600 2500

Temperatures Compressed air: +5 ... +40°C

Ambient: -10 ... +40°C
Hydraulic fluid: 0 ... +80°C (see also sect. 5)

2. Characteristic curve 1.4

Guideline figures for the pump delivery and pressure in dependance on the pneumatic pressure.
The guidelline figures for the air consumption are based on standard conditions.

2.1 Size LP 80

Standstill pressure

O Basic Perm. pressure rating max.

pr per type
es at Standstill Corresp. pneum.
r
ba

su ing
re a pressure (bar) pressure (bar)
L 6

p ir
p

L 7
Hydraulic operating pressures pHy (bar)

at

ba 8 700 7.1
n
io

r
pt

LP80- 10 630
Air consumption Qair (lpm)
um

1)
ns

12 430 10
co
r

16 240
Ai

pL = ppneum.

1) This reduced max. permissible pressure rating

for the standard version is caused by the com-
mon pressure outlet port P. This also applies to
hydraulic power packs acc. to D 7280 H

Delivery flow Q (lpm)

HAWE Hydraulik SE B 7280

STREITFELDSTR. 25 • 81673 MÜNCHEN Operation manuel pump LP

© 2001 by HAWE Hydraulik November 2001-03

B 7280 page 2

2.2 Size LP 125

Standstill pressures

2) Basic Perm. pressure rating max.

1)
type

Op ess
Standstill Corresp. pneum.

pr

r
er ure

ba
at
pressure (bar) pressure (bar)

L6
ing p L

p
Hydraulic operating pressures pHy (bar)

at
air 7 ba
8 700/(1500) 2) 2.9/ (6.2) 2)

n
io
pt
10 700/(1500) 2) 4.5/ (9.7) 2)

m
1)

su

Air consumption Qair (lpm)

12 700 6.5

on
rc
Ai
LP125-16 600

1)
18 470
20 380 10
25 240
30 160

pL = ppneum.

1) This reduced max. permissible pressure

rating for the standard version is caused by
the common pressure outlet port P. This
also applies to hydraulic power packs acc.
to D 7280 H
2) For the max. permissible pressure for version
..-8E and ...-10E (without piping)

Delivery flow Q (lpm)

2.3 Size LP 160

Standstill pressures

Basic Perm. pressure rating max.

2) type
Standstill Corresp. pneum.
Op ess
pr
er ure

pressure (bar) pressure (bar)

at

r
ba
in p L
g

8 700/(1500) 2) 1.8/ (3.8) 2)

Hydraulic operating pressures pHy (bar)

L6
air 7 b

p
at

10 700/(1500) 2) 2.8/ (5.9) 2)

d

Air consumption Qair (lpm)

an
ar

1) 12 4
em
rd

LP160-16 700 7.1

Ai

2)
18 9.2
1) 20 620
25 390 10
1) 30 265

pL = ppneum.

1) This reduced max. permissible pressure

rating for the standard version is caused by
the common pressure outlet port P. This
also applies to hydraulic power packs acc.
to D 7280 H
2) For the max. permissible pressure for version
..-8E and ...-10E (without piping)

Delivery flow Q (lpm)

 B 7280 page 3

3. Mounting instruction
Installation position like illustrated in the dimensional drawings (i.e. suction ports down, pressure ports and muffler up) as this
eases automatic bleeding of the hydraulic pump elements. A lateral or downward orientation is also possible, see sect. 3.2.2).

3.1 Installation in customer-furnished oil tanks

Note torque of fastening screws

(sections 3.2.3)

Oil level at max.

priming volume

Oil level after max.

withdrawal during
operation

Volume superseding:
Tank bottom LP 80.. appox. 0.9 l with fluid level distance h , 15 - 20 mm to the mounting area
LP 125.. appox. 2.2 l with fluid level distance h , 20 - 25 mm to the mounting area
LP 160.. appox. 3.1 l with fluid level distance h , 25 - 30 mm to the mounting area

3.2 Installation outside an oil tank

Position the pump in such a way that the oil level is always within the area of the upper half of the pump or higher. The pump should
not be installed at a position where it is permanently above the fluid level. This would involve use of foot valves to prevent the
suction pipe from running emty during prolonged stand-still periods. Place the opening of the return pipe below the lowest
expected oil level. The suction pipes must be well sealed (see also section 5.3).

3.2.1 Usual arrangement, with pump in factory adjusted original condition

Two possible fastening methods (for fastening thread, see section 3.2.3)

Hanging position, using fastening thread B 1; Side position, using fastening thread B 2
note torque (sect. 3.2.3)

Spacers between
tank and pump

Return pipe

Two suc-
tion pipes Example:
Suction pipes made from pre-
cision pipes, connected with
Tubing pipe fittings
Dirt strainer. e.g. wire grating with
mesh size approx. 0.6 ... 0.8 mm
B 7280 page 4

3.2.2 Silencer position horizontal or downward

While taking into consideration the best position for the suction pipes, or in special operating circumstances as in sect. 5, the pump
cylinders can be turned by 90° in to different positions after loosening the screws ».
Restriction for LP 80: The pump can only be installed laterally like in illustration a) as complete unit (state of delivery). It is not pos-
sible to rotate the hydraulic cylinders in relation to the pneumatic cylinder. The other installations like illustration b or below are not
possible due to design reasons.

Pump position with horizontal suction connection Pump position with suction connection
a) Pump, as assembled by HAWE entering vertically from bottom to top
Pump mounted with cylinders turned by 180°

Distance
plates for wall
spacing

Two suc-
tion pipes

b) Pump mounted with cylinders turned by 90°

Spacers be-
tween tank
Suction and pump
pipes to
oil tank
Suction pipes
to oil tank

Spacers between
tank and pump

3.2.3 Dimensions for mounting and piping

Fastening thread Max. torque Compressed Pressure Suction

B1 B2 (Nm) air connection port port (BSPP)
(BSPP) P1/P2 (BSPP)

LP 80 M8,15 deep M6,12 deep 19 G 1/4 G 1/4 G 3/8

LP 125 8-16 M8,15 deep M6,12 deep 23 G 3/8 G 1/4 G 1/2

18-30 G 3/8

LP 160 8-16 M8,15 deep M8,15 deep 23 G 1/2 G 1/4 G 1/2

18-30 G 3/8
 B 7280 page 5

4. Compressed air connection and initial operation

Source of com- Pressure gauge to de-
pressed air termine consumer end
5 [m pressure

Maintenance 3/2-way valve 1) with stan- Pump

unit dard rated flow as mainte- LP 80..,
nance unit, for starting and LP 125 .. or
stopping the pump with re- LP 160..
lief of the pump-side com-
pressed air supply pipe Pressure pipe
to consumer

1. Set the pressure reducing valve on the maintenance unit to the lowest supply air pressure (approx. 1.5 bar). The air start valve
should be on stop.
2. Loosen the pressure pipe at the consumer sufficiently so that enclosed air can escape. Open the air start valve and wait for the
oil to come.
3. Air start valve on stop. Tighten the pressure pipe, and after starting the pump again, pressurize the unloaded consumer several
times and move it to and fro. Then turn the pressure reducing valve up as in 1 to required supply air pressure (step by step if
necessary), unit the desired end pressure, e.g. standstill pressure, is shown on the manometer of the pressure pipe to the
hydraulic consumer.
The maintenance unit in the compressed air supply pipe is obligatory, since it alone ensures smooth operation by filtering, mois-
ture separation and oil ing (= preperation of compressed air). It has a pressure reducing valve to limit the air pressure, which is
necessary on the hydraulic side to fix the standstill pressure.
Attention: Observe the max. air pressure rating for air pumps piped by HAWE!
A pressure reducing valve has to be used when the pump is supplied via compressed air cylinders. The pumps type LP
do not feature any pressure valve on the pneumatic side!

Any industrial standard hydraulic oil (ISO VG 10) or spindle oil

(ISO VG 5 to 10) may be used in the pneumatic maintenance unit.
The dynamic seals of piloting and main plunger of the reversal
; > control valve should be lubed regularily when connected to
= oil-free pneumatics and frequent every-day use is intended.
Suited are longterm lubes e.g. Autol TOP 2000 from Co. Autol,
Paradiesstraße 14, D-97080 Würzburg.
The maintenance intervalls depend on the indivdual operation
conditions e.g. a 3-4 month interval for 3-shift permanent operation.
See also notes in sect. 5

< ;
=

?
>
@ ; Remove cover plate including O-rings.
< Push out the main plunger (any side) the sleeve remains in the
housing.
Lube the visible sections of the O-rings.
Reinstall the plunger in the housing (sleeve).
= Reinstall the cover plate including O-rings.
> Remove the tapped plugs including the copper seal rings. 1) Industrial standard pneumatic reducers
can be installed at port L, if the thread of
? Push the piloting plunger (any side) out of the housing.
port A at the pneumatic directional valve
Lube the visible sections of the O-rings.
and port L at the air driven pump type LP
Reinstall the plunger in the housing.
are differing. The largest possible diameter
@ Reinstall the tapped plugs including the copper seal rings. for the air line should be used always.
B 7280 page 6

5. Supplementing note for prolonged operation periods

Any pressurized gas (or gas mixture) will cool down due to the thermodynamic regularity, when decompressed suddenly
(adiabatic). This will cause also cool down of the surrounding material where the decompression happens and where the gas is
routed through. The stand still periods during normal usual working cycles are usually sufficient that these components come to
ambient temperature again.
But white frost or internal icing may occur (dep. on the moisture in the compressed air), when the pump is running for prolonged
periods. This effect is also visible at other pneumatic tools where the working speed is cut down and even stand-still is caused by
iced control elements. Pumps type LP are prone to such malfunction when permanently operated for more than 20 minutes and
air pressure is higher than 4 bar. A good preventive measure is adding anti-freeze-lubricant (like for truck brakes) in the service unit
of the compressed air. This will cut down the freezing point and will additionally lube the dynamic (moving) seals on the pneumatic
side of the pump. It is advantageous to install the pump with the silencer directing sideward or downwards as any excess antifreeze
condensing at the silencer will drop down and not drip into the movement reversal valve again. Evidently this is not possible with
complete hydraulic power packs from HAWE as the silencer is always vertically upwards.
Freezing of the pump components may happen when the air to drive the pump is too cold (below the perm. temperature range).
This may happen especially when cylinders are used as source but also when the pump is running over prolonged periods, as
compressed gases cool down strongly, when decompressed.
A recommended anti-freeze-lubricant is e.g. „Klüberbio LR 6-15“ from Co. Klüber Lubication, D-81379 München, Geisenhausenerstr. 7.

5.1 Optional leakage drain with type LP 125 and LP 160

A drain line is necessary, when the pump is installed outside the tank
and any leakage (drops only) are not permissible or unwanted, e.g.
due to clean room conditions etc.

The manual emergency actuation of

the piloting valve may be pushed alter-
nately inward when start-up problems
do occure (tool diameter max. 3 mm).

;> >;
Union pipe

<
<
=
Drain line to the tank

The line consists of:

; 3 Hose nipple 6020 070
< 2 Hose 6020 077 a
= 1 Hose clamp T-PK-4 (FESTO)

; > 3 Seal ring A 6x10x1 DIN 7603-Cu

>
 1(2)

BEDDING-IN PROCEDURE FOR DELLNER DISC BRAKES

General
In order to achieve the optimum performance from Dellner disc brakes for a
particular application, it is important that the interface between the brake pads and
the disc be properly bedded or burnished.

The bedding-in of the pads with the disc is generally a two step process. The first
step is to get the entire surface of the brake pads in full contact with the disc. Next is
to generate more and more heat between the pads and disc to burn off loose
particles of friction material and remove high spots from the pad surface.

Preparations
Before starting the process, check to be sure that the brake pads and the disc are
clean and dry. If the pads are contaminated with oil, it may be necessary to replace
them. Oil soaked pads will not provide the rated capacity of the brake. If the disc is
dirty with grease or oil, clean the surface with a solvent that leaves no residue. If the
braking area of the disc is rusty, clean it with a fine grade of abrasive paper and
remove the dust with a clean cloth and solvent.

Process time
The time required for the bedding process will vary depending of the severity of the
required braking duty. This can best be determined on the job site based on the
observed performance of the brake pads during the conditioning process.

Brakes that will be engaged frequently under dynamic conditions must first be
worked lightly to insure that the high spots are removed from the pads and that full
contact with the disc is achieved.

Pressure applied brakes

For pressure applied brakes, first apply 10% to 15% of the full pressure and allow the
unit to slip against the rotating disc until the surface reaches approximately 100 C.
Stop and allow the disc to cool. Slowly increase the pressure and slipping time until
the disc surface reaches approximately 200 - 250 C. (For the maximum
continuous operating temperature for the friction material being used - see Dellner
Bubenzer Technical Specification manual TS0001.)

Allow the disc to cool to near ambient and repeat the process until full rating of the
brake is achieved.

If the disc surface starts to glaze showing shiny deposits of friction material on the
AI04-011E-04

disc surface, reduce the pressure and/or disc speed and progress more slowly to full
brake capacity. Remove any glazing from the disc surface with a fine grade of
abrasive paper.
DELLNER BUBENZER AB Tel: Org.nr/VAT no: Internet / e-mail:
Teknikergatan 1 023-78 30 50 556553-1299 www.dellnerbubenzer.com
SE - 781 70 BORLÄNGE +46 23 78 30 50 SE556553129901 [email protected]
SWEDEN
 2(2)

Spring applied, pressure released brakes

Spring applied, pressure released brakes require the same conditioning, but pressure
on the brake pads is increased by slowly reducing the applied pressure (back
pressure) until the maximum run-in temperature and design capacity of the brake is
reached.

Brakes used in light duty service may provide sufficient capacity without the run-in
procedure. This can be determined on the job site before the units are put into full
service.

After the run-in procedure, adjust the air gap for spring applied brakes to the
recommended minimum, inspect and clean the units and they are ready to be put
into service.

AI04-011E-04

DELLNER BUBENZER AB Tel: Org.nr/VAT no: Internet / e-mail:

Teknikergatan 1 023-78 30 50 556553-1299 www.dellnerbubenzer.com
SE - 781 70 BORLÄNGE +46 23 78 30 50 SE556553129901 [email protected]
SWEDEN
 Document Headline Page no.
INFORMATION Tightening torques 1 (of 4)
Issuer Date Document ID. Issue
Olle Karlsson 2021-07-01 908128-13-863 2

1. Introduction
The following document describes guidelines for recommended tightening torques in screw
connections (bolt joints) and guide pins.
Tightening torques on drawings refers to Technical Provision (TB) no. 323272, in which this
document is enclosed.

The information has been downloaded from:

http://www.mattssons.com/
Wednesday 2018-09-12.

This GUIDELINE DOCUMENT is reserved from manufacture updates.

2. General information
GF = ratio of yield point
µg = total friction friction
Oil = Loctite 8032 or equivalent (lubricant with PTFE)
Paste = Molykote 1000 or equivalent (lubricant with graphite and copper)
 Document Headline Page no.
INFORMATION Tightening torques 2 (of 4)
Issuer Date Document ID. Issue
Olle Karlsson 2021-07-01 908128-13-863 2

3. Torque and Clamp load guidelines for bolts

3.1 Electro zinc plated steel bolts
Oil
Grade
Gf= 0,75
8.8 µ= 0,1
Bolt Pitch Torque Clamp
size [mm] [Nm] load [kN]
M8 1 21 17,6
M10 1,5 40 27,8
M12 1,75 70 40,5
M16 2 169 75,4
M20 2,5 331 117,6
M24 3 572 169,4
M27 3 826 220,3
M30 3,5 1127 269,3
M33 3,5 1522 333,1
M36 4 1961 392,2
M39 4 2520 468,5
M42 4,5 3130 538,1
M48 5 4687 707,0
M52 5 6011 843,8

Oil
Grade Gf= 0,75
10.9 µ= 0,1
M8 1 28 24,7
M10 1,5 56 39,2
M12 1,75 98 56,9
M16 2 238 106,0
M20 2,5 465 165,4
M24 3 804 238,3
M27 3 1161 309,8
M30 3,5 1582 378,7
M33 3,5 2133 468,5
M36 4 2761 551,5
M39 4 3543 658,8
M42 4,5 4395 756,7
M48 5 6588 994,3
M52 5 8454 1186,7
 Document Headline Page no.
INFORMATION Tightening torques 3 (of 4)
Issuer Date Document ID. Issue
Olle Karlsson 2021-07-01 908128-13-863 2

3.2 Non-plated steel bolts

Oil
Grade
Gf= 0,71
12.9
µ= 0,125
Bolt Pitch Torque Clamp
size [mm] [Nm] load [kN]
M8 1 40 28,1
M10 1,5 79 44,5
M12 1,75 136 64,6
M16 2 333 120,4
M20 2,5 649 187,9
M24 3 1120 270,7
M27 3 1620 352,0
M30 3,5 2210 430,2
M33 3,5 2980 532,2
M36 4 3850 626,5
M39 4 4940 748,4
M42 4,5 6140 859,6
M48 5 9190 1129,5
M52 5 11800 1348,0

3.3 Stainless steel bolts

Paste
Grade
Gf= 0,65
A4-80
µ= 0,14
Bolt Pitch Torque Clamp
size [mm] [Nm] load [kN]
M8 1 24 14,3
M10 1,5 47 22,6
M12 1,75 82 32,9
M16 2 199 61,2
M20 2,5 388 95,6
M24 3 671 137,7
M27 3 696 179,0
M30 3,5 1320 218,8
M33 3,5 1780 270,7
M36 4 2300 318,6
M39 4 2950 380,6
 Document Headline Page no.
INFORMATION Tightening torques 4 (of 4)
Issuer Date Document ID. Issue
Olle Karlsson 2021-07-01 908128-13-863 2
4. Torque and Clamp load guidelines for Guide pins

4.1 Steel guide pins

Oil
All grades Gf= 0,75
µ= 0,1
Bolt Pitch Torque
size [mm] [Nm]
M10 1,5 40
M12 1,75 70
M16 2 169
M20 2,5 331
M24 3 572

5. Stainless steel guide pins

Paste
All grades Gf= 0,65
µ= 0,14
Bolt Pitch Torque
size [mm] [Nm]
M10 1,5 47
M12 1,75 82
M16 2 199
M20 2,5 388
M24 3 671
BULKHEAD SEAL
 Lagersmit
Postbus 176, 2950 AD Alblasserdam
Nieuwland Parc 306, 2952 DD Alblasserdam

T +31 88 0216 200

F +31 88 0216 249
[email protected]
www.lagersmit.com

SUPREME® BHW seals

Installation and maintenance manual

Date Reference Version Status

December 3th, 2015 BHW 1 Final

Order number : LS57151

Serial number of SUPREME BHW seal : X28811X - X28812X

Size : 200

Assembly drawing : X70200AA200E

Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 2 of 12

Table of contents
INTRODUCTION .................................................................................................................................................... 3
1 THE SUPREME BHW SEAL ........................................................................................................................... 4
1.1 General .................................................................................................................................................... 4
1.2 Equipment checks and precautions before installation ............................................................................. 4
1.3 Installation precautions ............................................................................................................................ 5
1.4 Placement of the SUPREME BHW seal ................................................................................................... 6
2 START-UP PROCEDURE / INSPECTIONS / MAINTENANCE ....................................................................... 8
2.1 Preparation and checks before use .......................................................................................................... 8
2.2 Regular inspections.................................................................................................................................. 8
2.2.1 Inspection of the rotor seals .............................................................................................................. 8
2.3 Maintenance ............................................................................................................................................ 9
2.3.1 Injection of lubrication oil in to the seal .............................................................................................. 9
2.4 Points of interest during overhaul ........................................................................................................... 10
3 DISASSEMBLY AND REPAIR OF THE SEALS ............................................................................................ 11
3.1 Disassembly........................................................................................................................................... 11
3.2 Repair .................................................................................................................................................... 11
APPENDIX A SERVICE & SPARE PARTS .................................................................................................... 12
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 3 of 12

INTRODUCTION

This manual gives guidance for the professional installation, maintenance and disassembly of SUPREME
BHW seals.

The instructions in this manual are accompanied, where necessary, by special symbols indicating particular
hazards.

: Danger to the body and/or health

: Danger to the product and/or other machines

These hazardous situations can arise when:

 Inadequately trained staff service the product;
 The product is inexpertly installed, maintained or disassembled;
 The product is used for purposes other than those for which it was originally designed.

In addition to the above hazard symbols, additional information is accompanied by the following symbol:

: Extra information

All persons responsible for installation, maintenance or disassembly of the product must:
 Be familiar with the contents of this manual;
 Possess adequate technical skills.

Although the information in this manual has been composed and verified as accurately as possible and the
descriptions are as clear as possible, no liability can be accepted for errors and/or deficiencies in the work
done during maintenance, installation or startup procedures.

This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may
not be made public or disclosed, copied or otherwise reproduced or used in any form or by any means, without
prior permission in writing from Lagersmit.

DOCUMENT HISTORY

Release date Version Comment

03-12-2015 1 Original issue

Table P.1 Document history

Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 4 of 12

1 THE SUPREME BHW SEAL

1.1 General

The SUPREME water tight bulkhead seal is a special design to create a safe sealing at the shaft transit. The
bulkhead seal design is based on the proven technology of the SUPREME shaft seals. The housing of the
bulkhead seals are axially split, which means that the housing can be mounted and de-mounted while the
shaft is already placed. Figure 1.1 shows an example of a complete SUPREME bulkhead seal.

Fig. 1.1 SUPREME BHW seal (Actual seal might differ slightly from this example)

The use of SUPREME BHW seals is only for sealing of bulkheads at shaft transits.

1.2 Equipment checks and precautions before installation

 All assemblies and components supplied by Lagersmit. have been carefully inspected before shipment.
 Each component is suitably packed and protected to prevent damage or deterioration during shipment,
transit or storage. Any specific storage or handling requirements will be clearly identified on the package.
 Goods should be examined on receipt to verify the contents and their condition.
 Lagersmit should be immediately advised of any damage or discrepancy in the range of products supplied.
Damage which is clearly caused by handling in transit should be notified to the carrier.
 Keep goods in their original packing until just prior to installation in order to protect them optimally. Pipe
fittings/connections will be protected with tape plugs; do not remove them until necessary, just before
installation.
 Care must be taken during handling to prevent any mechanical damage occurring due to dropping, crushing
etc., especially on products containing electronic components.
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 5 of 12

1.3 Installation precautions

The following precautions must be taken before commencing the installation of the SUPREME BHW seal:
1. Check the shaft for damage and contamination;
 Clear the shaft of deficiencies such as dirt and/or damage/burrs.
2. Check the goods for transit damage and for completeness;
 If transport damage and/or shortages is/are noticed, please contact Lagersmit.
3. Check the connection dimensions and tapped holes1;
 The connection must correspond with measures on the assembly drawing, for the sealing unit to be
fitted. If not, please consult Lagersmit.
 The thread in the tapped holes must be the correct size and the holes must be undamaged.
4. Check the squareness of the bulkhead in accordance to the shaft.
 For the minimum required squareness see fig. 1.2. This squareness is to be checked just outside the
PCD.

Fig. 1.2 Squareness bulkhead opposite shaft

5. Centring of the housing component:

 Arrange the housing components as shown in the assembly drawing.

1
Only if the taped holes are already machined. See also chapter 1.4 – figure 1.4
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 6 of 12

1.4 Placement of the SUPREME BHW seal

The placement of the SUPREME BHW seal must be carried out as shown in fig. 1.2

Fig. 1.2 Placement of the SUPREME BHW seal (Actual seal might differ slightly from this example)

1. The Rotor seals (5) must be placed by a service engineer of Lagersmit around the shaft;
 Make sure that the direction of the rotor seals is correct. The “noses” of the rotor seals must be directed
to each other.

Placing SUPREME rotor seals around the shaft demands specialist skills / tools and
therefore needs to be done by a service engineer of Lagersmit or by a service engineer of
a service station recognized by Lagersmit

2. Put the locking chain (6) over the rotor seals (5);

3. Make a dovetail shaped cut in the gaskets (2) and place the gaskets around the shaft as shown in fig. 1.3;
 The gasket may be placed against the bulkhead using grease.

Fig.1.3 Gasket with a dovetail cut

Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 7 of 12

4. Place the gasket (2) against the bulkhead;

5. Assemble the divisible housing (1) over the rotor seals (5);
 Use therefor the HSH screws (1a) and dowel pins (1b).
 The surface of the division have to be sealed with a silicone sealant as shown in fig. 1.4

Fig. 1.4 Sealing of division

6. Mark the position of the mounting holes according fig. 1.5

 Pay heed to the mounting measurement of 5 [mm].
 Pay heed to the correct positioning of the plugs, see the assembly drawing.

Fig. 1.5 Marking the position of the mounting holes

7. Fit the bulkhead seal against the bulkhead using plain washers (4) and HSH screws (3) according fig. 1.5
 Pay heed to the correct positioning of the gasket (2) and HS plugs (7 and 8), see the assembly
drawing.
 Tighten the opposing HSH screws evenly.

Fig. 1.5 Mounting of the SUPREME BHW seal

8. Inject the seal with lubrication oil;

 See section 2.3.1
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 8 of 12

2 START-UP PROCEDURE / INSPECTIONS / MAINTENANCE

2.1 Preparation and checks before use

No special actions have to be taken to put the SUPREME BHW seal into operation.

2.2 Regular inspections

2.2.1 Inspection of the rotor seals

1. Remove the HS plug (7) of the inspection hole;

Fig. 2.1 Inspection hole.

2. Check visually if there isn’t any damage to the rotor seals;

 In case of damage, the rotor seals have to be replaces by a service engineer of Lagersmit.
 Turn the shaft in order to inspect the complete seal.

3. Check the position of the rotor seals (5) and the locking chains (6);
 The lips of the rotor seals have to be laying against the housing, according fig. 2.2

Fig. 2.2 Correct position of the rotor seals and locking chains.

4. Re-install the HS-plug (7) of the inspection hole;

Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 9 of 12

2.3 Maintenance

For safety reasons it is not allowed to turn the shaft during activities at the bulkhead seal.

The maintenance consists of injecting a small amount of lubrication oil in the bulkhead every three months.

2.3.1 Injection of lubrication oil in to the seal

1. Remove the HS plugs (7 and 8) of the inspection hole and drain;

Fig. 2.3 Position of the plugs.

2. Collect thin lubrication oil;

3. Re-install the HS plug (8) of the drain at the bottom;

4. Inject the seal with a lubrication oil of very low viscosity2;

 Inject the bulkhead seal with a maximum quantity of approximate 5 [cc] a time. Especially the inside
lateral surfaces have to be injected.

5. Re-install the HS plug (7) of the inspection hole at the top;

2
Only a silicone lubrication oil with a viscosity of 5 to 10 cSt. At 40°C may be used!
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 10 of 12

2.4 Points of interest during overhaul

The Rotor seals can be replaced without withdrawing the propeller shaft.

In the event of repairs, Lagersmit recommends renewing the lip seals and other “soft”
materials such as gaskets.

Overhauling SUPREME seals demands specialist skills / tools and as such needs to be done
by a service engineer from Lagersmit or by a service engineer from a service station
recognized by Lagersmit.
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 11 of 12

3 DISASSEMBLY AND REPAIR OF THE SEALS

This chapter describes the actions that may be necessary during disassembly and/ or repair of the seals.

While work is being done on the seal unit, the shaft must not be powered up.

Fig. 3.1 SUPREME BHW seal (Actual seal might differ slightly from this example)

3.1 Disassembly

To disassemble the SUPREME BHW seal, the following instructions must be followed:

1. Remove the HSH screws (3) and sealing rings (4) which fix the seal to the bulkhead;

2. Remove the HSH screws (1a) which fix the divisible housing (1) to each other;

Beware of the fact that the housing is divisible

3. Remove the locking chains (6);

4. Remove the rotor seals (5) and gasket (2);

 Cut though the lip seals with a knife.

3.2 Repair

Depending on the nature of the fault, the SUPREME seal unit may be repairable. This will primarily be the
case with replacement of those parts that are subject to wear.

In the event of repairs, Lagersmit recommends renewing the rotor seals and other “soft”
materials such as gaskets.
Date Reference Version Status Page
December 3th, 2015 BHW 1 Final 12 of 12

APPENDIX A SERVICE & SPARE PARTS

Lagersmit offers an appropriate spare parts service. If necessary, the Lagersmit Service Engineers are
available to deliver service where needed worldwide.

To ensure that the correct parts are supplied, the following information must be provided on the order:
 The information on the data sheet of this manual
 Description of the required parts
 Part number and/or code number of the required parts
 Quantity, desired delivery time and delivery details for the parts required

In addition to the required information for ordering spare parts, the following information should be provided
when ordering a service engineer:
 Desired starting date.

Orders for spare parts and/or a service engineer should be addressed to:

Lagersmit
P.O. Box 176
2950 AD Alblasserdam
The Netherlands

Telephone : +31 (0)88 0216 200

Service telephone : +31 (0)88 0216 300 (available 24/7)
Fax : +31 (0)88 0216 249
E-mail : [email protected]
Website : www.lagersmit.com
 REV DESCRIPTION NAME DATE
A 25-nov-2022
SECTION A-A (1:2) Original issue RVDVEEN

13 11 10 A
9°
Upon final assembly in the vessel, )
seal thread pos. 3 with loctite thread sealant. 8° (20x
1

n 0,5 A

5 Mounting measurement
4

2 1 3
2 2 , 5°

45
Inspection hole

°(
8x
Ra 0,8
A

)
P
45°
5 Partition

Shaft O 200
0
-1

O 525

O 325
O 600

Partition 10°

Maintenance instructions:
- Remove plug item 7 and item 8 (filling and drain);
Drain - Collect thin lubrication oil;
81 15 8 - Mount plug item 8 (drain);
- Every three months: Inject approximately 5 [cc] thin lubrication oil
into the bulkhead seal, especially on the inside lateral surfaces;
- Mount plug item 7 (filling);
- Spray a little bit of thin lubrication oil on both sides of the seal,
the shaft/liner ( Ø200) and against the lip seals;
- Repeat last procedure every three months;

- Roughness shaft 0,8 [um]

12 - Axial shaft movement max. ~ 30 [mm]
- Radial shaft movement max. ~ 4 [mm]
23 A - Squareness bulkhead opposite shaft < 0,5 [mm]

Static water pressure max. 2 [bar]

PCD. 300
13 20 Nut M20 D934 Steel 8 00185165
PCD. 560
12 20 HH Screw M20x60 D933 Steel 8.8 00141940
11 1 Gasket Bulkhead Passage NBR70 GBP5602022
10 1 Bulkhead passage S235J2 BP0600200
9 1 Name Plate Bronze 46255006
PARTITION VIEW (1:1)
8 1 HS Plug R3/8 DIN 906 A4 00602117
VIEW P (1:1) 7 1 HS Plug R1 DIN 906 A4 00602122
6 2 Locking chain Steel 46268950 L= 675 mm
5 2 Lip seal 200 NBR80 36261404
4

4 8 Plain washer M12 AISI304 00350210

4 [mm] clean 3 8 HSH Screw M12x100 - D912 A4-70 00252748
(no locitite silicone blue)
4 2 1 Gasket 200 AFCF 46268906
4

9 1 1 Housing 2/2 200 Aluminum HB070200-200

POS QTY Description Material Art. / DRAWING No REMARKS
This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any form or by
any means, including but not limited to use hereof for the design and manufacturing of identical or similar parts or products, without prior permission in writing from Lagersmit.
DRAWN RVDVEEN General tolerances acc. ISO 2768-mK
Shape and position tolerances acc. ISO 1101
DRAWN DATE

APPR.
25-nov-2022
CBOER LAGERSMIT Roughness Ra according ISO 1302
REF. DR:
THE ORIGIN OF SEALING SOLUTIONS
REMARK: APPR. DATE 16-jan-2023 -
Partition surfaces to be sealed REF. - TITLE: DRAWING NO.: REV.

with loctite silicone blue (See partition view) MATERIAL: SUPREME BHW-200 X70200AA200E A
MASS: 54,4 kg
Bulkhead seal assembly PROJ.: SCALE: UOM:
STATUS:

60 Shaft dia 200 1:1 (1:2) mm A1

SHAFT EARTHING
DEVICE
DRAWING TITLE DRAWING & INSTALLATION / OPERATION MANUAL

ITEM SHAFT EARTHING DEVICE

CLIENT BERG PROPULSION

PROJECT No. 7634M

K.C. LTD. REF. No. KS129479

K.C. LTD. MODEL. No. CATHSED

0 ORIGINALLY PREPARED H.M.K. NOV.22,22

REV DESCRIPTION DWN. APP. DATE

K.C. LTD. CAUTION

165, Mieumsandan 3-ro, THIS DOCUMENT CONTAINS CONFIDENTIAL
AND PROPRIETARY INFORMATION OF
Gangseo-gu, Busan 46744, Korea K.C. LTD.
THIS DOCUMENT ALWAYS REQUIRES PRIOR
Tel : +82 51 250 2830~35, 2840~43 WRITTEN CONSENT OF K.C. LTD.
FOR
Fax : +82 51 831 7726 (1) ITS REPRODUCTION BY ANY MEANS,
(2) ITS DISCLOSURE TO A THIRD PARTY,
(3) ITS USE FOR ANY PURPOSE OTHER THAN
E-mail : [email protected] THOSE FOR WHICH IT IS SUPPLIED
Web : http://www.iccp-mgps.com
 Shaft Earthing Device
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REV.7 : jun.09,22

INDEX
Description Page No
1. Specification & Scope 3
2. Introduction 4
3. Design base 5
4. Installation work by shipyard 5
5. Installation 5
6. Operation 10
7. Maintenance and service 11
8. The life time of brushes 11
9. Trouble shooting 12-13
<Drawings>
- General arrangement of shaft earthing device (DA-PSH) 14
- Detail of analog mV-meter 15
- Detail of Pan spring brush holder (DA-PSH) 16
- Detail of Shaft slip ring 17

K.C. LTD.
165, Mieumsandan 3-ro, Gangseo-gu, Busan 46744, Korea
Tel : +82 51 250 2830~35, 2840~43 Fax : +82 51 831 7726
E-mail : [email protected] Web : http://www.iccp-mgps.com

CATHSED○R K.C.LTD.
 Shaft Earthing Device
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1. Specification & Scope of supply

SHAFT Q’ty / SHIP 1 SET SLIP RING Q’ty / SHAFT 1 SET
INTERMEDIATE
Ø 200 TOTAL WEIGHT APPROX. 11.0 kg
SHAFT DIAMETER
Q’ty PART NO DESCRIPTION SKETCH

1 KCS0044 ANALOG mV-METER WITH CABLE GLANDS

3 KCBDA HIGH DENSITY SILVER GRAPHITE BRUSH

1 KCDHDA DOUBLE BRUSH HOLDER FOR EARTHING

1 KCSHDA SINGLE BRUSH HOLDER FOR MONITORING

1 KCS009 BRUSH HOLDER SUPPORT BAR

1 KCS010 INSULATED BRUSH HOLDER SUPPORT BAR

1 KCSEBDA SHAFT EARTH BENDING BAR

1 KCS005 SILVER ALLOY SLIP-RING

2 KCS011 STAINLESS STEEL BAND

1 KCS0151 PRESSURE TAPE (50mm, 2”)

1 KCS015 PRESSURE TAPE (19mm, 3/4”)

WARRANTY The system will be guaranteed against defective component design, workmanship and
material for a period of 12 months after delivery of ship or 24 months after delivery of
the goods, whichever is earlier.
We reserve the right to incorporate improvement in system design, without prior notice,
in the period between submission of this memorandum and confirmation of order. The
system will be supplied complete with all necessary instrumentation but cable, cable trays
etc., to interconnect the various components will be supplied by the shipyard.

CATHSED○R K.C.LTD.

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2. Introduction

A turning propeller shaft on a ship becomes electrically insulated from the hull by the lubricating oil
film in the bearings and by the use of non-metallic bearing materials in the tail shaft. When the
shaft is insulated in this way an electrical potential can be measured between the shaft and the
hull and this can accelerate corrosion in the ship.
If the ship has a system of cathodic protection, whether it is sacrificial anode or an impressed
current system, the shaft insulation will prevent the propeller and the boss from receiving
protection.

The electrical potential between the shaft and the hull can also cause a heavy current to flow in
bearings when the oil film breaks down or is contaminated with seawater. This current can cause
deep pitting of the bearing surface. Excessive wear on the shaft bearings can often be traced to
this cause.

Now in addition it’s necessary to reduce the spark erosion causing the excessive wear on main
engine metal bearings and this shaft earthing is the most appropriate method.

All the troubles can be avoided and cathodic protection can be extended to the propeller if the
shaft is properly earthed with a propeller shaft slip ring. The effectiveness of the shaft earthing
system should ensure a maximum contact resistance of no greater than 0.001 ohms.

Our own tests indicate that high silver content brushes running on a silver track have repeatable
low conductivity that can maintain these limits and ensure a low resistance contact is maintained
even under dirty conditions.

The shaft earthing assembly comprises a pair of high silver content / graphite compound brushes
mounted in balanced brush holder, running on a silver alloy slip ring.

Each brush holder has an adjustable spring tensioner which is supplied preset to the standard
pressure. At this pressure the expected life of the brush is approx. one year.
Do not adjust a spring tensioner without any approval from K.C.LTD.

CATHSED○R K.C.LTD.

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3. Design base

- Intermediate shaft diameter : Ø 200 mm

4. Installation work by shipyard

- Assembling the intermediate shaft earthing assembly

- Fixing the analog mV-meter & wiring
- Welding the brush holder support bar on the mounting post & Assembling the brush holder
- Fixing the shaft earth bending bar to support bar and double brush holder by bolting
tightly

5. Installation

5.1. Weld the mounting post(s) nearby shaft where slip ring is installed.
5.2. Weld the support bar(s) carefully on mounting post according to the drawing. (Dwg No.
SDAPSH03)
5.3. Slip ring

CAUTION : It is strictly required to install slip ring correctly according to following procedure for
the good performance of shaft grounding and longer life time of brushes.

5.3.1. Make clean the area where slip ring is positioned

(Use cleaning products for metal surface and do not use cleaning products which
contain oil constituent.)
The area should be cleaned and prepared for a bright bare steel.

KEEP CLEAN

SHAFT

Approx.130mm

CATHSED○R K.C.LTD.

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5.3.2. Fasten stainless steel bands (A & B) around the shaft temporarily.
BAND (A) BAND (B)
130mm

SHAFT

KEEP CLEAN

5.3.3. Put the slip ring (width: 70mm) around the shaft.
Fasten the slip ring around the shaft by tightening the stainless steel band (B)
temporarily.
Mark the overlapped part and move stainless steel band (B) next to the slip ring
after loosen the stainless steel band (B).

BAND (A) BAND (B)

SHAFT

Cut the overlapped part at an angle of 45o carefully, which is very

important job.

CATHSED○R K.C.LTD.

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After cutting properly rub both edges of inner surface of slip ring with a proper file.
If the edges are cut perfectly, don’t need to rub both edges of inner surface of slip
ring. Then secure slip ring very tightness around shaft;

5.3.4. Fasten the slip ring around the shaft by tightening the stainless steel band (B)
again. When the slip ring is tightly installed no protrusion or gap is found.
In case there happens with protrusion or gap smoothly rub the protrusion with a
proper file.
BAND (A) BAND (B)

SHAFT

5.3.5. Fasten both edges of slip ring with 3/4”(19mm) pressure tape for a preparation of
tight fastening of stainless steel band.
Apply the tape to the slip ring three times at the opposite direction of the shaft
rotation.

① First 1 layer

CATHSED○R K.C.LTD.

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② Second 2~3 layer

5.3.6. Fasten the stainless steel band(A) over the pressure tape by tightening the fixing
bolt around the edge of slip ring.

5.3.7. Fasten the stainless steel band(B) over the pressure tape tightly by tightening the
fixing bolt around the edge of slip ring.
After tightening bands (A, B), bend the end part of band to the opposite direction
to prevent loosening when the shaft rotates.

CATHSED○R K.C.LTD.

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5.3.8. Apply 2”(50mm) pressure tape over both stainless steel bands (A & B) at the
opposite direction of the shaft rotation finally. Keep the minimum 30mm width of
slip ring where brushes run.

5.4. Brush holder

5.4.1. Carefully study the drawing for correct installation and keep the distance of 3mm
between bottom of brush holder and slip ring surface. Also keep the distance
between center of support bar and slip ring surface acc to the shaft outdia. (Refer
to the drawing ‘SDAPSH03’)

5.4.2. Fit the brush holder to the support bar and align the assembly so that the brushes
are able to run centrally on the slip ring, and the brush holders assembly is to be
clear of the slip ring securing brackets when the shaft rotates.
And shaft earth bending bar to be tightened properly on the double brush holder
and end of support bar.
Secure the assembly in this position by tightening the hexagon headed bolt at the
top of the brush holder body.

5.4.3. The support bar for double brush holder should be connected to the hull electrically.
So the mounting post supplied by shipyard should be welded on the hull plate. The
touched mounting post surface should be galvanized to ensure metal touch in case
the mounting post will be installed by bolting.

5.4.4. No any insulation tape, tube, paint should be applied on the double brush holder
and support bar.

CATHSED○R K.C.LTD.

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REV.7 : jun.09,22

5.5. Analog mV-meter

5.5.1. The system comprises a bulkhead mounted panel that incorporates terminals and a
gauge meter. The system is self contained and requires no external power supply.

5.5.2. For ease of interpretation the gauge meter is scaled up to 150mV.

As the gauge meter reading rises above 80mV it is recommended that the slip ring
and brushes be checked and cleaned.

5.5.3. The contact point of earth cable of the analog mV-meter should be free from paint.

5.5.4. To prevent noise, the signal cable should be arranged separately with any other
power cables.

6. Operation

6.1. The analog mV-meter normally reads 150mV full scale.

6.2. Reading of below 80mV when shaft is turning at sea indicate proper grounding. If
readings are above 80mV, clean the faces of slip ring and brushes with a clean cloth.

6.3. The analog mV-meter will read '0' when shaft is at rest because of the current entering
the propeller will return to the hull through main engine bearings and engine foundation.

6.4. Check according to troubleshooting in case the analog mV-meter reading is '0' when shaft
is turning at sea.

CATHSED○R K.C.LTD.

- 10 -
 Shaft Earthing Device
Shaft Earthing Device Documents
REV.7 : jun.09,22

7. Maintenance and service

7.1. This grounding assembly should be checked at least twice a week for cleanliness.

7.2. If there has been a build-up of oil, dirt, scale and rust on the slip ring face or between slip
ring and shaft, this should be removed with a degreaser, emery paper and clean cloth.

7.3. Inspect and clean the brushes and brush holder to prevent their moving due to dirt build-
up. Inspect the brush copper leads (pig tails) to ensure they have not become loose or
corroded. The brush wear-down should be noted.

7.4. At the time of every dry dock, disassemble the slip ring and clean the surface of the shaft
right thereunder.

8. The life time of brushes

8.1. The brushes are getting worn out by metal touch with slip ring.
Therefore it’s strictly required to keep clean and smooth surface of slip ring, also to carry
out proper installation / alignment of brush holders as per our manual and drawing.
Otherwise it’s very hard to obtain the proper earthing and the proper life time of brushes.

8.2. The brushes are consumable parts with wearing ratio approximately 2~3mm per 1,000
hours shaft rotation under proper installation. The replacement time is shown by
engraving the line (15mm from the top) on the brushes.
Customer is requested to replace brushes with spares when the time comes.

8.3. Brushes are consumable parts as stated above and they are often consumed earlier but
it’s not a matter of guarantee claim for supplying extra brushes.

8.4. Use only our genuine silver graphite brushes for longer life and higher earthing efficiency.
Contact K.C. LTD. for purchasing and indicate part number.

CAUTION
Customers are recommended for the purchase of genuine spare parts as imitated parts
make the system get fatally wrong.
Of course a quick technical support and maintenance services are guaranteed with only
our genuine parts.

CATHSED○R K.C.LTD.

- 11 -
 Shaft Earthing Device
Shaft Earthing Device Documents
REV.7 : jun.09,22

9. TROUBLE SHOOTING

NO FAILURE POSSIBLE REASON REQUIRED ACTION

.
01 “O” millivolt 1) Shaft is at rest. 1) Check while engine runs.
on the analog
2) Insulator of support bar is 2) Tighten the insulator on the support bar
mV-meter.
loosened/missing. for single brush holder.
3) Cable connection on the 3) Check signal/earth cable are correctly
terminal block or inside the connected according to the internal
analog mV-meter is wrong. wiring.
4) Cable connection between 4) Make sure cable connection of single
single brush holder(insulated brush holder(insulated support bar) is out
support bar) and the analog of touch with hull.
mV-meter is untightened /
short circuit.
5) The gauge meter is faulty. 5) Check the reading at the analog mV-
meter and at the same time measure the
reading of millivolt before the analog mV-
meter by tester during ship's sailing.
Compare and judge. Then replace the
gauge meter.
6) Brush on single brush holder 6) Replace/install brush.
is worn down/not installed.
7) Millivolt value is in tolerance 7) Refer to below ‘2. For good working
of the analog mV-meter. measurement’.

We often receive claim of the analog mV-meter’s malfunction due to "0" reading.
※ Special remark
But the zero reading doesn't always mean faulty grounding. So check
regularly(once a week) for maintenance and confirm the device is working in
normal condition as follows;

1. For good installation

① Check if all brushes tightly get in touch with slip ring.
② Check the contact surface of sharp edge on slip ring.
③ Check and clear the surface of slip ring or between slip ring and shaft from any
oil/grease and rust.
④ Check tight connection of shaft earth bending bar.

2. For good working measurement

① Check the reading after removing one of the brushes fitted on double brush
holder during ship's sailing. Reading is zero or above zero.
② Check the reading after removing all brushes fitted on double brush holder
during ship's sailing. Reading is far above zero.

From the above check you can find the reading above 1mV with brush(es) removed
from double brush holder and also 0mV with double brushes fitted, which means
present 0mV reading proves good shaft grounding.
So don't worry about "0" reading at the present.

※ Remark : The readings of shaft mV cannot be correctly secured when ship is

sailing in fresh/brackish water.

CATHSED○R K.C.LTD.

- 12 -
 Shaft Earthing Device
Shaft Earthing Device Documents
REV.7 : jun.09,22

NO FAILURE POSSIBLE REASON REQUIRED ACTION

.
02 Too high 1) Shaft earth bending bar is 1) Tighten shaft earth bending bar by
millivolt loosened. bolting.
(above 80 mV) 2) Surface of slip ring/brushes 2) Clean the surface of slip ring/brushes with
on the analog are not clean due to build-up a degreaser, sand(emery) paper and
mV-meter. of oil, dirt, scale and rust. clean cloth.
3) Between slip ring and shaft is 3) Dismantle. Then clean slip ring and shaft
not clean due to build-up of with a degreaser, sand(emery) paper and
oil, dirt, scale and rust. clean cloth.
4) Brushes on double brush 4) Replace/install brushes.
holder are worn down/not
installed.
5) The imitated brushes are 5) Replace our high density low resistant
used. silver graphite brushes as genuine spares.
6) The distance between bottom 6) Adjust the distance between bottom of
of brush holder and surface brush holder and surface of slip ring on
of slip ring is far. 3 mm.

7) Support bar/mounting post 7) Please make sure 0 ohm between support

are insulated with the hull. bar/mounting post and the hull by
welding/bolting or removing painting.
8) Slip ring is not tightly 8) Check the electrical resistance between
installed on the shaft. slip ring and shaft by tester. The
measuring result should be no greater
than 0.001 ohm. If not dismantle slip ring
and tightly install again.
9) The gauge meter is faulty. 9) Check the reading at the analog mV-
meter and at the same time measure the
reading of millivolt before the analog mV-
meter by tester during ship's sailing.
Compare and judge. Then replace the
gauge meter.
03 The millivolt 1) The edge of slip ring is not 1) Make smooth edge preparation by a
value is varied smooth. proper file.
widely. 2) The gap is found on the edge 2) Dismantle and tightly install again to
of slip ring. remove the gap.
In case there happens with overlapped
part smoothly rub the overlapped part
with a proper file.
3) The surface of slip ring got 3) Replace the old slip ring with new one.
damaged.
4) The gauge meter is faulty. 4) Check the reading at the analog mV-
meter and at the same time measure the
reading of millivolt before the analog mV-
meter by tester during ship's sailing.
Compare and judge. Then replace the
gauge meter.

CATHSED○R K.C.LTD.

- 13 -
 SH A FT EA R T H IN G D EV IC E MILLI-VOLT METER
- 14 -
 SHAFT EARTHING DEVICE MILLI-VOLT METER
O PERATION NOTICE
* The meter will read '0' when the shaft is at rest. 1. DO NOT OPERATE MAIN ENGINE WHEN THE
* The meter reading below 80mV indicates proper SHAFT EARTHING DEVICE IS REMOVED.
earthing.
* In case the reading is above 80mV clean surface of 2. USE ONLY GENUINE SILVER GRAPHITE BRUSH FOR
the slip ring, brush holders inside and brushes with EA RTHING EFFICIENCY AND LONGER LIFE.
clean cloth when the shaft stops. Renew genuine
3. DO NOT A DJUST THE CENTER PIN OF mV
SHAFT
spares if needed.
GA UGE WITHOUT APPROVAL FROM K.C.LTD.
- 15 -

K.C.LTD.
ADDRESS : 165, Mieumsandan 3-ro, Gangseo-gu, Busan, Korea
TEL : +82 51 250 2855 FAX : +82 51 831 7726
E-MAIL : [email protected]
WEB : http://www.iccp-mgps.com Seria l No.: KS
- 16 -
- 17 -
SLEEVE
COUPLING
 Power Transmission Solutions
Regal Beloit America, Inc.
FORM
7120 New Buffington Road IMO002672 Rev. 01
Florence, KY 41042
Installation Manual Revised
Application Engineering: 800 626 2093
Jaure® JHC-S & JHC-HF-S® Couplings regalbeloit.com/Jaure Dec 2022

• Indicates a hazardous situation, if not avoided, will result in • Indicates a hazardous situation, if not avoided, could result in minor
death or serious personal injury. or moderate injury.

• Indicates a hazardous situation, if not avoided, could result in • Indicates information considered important, related with property
death or serious personal injury. damage, not related with personal injury.

Index
1 Safety instructions ....................................................................................................................................................................................... 2

2 General information .................................................................................................................................................................................... 2

3 Transport, storage and packaging................................................................................................................................................................ 2

4 Equipment ................................................................................................................................................................................................... 3

4.1 Oil recommendations ............................................................................................................................................................................ 3

4.2 Pumps recommendations ...................................................................................................................................................................... 3

5 Assembly instruction ................................................................................................................................................................................... 4

5.1. How to assembly the coupling on the shafts ......................................................................................................................................... 4

5.2. How to measure coupling outer diameter ............................................................................................................................................ 5

5.3. Pull-up procedure .................................................................................................................................................................................. 6

6 Disassembly instructions ............................................................................................................................................................................. 8

7 Maintenance & Spare parts ......................................................................................................................................................................... 8

1 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 1 Safety instructions
The installation of couplings must be carried out by qualified personnel only. This is important to ensure that the parts are handled
correctly and as per the procedure mentioned in this document.

Failure to follow below instructions will result in death or serious injury:

• Arc flash and shock hazard. Appropriate Personal Protective Equipment (PPE) needed.

Failure to follow below instructions could result in death or serious injury:

• Disconnect and lockout power before installation and maintenance to avoid working on or near energized equipments.
• Couplings are potentially dangerous rotating parts.
Always use proper guards to prevent accidents and comply with local safety regulations.
• Do not operate equipment without guards in place.
• Ensure all equipments are in proper condition.
• The mounting of the couplings should only be carried out by qualified personnel.
• Do not stay below the components during lifting and installation process.

Failure to follow below instructions could result in minor or moderate personal injury:
• Periodic inspections and proper maintenance should be performed.
• Use protection glasses and gloves.
• Make sure that machines should not be started up accidentally.
• The lifting and hoisting equipment of the working area must be carefully analyzed before moving any heavy component. Considering the
length of some components, special arrangements may be necessary to avoid any risk.

Failure to follow below instructions could result in property damage and/or premature product failure:
• Before installing the couplings and when handling them, always avoid any damage to the coupling.
• Ensure that all holes for bolts are clean and free from rust, paint or any rust preventive product before mounting.
• Working area must be free of any obstructions.
• Handle the components always by lifting through their Center of Gravity.
• Do not strike or hammer on any component of the coupling and or shaft. Impact can result in damage to the coupling that may cause
reduction in coupling performance and may lead to equipment failure and personal injury.

2 General information
JHC-HF® couplings provide reliable transmission of mechanical power from driving to driven machines.
The following instructions are valid for all JHC-HF-S models.
Unless having RegalRexnord’s written approval in advance, the couplings must not be modified, otherwise the guarantee will expire
automatically.

• Make sure that this is the latest version of instruction. Failure to do so could result in personal injury and/or product damage.

• Follow General Assembly (GA) drawing, if the drawing calls for specific installation instructions other than standard.
• In case of doubt, contact RegalRexnord engineering department.

3 Transport, storage and packaging

The volume of the supply is indicated in the shipping documentation. The condition of the goods supplied should be checked at the
time of receipt. If there are any damages due to transportation or parts that are missing, notify RegalRexnord.
The coupling may be packed differently depending on the transportation route and the size. Unless agreed upon otherwise in the
contract, the packaging shall be the standard packaging of Jaure® couplings.

• The pictograms affixed to the packaging should be kept in mind during hoisting. These operations shall be carried out by qualified
personnel with using certified equipment.
• If required, ensure the use of appropriate lifting means.
• For handling or hoisting do not place chains directly over components.
• Humid stores (with humidity greater than 65%) are not suitable. There should be no condensation in the storage areas.

2 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 4 Equipment
To pump oil through the 1/4" G oil port to the low pressure chamber a 700 bar Air Driven or Electrical pump with 30 libres oil container
is required.
To pump oil through the 3/4" G oil ports to the high pressure chamber, 3000 bar Air Driven pumps are required.

The number of 3000 bar air driven pumps depends on the number of 3/4" G oil ports machined in the coupling.
Pumps need to be equipped with manometers.

4.1 Oil recommendations

For low pressure chamber (low pressure pump) an oil with a viscosity of approximately 46cSt shall be use as a hydraulic fluid, e.g. AVIA
FLUID RSL 46.
For high pressure chamber (high pressure pump) an oil with a viscosity between 100 & 150cSt shall be used as a hydraulic fluid, e.g.
AVIA FLUID RSL 150.

4.2 Pumps recommendations

MANUFACTURER ENERPAC BVA
MODEL PUJ-1201-B/E PU20M3
HYDRAULIC PRESSURE 700 Bar (10153 psi) 700 Bar (10153 psi)
OIL OUTLET CONNECTION 3/8”G-18NPTF 3/8”G-18NPTF

MANUFACTURER SKF OLMEC

MODEL THAP 300E P830-528/M-SP-O
HYDRAULIC PRESSURE 3000 Bar (43500 psi) 3000 Bar (43500 psi)
AIR PRESSURE 7 Bar (101,5 psi) 7 Bar (101,5 psi)
AIR CONSUMPTION 200 l/min (7,1ft³/min) 400 l/min (14ft³/min)
VOLUME FOR STROKE 10cm³ (0,61 in³) 1,3cm³ (0,08 in³)
OIL OUTLET CONNECTION 3/4”G 1/4"G-120°

- Hydraulic oil for high pressure pumps:

o It shall be an oil with around 300mm²/s (cSt) of viscosity on working temperature. This viscosity is achieved with
different types of oil:

Designation Range of Temperatures

ISO-VG 150 Hydraulic Oil 15°C-40°C
ISO-VG 100 Hydraulic Oil 0°C-20°C

3 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 5 Assembly instruction
The coupling is supplied in assembled condition as it is shown in the picture below (Figure 5.1)

Figure 5.1

A Rigid Hub F Oil Plug (3/4”G - High Pressure)

B Bushing G Oil Plug (1/4”G - Low Pressure)
C Nut H Set screw
D Seal I Ball
E O-ring

5.1. How to assembly the coupling on the shafts

1. The rigid hub (A) has some lifting holes machined in the outer diameter to use eyebolts for lifting.

Check the load carrying capacity of cranes.

2. Support the coupling using cranes ropes or eyebolts properly.
3. Slide the coupling along the shaft and guide it carefully to avoid any damage on the shaft.
4. Insert the coupling until there is enough space between coupling end and shaft edge (W) to be able to fix the alignment tools.

Figure 5.2

4 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 5. Bring the AFT Side shaft closer to FWD Side shaft and proceed to the alignment with precision, vertically and horizontally. The shaft
ends should be in contact, but a gap of not more than 1% of the shaft diameter is acceptable. During alignment make sure that the
coupling does not weigh on the shaft.
6. After shaft alignment, make a mark in the shaft where the coupling will be finally placed. This distance (T) is indicated in the general
assembly drawing.

Figure 5.3

7. Displace the coupling carefully along the shafts until nut (C) front face matches with the mark made on the shaft.

Figure 5.4

5.2. How to measure coupling outer diameter

• The coupling is delivered according to Start Up position. The Start Up position is shown in Figure 5.5 as “X”, which is the
distance between rigid hub (A) & bushing (B) ends. At this position is fixed the coupling when supplied.
• Measure the Outer Diameter of the rigid hub (A) at distance “Z” with a micrometer. Distance “Z” is indicated in general
assembly drawing. Measure “X” value shown in Figure 5.5 as well. Record both values.

The distance “Z” and diametrical expansion are indicated (stamped) in the rigid hub (A) outer diameter.

5 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 Figure 5.5

5.3. Pull-up procedure

1. Place the coupling so that the Low Pressure Chamber purge hole is at the top (12 o’clock). This purge hole is covered by set
screw (H).
2. Remove 3/4”G & 1/4”G oil plugs (F & G).
3. Loosen set screw (H). Do not remove completely the set screw (H).
4. Fix the high pressure (HP) and low pressure (LP) pumps to the oil ports.

Fix the high and low pressure pumps fittings and hoses in such a way as to prevent them from being thrown out in case of
failure of the connections to the oil ports.
5. Start filling the Low Pressure Chamber slowly. When the oil starts to overflow from the hole where the set screw (H) is located,
stop the low pressure pump and tighten the set screw (H). In this way the Low Pressure Chamber will be purged. Be care
because the Low Pressure Chamber will be full filled quickly!
6. Purge the high pressure hoses: the 3/4" connectors shall be slightly untightened, so once the high pressure pumps start
working, all the air from the hoses would go out through that connection. When there is just oil coming out, tighten the
connectors properly.
7. Start pumping oil through high pressure pumps until oil leakages by the rear face of the coupling. This leaking oil assures that
all tapered surface has the necessary oil film, so continue pumping for a few minutes. This excess of oil can be collected with a
cube. The low pressure pump return must be opened during taper surface lubrication, if not, the pull up will start.
8. After that, the pull-up can be started by pumping oil through low pressure pump. The high pressure pumps shall keep working.
9. The rigid hub (A) will start moving towards the back side of the coupling. During the whole process, the high pressure pumps
shall be working every time to assure a proper lubrication.
10. When rigid hub (A) reaches 10mm, stop pumping through low pressure pump. Wait 2 minutes before start pumping again low
pressure pump keeping working the high pressure pumps at all times.

The rigid hub (A) is travelling in steps of 10mm, no more. Wait 2 minutes between steeps before start pumping again low
pressure pump keeping working the high pressure pumps at all times.
11. Repeat the process until rigid hub (A) outer diameter reaches the required diametrical expansion (∆OD). The diametrical
expansion and at which distance must to be measured (Z) are stamped on the rigid hub (A) outer diameter and indicated in
General Assembly drawing. Nominal pull-up value (X-Y) is also shown in the general assembly drawing.

6 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 Figure 5.6

The pressure in the Low-Pressure chamber should not exceed 300 Bar at any time! If this value is exceeded, get in contact with
JAURE.
12. Once required diametrical expansion (∆OD) has been reached, stop pumping. Keep the pressure in the low pressure chamber
and open the return valve on the high pressure pumps.

IMPORTANT: The required diametrical expansion (∆OD) value is applicable once the coupling has been settled (oil removed).
Therefore, the value to be measured during installation process is around 25% higher.
13. After 15 minutes, confirm the diametrical expansion (∆OD) and release the pressure on the Low Pressure Chamber.
14. Then remove from the coupling the low and high pressure pumps.
15. Mount the oil plugs (F & G) and clean the oil residue.
16. The nut (3) acts as counter support and should not be manipulated.

For next installations on the same shafts, instead of diametrical expansion (∆OD), actual Pull-Up (X-Y) could be used as installation
reference. For that purpose, record the actual Pull-Up (nominal value is shown in the drawing).

7 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
 6 Disassembly instructions
1. Place the coupling so that the Low Pressure Chamber purge hole is at the top (12 o’clock). This purge hole is covered by set
screw (H).
2. Remove 3/4”G & 1/4”G oil plugs (F & G).
3. Loosen set screw (H). Do not remove completely the set screw (H).
4. Fix the high pressure (HP) and low pressure (LP) pumps to the oil ports.
5. Start filling the Low Pressure Chamber slowly. When the oil starts to overflow from the hole where the set screw (H) is located,
stop the low pressure pump and tighten the set screw (H). In this way the Low Pressure Chamber will be purged.
6. Pump into low pressure chamber until the pressure rises-up to 70-80 Bar. Then stop the pump and keep the pressure.
7. Start pumping oil through high pressure pumps until oil leakages by the rear face of the coupling. This leaking oil assures that all
tapered surface has the necessary oil film. This excess of oil can be collected with a cube.
8. When rigid hub (A) starts to move, return valve of the low pressure pump shall be opened. The high pressure pump must remain
pumping at all times, until the rigid hub (A) slides completely down on the bushing (B) to the initial position.

If there is not movement of the rigid hub (A), keep on pumping through high pressure pump 2 minutes after oil leakages by the rear
face of the coupling and then open the return valve of the low pressure pump. The high pressure pump must remain pumping at all
times, until the rigid hub (A) slides completely down on the bushing (B) to the initial position.
9. Finally remove from the coupling the low and high pressure pumps.

Figure 5.7

7 Maintenance & Spare parts

The coupling is nearly maintenance free.
If the sealing (D) or o-ring (E) placed on the nut (C) needs to be replaced without the coupling being able to be dismounted from the
shafts, it is necessary to use the service of a professional with proper hydraulic equipment and knowledge. The incorrect
manipulation of these sealing could lead to seizing of the rigid hub (A).

List of spare parts:

D Seal G Oil Plug (1/4”G - Low Pressure)

E O-Ring H Set screw
F Oil Plug (3/4”G - High Pressure) I Ball

8 ©2020 Regal Beloit Corporation, All Rights Reserved. MCIM19047E • Form# IMO001718E
Uncontrolled Copy
GEARBOX PUMP
STARTER
 PROJECT INFORMATION PACKAGE
PART NO. : EB97269 REMARKS:
A) System Voltage / Frequency and Name Plate Details is Based On the
Project Information Accordingly.
PROJECT NO. : 7634

CUSTOMER :

PRODUCT : DOL Starter for GB Standby Pump

RATING : 400V, 50Hz, 3PHASE, 3WIRE, 11kW

ENCLOSURE : IP 44

COLOR : RAL 7035

HULL NO. : -

QUANTITY : 2 UNITS

MARINE CLASS : -
This document must not be copied without our written permission,
1 2 3 4 5 6 7 8 9 10
nor be used for any unauthorized purpose. Contravention will be
and the contents thereof must not be imparted to a third party

prosecuted in accordance with Swedish law.

C C
PRODUCT : 11kW DOL STARTER PANEL

APPLICATION : GEARBOX STANDBY PUMP

D D

E E

F F

G G

H H

I I

Product Sheet No.

Electrical drawing Mechanical drawing
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 01 of 07
Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
SS-ISO 2768-1
Capacitance in nF
RAM WANG HU No connection Connection Induktance in mH A3
Title Date Revision

J 07 DEC 2022 A J
COVER PAGE Drawing No.

97269
1 2 3 4 5 6 7 8 9 10
This document must not be copied without our written permission,
1 2 3 4 5 6 7 8 9 10
nor be used for any unauthorized purpose. Contravention will be
and the contents thereof must not be imparted to a third party

prosecuted in accordance with Swedish law.

A
S/No. DRAWING NO. SHT. DESCRIPTION REV. A REV. B REV. C REV. D REV. E REV. F REV. G REV. H REV. I REV. J REV. K
1 97269 01 COVER PAGE 07 DEC 2022

2 97269 02 INDEX PAGE 07 DEC 2022

3 97269 03 GENERAL ARRANGEMENT & OVERALL DIMENSION 07 DEC 2022

4 97269 04 CIRCUIT DIAGRAM - PUMP 07 DEC 2022

B
5 97269 05 TERMINAL DIAGRAM - PUMP 07 DEC 2022

6 97269 06 NAME PLATE 07 DEC 2022

7 97269 07 MATERIAL LIST 07 DEC 2022

C C

D D

E E

F F

G G

H H

I I

Product Sheet No.

Electrical drawing Mechanical drawing
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 02 of 07
Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
SS-ISO 2768-1
Capacitance in nF
RAM WANG HU No connection Connection Induktance in mH A3
Title Date Revision

J 07 DEC 2022 A J
INDEX PAGE Drawing No.

97269
1 2 3 4 5 6 7 8 9 10
This document must not be copied without our written permission,
1 2 3 4 5 6 7 8 9 10
nor be used for any unauthorized purpose. Contravention will be
and the contents thereof must not be imparted to a third party

prosecuted in accordance with Swedish law.

200 500

6 15 450 440
2
Ø1
LEGEND B

50
INDICATION LAMPS:
NP01
H1 : CONTROL POWER ON WHITE
W25 x H65
H2 : RUN GREEN

DS1

K1
T1
TR1
F1
F2
F3
F4
K11
MAIN SWITCH
H3 : TRIP RED

W25 x H65
OT16-40F3

OTHERS:
C C
S1 : MAN / OFF/ AUTO SELECTOR SWITCH BLACK
DS1
DS1 : MAIN SWITCH

440
600

600

500

550
CONTROL
POWER ON
RUN TRIP MAN/OFF/AUTO W25 x H65
OLR PANEL DETAIL
H1 H2 H3 S1 PANEL TYPE : WALL MOUNTED

X4
X1

X2

X3
XF1 CABLE ENTRY : BOTTOM
D MATERIAL : SHEET STEEL 2.0mm D
ENCLOSURE : IP44
PE
2
Ø1 COLOR : RAL 7035
50

CABLE COLOR
DOOR STOP
50 POWER CABLE (L1,U / L2,V / L3,W) : BLACK COLOR WITH (BROWN / BLACK / GRAY) MARKER
E E
SIDE VIEW EXTERNAL VIEW INTERNAL VIEW CONTROL CABLE (AC) : BROWN / BLACK
EARTH CABLE (PE) : GREEN-YELLOW

500

F 400 F
200

150

G G

BOTTOM VIEW

H H

I I

Product Sheet No.

Electrical drawing Mechanical drawing
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 03 of 07
Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
SS-ISO 2768-1
Capacitance in nF
RAM WANG HU No connection Connection Induktance in mH A3
Title Date Revision

J 07 DEC 2022 A J
GENERAL ARRANGEMENT VIEW Drawing No.

97269
1 2 3 4 5 6 7 8 9 10
This document must not be copied without our written permission,
1 2 3 4 5 6 7 8 9 10
nor be used for any unauthorized purpose. Contravention will be
and the contents thereof must not be imparted to a third party

FIELD L11
*Note:
=-X1
prosecuted in accordance with Swedish law.

Remove Jumper if
*Refer Project Information Package page for 1 Emergency Stop is Required.
System Voltage / Frequency. A
Emergency
Stop
(If Required)

*Jumper
*System
Power Supply 2

97
-3
Yard -K1 -OLR1
4F 2D

-4

98
B

95
1 2 3
=-X3 -OLR1
2D

96
1

=-DS1 0441
3P, 40A
Disconnect 1 0
=-F1 =-F3 2
2

5G
Switch
2A 6A
C C

3
F1 F3 L11

3
1
0
2
=-S1
F2 F4 N11 1.Man

4
0.Off
=-F2 =-XF1 =-F4 2.Auto
Pri: *System Voltage
2A 6A
Sec: 24V =-X1
L1

L2

L3

*Note:
100VA 3 Remove Jumper if
Spare Spare Interlock is Required.
D Interlock D
(If Required)

*Jumper
4
1

=-K1
3P, 26A
=-X1
4F
2

5
E E
Closed When
Engine Running
4B

9B

6
95

97

=-OLR1
Setting 20..24A =-X1
7
96

98

Closed When
F Low Pressure P F

16
18
-T1
5F
15
0442

0461

0481

0491
=-X4
G 1 2 3 G

A1
A1

14

14
X1

X1

X1
PE
=-K1 =-K11 =-T1 =-H1 =-H2 =-H3 =-TR1
Yard White Green Red
A2

13

13
A2

X2

X2

X2
N11
W
V
U

START / STOP START / STOP ON DELAY CONTROL RUNNING OVERLOAD OVERLOAD TRIP
H CONTACTOR RELAY TIMER POWER ON TRIP RELAY H
PE

1D 1 2 2G 5 5E 18 5
1D 3 4 2G 1 9 16 15 1 9
M 1D 5 6 3G 6 6

3~ 8B -3 -4 3G 2 10 2 10
7 4G 7
11kW 3 11 4G 3 11
PUMP 8 8
I I
4 12 4 12

Product Sheet No.

Electrical drawing Mechanical drawing
-3
1

3
5

-S1
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 04 of 07
-K11 -K11 -TR1 Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
4F 4F 9F 5C Capacitance in nF
SS-ISO 2768-1
11

-4

MOTOR
10

RAM WANG HU A3
9

=-X2 No connection Connection Induktance in mH

1 2 3 4 5 6 7 8 9 10 11 Title Date Revision

J 07 DEC 2022 A J
CIRCUIT DIAGRAM - PUMP
Running Running Trip Auto FIELD
Drawing No.

Mode 97269
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 FIELD
5 WIRING 6 7 8 9 10
This document must not be copied without our written permission,

nor be used for any unauthorized purpose. Contravention will be

and the contents thereof must not be imparted to a third party

*Refer Project Information Package page for

GB STANDBY PUMP STARTER PANEL System Voltage / Frequency. SHIP SUPPLY
prosecuted in accordance with Swedish law.

1 1
X3-1 L1
2 - 2
A
*System Power Supply X3-2 L2 *System Power Supply
3 3
X3-3 L3

PE

MOTOR B
1 1
X4-1 U
Outgoing Power X4-2
2 - 2
V M 11kW
3
X4-3
3 3
W ~
PE PE

C C
*Jumper
Emergency Stop X1-1 *Note:
(Spare) Remove Jumper if Emergency Stop is Required.
X1-2
*Jumper
Spare Interlock X1-3 *Note:
(Spare) X1-4 Remove Jumper if Spare Interlock is Required. ENGINE
1 1 -
Engine X1-5 1x2Cx0.75 sq.mm Engine
Running 2 2 - Running
D X1-6 D

GEAR BOX
1 1 -
Low X1-7 1x2Cx0.75 sq.mm Low
Pressure 2 2 - Pressure
X1-8
E E

ALARM SYSTEM
1 1 -
X2-1 1x2Cx0.75 sq.mm Pump
2 2 - Running
Running X2-2
F F
X2-3

X2-4
Running
X2-5
(Spare)
X2-6

X2-7
Tripped
G (Spare) X2-8 G
X2-9

Auto Mode X2-10

(Spare) X2-11

H Note: H
1) Field Wiring is by yard.
2) Wire size is for Recommandation only.

I I

Product Sheet No.

Electrical drawing Mechanical drawing
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 05 of 07
Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
SS-ISO 2768-1
Capacitance in nF
RAM WANG HU No connection Connection Induktance in mH A3
Title Date Revision

J 07 DEC 2022 A J
TERMINAL DIAGRAM - PUMP Drawing No.

97269
1 2 3 4 5 6 7 8 9 10
This document must not be copied without our written permission,
1 2 3 4 5 6 7 8 9 10
nor be used for any unauthorized purpose. Contravention will be
and the contents thereof must not be imparted to a third party

prosecuted in accordance with Swedish law.

230 35

220
Ø4

NP01 - Each 1 No CONTROL RUN TRIP B

20
Material : Acrylic POWER ON
LABEL

33
7634-11kW DOL STARTER GB PUMP-1
Dimension : Refer fig
NP01
30

Text color : Black color

Background: White color Ø23
Text Height: 13mm
C C

R1
Font type 'Univers LT 67 Condensedbold'

7634-11kW DOL STARTER GB PUMP-2

5
NP01
30

MAN/OFF/AUTO
LABEL

D D

60
50 NP02 - Each 2 Nos

Ø4
LABEL - Each 2 Nos
Material : Acrylic
Material : Acrylic
PUMP
NP02

15
Dimension : Refer fig
E MAIN SWITCH Dimension : Refer fig E
Text color : White color
Text color : Black color
Background: Red color
Background: White color
Text Height: 4mm
Text Height: 4mm
Font type 'Univers LT 57 Condensed
Font type 'Univers LT 57 Condensed

F F

G G

H H

I I

Product Sheet No.

Electrical drawing Mechanical drawing
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 06 of 07
Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
SS-ISO 2768-1
Capacitance in nF
RAM WANG HU No connection Connection Induktance in mH A3
Title Date Revision

J 07 DEC 2022 A J
NAME PLATE Drawing No.

97269
1 2 3 4 5 6 7 8 9 10
This document must not be copied without our written permission,
1 2 3 4 5 6 7 8 9 10
nor be used for any unauthorized purpose. Contravention will be
and the contents thereof must not be imparted to a third party

prosecuted in accordance with Swedish law.

C C

D D

E E

F F

G G

H H

I I

Product Sheet No.

Electrical drawing Mechanical drawing
DOL GEARBOX STANDBY PUMP Unless otherwise noted Unless otherwise noted 07 of 07
Drawn by Drawing checked by Approved for prod. by Resistance in E Tolerance Scale Size
SS-ISO 2768-1
Capacitance in nF
RAM WANG HU No connection Connection Induktance in mH A3
Title Date Revision

J 07 DEC 2022 A J
MATERIAL LIST Drawing No.

97269
1 2 3 4 5 6 7 8 9 10
WATER QUALITY
SYSTEM
Installation, Operation
and
Maintenance Instructions for
Open Water Quality System
Svenska Bearing Open Water Quality System (WQS-O) for stern tube
bearing lubrication.

Revision: B
 INSTALLATION MANUAL

Installation - Operation & Maintenance

Instructions for Open Water Quality System

Svenska Bearing S.L.

Polígono Industrial Sete Pías – Parcela 34
36 635 Cambados, Pontevedra, SPAIN
Telephone: +34 986 52 09 09
[email protected]

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 2 of 32
 LIST OF CONTENTS
TABLE OF CONTENTS
1. GENERAL ........................................................................................ 4
2. TRANSPORT, LIFTING & STORAGE ........................................... 5
3. INSTALLATION .............................................................................. 6
3.1. Location ...................................................................................... 6
3.2. Cleanliness .................................................................................. 7
3.3. Pipework ..................................................................................... 7
3.4. Electrical equipment ................................................................... 8
3.5. Shaft Rotation Sensor ................................................................. 8
4. INITIAL SETUP ............................................................................... 9
4.1. Names of machine parts and functions ....................................... 9
4.2. Starting-Up Procedure .............................................................. 12
5. STARTING-UP ............................................................................... 16
5.1. Checklist ................................................................................... 16
5.2. Starting-Up................................................................................ 16
6. IAMCS ............................................................................................ 17
6.1. Integrated Alarm Monitoring Control System .......................... 17
6.2. HMI Panel ................................................................................. 18
6.3. HMI Instruction Manual ........................................................... 19
7. MAINTENANCE ............................................................................ 25
7.1. Daily attention........................................................................... 25
7.2. Periodic maintenance ................................................................ 25
7.3. Low pressure pumps ................................................................. 25
7.3.1. Circulation pumps ............................................................. 25
7.4. Pipework ................................................................................... 25
7.5. Servicing ................................................................................... 25
8. TROUBLESHOOTING .................................................................. 27
8.1. Repair work............................................................................... 27
8.2. Reset pump after reparation. ..................................................... 27
8.3. Reset WQS-unit after blackout. ................................................ 27
8.4. Troubleshooting list for the WQS-O unit ................................. 28

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 3 of 32
 GENERAL

1. GENERAL

These instructions must be read carefully prior to installation and in its

whole notified those responsible for operation and maintenance.

Installation and service must be performed by personnel with proven

skills or experience in the field.

The operation of the equipment must be carried out with high degree of
cleanliness, follow the instructions and requirements in order to maintain
the proper function and longevity of the system.

Spare parts to remedy the fault should be stored on the vessel by the user.
The extent of this depends from case to case and depends on the user's
requirements for availability.

Service agreement is recommended and can be set up between user and

Svenska Bearing. Please contact Svenska Bearing for more information.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 4 of 32
 TRANSPORT, LIFTING & STORAGE

2. TRANSPORT, LIFTING & STORAGE

This section describes procedures for Transportation, Lifting and Storage

Transportation

Packaging must be carried out with respect to transport and destination.

Lifting

The unit is equipped with lifting bolts and should be used together with
lifting equipment suitable for WQS-O system's dimensions and mass.

None of the other components that are fitted on the system can be used to
provide lift support.

Storage

The unit should be stored in clean, dry and temperate areas.

Before use, it may be necessary to disassemble and clean valves and

pumps.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 5 of 32
 INSTALLATION

3. INSTALLATION

This section describes the general considerations to be taken when

installing the WQS-O unit.

3.1. Location
The WQS-O unit should be mounted horizontally and placed well clear
of any bulkhead or other equipment for the best possible air circulation
for cooling purposes. The distance from the nearest bulkhead or
equipment should permit full service of the unit. For more information
see interface drawing for service area.

The location of the unit should permit convenient reading of the

operational data and alarms through the display mounted on the IAMCS
cabinet (Integrated Alarm Monitoring Control System).

The unit may be mounted directly on the floor, to which it need be bolted
down or welded. Support brackets for aligning the WQS is preferably
used for this.

Electric motors and pumps shipped as a unit are carefully aligned when
assembled and therefore need only be checked before starting-up for
possible damage during shipment.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 6 of 32
 INSTALLATION
3.2. Cleanliness
All pump units are thoroughly cleaned before delivery and all pipes and
valves are checked. Before installation check that no foreign matter has
entered the unit or pipe connections during shipment and storage.

Excessive dirt = severe abrasion = rapid wear and operational problems.

All pipes and other components connected to a lubrication system must

be clean. Dirt present in a hydraulic system will act as an abrasive when
the system is in operation.

3.3. Pipework
Piping from the WQS-O unit must be connected in accordance with the
layout diagram (P&ID). Pipe sizes are selected according to pressure
class and flow.

Piping must be secured against vibration and other movement with a

distance between clamps of 75-150 cm or otherwise as suitable.

Couplings must not be allowed to transmit external forces, regardless of

the coupling type - threaded, flanged or welded.

To reduce noise levels, it is recommended that hoses are used between

the WQS-O unit and the piping system. Hoses are subject to the same
requirements as piping regarding pressure classes and sizes.

In case of using hydraulic hoses note that hoses cannot withstand

torsional deformation; also, that each type is subject to a recommended
minimum bending radius. The supplier will provide details.

Always follow the supplier's instructions carefully when cutting,

cleaning, fitting and retightening hoses, piping and couplings.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 7 of 32
 INSTALLATION
3.4. Electrical equipment
Check that rated voltage, connections, and frequency are in accordance
with the electrical supply. Do not check the pump's direction of rotation
until the sea water supply to pumps is ensured. See starting-up
instructions for more information.

The correct direction of rotation is shown by an arrow on the pump

house. If the arrow is missing then the correct direction can be seen on
the pump data-plate: R = CW, L = CCW. As a rule, this is the same as
the direction of rotation of the electric motor cooling fan.

The WQS-O unit is tested before delivery. All pumps have the correct
direction of rotation between the motors and the starting cabinet. If
wrong direction is identified during start-up, please shift the phase on
incoming terminal.

The general layout diagram shows where the sensors are placed in the
system. All connections are linked to IAMCS cabinet and alarm levels
are set and ready for start-up.

3.5. Shaft Rotation Sensor

For the bearing wear monitoring system (if equipped), the supplied shaft
rotation sensor must be assembled with the supplied mounting bracket.

The sensor must be mounted with a maximum distance of 15mm from

the rotating propeller shaft. Bolted flange coupling, to ensure correct
reading from the sensor.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 8 of 32
 INITIAL SETUP

4. INITIAL SETUP

This section describes the general considerations to be taken when

installing the Open Water Quality System unit.

4.1. Names of machine parts and functions

1 5

4
6

Figure 1- Electrical cabinet front door.

1. Human machine interface (HMI).

2. Start Pump LP1 S3/Stop Pump LP1 S2 (Only Manual Mode).
3. Start Pump LP2 S3/Stop Pump LP2 S2 (Only Manual Mode).
4. Emergency Stop S9.
5. Failure Fault Lamp H3.
6. Safety Switch. Machine electrical Power Supply ON/OFF switch. Two positions “I” ON and “O” OFF.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 9 of 32
 INITIAL SETUP

Figure 2- Terminal connections block.

Manual Operation Mode General Description

In order to operate individually in manual mode each of the low-pressure

pumps (LP1 and LP2), you would need to open the front door of the
electrical cabinet, where you will find the switch S-05 (see picture).

First, turn on the power supply by switching “SAFETY SWITCH” to “I”

position and make sure switch S04 is in manual mode.

Turn Switch to
right to enter
Manual mode.

Figure 3. Manual Mode activation procedure.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 10 of 32
 INITIAL SETUP
Start the pump by pressing the GREEN start button (S3 for LP1 or S5
for LP2). The pump will start and keep running until you shut it down by
pressing stop button.

Stop the pump by pressing the RED stop button (S2 for LP1 or S4 for
LP2).

If pump is activated manually and then you switch to “AUTO” mode, the
pump will be shut down, unless the RUN signal is active from ECR
through terminals 76-77. For more information about hardwired
connections please see chapter 4.2.

If you switch again to AUTO mode, these buttons will be deactivated,

that means that you will not be able to start/stop the pumps by pressing
the buttons at the front door of the cabinet.

Figure 4. Start/Stop Buttons for pumps LP1 and LP2

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 11 of 32
 INITIAL SETUP
4.2. Starting-Up Procedure
Please, before carrying out any electrical or mechanical connection, make
sure “SAFETY SWITCH” placed at the front door of the electrical
cabinet is in position “O” to avoid any electrical hazards.

Electric power input connected to the terminals 1-2-3 in accordance

with drawing “Power Circuit”.

Electric power output to Low-Pressure Pump 1 (LP1) according to

drawing “Power Circuit” is to be connected to the terminals 4 - 5 - 6.
(check that the direction of rotation is correct).

Electric power output to Low-Pressure Pump 2 (LP2) according to

drawing “Power Circuit” is to be connected to the terminals 7 - 8 - 9.
(check that the direction of rotation is correct).

Solenoid Valve LP1 for draining the cyclone filter of pump LP1
connects in terminals 10-11.

Solenoid Valve LP2 for draining the cyclone filter of pump LP2
connects in terminals 12-13.

Bearing wear FWD sensor for condition monitoring of the FWD

bearing wear connects in terminals (L+) - (L-)-20.

Bearing wear AFT sensor for condition monitoring of the AFT bearing
wear connects in terminals (L+) - (L-) -21.

This bearing wear sensors will monitor the wear condition of the bearings
in real time, so if the measured value exceeds the set-up alarm value an
alarm message will show up in the HMI screen at the front door of the
cabinet and an alarm signal will be sent through terminals 72-73 (FWD)
or 74-75 (AFT) (hardwired signals).

Flow switch sensor LP1 connects in terminals (L+) - (L-) -49.

This flow switch will indicate that there is a lack of flow at the outflow of
the pump LP1, by a message in the HMI screen placed at the front door
of the cabinet and an alarm signal to ECR through the terminals 64-65 as
well (hardwired signal).

The pump will stop automatically 20 seconds after detecting a lack of

flow in the outflow and will also activate the flow alarm in the HMI
screen and send it to the ECR through terminals 64-65. Then, the Pump
LP2 will start automatically to ensure the sea water flows into the
stern tube. If the flow sensor detects flow again in the next operation,
the pump will work normally, under continuous regime.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 12 of 32
 INITIAL SETUP
Flow switch sensor LP2 connects in terminals (L+) - (L-) -50.

This flow switch will indicate that there is a lack of flow at the outflow of
the pump LP2, by a message in the HMI screen placed at the front door
of the cabinet, and a hardwired alarm signal to ECR through the
terminals 66-67 as well.

The pump will automatically stop 20 seconds after detecting a lack of

flow in the outflow and will also activate the flow alarm in the HMI
screen and send it to the ECR through terminals 64-65. Then, the Pump
LP1 will start automatically to ensure the sea water flows into the
stern tube. If the flow sensor detects flow again in the next operation,
the pump will work normally, under continuous regime.

General Alarm to ECR will be sent through the hardwired terminals 58-
59 if some of the possible alarms managed by the unit come up and,
leading to an interruption of the normal operation of the unit.

A message for this alarm will also be shown up on the HMI screen at the
front door of the cabinet.

Emergency Alarm to ECR will be sent through the hardwired terminals

78-79 in case that the emergency stop button is pushed, leading to an
interruption of the normal operation of the unit.

A message for this alarm will also be shown up in the HMI screen at the
front door of the cabinet.

Pump LP1 running signal to ECR connects in terminals 60-61 as

hardwired signal. This is a tension-free contact (KA2).

Pump LP2 running signal to ECR connects in terminals 62-63 as

hardwired signal. This is a tension-free contact (KA3).

The WQS unit will send to the ECR a digital signal (1) through terminals
60-61 (if pump LP1 is running) or 62-63 (if pump LP2 is running) to
confirm that one of the pumps is running. In order to be sent, this signal
will be conditioned to two things: Enough water flow detected in the
sensor and no circuit breaker fault in the pump (pump running).

You should use the detection of at least one of this two signals as an
INTERLOCK for your central system.

The HMI screen will also show the condition of the pumps, showing
which of them is working and which of them is stopped.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 13 of 32
 INITIAL SETUP
Flow pump LP1 alarm connects in terminals 64-65. This hardwired
alarm will be sent to the ECR 20 seconds after detecting a lack of flow in
the outflow of this pump. The pump will stop automatically when this
alarm is detected.

An alarm message will also be shown in the HMI screen at the front door
of the cabinet.

Under these circumstances, pump LP2 will start automatically to ensure

the sea water flow into the stern tube.

Flow pump LP2 alarm connects in terminals 66-67. This hardwired

alarm will be sent to the ECR 20 seconds after detecting a lack of flow in
the outflow of this pump. The pump will stop automatically when this
alarm is detected.

An alarm message will also be shown in the HMI screen at the front door
of the cabinet.

Under these circumstances, pump LP1 will start automatically to ensure

the sea water flows into the stern tube.

Circuit breaker pump LP1 alarm connects in terminals 68-69. This

hardwired alarm will be sent to the ECR automatically after detecting a
thermal fault or overcurrent in the circuit breaker of this pump.

Pump LP2 will start automatically to ensure enough sea water flow
pumped into the stern tube, until the LP1 circuit breaker is rearmed.

Circuit breaker pump LP2 alarm connects in terminals 70-71. This

hardwired alarm will be sent to the ECR automatically after detecting a
thermal fault or overcurrent in the circuit breaker of this pump.

Pump LP1 will start automatically to ensure enough sea water flow
pumped into the stern tube, until the LP2 circuit breaker will be rearmed.

The system is redundant, so in the case there is an alarm situation in any

of the pumps the other one will start automatically.

You only should stop propulsion under these approaches:

- Pump LP1 running signal and Pump LP2 running signal detection
get lost at the same time. That means that you do not have
confirmation that at least one out of the two LP pumps are
pumping sea water flow into the stern tube. That also means that
you will receive some flow/circuit breaker alarms from the two
LP pumps at the same time.
- Emergency Alarm from the unit. The emergency stop button has
been pushed so the unit is not capable of pumping any sea water
flow into the stern tube.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 14 of 32
 INITIAL SETUP
Remote start/stop command. Connects to terminals 76-77, power
supply 220V AC.
Make sure the switch “S-05” is in “Automatic mode”.
When the power supply is activated pump LP1 or LP2 will start working
(The last that was working in the previous run signal).

The pumps will work alternatively within a period which is set-up

through the HMI of the machine (see section 6.2 for further information).
When power supply is deactivated the LP pumps shuts down/ remains
off.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 15 of 32
 STARTING UP

5. STARTING-UP

This section describes the start-up procedure. Go through the checklist

before Starting-Up the system when the propeller shaft RPM is zero.

5.1. Checklist

• Connections and joints are fitted properly.

• Make sure that the connections and piping are according to the
layout diagram.

• Valves are in correct operation position (see P&ID)

• Electrical power supply in accordance with installation section

• Switch on the power and make sure that the main display is
working (chapter 6.3).

• Switch AUTO-MAN switch to enter manual mode.

• Start-up the pumps with the local start button

• Run the system 30min.

• Switch AUTO-MAN switch to enter automatic mode.

5.2. Starting-Up
Follow the checklist above.

For the first commissioning / start-up the system must run at least 30
minutes before the shaft starts to rotate in order to evacuate any air
pockets in the system.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 16 of 32
 IAMCS

6. IAMCS

6.1. Integrated Alarm Monitoring Control System

The WQS-O unit has an integrated cabinet for pumps, alarms, shaft wear
monitoring and HMI (Human Machine Interface)

Figure 5- Electrical Cabinet

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 17 of 32
 IAMCS
6.2. HMI Panel
A 7’’ wide HMI touch screen panel is mounted in the IAMCS cabinet.
The HMI panel has below feature’ and displays all sensors:

- System overview showing all monitoring points.

- Shaft bearing wear monitoring set-points / displays the current
bearing wear.
- Parameter settings for alarm and monitoring points:
o Flow alarms
o Low pressure pumps cycling period.
o Automatic log file report set-up (depending on service
agreement)

For the system to function the electrical panel must be fed with power
input in accordance with the drawing “Power Circuit”.

. in the power terminals (L1, L2, L3 and PE).

The WQS system comes with overload protection in mode “OFF” as

factory default.

Do not switch the overload protection to mode “ON” until the pipes are
installed correctly.

Once the power source is connected turn “Main Switch” of the electrical
panel to position 1 (AUTO). (See Electrical Cabinet Figure 1)

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 18 of 32
 IAMCS
6.3. HMI Instruction Manual

Figure 6- Start screen

The touchscreen panel should be lit up and begin loading and show a
welcome message (see picture 2).

By pressing the blue button CONTINUE the main screen will appear
showing the Layout for the system and its functions.

• Bearing Wear Monitor (if equipped)

• Pumps State Monitor
• Purge Cyclone Filter Monitor
• Flow Sensors

Figure 7- Layout

In this screen all values from the sensors connected to the WQS are
shown.

At the bottom right corner part of the screen there is ONE button: MAIN.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 19 of 32
 IAMCS
By pressing the MAIN button, it will take you to the Main menu screen
from where it’s possible to view following settings:

Figure 8- Main Menu

From this screen its possible return to the “Layout” screen by pressing
the LAYOUT button, or to get access to the alarms register.

Alarm Signals ECR:

From this menu is it possible to test the functions for alarms connected to
ECR.

Figure 9- Lamp Test

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 20 of 32
 IAMCS
ALARM:

By pressing the blue ALARM-button at the top right corner of the main
menu screen a list with the alarm history will appear.

The wanings are shown as flashing indicators in the ECR control panel
and on the WQS unit. Both with the “Fault Lamp” and on the HMI-
screen.

If it was an alarm that trigger the flashing fault indicator the light will
then be active untill the casue is resolved.

All notified warnings and alarms (system or human generated) will be

saved and stored in real time with date and time.

Only authorized staff can delete the Warning and Alarm history.
However in case the memory buffer is full it will start overwrite the
oldest and replace it with the newest.

The list of possible alarms is:

• Flow pump LP1 alarm

• Flow pump LP2 alarm
• Circuit breaker pump LP1 alarm
• Circuit breaker pump LP2 alarm
• Bearing wear FWD alarm (if equipped)
• Bearing wear AFT alarm (if equipped)
• Emergency stop alarm
• General alarm

Figure 10- Alarm List

Following screens can not be adjusted, their purpose is only to show

calibrated values.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 21 of 32
 IAMCS
Running Hours:

This menu shows information regarding the running time of each pump
and the system in total.

Figure 11- Running Hours

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 22 of 32
 IAMCS
Bearing Wear:
This menu shows the current Bearing wear, Installed reference value and
Alarm Limit both as separate diagram charts and numeric values.

Figure 12- Bearing Wear

This screen has two buttons at the top: WEARING HISTORY AFT and
BEARING WEAR FWD.

From WEAR HISTORY AFT we access the stored wear history values
for the bearing wear sensor.

From BEARING WEAR FWD we access the equivalent screen for

bearing wear sensor FWD.

Wear History:
This menu shows the last 26 stored values from the bearing wear sensor.
The values are stored every time the shaft stops for more than 5min.
When value number 27 is stored it will automatically overwrite the first
value and so on.
The overwritten values will NOT be deleted from the history when it
overwritten in the screen. The values will only be deleted from this menu
but still be stored on the memory and accessible by export file.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 23 of 32
 IAMCS

Figure 13- Wear History

Low Pressure Pump 1 & 2

This screen shows the alternancy value in hours set-up for the pumps
(24h, 48h, …) and the flow alarm timeout value.

Figure 14- Low Pressure Pumps Settings

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 24 of 32
 MAINTENANCE

7. MAINTENANCE

This section gives guidelines for maintenance.

7.1. Daily attention

Check all pumps, pipes and hoses for leaks.

7.2. Periodic maintenance

Analysis covers cleanliness level according, viscosity, oxidation, and
particles.

7.3. Low pressure pumps

The WQS-Unit is equipped with two low pressure (LP) pumps for
circulation.

7.3.1. Circulation pumps

Checking of the centrifugal pump’s operational conditions must be

carried out regularly every 1,000 working hours or, in the event of a
deterioration in performance.

7.4. Pipework
Check all pipes and hoses, as well as pumps for leaks.

Retighten, couplings/connections, clamps and brackets and replace seals

as required.

7.5. Servicing
Most customers will be able to carry out routine service. If required,
SVENSKA BEARING is always ready to help.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 25 of 32
 NOTES

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 26 of 32
 TROUBLESHOOTING

8. TROUBLESHOOTING

This section will guide through troubleshooting the WQS-unit.

8.1. Repair work.

Before start with any repair work of the pumps, switch off the overload
protection to the pump in question.

• LOW PRESSURE PUMP 1 – Q2

• LOW PRESSURE PUMP 2 – Q3

8.2. Reset pump after reparation.

After reparation or maintenance reset the pump by switch on the overload
protection.

Quick reset of pump: Switch the overload protection “OFF” and “ON”

8.3. Reset WQS-unit after blackout.

Reset the WQS-Unit after a blackouts/power failure by push the
“Emergency Stop” and reset “Emergency Stop” this will reset the unit.

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 27 of 32
 TROUBLESHOOTING
8.4. Troubleshooting list for the WQS-O unit

SYMTOM LIKELY CAUSE REMEDY

Failure to start No power supply Check main power

supply

Check Fuses

Check individual
cable connections

Individual pump Check connections

motor failure between starting
cabinet and motor

Check fuses

No or low Pump running in Reverse direction

lubrication flow wrong direction
from pump

Valves in wrong Check valves

position

No suction Checking piping and

valves on suction
side

SYMTOM LIKELY CAUSE REMEDY

Pump wheel fault Check pump wheel

Unusual noise in Suction valve closed. Open valve. Check

pump No or inadequate, feed pressure
feed pressure

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 28 of 32
 TROUBLESHOOTING

Unusual noise in Air leakage Check suction pipe

pump for leaks

Wrong direction of Reverse direction

rotation

Worn pump Change or renovate

pump

Excessive wear Abrasive material in Check pipes and

circulation replace them if
necessary. Observe
proper intervals

Inadequate lube flow Check pumps

High system oil temp Inadequate cooling Check cooler and

cooling water supply

Internal leakage in Replace or renovate

pump pump

Switch circulation
pump

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 29 of 32
 NOTES

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 30 of 32
 NOTES

INSTALLATION – OPERATION AND MAINTENANCE INSTRUCTIONS WQS-O

Page 31 of 32
 PART LIST
&
ASSEMBLY DRAWINGS
 ED AMENDMENT DATE SIGN

1700

13 2 Each SCV 1016 PE 4,4 kg Cyclone filter (10-16 m3/h) inlet/outlet:1½" F PE-100
12 2 Each DM 15 30,0 kg DM15 CASSA 90=1,5kW Steel
11 4 Each DIN 580 - M16 0,3 kg Lifting Eyebolt Steel, Mild
10 1 Each 185586515 3,5 kg Pressure Retaining Valve Type 586 d40DN32 PP
9 1 Each 200-1062 0,3 kg Cyclone Purge Assy pt2 PP/PE-100
8 1 Each 200-1061 3,5 kg Cyclone Purge Assy pt1 PP/PE-100
7 1 Each 200-1060 0,4 kg Pressure Regulating Valve Assy PP/PE-100
6 1 Each 200-1059 1,8 kg Outlet Stern Tube PP/PE-100
5 1 Each 200-1057 1,8 kg Cyclone Filter outlet PP/PE-100
4 2 Each 200-1056 1,2 kg Pump Outlet PP/PE-100
00

3 1 Each 200-1055 5,1 kg Water inlet PP/PE-100

12

2 1 Each 200-1052 25,0 kg ELECTRICAL BOX WQS-O N/A

1 1 Each 200-1050 123,0 kg WQS Structure Steel
80
0

ITEM UNIT DRAWING No. ITEM MASS MATERIAL

QTY. DENOMINATION SIZE/DIMENSION
No. ARTICLE/GROUP No.
WQS Open Size 1 MASS 237 kg

GENERAL SCALE 1 : 10
INTERFACE APPROVED BY

"PE100" CHECKED BY
Existing law protects Svenska Bearing's right of possession to TOLERANCE SYSTEM SIZE CUSTOMER: DRAWN MME
this drawing. The design or the drawing must not, without A3
permission of the company, be published, copied, reproduced, ISO 128 DATE 2022-06-29
PROJECT:
manufactured or exploited in any other unauthorized way.
Polígono de Tragove, Nave 1 DRAWING No. SHEET ED
36634 Cambados - Pontevedra España
Telephone: +34 986 520 909. 200-1045 1 (3 ) A
 ED AMENDMENT DATE SIGN

11 1 11

2 5

4 13

1700
10

9 12 800
122 1200

ITEM UNIT DRAWING No. ITEM MASS MATERIAL

QTY. DENOMINATION SIZE/DIMENSION
No. ARTICLE/GROUP No.
WQS Open Size 1 MASS 237 kg

GENERAL SCALE 1 : 10
INTERFACE APPROVED BY

"PE100" CHECKED BY
Existing law protects Svenska Bearing's right of possession to TOLERANCE SYSTEM SIZE CUSTOMER: DRAWN MME
this drawing. The design or the drawing must not, without A3
permission of the company, be published, copied, reproduced, ISO 128 DATE 2022-06-29
PROJECT:
manufactured or exploited in any other unauthorized way.
Polígono de Tragove, Nave 1 DRAWING No. SHEET ED
36634 Cambados - Pontevedra España
Telephone: +34 986 520 909. 200-1045 2 (3 ) A
 ED AMENDMENT DATE SIGN

SEAWATER OUTLET STERN TUBE

DN32" FLANGE

FILTER PURGE
G3/4" (FEMALE)

170
128

96
150 113

498

SEAWATER INLET
DN40" FLANGE
A(1:5)

ITEM UNIT DRAWING No. ITEM MASS MATERIAL

QTY. DENOMINATION SIZE/DIMENSION
No. ARTICLE/GROUP No.
WQS Open Size 1 MASS 237 kg

GENERAL SCALE 1 : 10
INTERFACE APPROVED BY

"PE100" CHECKED BY
Existing law protects Svenska Bearing's right of possession to TOLERANCE SYSTEM SIZE CUSTOMER: DRAWN MME
this drawing. The design or the drawing must not, without A3
permission of the company, be published, copied, reproduced, ISO 128 DATE 2022-06-29
PROJECT:
manufactured or exploited in any other unauthorized way.
Polígono de Tragove, Nave 1 DRAWING No. SHEET ED
36634 Cambados - Pontevedra España
Telephone: +34 986 520 909. 200-1045 3 (3 ) A
 INDEX
INDEX ED. AMENDMENT DATE SIGN.
No.
1(1) GENERAL WQS INFORMATION

ITEM DRAWING No.

QTY. UNIT ITEM MASS DENOMINATION TYPE SIZE/DIMENSION MATERIAL
No. ARTICLE/GROUP No.

MASS 0.0
WQS OPEN "PE" General Scale 1:1
PID See draw.list

DRAWING PRODUCED ON AUTOCAD

APPROVED BY
200-1068

CHECKED BY

DRAWN MME
DATE 2022-10-13
Existing law protects Svenska Bearing's right of possession to this drawing.
TOLERANCE SYSTEM ISO 128 DRAWING No. SHEET ED
The design or the drawing must not, without permission of the company, be
CONTRACT No.
published, copied, reproduced, manufactured or exploited in any other
unauthorized way.
-
SVENSKA BEARING
200-1068 1( 1 ) A
 INDEX
INDEX ED. AMENDMENT DATE SIGN.
No.
1(1)

ITEM DRAWING No.

QTY. UNIT ITEM MASS DENOMINATION TYPE SIZE/DIMENSION MATERIAL
No. ARTICLE/GROUP No.

MASS 0.0
WATER QUALITY SYSTEM General Scale 1:1
PID See draw.list

DRAWING PRODUCED ON AUTOCAD

APPROVED BY
200-1070

CHECKED BY
OPEN CIRCUIT
DRAWN MME
DATE 2022-07-08
Existing law protects Svenska Bearing's right of possession to this drawing.
The design or the drawing must not, without permission of the company, be
TOLERANCE SYSTEM ISO 128 DRAWING No. SHEET ED

CONTRACT No.
published, copied, reproduced, manufactured or exploited in any other
unauthorized way.
SVENSKA BEARING
STANDARD DRW
200-1070 1( 1 ) A
 0 1 2 3 4 5 6 7 8 9

Svenska Bearing

Pol. Ind. Sete Pías 34

36635 - Cerenxeira; Cambados
Pontevedra

Company / customer SVENSKA BEARING

Project description Open WQS Unit
Job number 3-100-2109-800

Manufacturer (company) Svenska Bearing

Path Power: 400V; 50Hz

Project name 3-100-2109-800
Make
Type
Place of installation
Responsible for project

Created on 07/02/2023
Edit date 20/07/2023 DAVID Number of pages 33

2
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=C1+BOX&1-COVER PAGE/2 Table of contents 19/07/2023 DAVID

=C1+BOX&1-COVER PAGE/2.b Table of contents 19/07/2023 DAVID X

=C1+BOX&1-COVER PAGE/3 Table of contents 19/07/2023 DAVID

=C1+BOX&2-LAYOUT/5 LAYOUT 19/07/2023 DAVID

=C1+BOX&2-LAYOUT/6 Safety instructions 19/07/2023 DAVID X

=C1+BOX&2-LAYOUT/7 Summarized parts list 19/07/2023 DAVID X

=C1+BOX&2-LAYOUT/7.a Summarized parts list 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/9 POWER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/10 POWER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/10.a MANEUVER 24VDC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/11 PUMP LOW PRESSURE 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/12 HMI 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/13 INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/14 INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/15 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/16 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/17 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/18 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/19 ANALOG INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/29 MANEUVER OUTPUTS 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/30 MANEUVER OUTPUTS 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/31 MANEUVER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/32 SECURITY SWITCH 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/32.a MANEUVER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/33 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/33.a PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/34 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/35 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/36 Terminal-connection diagram -X1 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/37 Terminal-connection diagram -X2 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/38 Terminal-connection diagram -X3 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/39 Terminal-connection diagram -X4 19/07/2023 DAVID X

1 3
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Page Page description supplementary page field Date Edited by X

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=C1+BOX&1-COVER PAGE/2.a Table of contents 19/07/2023 DAVID X

=C1+BOX&1-COVER PAGE/2.b Table of contents 19/07/2023 DAVID X

=C1+BOX&1-COVER PAGE/3 Índice de páginas : =C1+BOX&1-COVER PAGE/1 - =C1+BOX&3-DRAWINGS/39 19/07/2023 DAVID

=C1+BOX&2-LAYOUT/5 LAYOUT 19/07/2023 DAVID

=C1+BOX&2-LAYOUT/6 Safety instructions 19/07/2023 DAVID X

=C1+BOX&2-LAYOUT/7 Summarized parts list 19/07/2023 DAVID X

=C1+BOX&2-LAYOUT/7.a Summarized parts list 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/9 POWER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/10 POWER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/10.a MANEUVER 24VDC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/11 PUMP LOW PRESSURE 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/12 HMI 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/13 INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/14 INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/15 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/16 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/17 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/18 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/19 ANALOG INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/29 MANEUVER OUTPUTS 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/30 MANEUVER OUTPUTS 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/31 MANEUVER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/32 SECURITY SWITCH 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/32.a MANEUVER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/33 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/33.a PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/34 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/35 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/36 Terminal-connection diagram -X1 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/37 Terminal-connection diagram -X2 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/38 Terminal-connection diagram -X3 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/39 Terminal-connection diagram -X4 19/07/2023 DAVID X

2 4
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Modification Date Name Original Page 33
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Page Page description supplementary page field Date Edited by X

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=C1+BOX&1-COVER PAGE/2 Índice de páginas : =C1+BOX&1-COVER PAGE/1 - =C1+BOX&3-DRAWINGS/39 19/07/2023 DAVID

=C1+BOX&1-COVER PAGE/3 Índice de páginas : =C1+BOX&1-COVER PAGE/1 - =C1+BOX&3-DRAWINGS/39 19/07/2023 DAVID

=C1+BOX&1-COVER PAGE/4 Índice de páginas : =C1+BOX&1-COVER PAGE/1 - =C1+BOX&3-DRAWINGS/39 19/07/2023 DAVID

=C1+BOX&2-LAYOUT/5 LAYOUT 19/07/2023 DAVID

=C1+BOX&2-LAYOUT/6 Safety instructions 19/07/2023 DAVID X

=C1+BOX&2-LAYOUT/7 Summarized parts list 19/07/2023 DAVID X

=C1+BOX&2-LAYOUT/7.a Summarized parts list 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/9 POWER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/10 POWER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/10.a MANEUVER 24VDC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/11 PUMP LOW PRESSURE 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/12 HMI 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/13 INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/14 INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/15 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/16 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/17 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/18 OUTPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/19 ANALOG INPUT PLC 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/29 MANEUVER OUTPUTS 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/30 MANEUVER OUTPUTS 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/31 MANEUVER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/32 SECURITY SWITCH 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/32.a MANEUVER 19/07/2023 DAVID

=C1+BOX&3-DRAWINGS/33 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/33.a PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/34 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/35 PLC DIAGRAM 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/36 Terminal-connection diagram -X1 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/37 Terminal-connection diagram -X2 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/38 Terminal-connection diagram -X3 19/07/2023 DAVID X

=C1+BOX&3-DRAWINGS/39 Terminal-connection diagram -X4 19/07/2023 DAVID X

3 &2-LAYOUT/5
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Appr 3-100-2109-800 Page 4
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

-CUADRO

-KF1
ABB.2TLA010050R0000
-JC1 Sentry SSR10 24VDC
17 -TB1
-JC1-1 -JC1-2

KA10

KA11

KA12
KA2

KA3

KA4

KA5

KA6

KA7

KA8

KA9
-PD1
A-B.2711R-T7T
203

-FF1 -FF2 -FF3 -FF4 -FF5 -FF6 -FF7 -QE1 -QE2 -QA1 -QA2

-QD1
SE.KCF1PZ
KCF1PZ
204

&1-COVER PAGE/4 6
Date 19/07/2023 LAYOUT
Ed. DAVID
Appr 3-100-2109-800 Page 5
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

SAFETY REGULATIONS Svenska Bearing

Pol. Ind. Sete Pías 34

36635 - Cerenxeira; Cambados

GENERAL SAFETY REGULATIONS

During plant operation certain items are under dangerous voltage!
Non-observance of safety instructions can result in death, serious injuries or material damage.

Only specialist personnel may carry out transport, installation and commissioning work.
DANGER!

The applicable valid standards as well as the national and / or company-specific accident prevention regulations are to
observed.

The following safety instructions are to be observed:

The erection, commissioning, troubleshooting as well as repair of the plant may only be carried out by qualified personnel that is familiar with the corresponding operating instructions.

Mounting of the devices has to be effected in accordance with the valid standards, state and local regulations.
Proper grounding and conductor dimensioning as well as proper short-circuit proofing have to be ensured.
These measures serve to ensure the safety of the plant and of the operating personnel.

Before carrying out safety checks, maintenance work and repair measures ensure that all the power supplies are switched off, are secured against being switched on unintentionally and are marked
correspondingly.

Only test devices that are in a technically perfect condition and are suitable for the respective measurement may be used to carry out measurements!

The instructions specified in the respective operating instructions are to be followed strictly!
It is mandatory that hazard, warning and safety instructions be observed!

All doors and covers are to be kept closed during the plant operation.
If cooling devices are installed in the plant, ensure that these systems operate trouble-free.
These include the regular cleaning of the filters, in as far as they exist.

5 7
Date 19/07/2023 Safety instructions
Ed. DAVID
Appr 3-100-2109-800 Page 6
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

Summarized parts list F02_001

Description Type number Manufacturer

Order number Quantity Unit price Total price Pos
Designation Part number Supplier

3 2080 A-B
2080-LC50-24QWB 0,00 0,00
piece Micro850 24 I/O EtherNet/IP Controller A-B.2080-LC50-24QWB

0
0,00

5 77 UNEX
80.30.77 0,00 0,00
M. Unex slotted trunking 80x30 in U23X UNEX.80.30.77 UNEX

1 PT-010-SEG14-A-ZVG/US/ /W IFM
PT5404 0,00 0,00
Electronic pressure sensor IFM.PT5404 IFM

1
0,00
SE.NSYS3DE6620P

1 DF103 SE
DF103 0,00 0,00
TeSys fuse holder - 3 P 32A SE.DF103 SE

6 DF101 SE
DF101 0,00 0,00
TeSys fuse holder - 1 P 32A SE.DF101 SE

6
0,00
TP.10382A

2 SAEXXXXBFRKG/US-100 IFM
SA4100 0,00 0,00
Piece Flow sensor IFM.SA4100

1 2085 A-B
2085-OB16 0,00 0,00
Micro800 Output Module A-B.2085-OB16 A-B

1 2085 A-B
2085-IF4 0,00 0,00
Micro800 Input Module A-B.2085-IF4 A-B

11 TRZ 24VDC 1CO WEI

1122880000 0,00 0,00
Piece Relay module WEI.1122880000 WEI

1 Sentry SSR10 24VDC ABB

2TLA010050R0000 0,00 0,00
PCE Sentry SSR10 24VDC ABB.2TLA010050R0000 ABB

1
0,00
A-B.2711R-T7T

2 LC1-D 3P 9A SE
LC1D09BL 0,00 0,00
Contactor TeSys LC1-D - 3P - AC-3 440V 9 A, Coil 24 V DC SE.LC1D09BL SE

2 LADN11 SE
LADN11 0,00 0,00
Piece Auxiliary contact block, TeSys Deca, 1NO + 1NC, front mounting, screw clamp SE.LADN11
terminals SE

1 V1 SE
V1 0,00 0,00
TeSys VARIO Switch Disconnector Body SE.V1 SE

1 KCF1PZ SE
KCF1PZ 0,00 0,00
TeSys VARIO / Mini VARIO - front and RED rotary handle SE.KCF1PZ SE

2 GV2ME08 SE
GV2ME08 0,00 0,00
Thermal Magnetic Motor Circuit Breaker TeSys GV2ME - 3P - 2.5...4 A SE.GV2ME08 SE

6 7.a
Date 19/07/2023 Summarized parts list
Ed. DAVID
Appr 3-100-2109-800 Page 7
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

Summarized parts list F02_001

Description Type number Manufacturer

Order number Quantity Unit price Total price Pos
Designation Part number Supplier

2 GVAE11 SE
GVAE11 0,00 0,00
TeSys GVAE11 - auxiliary contact - 1 NO + 1 NC SE.GVAE11 SE

4 800F A-B
800F-X01 0,00 0,00
Contact Block A-B.800F-X01 A-B

1 800F A-B
800FP-MT44 0,00 0,00
Twist-to-Release, 40mm A-B.800FP-MT44 A-B

1 800F A-B
800F-ALP 0,00 0,00
Plastic Latch A-B.800F-ALP A-B

1 PRO ECO3 120W 24V 5A WEI

1469530000 0,00 0,00
Piece Power supply WEI.1469530000

7 &3-DRAWINGS/9
Date 19/07/2023 Summarized parts list
Ed. DAVID
Appr 3-100-2109-800 Page 7.a
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

L1.1 L1.1
L1.1 / 10.0
L2.1 L2.1
L2.1 / 10.0
L3.1 L3.1
L3.1 / 10.0

CAUTION!

Remains energized when main

switch is opened

2/T1 4/T2 6/T3

-QD1
32A
1/L1 3/L2 5/L3

L3
L2
L1

PE / 10.0

-X1 1 2 3 4 -X2 7 8

YARD SUPPLY
11KW; 25A
POWER LINE 4X6mm

&2-LAYOUT/7.a 10
Date 19/07/2023 POWER
Ed. DAVID
Appr 3-100-2109-800 Page 9
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

9.9 / L1.1 L1.1 / 11.0

9.9 / L2.1 L2.1 / 11.0

9.9 / L3.1 L3.1 / 11.0

9.4 / PE PE / 11.0

1 3 5

-FF1
2A
2 4 6

09

08

07

Weidmüller
-TB1 L1(+) L2(-) L3 PE
PROeco3

Adjust
22-28 V

+ + - - 13 14

601

043
043B / 10.a.0
011
011

010
010

1 1 1 1 1 1

-FF2 -FF3 -FF4 -FF5 -FF6 -FF7

2A 2A 2A 2A 2A 2A
2 2 2 2 2 2

012 043 013 403 014 036 049 051 053 054 600 601

012 043 401 013 403 014 036 049 051 053 054 600 601
31.1 13.0 31.1 31.1 31.1 32.0 32.a.0 12.1 12.1 15.0 15.0 19.0 19.0

CIRCUIT CIRCUIT
DRAINING DRAINING CIRCUIT CIRCUIT CIRCUIT CIRCUIT
VALVE LP1 VALVE LP2 CONTROL PLC+HMI OUT-PLC DIG/ANA IN PLC

9 10.a
Date 19/07/2023 POWER
Ed. DAVID
Appr 3-100-2109-800 Page 10
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

10.5 / 043B
043

-XC1 1 2 3 4 5 6 7 8 9 10 11 12

10 11
Date 19/07/2023 MANEUVER 24VDC
Ed. DAVID
Appr 3-100-2109-800 Page 10.a
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

L1.1
10.7 / L1.1
L2.1
10.7 / L2.1
L3.1
10.7 / L3.1

-QE1 -QE2
/32.a.5 1 3 5 /32.a.1 1 3 5
/13.7 /13.8
2,5-4A 2,5-4A

I> I> I> I> I> I>

2 4 6 2 4 6

01 04

02 05

03 06

1/L1 3/L2 5/L3 1/L1 3/L2 5/L3

-QA1 -QA2
/29.1 2/T1 4/T2 6/T3 /29.2 2/T1 4/T2 6/T3

1 4

2 5

3 6

10.7 / PE PE / 12.1

-X1 5 6 7
8
9 10 11
12

-W_M1 -W_M2
4G1,5mm BK BN GY GNYE 4G1,5mm BK BN GY GNYE

U1 V1 W1 PE U1 V1 W1 PE

M M
-M1 -M2
1,5KW;3,5A 3 1,5KW;3,5A 3
PUMP LP1-M1 PUMP LP2-M2
LOW PRESSURE LOW PRESSURE

10.a 12
Date 19/07/2023 PUMP LOW PRESSURE
Ed. DAVID
Appr 3-100-2109-800 Page 11
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

10.4 / 049

10.4 / 051

11.8 / PE PE /

049

051

-JC1
/13.0
/14.1
/15.1
/16.2

-PD1
DC + DC - PE T T- R R- 2080
5

(S 485

5
48

48

48

48
/R )
-4 ield
S-

S-

S-

S-

S-
/R

/R

/R

/R

h
22

22

22

22

22
-4

-4

-4

-4
RS

RS

RS

RS

RS
S

PanelView Component, 800 Model,

7 in., Color (TFT)
rt

A-B.2711R-T7T
po

rt
t
or

po
ce
tp
rt

st
vi
po

ne

ho
de
-2 ial

r
he

B
r
32

US

US
Se

Et
5
-4
RS

RJ

RS232/485
PD1-E RJ45
USB

11 13
Date 19/07/2023 HMI
Ed. DAVID
Appr 3-100-2109-800 Page 12
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

13.9 / +24VDC +24VDC / 13.0

10.1 / 043 043 / 14.0

32.4
041
-FS_LP1 SA4100 -FS_LP2 SA4100 042
0...6 m/s 0...6 m/s
13.9 / 042 042 / 13.7
2 1 2 1
3 4
M12
3 4
M12
041
18...30 VDC 18...30 VDC
L+ L- Out 1 Out 2 L+ L- Out 1 Out 2 040
1 3 4 2 1 3 4 2
31.2 / 040

11 (COM) 21 21
-KA13 -QE1 -QE2
/30.2 14 (NO) 12 (NC) /11.0 22 /11.4 22

601, 601.
19.2 19.2
600, 600.
19.2 19.2

32.a.6 32.a.2 32.4

025.1 033.1 045

-X3 3 6

043 602 605 025.1 033.1 044 045 046 047

COM0 I-00 I-01 I-02 I-03 I-04 I-05 I-06 I-07

-JC1 1 2 3 4 5 6 7 8 9
/12.3
PLC Rack I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7
Slot
2080 -FS_LP1:4 -FS_LP2:4 -QE1:14 -QE2:14 -KA13:14 (NO) -KF1:24 -QE1:22 -QE2:22

MOTOR PROTECTOR MOTOR PROTECTOR

FLOW SENSOR FS-LP1 FLOW SENSOR FS-LP2 CM_B1 CM_B2 RUN SIGNAL EMERGENCY STOP PUMP LP1-M1 PUMP LP2-M2

12 14
Date 19/07/2023 INPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 13
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

14.8 / +24VDC +24VDC / 14.0

-0VDC /

042 042.1
32.4 / 042

11 (COM) 13
-KA14 -SA1
/30.3 14 (NO) 12 (NC) /32.a.1 14
/32.a.5

13.9 / 043

043 048 I0.9

COM1 I-08 I-09 I-10 I-11 I-12 I-13

-JC1 10 11 12 13 14 15 16
/12.3
PLC Rack I0.8 I0.9 I0.10 I0.11 I0.12 I0.13
Slot
2080 -KA14:14 (NO) -SA1:14

RESET ALARM AUTOMATIC MODE SPARE SPARE SPARE SPARE

13 15
Date 19/07/2023 INPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 14
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

-JC1 START/STOP START/STOP ALARM TO ECR ALARM FLOW LP1 ALARM FLOW LP2 ALARM THERMAL LP1
/12.3 PUMP LP1-M1 PUMP LP2-M2
PLC Rack
Slot -KA2:+A1 -KA3:+A1 -KA4:+A1 -KA5:+A1 -KA6:+A1 -KA7:+A1
2080
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5
4 1 6 5 7 8 9 10 11 1 2
O-00 COM0 O-01 CM1 CM2 O-02 O-03 O-04 O-05 +DC24 -DC24

056 057 058 059 060 061

+A1 +A1 +A1 +A1 +A1 +A1

-KA2 -KA3 -KA4 -KA5 -KA6 -KA7
-A2 -A2 -A2 -A2 -A2 -A2

053 053 053 053 054 055

10.5 / 053 053 / 17.0

055 / 16.0

10.5 / 054

14 (NO) 14 (NO) 14 (NO) 14 (NO) 14 (NO) 14 (NO)

12 (NC) 11 (COM) /32.a.6 12 (NC) 11 (COM) /32.a.2 12 (NC) 11 (COM) /32.a.3 12 (NC) 11 (COM) 12 (NC) 11 (COM) 12 (NC) 11 (COM)
14 14 14
12 11 /29.4 12 11 /29.5 12 11 /29.6

14 16
Date 19/07/2023 OUTPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 15
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

-JC1
/12.3
PLC Rack ALARM THERMAL LP2
Slot -KA8:+A1
2080
Q0.6 Q0.7 Q0.8 Q0.9
1 13 14 15 16
+DC24 O-06 O-07 O-08 O-09

062

+A1
-KA8
-A2

+24VDC 055

16.8 / +24VDC +24VDC / 16.0

15.8 / 055 055 / 17.0

14 (NO)
12 (NC) 11 (COM)
14
12 11 /29.7

15 17
Date 19/07/2023 OUTPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 16
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

-JC1-1
/18.0
Output Terminal Block 1 16-Point Source 12/24V DC Output 2085-OB16
24 VDC
DRAINING VALVE LP1 DRAINING VALVE LP2 ALARM FWD ALARM AFT

Q1.00 Q1.01 Q1.02 Q1.03 Q1.04 Q1.05 Q1.06 Q1.07

1 2 3 4 5 6 7 8 9 10 11 12
+CM0 O-00 O-01 O-02 O-03 -CM0 O-04 O-05 O-06 O-07 -CM0 NC

053 063 064 065 066

+A1 +A1 +A1 +A1

-KA9 -KA10 -KA11 -KA12
-A2 -A2 -A2 -A2

055 055 055 055

15.8 / 053

16.8 / 055

14 (NO) 14 (NO) 14 (NO) 14 (NO)

12 (NC) 11 (COM) 12 (NC) 11 (COM) 12 (NC) 11 (COM) 12 (NC) 11 (COM)
14 14 14 14
12 11 /31.1 12 11 /31.3 12 11 /29.8 12 11 /30.0

16 18
Date 19/07/2023 OUTPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 17
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

-JC1-1
/17.0
Output Terminal Block 2 16-Point Source 12/24V DC Output 2085-OB16
24 VDC

Q1.08 Q1.09 Q1.10 Q1.11 Q1.12 Q1.13 Q1.14 Q1.15

13 14 15 16 17 18 19 20 21 22 23 24
+CM1 O-08 O-09 O-10 O-11 -CM1 O-12 O-13 O-14 O-15 -CM1 NC

17 19
Date 19/07/2023 OUTPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 18
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

10.6 / 601

13.3 / 601.

13.1 / 601,

601
-X3 1 4 7 10 13 16 19

-BP1 2 1 PT5404
0-10 bar M12
13.3 / 600.
8,5-36 VDC 4...20 mA
13.1 / 600,
L+ OUT
1 2
10.6 / 600
600
-X3 2 5 8 11 14 17 20

-X3 9 12 15 18

607 610 613 601

CI-0 VI-0 COM0 CI-1 VI-1 COM1 CI-2 VI-2 COM2 CI-3 VI-3 COM3

-JC1-2 1 2 3 4 5 6 7 8 9 10 11 12
10V, 20mA
IW2.0 IW2.1 IW2.2 IW2.3

BEARING WEAR BEARING WEAR PRESSURE SENSOR SPARE

SENSOR FWD SENSOR AFT 4 Analog Inputs -10…+10V, 0…20mA
Input Terminal Block 1 2085-IF4

18 29
Date 19/07/2023 ANALOG INPUT PLC
Ed. DAVID
Appr 3-100-2109-800 Page 19
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

53 53 11 11 11 11 11 11
-QA1 -QA2 -KA1 -KA5 -KA6 -KA7 -KA8 -KA11
/32.a.5 54 /32.a.1 54 /32.a.3 14 12 /15.5 14 12 /15.6 14 12 /15.7 14 12 /16.3 14 12 /17.3 14 12
/11.1 /11.4
/32.a.6 /32.a.1
140 A AC 140 A AC

900 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915

-X4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

RUNNING RUNNING ALARM FLOW ALARM FLOW ALARM ALARM

LP1-M1 LP2-M2 FAILURE ECR LP1 LP2 THERMAL LP1 THERMAL LP2 ALARM FWD

19 30
Date 19/07/2023 MANEUVER OUTPUTS
Ed. DAVID
Appr 3-100-2109-800 Page 29
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

11 A2 A2
-KA12 -KA13 -KA14
/17.4 14 12 A1 A1

916 917 920 921 922 923

-X4 17 18 21 22 23 24 25 26 27 28

ALARM AFT RELAY START 24VDC RELAY START 24VDC

14 (NO) 14 (NO)
12 (NC) 11 (COM) /13.5 12 (NC) 11 (COM) /14.3

29 31
Date 19/07/2023 MANEUVER OUTPUTS
Ed. DAVID
Appr 3-100-2109-800 Page 30
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

10.2 / 013
040
10.1 / 012 040 / 13.5

012 013

11 11
-KA9 -KA10
/17.1 14 12 /17.2 14 12

400 402

-X2 1 3 5 6

x1 x1

x2 x2

-X2 2 4

401 403

10.2 / 401

10.2 / 403

DRAINING DRAINING
VALVE LP1 VALVE LP2

30 32
Date 19/07/2023 MANEUVER
Ed. DAVID
Appr 3-100-2109-800 Page 31
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

10.3 / 014 015 / 32.a.3

/ 038 039 /

1 1

-SC1
2 2 13.6 14.0
041 042

014 041 042

-X4 19

014 038 068 069 070 071 918

-KF1 (+) (-)

24VDC A1 A2 T1 R1 T2 R2 13 23 33 41

CH1 CH2
Jokab Safety
CH1
Sentry SSR10 24VDC MODE
2TLA010050R0000 CH2
M
xA
X1 X4 14 24 34 42
Reset/ Test Lamp/ Ind.

016 045 919

-X4 20

016 045
32.a.0 13.6

31 32.a
Date 19/07/2023 SECURITY SWITCH
Ed. DAVID
Appr 3-100-2109-800 Page 32
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

32.3 / 016

016 019 019 019

11 11 (COM) 32.8 11 11 (COM)
SB2-1 -KA3 015 SB1-1 -KA2
12 /15.2 14 (NO) 12 (NC) 12 /15.1 14 (NO) 12 (NC)

015
029 029 017 017

13 13 11 (COM) 13 13
-SB2-2 -QA2 -KA4 -SB1-2 -QA1
14 /29.2 14 /15.4 14 (NO) 12 (NC) 14 /29.1 14

030 031 026 034 020 021 023

1 11

-SA1 -SA1
/32.a.5 /32.a.1
2 12
/14.4 /14.4

027 022

13 13
-QE2 -QE1
/11.4 14 /11.0 14
/13.8 /13.7

032 024

032 033 033.1 034 035 024 025 025.1

A1 x1 A1 x1 A1 x1
-QA2 -SB1-3 033.1 -KA1 -PF1 -QA1 -SB2-3 025.1
24VDC A2 x2 13.4 A2 x2 24VDC A2 x2 13.4

036 039 037 067 037 067

10.3 / 036

53 54 /29.2 14 53 54 /29.1
61 62 12 11 /29.3 61 62
1/L1 2/T1 /11.4 1/L1 2/T1 /11.1
3/L2 4/T2 /11.5 3/L2 4/T2 /11.1
5/L3 6/T3 /11.5 5/L3 6/T3 /11.1
13 14 /32.a.1 13 14 /32.a.6
21 22 21 22

CONTACTOR RUNNING CONTACTOR RUNNING

PUMP LP2-M2 PUMP LP2-M2 RELAY ALARM ALARM PUMP LP1-M1 PUMP LP1-M1

32 33
Date 19/07/2023 MANEUVER
Ed. DAVID
Appr 3-100-2109-800 Page 32.a
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

PLC diagram F19_003

PLC-Designation =C1+BOX-JC1

Address Function text Placement Rack Module Symbolic address Terminal Manufacturer

&3-DRAWINGS/13.1 1 A-B

&3-DRAWINGS/14.2 10 A-B

&3-DRAWINGS/16.2 1 A-B

&3-DRAWINGS/15.8 2 A-B

3 A-B

&3-DRAWINGS/15.2 5 A-B

&3-DRAWINGS/15.3 7 A-B

12 A-B

1 A-B

1 A-B

1 A-B

&3-DRAWINGS/15.7 1 A-B

&3-DRAWINGS/15.1 1 A-B

I0.0 FLOW SENSOR FS-LP1 &3-DRAWINGS/13.2 =C1+BOX-FS_LP1:4 2 A-B

I0.1 FLOW SENSOR FS-LP2 &3-DRAWINGS/13.3 =C1+BOX-FS_LP2:4 3 A-B

I0.2 CM_B1 &3-DRAWINGS/13.4 =C1+BOX-QE1:14 4 A-B

I0.3 CM_B2 &3-DRAWINGS/13.4 =C1+BOX-QE2:14 5 A-B

I0.4 RUN SIGNAL &3-DRAWINGS/13.5 =C1+BOX-KA13:14 (NO) 6 A-B

I0.5 EMERGENCY STOP &3-DRAWINGS/13.6 =C1+BOX-KF1:24 7 A-B

I0.6 MOTOR PROTECTOR PUMP LP1-M1 &3-DRAWINGS/13.7 =C1+BOX-QE1:22 8 A-B

I0.7 MOTOR PROTECTOR PUMP LP2-M2 &3-DRAWINGS/13.8 =C1+BOX-QE2:22 9 A-B

I0.8 RESET ALARM &3-DRAWINGS/14.3 =C1+BOX-KA14:14 (NO) 11 A-B

I0.9 AUTOMATIC MODE &3-DRAWINGS/14.4 =C1+BOX-SA1:14 12 A-B

I0.10 SPARE &3-DRAWINGS/14.4 13 A-B

I0.11 = &3-DRAWINGS/14.5 14 A-B

I0.12 = &3-DRAWINGS/14.6 15 A-B

I0.13 = &3-DRAWINGS/14.7 16 A-B

Q0.0 START/STOP PUMP LP1-M1 &3-DRAWINGS/15.1 =C1+BOX-KA2:+A1 4 A-B

32.a 33.a
Date 19/07/2023 PLC DIAGRAM
Ed. DAVID
Appr 3-100-2109-800 Page 33
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

PLC diagram F19_003

PLC-Designation =C1+BOX-JC1

Address Function text Placement Rack Module Symbolic address Terminal Manufacturer

Q0.1 START/STOP PUMP LP2-M2 &3-DRAWINGS/15.2 =C1+BOX-KA3:+A1 6 A-B

Q0.2 ALARM TO ECR &3-DRAWINGS/15.4 =C1+BOX-KA4:+A1 8 A-B

Q0.3 ALARM FLOW LP1 &3-DRAWINGS/15.5 =C1+BOX-KA5:+A1 9 A-B

Q0.4 ALARM FLOW LP2 &3-DRAWINGS/15.6 =C1+BOX-KA6:+A1 10 A-B

Q0.5 ALARM THERMAL LP1 &3-DRAWINGS/15.7 =C1+BOX-KA7:+A1 11 A-B

Q0.6 ALARM THERMAL LP2 &3-DRAWINGS/16.3 =C1+BOX-KA8:+A1 13 A-B

Q0.7 &3-DRAWINGS/16.4 14 A-B

Q0.8 &3-DRAWINGS/16.5 15 A-B

Q0.9 &3-DRAWINGS/16.6 16 A-B

33 34
Date 19/07/2023 PLC DIAGRAM
Ed. DAVID
Appr 3-100-2109-800 Page 33.a
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

PLC diagram F19_003

PLC-Designation =C1+BOX-JC1-1

Address Function text Placement Rack Module Symbolic address Terminal Manufacturer

&3-DRAWINGS/17.0 1 A-B

&3-DRAWINGS/17.5 6 A-B

&3-DRAWINGS/17.9 11 A-B

&3-DRAWINGS/17.9 12 A-B

&3-DRAWINGS/18.0 13 A-B

&3-DRAWINGS/18.5 18 A-B

&3-DRAWINGS/18.9 23 A-B

&3-DRAWINGS/18.9 24 A-B

Q1.00 DRAINING VALVE LP1 &3-DRAWINGS/17.1 =C1+BOX-KA9:+A1 2 A-B

Q1.01 DRAINING VALVE LP2 &3-DRAWINGS/17.2 =C1+BOX-KA10:+A1 3 A-B

Q1.02 ALARM FWD &3-DRAWINGS/17.3 =C1+BOX-KA11:+A1 4 A-B

Q1.03 ALARM AFT &3-DRAWINGS/17.4 =C1+BOX-KA12:+A1 5 A-B

Q1.04 &3-DRAWINGS/17.5 7 A-B

Q1.05 &3-DRAWINGS/17.6 8 A-B

Q1.06 &3-DRAWINGS/17.7 9 A-B

Q1.07 &3-DRAWINGS/17.8 10 A-B

Q1.08 &3-DRAWINGS/18.1 14 A-B

Q1.09 &3-DRAWINGS/18.2 15 A-B

Q1.10 &3-DRAWINGS/18.3 16 A-B

Q1.11 &3-DRAWINGS/18.4 17 A-B

Q1.12 &3-DRAWINGS/18.5 19 A-B

Q1.13 &3-DRAWINGS/18.6 20 A-B

Q1.14 &3-DRAWINGS/18.7 21 A-B

Q1.15 &3-DRAWINGS/18.8 22 A-B

33.a 35
Date 19/07/2023 PLC DIAGRAM
Ed. DAVID
Appr 3-100-2109-800 Page 34
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

PLC diagram F19_003

PLC-Designation =C1+BOX-JC1-2

Address Function text Placement Rack Module Symbolic address Terminal Manufacturer

&3-DRAWINGS/19.2 2 A-B

&3-DRAWINGS/19.2 3 A-B

&3-DRAWINGS/19.4 5 A-B

&3-DRAWINGS/19.4 6 A-B

&3-DRAWINGS/19.6 8 A-B

&3-DRAWINGS/19.6 9 A-B

&3-DRAWINGS/19.8 11 A-B

&3-DRAWINGS/19.8 12 A-B

IW2.0 BEARING WEAR SENSOR FWD &3-DRAWINGS/19.1 1 A-B

IW2.1 BEARING WEAR SENSOR AFT &3-DRAWINGS/19.3 4 A-B

IW2.2 PRESSURE SENSOR &3-DRAWINGS/19.5 7 A-B

IW2.3 SPARE &3-DRAWINGS/19.7 10 A-B

34 36
Date 19/07/2023 PLC DIAGRAM
Ed. DAVID
Appr 3-100-2109-800 Page 35
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

Terminal-connection diagram F11_006

=C1-QD1

=C1-QD1

=C1-QD1

=C1-QA1

=C1-QA1

=C1-QA1

=C1-QA2

=C1-QA2

=C1-QA2

=C1-PD1
=C1-TB1
-X2
+BOX-X1

10

11

12
1

9
4G1,5mm mm²

4G1,5mm mm²
-W_M1

-W_M2

BK BN GY GNYE BK BN GY GNYE
U1 V1 W1 PE U1 V1 W1 PE
U1 V1 W1 PE U1 V1 W1 PE

M M
3 3

=C1-M1 =C1-M2

35 37
Date 19/07/2023 Terminal-connection diagram -X1
Ed. DAVID
Appr 3-100-2109-800 Page 36
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

Terminal-connection diagram F11_006

=C1-KA10
=C1-KA9

=C1-TB1
=C1-JC1

=C1-JC1

-X1
+BOX-X2

x1 x2 x1 x2
x1

x2

=C1

36 38
Date 19/07/2023 Terminal-connection diagram -X2
Ed. DAVID
Appr 3-100-2109-800 Page 37
Modification Date Name Original Page 33
 0 1 2 3 4 5 6 7 8 9

Terminal-connection diagram F11_006

=C1-JC1-2

=C1-JC1-2

=C1-JC1-2
=C1-JC1

=C1-JC1
+BOX-X3

10

11

12

13

14

15

16

17

18

19

20
1

- 2 1 4 3 1 4 3 1 2 1
1

4 4 2
- Out 1 Out 1 OUT
2

=C1-TB1 =C1-FF7 =C1-FS_LP1 =C1-FS_LP2 =C1-BP1

37 39
Date 19/07/2023 Terminal-connection diagram -X3
Ed. DAVID
Appr 3-100-2109-800 Page 38
Modification Date Name Original Page 33
 38

Modification
0

Date
+BOX-X4

Name
1 =C1-QA1

2 =C1-QA1
1

Ed.
Date

Appr
Original
3 =C1-QA2

4 =C1-QA2

DAVID
19/07/2023
5 =C1-KA1

6 =C1-KA1

7 =C1-KA5
2

Terminal-connection diagram

8 =C1-KA5

9 =C1-KA6

10 =C1-KA6

11 =C1-KA7

12 =C1-KA7
3

13 =C1-KA8

14 =C1-KA8

15 =C1-KA11

16 =C1-KA11

17 =C1-KA12

=C1-KA12
4

18

19 =C1-KF1

20 =C1-KF1

21 =C1-KA13

22 =C1-KA13

23 =C1-KA14
5

24 =C1-KA14

25

26

27

28
6

Terminal-connection diagram -X4

7

3-100-2109-800
8
9

Page
Page
F11_006

33
39
6. ALARM SYSTEM
System Alarms
Manual
BERG® Main Propeller MPP620F
 SYSTEM ALARMS MANUAL

SYSTEM ALARMS

Designer:
Shipyard: 189 SHIPYARD
Vessel Type: Patrol Boat
Yard No/Reference: SAR 631

Berg Project Number: 400172M

Berg Order Number: 7634M
 SYSTEM ALARMS MANUAL

3. ALARM LIST

TABLE OF CONTENTS
1 Central Unit .................................................................................................................................. 1
2 Local Control Unit ........................................................................................................................ 1
3 Hydraulic Tank Unit ..................................................................................................................... 1
4 Starter Unit - Pump 1 ................................................................................................................... 2
5 Starter Unit - Pump 2 ................................................................................................................... 2
 SYSTEM ALARMS MANUAL

1 CENTRAL UNIT
Description Signal Type Function Set point Delay Comment
Control System A Fault On/Off Potential Free Contact NC See MPC display alarm page.
Control System B Fault On/Off Potential Free Contact NC See MPC display alarm page.
Power Supply A Failure On/Off Potential Free Contact NC
Power Supply B Failure On/Off Potential Free Contact NC
Hub Lubrication Fault On/Off Potential Free Contact NC See MPC display alarm page.
80% Load Alarm FIFI On/Off Potential Free Contact NC
100% Load Alarm FIFI On/Off Potential Free Contact NC

2 LOCAL CONTROL UNIT

Description Signal Type Function Set point Delay Comment
Local Control Power Failure On/Off Potential Free Contact NC

3 HYDRAULIC TANK UNIT

Description Signal Type Function Set point Delay Comment
Oil Pressure Pitch Pump 1 Low On/Off Pressure Switch NC <10 bar 8 Autostart Pitch Pump 2
Oil Pressure Pitch Pump 2 Low On/Off Pressure Switch NC <10 bar 8 Autostart Pitch Pump 1
Oil Pressure Pitch System Low 4-20mA Pressure Sensor - <6 bar 5
Oil Temperature Pitch High On/Off Temp. Switch NC >60°C 5
Oil Level (Pitch) Low On/Off Level Switch NC <70% 4
Oil Pressure Pitch High 4-20mA Pressure Sensor - >55 bar 5
Oil Filter Pitch Blocked On/Off Pressure Switch NC >5 bar Differential pressure
Oil Filter Lubrication Blocked On/Off Pressure Switch NC >2 bar Differential pressure
 SYSTEM ALARMS MANUAL

4 STARTER UNIT - PUMP 1

Description Signal Type Function Set point Delay Comment
Pump Started (103-105 Closed) On/Off Potential Free Contact <10 bar Delay set in starter
Phase Fault Alarm & Voltage Alarm On/Off Potential Free Contact 20V Treshold Voltage Window +/-20V

5 STARTER UNIT - PUMP 2

Description Signal Type Function Set point Delay Comment
Pump Started (103-105 Closed) On/Off Potential Free Contact <10 bar Delay set in starter
Phase Fault Alarm & Voltage Alarm On/Off Potential Free Contact 20V Treshold Voltage Window +/-20V
7. SPARE PARTS
7.1. SPARE PARTS LISTS
Spare parts lists are included with each drawing.

7.2. ORDERING SPARE PARTS

When ordering, please state the Berg Propulsion order number (or the vessel IMO Number). In
addition, please specify the drawing number, the item number, the description, the part number and
the quantity of the desired part.

Global Technical Support

24h Emergency Support Line:
+46 31 96 94 92
E-mail Support:
[email protected]

Spare Parts
[email protected]

Service
[email protected]
8. SPECIAL TOOLS
8.1. GENERAL
This chapter describes special tools that are used for assembling Berg Propulsion MPP units.

Information: Tools displayed in this section might not be applicable in every

case. Actual required tools depend on system configuration.

8.2. SHAFT NUT KEY

Figure 58. Shaft nut key.

Application
The shaft nut key is used for mounting an OMC coupling.

Function
Screw the shaft nut up close to the surface of the shaft using the shaft nut key. Coat the outer sealing
surface on the shaft nut with mineral oil. Make sure not to damage the sealing rings.
8.3. HYDRAULIC PUMP AND INJECTORS

Figure 59. Hydraulic pump (left) and injector (right).

Application
The manual hydraulic pump and the injectors are used when applying hydraulic nuts during mounting.
The injectors are also used for creating an oil film under the crown wheel, for removing bearing house
assemblies, and for dismounting bearings on the adapter sleeve.

8.4. IMPACT SOCKET

Figure 60. Impact socket.

Application
The impact socket is used when fastening propeller blades.
9. APPENDIX - DRAWINGS
9.1. MECHANICAL DRAWINGS
Drawing Name Drawing Number
PROPULSION AR-MAIN 73415 rev C
HUB GP-PROPELLER 51930 rev A
PCU MECHANICAL 50381
DISTRIBUTOR GP-OIL 73667
SHAFT GP-PROP 73655 rev A
SHAFT GP-INTMD 73711
 Dev. Order Deviation comprises Date Sign Check. Appr. Revis. Revision comprises Date Sign. Check. Appr.
Surface texture ISO/R 1302 Ra µm
A ITEM 50 WAS TO2254 REPLACED WITH ITEM 18 BK59176. EC244066 8 May 2018 MA BW NL
When not otherwise stated :
Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column.
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column. (See the table below)

TO BE LOCKED IN BLADE ROOT TIGHTENING TORQUE: 910 Nm Basic size Tolerances Basic size Tolerances
WITH LOCTITE 242 OR EQUIVALENT OVERRULED BY TIGHTENING ANGLE, SEE SKETCH (0,5)- 3 ±0,1 (1000)- 2000 ±1,2
30 TIGHTENING TORQUE: 550 Nm (3)-
(6)- 30
6 ±0,1
±0,2
(2000)- 4000
(4000) 8000
±2
±3
OVERRULED BY TIGHTENING ANGLE, SEE SKETCH (30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
16 9 7 48
28 8 47
21
a3 2x10 A
LOCTITE 243

26° a3 2x20
37 38 35
12
11,
20% OF TIGHTENING TORQUE 9

FULL TIGHTENING 29
°
7 11
,4
20% OF TIGHTENING TORQUE 11
,3
D (1.3 : 1)
8 FULL TIGHTENING

53

C (1.3 : 1) TORQUE:
60 SEE EXPANSION 45
B DOWEL DRAWING

187 Nm 10 45 1 54 12 49 5
A
18 A 36 31 32

17 B-B (1 : 4)

540
BLADE SEAL
52 OIL TYPE PART No.
MINERAL TO4480
EAL TO4480-V
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

149 FEATHERING 60 8 WELD LOCKING LS1516

50
ASTERN 54 1 O-RING TO2855
53 1 O-RING 379,3x5,7 SMS 1586/87

TO2795
70 AHEAD 52 1 O-RING TO2772
99 51 1 O-RING 89,5x3 SMS 1586/87

TO2289
126 A 50
D 49 4 O-RING TO2249
C 48
47
24 O-RING
16 O-RING
TO1139
TO1136
E 46 1 O-RING TO2219
45 4 BLADE SEAL SEE TABLE

38 2 SEAL SUPPORT DX4470

37 2 PISTON ROD SEAL TX3039
36 1 PISTON SEAL CR GH 390x365.5x8.1-AE1

TX4680
35 2 GUIDE RING LX4465

32 30 LOCKING WASHER BL3016

31 30 BOLT MC6S SM7040
30 8 BOLT MF6S SM3824
29 1 BOLT M6S SM1018
28 4 RETAINING RING LR3050
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Yellow Confidential

27 6 CIRCLIP LR3020-1
26 6 PLUG SR4087
25 4 PLUG SR4020

A 18 1 WASHER-SEAL 59176 BK59176

17 4 WIRE WINDER 46361 SEE ORDER
16 8 SLIDING DISC 29282 LB29282
15 1 PIPE GP-HUB 51928 AR51928
14 1 NUT GP-TENSION 54486 MA54486
LOCTITE 638 13 1 NUT GP-TENSION 55148 SEE ORDER
12 4 EXPANSION DOWEL 43912 CP43912
25 46 11 1 HEAD GP-ROD 51754/ 51755 SEE ORDER
10 4 MOUNT-BLADE SEE ORDER
9 4 TORQUE PIN 43879 CP43879
8 16 BOLT, SHAFT 43911 /46408 ICE SEE ORDER
27 Litre 7 24 BOLT, BLADE 43910 /46407 ICE SEE ORDER
6 1 DISC-PISTON 51651 MA51651
15 29 2 14 51 3 6 4 53 5 4 GUIDE BLOCK 46503 BT46503
4 1 ROD-HUB 51927 DS51927
3 1 PISTON-HUB 51650 CK51650
TORQUE: SEE MARKING ON NUT BODY 2 1 CYLINDER-HUB 51671 CK51671
11 27 26 13
LOCTITE 243 43 Litre B 1 1 HOUSING-HUB
ItemNo No.of Description
51804
Reference Material
PN51804
Part No.
Drawn Checked Approved Previous dwg. Tot.weight
TIGHTENING TORQUE: 255 Nm TORQUE: SEE MARKING BW Amm JG
E
851
ON NUT BODY Sheet of Date
OVERRULED BY TIGHTENING ANGLE: 1 1 17 Aug 2015
APPLY 20% OF TIGHTENING TORQUE FOR START POSITION 320 HUB GP-PROPELLER
Part No. Scale
THEN TURN 100°±22,5° TO FULL TIGHTENING PN51930 1:2.2 A1
600 (MPP 620F - 05)
Revis.

51930
425 E (1 : 1.5)
A-A A
 Dev. Order Deviation comprises Date Sign Check. Appr. Revis. Revision comprises Date Sign. Check. Appr.
Surface texture ISO/R 1302 Ra µm
When not otherwise stated :
Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column.
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column. (See the table below)

Basic size Tolerances Basic size Tolerances

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2

6 (3)-
(6)- 30
6 ±0,1
±0,2
(2000)- 4000
(4000) 8000
±2
±3
(30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6

50
7 D A B L

A
CONNECTION FLANGE
SEE PCU ASSEMBLY
5

D
4

LENGTH OF HOSES, 1m

B
5

3 L
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

~280

50 65
504

2 92, MIN DISMANTLING SPACE

660
Confidential ® BERG Propulsion AB

25
°
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG:

8 1 HYDRAULIC HOSE 47530 HS47530

7 1 HYDRAULIC HOSE 47529 HS47529
6 2 HYDRAULIC HOSE 47528 HS47528
5 2 WASHER BG1516
4 2 WASHER BG1515
3 1 PITCH SCALE 51838 NS51838
2 1 SENSOR HOUSING 49899 HD49899
30

1 1 OD BOX ASSEMBLY 50361 HDM50361

5

ItemNo No.off Description Reference Material Part No.

5

Drawn Checked Approved Previous dwg. Tot.weight

0
1,

E
26

Amm BW JG 97
19

Sheet of Date
CAN BE ROTATED IN STEPS OF 45° PCU MECHANICAL 1 1 08 Apr 2015
TO SUIT PIPING AND VISIBILITY. CAN BE ROTATED IN STEPS OF 90°. Part No. Scale

HDX 75 / 273 HD50381 1:2 A1

Revis.

50381 -
 1 2 3 4 5 6 7 8 9 10
Rev. Revision comprises Date Sign. Check. Appr. Indication of surface texture ISO/R 1302 Ra µm
A Updated potentiometer according to feathering 14 Nov 2022 AKU
Edges of undefined shape ISO 13715
When not otherwise stated :
Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column:
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column:
Basic size Tolerances Basic Tolerances
( 0,5 ) - 3 ±0,1 ( 1000 ) - 2000 ±1,2
A (3)-6 ±0,1 ( 2000 ) - 4000 ±2
A
( 6 ) - 30 ±0,2 ( 4000 ) - 8000 ±3
( 30 ) - 120 ±0,3 ( 8000 ) - 12000 ±4
( 120 ) - 400 ±0,5 ( 12000 ) - 16000 ±5
( 400 ) - 1000 ±0,8 ( 16000 ) - 20000 ±6

B B

PIPE DESIGN LENGTH = 1154

36

D=29

C C

D D

7 2 1
6 5
E 3 E
197 Nm
500 654 569

92 MIN: DISMANTLING SPACE

The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

SECTION A-A
SCALE 1 : 3.5

F F

6x 17,5
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: Yellow Confidential ® BERG Propulsion AB

G G

242
200 f7

P.C.D =
H H

A
7 1 POTENTIOMETER EP3271
6 1 O-RING TO2709
5 6 BOLT MC6S SM2928
4 1 EXTENSION PIPE 54392 AR54392
3 1 FLANGE–CONNECTION 73666 AF73666
2 1 PCU ELECTRICAL 61396 HD61396
1 1 PCU MECHANICAL 50381 HD50381
*Req spare Item No. No.of Description Reference Material Part No.
Drawn Checked Approved Order No. Previous dwg. Tot.weight
E
J AKU BW 117 J
CONNECTION FLANGE INTERFACE Sheet Date
DISTRIBUTOR GP–OIL 1 of 1 1 Nov 2022
Part No. Scale
(HDX75 6xM16) HD73667 1:20 A1

73667
Revis.

A
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10
Rev. Revision comprises Date Sign. Check. Appr. Indication of surface texture ISO/R 1302 Ra µm
A Updated O ring to TO2738 (was TO2737) 15 Aug 2023 AKU Edges of undefined shape ISO 13715
When not otherwise stated :
Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column:
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column:
A Basic size Tolerances Basic Tolerances
A
( 0,5 ) - 3 ±0,1 ( 1000 ) - 2000 ±1,2
(3)-6 ±0,1 ( 2000 ) - 4000 ±2
PROPELLER SHAFT LENGTH Y = 12265 ( 6 ) - 30 ±0,2 ( 4000 ) - 8000 ±3
( 30 ) - 120 ±0,3 ( 8000 ) - 12000 ±4
( 120 ) - 400 ±0,5 ( 12000 ) - 16000 ±5
( 400 ) - 1000 ±0,8 ( 16000 ) - 20000 ±6

B B
ADD CORTEC VPCI-368 OR SIMILAR
FROM RECESS TO CLADDED SURFACE AK93809

C C
3
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

D D

E E
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: Yellow Confidential ® BERG Propulsion AB

4 9 1 2

A
F 99 F

126 TOTAL PIPE DESIGN LENGTH = 11939 L = 227

G G
44 Nm

8 7 6 5 9 1 O-RING TO2738
8 1 O - Ring TO7035
7 8 LOCKING WASHER BL3010
6 8 BOLT MC6S SM6822
H 5 1 RING-SEALING 73660 TR73660 H
4 1 GUARD-PROTECTIVE 73659 SK73659
DRIVE UP LENGTH ACCORDING 3 1 SEALING SLEEVE ASSY 73657 TR73657
TO JAURE DRW: OF-45265 2 1 PIPE GP-PROP 73534 AR73534
1 1 SHAFT–PROP 73521 AP73521
*Req spare Item No. No.of Description Reference Material Part No.
POWER = 2525 kW Drawn Checked Approved Order No.
E
Previous dwg. Tot.weight

PROPELLER SPEED = 318rpm AKU BW AE 7634M 4398

Sheet Date
CLASSIFICATION = ABS, No Ice SHAFT GP-PROP 1 of 1 27 Oct 2022 J
J
Part No. Scale
VIEW B (MPP620F) AP73655 1:3 A2
SCALE 1 : 1
73655
Revis.

A
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10
Rev. Revision comprises Date Sign. Check. Appr. Indication of surface texture ISO/R 1302 Ra µm
Edges of undefined shape ISO 13715
When not otherwise stated :
Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column:
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column:
A Basic size Tolerances Basic Tolerances
A
( 0,5 ) - 3 ±0,1 ( 1000 ) - 2000 ±1,2
(3)-6 ±0,1 ( 2000 ) - 4000 ±2
( 6 ) - 30 ±0,2 ( 4000 ) - 8000 ±3
( 30 ) - 120 ±0,3 ( 8000 ) - 12000 ±4
( 120 ) - 400 ±0,5 ( 12000 ) - 16000 ±5
( 400 ) - 1000 ±0,8 ( 16000 ) - 20000 ±6

B B
227 F1 = 3015

C C
GB FLANGE
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

D D

1457 Nm
E E
3 4
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: Yellow Confidential ® BERG Propulsion AB

F F

1 2

PIPE DESIGN LENGTH = 2875,5 366,5

G G

H 5 1 O-RING TO2738 H
4 12 NUT MM2036
3 12 BOLT-FLANGE 73713 SE73713
2 1 PIPE GP-PROP INTMD 73661 AR73661
1 1 SHAFT - INTMD 73573 AM73573
*Req spare Item No. No.of Description Reference Material Part No.
Drawn Checked Approved Order No. Previous dwg. Tot.weight
E
AKU BW AE 7634M 789
Sheet Date

J SHAFT GP- INTMD 1 of 1 24 Nov 2022 J

Part No. Scale
(MPP620F) AM73711 1:7 A2

73711
Revis.

-
1 2 3 4 5 6 7 8 9 10
9.2. HYDRAULIC DRAWINGS
Drawing Name Drawing Number
SCHEMATIC HYDRAULIC 73601
HPU AR 72832
CONNECTION GP-ELECTRICAL 62555
D.O.L. STARTER UNIT 61336
CABLE SPECIFICATION
 1 2 3 4 5 6 7 8 9 10
TECHNICAL DATA Rev. Revision comprises Date Sign. Check. Appr. Indication of surface texture ISO/R 1302 Ra µm
Edges of undefined shape ISO 13715
TANK SIZE 500 LITER
When not otherwise stated :
NORMAL OIL VOLUME 360 LITER Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column:
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column:
A MIN OIL LEVEL (ALARM) 260 LITER
Basic size Tolerances Basic Tolerances
A
PUMP SIZE 55cc
( 0,5 ) - 3 ±0,1 ( 1000 ) - 2000 ±1,2
PUMP ROTATION CCW, seen from shaft end (3)-6 ±0,1 ( 2000 ) - 4000 ±2
MAX OIL FLOW (at 60 Hz) 86 L/min per pump ( 6 ) - 30 ±0,2 ( 4000 ) - 8000 ±3
PTO MAX SPEED 2400 rpm ( 30 ) - 120 ±0,3 ( 8000 ) - 12000 ±4
MAX PTO OIL FLOW 115 L/min ( 120 ) - 400 ±0,5 ( 12000 ) - 16000 ±5
( 400 ) - 1000 ±0,8 ( 16000 ) - 20000 ±6
EL-MOTOR 132M-4
EL POWER 7,3 kW (380VAC, 50 Hz)
B 7,5 kW (400VAC, 50 Hz) B
7,3 kW (415VAC, 50 Hz)
7,3 kW (690VAC, 50 Hz
8,75 kW (440VAC, 60 Hz)
9,0 kW (480VAC, 60 Hz)
7,3 kW (690VAC, 60 Hz)
WEIGHT (WITHOUT OIL) ~ 465 kg
PUMP PRESSURE 50 bar
C C
DESIGN PRESSURE 65 bar 5
TEST PRESSURE 100 bar
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

9
AREA FOR 1
CLASS STAMP
D D
2 8

1209
10

E E

598
7
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: Green Confidential ® BERG Propulsion AB

561 377
F 1150 F
750
1304

6 4 3 HYDRAULIC DIAGRAMS
73601 (GREEN)
71835 (YELLOW)
G G
SENSOR SETTINGS
256466

10 1 PIPE GP 73008 VB73008

9 1 PUMP GP-EMERGENCY 71817 AU71817
8 1 CONNECTION GP-ELECTRICAL 62555 EF62555
7 1 MOUNTING GP-WIRING 72420 HT72420
6 1 VALVE GP-CONTROL 71814 VB71814
H CONFIGURATION 5 1 FILTER GP-HPU 71807 FV71807 H
TANK C500 4 1 PUMP GP 71803 MT71803
PUMP 55CC 3 1 PUMP GP 72796 PU72796
EM. PUMP HAND PUMP 2 1 TANK GP 71856 HT71856
1 1 MANIFOLD GP 71796 VB71796
HUB CIRC PC
*Req spare Item No. No.of Description Reference Material Part No.
PTO YES Drawn Checked Approved Order No. Previous dwg. Tot.weight
O.D. BOX HDX Avs Pnm
E
465
COOLER NO Sheet Date

J STARTERS NO HPU AR 1 of 2 10 Oct 2022 J

Part No. Scale
(C500-55CC, PTO) HT72832 1:10 A2

72832
Revis.

-
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10
Rev. Revision comprises Date Sign. Check. Appr.
- See Sheet1 - - - -
THE HPU IS PREPARED FOR:
• WELDED INSTALLATION INTERMITTET WELDING ALONG THE SHORT SIDES
A • BOLTED INTALLATION USE M16 OR 5/8 UNC BOLTS A
• RESILIENT MOUNTS INSTALLATION
SEE RESILIENT MOUNTS DRAWING.

SERVICE

min 500
SPACE
B B

(4x) 17

100
C C
a4 5x50(100)

550
a4 5x50(100)

100
FOR GROUNDING
(4x) 8
D D
1066

30
42 42
SECTION B-B
SERVICE DRAIN PORT G1/2" (SPACE SECTION)*
50 50 SPACE
min 500
750 DRAIN SPACE G1/2" *
*IT IS RECOMMENDED TO
REPLACE STEEL BLANKNING
PLUG WITH A BALL VALVE
B B BEFORE FILLING WITH OIL
E E
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

D(PC) ~252
LT ~484 P,S,Dr ~1031
L/LP,CL ~81 A ~292

P1C ~131
P1C ~368

Dr ~199
F LT ~64 F

S ~329
P ~459
B ~217
A,B ~61 D(PC), L/LP, CL ~147

P1C
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: Green Confidential ® BERG Propulsion AB

P
S
G Dr G

A~78
B~96
P1C ~18
LT ~8
D(PC) ~68

CL ~18
L/LP ~63

H H
PORT INTERFACE
A BSPP G1 1/2"
B BSPP G1 1/2"
CL BSPP G3/4"
D(PC) BSPP G3/4"
L/LP BSPP G3/4"
LT BSPP G1"
S G2"
P G1" Drawn Checked Approved Order No. Previous dwg. Tot.weight
Dr G1/2"
E
J Avs Pnm 465 J
P1C GE 10L Sheet Date

ALL CONNECTION PORTS ARE SCREW PLUGS HOLES TYPE BSPP (ISO 1179-1) P Pump SAE J518C 1" HPU AR 2 of 2 10 Oct 2022
Part No. Scale
USE MALE STUD FITTINGS WITH ED-SEALS (ISO 1179-2) TO S Pump SAE J518C 2" (C500-55CC, PTO) HT72832 1:8 A1
CONNECT TO THE TUBE FITTNING SYSTEM. P1C Pump DIN 3852 M14x1.5
72832
Revis.
Dr Pump DIN 3852 M22x1.5 -
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10
Rev. Revision comprises Date Sign. Check. Appr. Fluid power systems and components
Graphical symbols and circuit diagrams ISO 1219-(1, 2)
Electrical drawings and Hydraulic drawings
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

A No connection Connection A

B B

C C
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: Yellow Confidential ® BERG Propulsion AB

D D

E E

F F

2 NOTE:
FREE OF BURRS, DIRT, DUST AND CONTAMINATION
G G
HARNESS FULLY ATTACHED TO TERMINALS IN CONNECTION BOX.
SEE ELECTRICAL DRAWING FOR CONNECTION.

2 1 HARNESS GP 62554 EM62554

H 1 1 BOX GP-CONNECTION 62553 EF62553 H
*Req spare Item No. No.of Description Reference Material Part No.
1 Drawn Checked Approved Order No.
E
Previous dwg. Tot.weight
Snm Ucv 21
Sheet Date
CONNECTION GP-ELECTRICAL 1 of 1 24 Nov 2021
Part No. Scale
J (HPU06) EF62555 1:6 A3 J
Revis.

62555
1 2 3 4 5 6 7 8 9 10
 12 12 12 12 12

11 11 11 11 11

14 14 14 14 14
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

6-24 6-24 6-24 6-24 6-24

V= V= V= V= V=

A1 A1 A1 A1 A1

A2 A2 A2 A2 A2
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K FIXED NUMBERS FOR QS1 31-OCT-2022 Mna - -

J UPDATED AUX. CONTACTS 15-JUL-2022 Mna - - Order No. Drawn Checked Approved Sheet
I NEW LOGO 19-NOV-2021 UcV - - - LGG B.J. - 1 of 7
H AUX POLES QS1, X1/7-10, H5, K4, K5, F3 22-NOV-2018 B.J. F.K. T.H. Part No. Date
D.O.L. STARTER UNIT, PUMP
F TR1 SETTING: 8s 15-NOV-2016 B.J. T.H. - 350VAC...690VAC/45-63A EB61336 22-NOV-2018
Rev.
350V/30kW....690V/55kW
F
Rev.
"LOCAL" TEXT CHANGED TO "LOCAL/ON"
Revision Comprises
15-NOV-2016
Date
B.J.
Sign.
T.H.
Check
-
Appr. - 61336 K
 Item Description Type Art. No. Qty.
AS1 CABINET RAL 7035 500x500x300mm EM95201 1
DOOR STOP, WALL MOUNT BRACKETS A4 EM95210, EM95208 1
MOUNTING RAIL TS35 X 15FH EM2160 1
QS1 MAIN SWITCH, 3 POLE 63A EB3120 1
DOOR SWITCH IP 54 FOR EB3120 EB3121 1
SHAFT FOR EB3120 EB3122 1
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

PLATE "MAIN SWITCH" NS3525 1

ELECTRICITY HAZARD SIGN NS7175 1
RAW MATERIAL NAME PLATE EL6132 1
T1 TRANSFORMER 350<690//<240VAC, 200VA EM2110 1
TV1 AC/DC CONVERTER 85<277VAC//24VDC 3A EM3151 1
F1 TRANSFORMER PROTECTION 0.45...0.63A EB3210 1
F2 AUTOMATIC FUSE MCB - 1P C 1A EL1079 1
QF1 MOTOR PROTECTION 45-63A EB3214 1
AUX CONTACT FOR QF1 (2N.O+2N.C) EB3216 1
C1 CONTACTOR 30kW 20-33VUC AUX 1NO&1NC EB3218 1
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ©BERG Propulsion AB

SIDE AUX CONT. FOR 3RT2 1NO+1NC EB3219 1

K1, K2, K3, K4 RELAY 1 POLE 24VDC EL2500 4
MR1 UNDER VOLTAGE MONITORING RELAY EM3163 1
TR1 TIME RELAY, ON-DELAY, 2C ER2441 1
H1 LED-LAMP, "POWER ON", WHITE 24V AC/DC EB2331, NS3521 1
H2 LED-LAMP, "FAULT", RED 24V AC/DC EB2333, NS3523 1
H3 LED-LAMP, "STANDBY" YELLOW 24V AC/DC EB2334, NS3524 1
H4 LED-LAMP, "RUN" GREEN 24V AC/DC EB2332, NS3522 1
S1 SELECTOR SWITCH "LOCAL/ON-OFF-REMOTE" EB2173, EB2036, NS3134 1
S2 SELECTOR SWITCH, "MAN-AUTO" EB2035, EB2056, NS3361 1
PLATE HOLDER FOR ZB4 EB2031 6
TA1 TIME COUNT. 48X48MM DC 10-80V EK1301 1
RUST PREVENTING EMITTER FM3620 1
SCREW SELF DRILL 4,2X14 PHILLIP 2 SM3626 25
X2/ TERMINAL TWIN 2,5 EL6000 12
ENDPLATE TWIN EL6005 1
PE TERMINAL PE EL2226 3
END BRACKET EL2262 7
TERMINAL MARKING EL6049 12
T2 CURRENT TRANSFORMER EI96100 1
A1 AMMETER, PANEL EI96099 1
I NEW LOGO 19-NOV-2021 UcV - -
H K4, K5 22-NOV-2018 B.J. F.K. T.H. Order No. Drawn Checked Approved Sheet
F S1 TEXT CHANGED TO "LOCAL/ON - OFF - AUTO" 07-NOV-2016 B.J. - - - LGG B.J. - 2 of 7
F CHANGED F1, F2. TERM. X1/1...6 & F101 REMOVED 07-NOV-2016 B.J. - - Part No. Date
D.O.L. STARTER UNIT, PUMP
F ADDED TV1, T2, A1, TA1, K3. TWIN TERM. 07-NOV-2016 B.J. - - 350VAC...690VAC/45-63A EB61336 22-NOV-2018
Rev.
350V/30kW....690V/55kW
D
Rev.
ADDED EB3206
Revision Comprises
03-JUL-2015
Date
B.J.
Sign.
-
Check
-
Appr. - 61336 K
 Item Description Type Art. No. Qty.
H5 LED-LAMP BLUE 230V AC EB2335 1
H5 LABEL "HEATER ON" PLASTIC, BLACK LETTERS NS3526 1
F3 AUTOMATIC FUSE MCB - 2P C 6A EL1090 1
AUX POLE FOR EB3120 EB3119 2
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ©BERG Propulsion AB

Order No. Drawn Checked Approved Sheet

- LGG B.J. - 3 of 7
Part No. Date
D.O.L. STARTER UNIT, PUMP
I NEW LOGO 19-NOV-2021 UcV - - 350VAC...690VAC/45-63A EB61336 22-NOV-2018
Rev.
350V/30kW....690V/55kW
H
Rev.
NEW SHEET, H5, F3, AUX POLE FOR EB3120
Revision Comprises
22-NOV-2018
Date
B.J.
Sign.
F.K.
Check
T.H.
Appr. - 61336 K
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ©BERG Propulsion AB

F
H

Rev.
NEW LOGO

Revision Comprises
STANDSTILL HEATER, H5, F3, X1/7-10
TV1, F1, F2, TERMINAL X1/1...6 & F101 REMOVED
Date
07-NOV-2016
22-NOV-2018
19-NOV-2021

Sign.
B.J.
B.J.
UcV

-
-
F.K.

Check
-
-

Appr.
T.H.

-
-
Order No.

350V/30kW....690V/55kW
350VAC...690VAC/45-63A
D.O.L. STARTER UNIT, PUMP
LGG
Drawn

Part No.
EB61336
B.J.

61336
Checked
-
Date
Approved

K
Rev.
22-NOV-2018
Sheet
4 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ©BERG Propulsion AB

F
D
H

Rev.
NEW LOGO

Revision Comprises
REMOVED TEXT PSW3
STANDSTILL HEATER, K4, K5
CHANGED S1 PLATE, ADDED K3

Date
03-JUL-2015
07-NOV-2016
22-NOV-2018
19-NOV-2021

Sign.
B.J.
B.J.
B.J.
UcV

-
-
-
F.K.

Check
-
-
-

Appr.
T.H.

-
-
Order No.

350V/30kW....690V/55kW
350VAC...690VAC/45-63A
D.O.L. STARTER UNIT, PUMP
LGG
Drawn

Part No.
EB61336
B.J.

61336
Checked
-
Date
Approved

K
Rev.
22-NOV-2018
Sheet
5 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ©BERG Propulsion AB

I
H
Rev.
NEW LOGO

Revision Comprises
NEW SHEET, H4
Date
22-NOV-2018
19-NOV-2021

Sign.
B.J.
UcV
F.K.
Check
Appr.
T.H.
-
-
Order No.

350V/30kW....690V/55kW
350VAC...690VAC/45-63A
D.O.L. STARTER UNIT, PUMP
LGG
Drawn

Part No.
EB61336
B.J.

61336
Checked
-
Date
Approved

K
Rev.
22-NOV-2018
Sheet
6 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ©BERG Propulsion AB

I
F
Rev.
ADDED K3
NEW LOGO

Revision Comprises
Date
07-NOV-2016
19-NOV-2021

Sign.
B.J.
UcV
-
-

Check
-
-

Appr.
-
-
Order No.

350V/30kW....690V/55kW
350VAC...690VAC/45-63A
D.O.L. STARTER UNIT, PUMP
LGG
Drawn

Part No.
EB61336
B.J.

61336
Checked
-
Date
Approved

K
Rev.
22-NOV-2018
Sheet
7 of 7
CABLE SPECIFICATION

All cables shall meet the requirements of IEC Publications of the series 60092-3.., plus any additional
requirements from the relevant Classification society.

Communication bus cables (RS-485) and signal cables such as digital inputs and 4-20mA, 0-10VDC
analogue signals:
0.75 twisted pair, screen cable.

Signal cables such as digital outputs and PWM etc.:

Multicore screened cable.
Note: Cable diameter is dependent on power and cable length.

Power cables for systems 24VDC power:

Multicore cable screen is recommended.
Note: Cable diameter is dependent on power and cable length.

To avoid voltage drop within the 24VDC power system the following table shall be used for cable
sizes.
Distance between Units in Meters Cable Size mm2
0-30 4
30-70 6
70-100 10
Distances > 100M between ECR Central Unit and bridge units will require an
additional power unit for local power supply on the Bridge

The dimension information given in the cable list and on the drawings is the minimum requirement.
9.3. REMOTE CONTROL SYSTEM DRAWINGS
INTERFACE LIST
LAYOUT AND CABLE PLAN – CONTROL SYSTEM 62710 rev C
LAYOUT AND CABLE PLAN – HYDRAULIC 62715 rev A
CENTRAL UNIT 32244
I/O EXTENSION UNIT 61871 rev I
LOCAL CONTROL UNIT 60854 rev H
ECR PANEL RH 61089 rev E
ECR PANEL LH 61090 rev E
BRIDGE TWIN PANEL FWD 61086 rev D
PANEL TERMINAL STRIP 61058 rev G
SHAFT SPEED SENSORS 61277 rev B
SENSOR ARRANGEMENT 61396 rev E
CONNECTION GP-BOX 62608 rev A
D.O.L STARTER UNIT 61333 rev M
LOGGER AND REMOTE MONITORING UNIT 62645 rev B
 EXTERNAL INTERFACE

4. INTERFACE LIST

TABLE OF CONTENTS
1 General Information ..................................................................................................................... 1
2 Voyage Data Recorder / Conning System .................................................................................. 2
3 Alarm System .............................................................................................................................. 3
4 Prime Mover Single Diesel .......................................................................................................... 3
5 Gearbox Single Engine ................................................................................................................ 4
6 Main Swith Board......................................................................................................................... 4
7 Pitch Sensors............................................................................................................................... 4
8 Hydraulic System ......................................................................................................................... 4
9 Local Control Unit ........................................................................................................................ 5
10 Shaft Speed Sensor .................................................................................................................... 5
11 Mode Selection Switch ................................................................................................................ 5
12 Joystick System ........................................................................................................................... 5
13 Shaft Brake .................................................................................................................................. 5
14 Fire Fighting Mode 1 .................................................................................................................... 6
 EXTERNAL INTERFACE

1 GENERAL INFORMATION
Please note that not all signals specified are mandatory.

SIGNALS FROM EXTERNAL EQUIPMENT

Type Signal condition MPC800 specification Requirement on external equipment
Digital input Closed = TRUE Contact load Max 50mA/24V Potential free contact
Analog input (mA) 4-20mA Receiver load is 250Ω Active transmitter galvanically isolated
Analog input (V) 0-10V Internal interface 10V signal supply 1-10 kΩ potentiometer interface

SUPPLY FROM EXTERNAL EQUIPMENT

Type Connector MPC800 specification Requirement on external equipment
CU - POWER SUPPLY A F1:+02/-04 Minimum UPS: 24VDC ± 10% @ 10A1
CU - POWER SUPPLY B F2:+02/-04 Minimum BATT: 24VDC ± 10% @ 10A1
LCU - POWER SUPPLY C F1:+02/-04 Minimum 24VDC ± 10% @ 4A

SIGNALS TO EXTERNAL EQUIPMENT

Type Signal condition MPC800 specification Requirement on external equipment
Digital output NO-COM closed = TRUE Potential free contact Contact load Max 0.5A/50V
Analog output (mA) 4-20mA Active transmitter galvanically isolated Max 750Ω receiver load
NMEA0183 4800 - 8 - N - 1 $RCPRC - Propulsion Control Data RS-422
$RCRPM - Propulsion Response Data
PWM – Pulse Width Modulation 0-22.5V Internal interface Max 1.5A. 100 - 400Hz

SUPPLY TO EXTERNAL EQUIPMENT

Type Connector MPC800 specification Requirement on external equipment
CU - HYDRAULIC TANK UNIT X01:+05/-06
CU - MAGNETIC PITCH SENSOR X01:+07/-08 24VDC / 1A in total
CU - EXTERNAL 24V X01:+09/-10
LCU - POWER SUPPLY C X01:+03/-04 24VDC / 2A
Panel terminal strip - EXTERNAL X03 24VDC / 0.5A
24V
1 CU uses 4A and each control panel 1.5A with a maximum of six panels = 13A + voltage drop.
 EXTERNAL INTERFACE

2 VOYAGE DATA RECORDER / CONNING SYSTEM

RS-422 NMEA0183 interface, 4800 Baud, 8 data bits, no parity and 1 stop bit (4800-8-N-1)
Two NMEA sentences are sent out every second:

2.1. PRC – Propulsion Remote Control Status

This sentence provides the status of control data for main propellers.

1 2 3 4 5 6 7 8
| | | | | | | |
$MPPRC,x.x,a,x.x,a,x.x,a,a,x*hh<CR><LF>

1. Lever demand position: -100 - 0 - +100 %

2. Lever demand status: A = data valid, V = data invalid
3. Rpm demand value: 0 - 100 %, +/- rpm, V = data invalid
4. Rpm mode indicator: P = %, R = rpm, V = data invalid
5. Pitch demand value, "-" means astern: -100 - 0 - +100 %, +/- degrees, V = data invalid
6. Pitch mode indicator: P = %, D = degrees, V = data invalid
7. Operating location indicator: B = bridge/other, P = port, S = starboard, C = ECR, D = DP, J = JS, T = ETA, U = backup
8. Engine or shaft number: 0 = center, odd = starboard, even = port

2.2. RPM – Revolutions

This sentence provides the response data for main propellers.

1 2 3 4 5
| | | | |
$MPRPM,a,x,x.x,x.x,a*hh<CR><LF>

1. Source: S = shaft, E = engine

2. Engine or shaft number: 0 = center, odd = starboard, even = port
3. Speed, Revolutions per minute: +/- rpm
4. Propeller pitch, % of maximum, "-" means astern: -100 - 0 - +100 %
5. Status: A = data valid, V = data invalid
 EXTERNAL INTERFACE

3 ALARM SYSTEM
Item Signal Type Dir Signal description
CONTROL SYSTEM A FAULT Digital OUT Open contact=control fault
CONTROL SYSTEM B FAULT Digital OUT Open contact=control fault
POWER SUPPLY A FAIL Digital OUT Open contact=power fault
POWER SUPPLY B FAIL Digital OUT Open contact=power fault
HUB LUBRICATION FAULT Digital OUT Closed=Water saturation or temperature high fault for hub
HYDRAULIC OIL PRESSURE LOW Digital OUT Closed=Hydraulic Oil Pressure Low
FIFI 80% LOAD Digital OUT Closed=Fifi configured and LOAD>80%
FIFI 100% LOAD Digital OUT Closed=Fifi configured and LOAD>100%

4 PRIME MOVER SINGLE DIESEL

Item Signal Type Dir Signal description
SPEED REFERENCE 4-20mA OUT 4-20mA=0-100%, RPM demand signal to ME
SLOWDOWN Digital IN Closed=Pitch reduction->80% request from ME
SHUTDOWN Digital IN Closed=ME stopped => Auto declutch & pitch->0%
ME START PERMIT Digital OUT Closed=Clutch disengaged*, OK to start ME
LOAD FEEDBACK 4-20mA IN 4-XXmA=0-100%, 20mA=105-125%
SPEED FEEDBACK 4-20mA IN 4-20mA=0-100%, Indication, load control, clutch interlocks
ME REMOTE CONTROL ALLOWED Digital IN Closed=MPC800 allowed to take over engine control (3-step)
ME REMOTE CONTROL REQUEST Digital OUT Closed=MPC800 requests to take over engine control (2/3-step)
ME REMOTE CONTROL PERMITTED Digital IN Closed=MPC800 has control of engine speed (1/2/3-step)
ME RUNNING Digital IN Closed=Engine running
 EXTERNAL INTERFACE

5 GEARBOX SINGLE ENGINE

Item Signal Type Dir Signal description
MAIN CLUTCH ENGAGED Digital IN Closed=Main Clutch Engaged
MAIN CLUTCH IN PWM OUT 5s Pulse/Hold=Main Clutch In
MAIN CLUTCH OUT PWM OUT 5s Pulse/Hold=Main Clutch Out
GEARBOX ALARM SUPPRESSION Digital OUT Xs Pulse=During clutch in

6 MAIN SWITH BOARD

Item Signal Type Dir Signal description
SHAFT GENERATOR ONLINE Digital IN Closed=Shaft Generator Online
C.RPM SELECTED Digital OUT Closed=CRPM Active

7 PITCH SENSORS
Item Signal Type Dir Signal description
7.1 PITCH FEEDBACK A 0-10V IN Pitch feedback system A for regulation & indication
7.2 PITCH FEEDBACK B 0-10V IN Pitch feedback system B for regulation & indication

8 HYDRAULIC SYSTEM
Item Signal Type Dir Signal description
8.1 OIL PRESSURE PITCH 4-20mA IN Used for Hydraulic Oil Pressure Low alarm
8.2 HUB OIL WATER SATURATION 4-20mA IN Used for Hub Lube alarm, and hub lube log
8.3 HUB OIL TEMPERATURE 4-20mA IN Used for Hub Lube alarm, and hub lube log
 EXTERNAL INTERFACE

9 LOCAL CONTROL UNIT

Item Signal Type Dir Signal description
9.1 LOCAL PITCH CONTROL ON Digital IN Closed=Pitch is in local control
9.2 PITCH VALVE AHEAD PWM OUT Connected to MPC800M PWM output
9.3 PITCH VALVE ASTERN PWM OUT Connected to MPC800M PWM output

10 SHAFT SPEED SENSOR

Item Signal Type Dir Signal description
10.1 SHAFT SPEED SENSOR Digital IN Shaft Speed feedback for indication

11 MODE SELECTION SWITCH

Item Signal Type Dir Signal description
JS SELECTED Digital IN Closed=JS mode selected from JS system

12 JOYSTICK SYSTEM
Item Signal Type Dir Signal description
JS READY Digital OUT Closed=Pitch controlled by JS system
JS AVAILABLE Digital OUT Closed=Pitch available for JS control
JS PITCH DEMAND 4-20mA IN 4mA=Astern, 12mA=0%, 20mA=Ahead
JS ACTUAL PITCH 4-20mA OUT 4mA=Astern, 12mA=0%, 20mA=Ahead
PITCH REDUCED Digital OUT Closed=Pitch reduced (slowdown, shutdown, load reduction etc)

13 SHAFT BRAKE
Item Signal Type Dir Signal description
SHAFT BRAKE ENGAGED Digital IN Closed=Shaft brake engaged
ENGAGE SHAFT BRAKE Digital OUT Closed=Shaft brake activated
 EXTERNAL INTERFACE

14 FIRE FIGHTING MODE 1

Item Signal Type Dir Signal description
FIFI PUMP ENGAGED Digital IN Closed=Fifi pump clutch engaged
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
Rev.B 28-08-2023 10
Rev.C 01-09-2023 4, 11

Rev.A 02-02-2023 8, 9, 10
Update on ECR control panel (RH/LH)
Updated the connections for hydraulic junction box 62608.
Corrected terminal number for Datalogger on STBT wiring .
LeA
LGG
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7634M

MPC800M CONTROL SYSTEM

LAYOUT AND CABLE PLAN PORT

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All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

MPC800M CONTROL SYSTEM

POWER AND DATA BUS PORT

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The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM PORT

MPC800M CONTROL SYSTEM
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All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM PORT

MPC800M CONTROL SYSTEM
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The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM PORT

MPC800M CONTROL SYSTEM
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The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM PORT

MPC800M CONTROL SYSTEM
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2022-09-20

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62710
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W101 2x6 2 External Power Supply A 24DC/10A Central Unit

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W102 2x6 2 External Power Supply B 24DC/10A Central Unit
W103 2x4 2 Central Unit I/O Extension Unit
W104 1x2x0,75 2 Central Unit I/O Extension Unit
W105 2x4 2 Central Unit I/O Extension Unit
W106 1x2x0,75 2 Central Unit I/O Extension Unit
W107 2x4 2 I/O Extension Unit ECR Control Panel
ECR Control Panel

MPC800M CONTROL SYSTEM

W108 1x2x0,75 2 I/O Extension Unit
W109 2x4 2 I/O Extension Unit ECR Control Panel
W110 1x2x0,75 2 I/O Extension Unit ECR Control Panel

7634M
W111 2x4 2 ECR Control Panel Main Bridge Control Panel
W112 1x2x0,75 2 ECR Control Panel Main Bridge Control Panel

CABLE LIST PORT

W113 2x4 2 ECR Control Panel Main Bridge Control Panel
W114 1x2x0,75 2 ECR Control Panel Main Bridge Control Panel

LGG
W119 1x2x0,75 2 Central Unit Main Bridge Control Panel

W121 1x2x0,75 2 Main Bridge Control Panel VDR System

W122 2x2x0,75 4 Main Bridge Control Panel Data Logger
W123 2x2x0,75 4 ECR Control Panel Hydraulic Junction Box Pitch Indicator

LGG
W124 1x2x0,75 2 ECR Control Panel Conning System

W131 4x2x0,75 5 Central Unit Hydraulic Tank Unit

W132 4x2x0,75 6 Central Unit Pitch Position Sensor Unit
W133 2x2x0,75 3 Central Unit Shaft Speed Sensor Unit

LeA
W134 4x2,5 4 Central Unit Local Control Unit
W135 2x2x0,75 2 Central Unit Local Control Unit
W136 10x2x0,75 14 Central Unit Main Engine
W137 2x2x0,75 4 Central Unit Main Engine
W138 2x2x0,75 2 Central Unit Main Engine

W141 12x1,5 8 Central Unit Gearbox

W142 4x2x0,75 4 Central Unit Main Switchboard
W143 4x2x0,75 4 Central Unit Shaft Brake
W144 4x2x0,75 2 Central Unit FIFI
W145 10x2x0,75 16 Central Unit Alarm System

W151 2x2x0,75 2 I/O Extension Unit JS System

W152 6x2x0,75 10 I/O Extension Unit JS System
W153 2x2,5 2 Local Control Unit External Power Supply C 24VDC/4A
W154 2x2x0,75 4 Local Control Unit Pitch Position Sensor Unit
W155 2x2x0,75 3 Local Control Unit Shaft Speed Sensor Unit
W156 2x2,5 2 Local Control Unit Control Valve Pitch Ahead
W157 2x2,5 2 Local Control Unit Control Valve Pitch Astern
W158 2x2x0,75 2 Local Control Unit External Alarm System

All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

MPC800M CONTROL SYSTEM

LAYOUT AND CABLE PLAN STBD

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2022-09-20
MPP620F
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

MPC800M CONTROL SYSTEM

POWER AND DATA BUS STBD

9 of 14
-

-EN62710

62710
C
2022-09-20
MPP620F
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM STBD

MPC800M CONTROL SYSTEM
10 of 14
-

-EN62710

62710
C
2022-09-20
MPP620F
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM STBD

MPC800M CONTROL SYSTEM
11 of 14
-

-EN62710

62710
C
2022-09-20
MPP620F
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM STBD

MPC800M CONTROL SYSTEM
12 of 14
-

-EN62710

62710
C
2022-09-20
MPP620F
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

TERMINAL DIAGRAM STBD

MPC800M CONTROL SYSTEM
13 of 14
-

-EN62710

62710
C
2022-09-20
MPP620F
 MPP620F

2022-09-20

C
62710
-
EN62710
-
W201 2x6 2 External Power Supply A 24DC/10A Central Unit

14 of 14
W202 2x6 2 External Power Supply B 24DC/10A Central Unit
W203 2x4 2 Central Unit I/O Extension Unit
W204 1x2x0,75 2 Central Unit I/O Extension Unit
W205 2x4 2 Central Unit I/O Extension Unit
W206 1x2x0,75 2 Central Unit I/O Extension Unit
W207 2x4 2 I/O Extension Unit ECR Control Panel
ECR Control Panel

MPC800M CONTROL SYSTEM

W208 1x2x0,75 2 I/O Extension Unit
W209 2x4 2 I/O Extension Unit ECR Control Panel
W210 1x2x0,75 2 I/O Extension Unit ECR Control Panel

7634M
W211 2x4 2 ECR Control Panel Main Bridge Control Panel
W212 1x2x0,75 2 ECR Control Panel Main Bridge Control Panel

CABLE LIST STBD

W213 2x4 2 ECR Control Panel Main Bridge Control Panel
W214 1x2x0,75 2 ECR Control Panel Main Bridge Control Panel

LGG
W219 1x2x0,75 2 Central Unit Main Bridge Control Panel

W221 1x2x0,75 2 Main Bridge Control Panel VDR System

W222 2x2x0,75 4 Main Bridge Control Panel Data Logger
W223 2x2x0,75 4 ECR Control Panel Hydraulic Junction Box Pitch Indicator

LGG
W224 1x2x0,75 2 ECR Control Panel Conning System

W231 4x2x0,75 5 Central Unit Hydraulic Tank Unit

W232 4x2x0,75 6 Central Unit Pitch Position Sensor Unit
W233 2x2x0,75 3 Central Unit Shaft Speed Sensor Unit

LeA
W234 4x2,5 4 Central Unit Local Control Unit
W235 2x2x0,75 2 Central Unit Local Control Unit
W236 10x2x0,75 14 Central Unit Main Engine
W237 2x2x0,75 4 Central Unit Main Engine
W238 2x2x0,75 2 Central Unit Main Engine

W241 12x1,5 8 Central Unit Gearbox

W242 4x2x0,75 4 Central Unit Main Switchboard
W243 4x2x0,75 4 Central Unit Shaft Brake
W244 4x2x0,75 2 Central Unit FIFI
W245 10x2x0,75 16 Central Unit Alarm System

W251 2x2x0,75 2 I/O Extension Unit JS System

W252 6x2x0,75 10 I/O Extension Unit JS System
W253 2x2,5 2 Local Control Unit External Power Supply C 24VDC/4A
W254 2x2x0,75 4 Local Control Unit Pitch Position Sensor Unit
W255 2x2x0,75 3 Local Control Unit Shaft Speed Sensor Unit
W256 2x2,5 2 Local Control Unit Control Valve Pitch Ahead
W257 2x2,5 2 Local Control Unit Control Valve Pitch Astern
W258 2x2x0,75 2 Local Control Unit External Alarm System

All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

LAYOUT AND CABLE PLAN

HYDRAULI & ALARM CONNECTIONS
1 of 10
MPP620F

------

62715
A
2022-09-27
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG

TERMINAL DIAGRAM
7634M

HYDRAULI & ALARM CONNECTIONS

2 of 10
MPP620F

------

62715
A
2022-09-27
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG

TERMINAL DIAGRAM
7634M

HYDRAULI & ALARM CONNECTIONS

3 of 10
MPP620F

------

62715
A
2022-09-27
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG

TERMINAL DIAGRAM
7634M

HYDRAULI & ALARM CONNECTIONS

4 of 10
MPP620F

------

62715
A
2022-09-27
 2022-09-27

A
62715
-
-----
MPP620F
W131 4x2x0,75 5 Central Unit Hydraulic Junction Box

5 of 10
W145 10x2x0,75 16 Central Unit Alarm System
W156 2x2,5 2 Local Control Unit Hydraulic Junction Box
W157 2x2,5 2 Local Control Unit Hydraulic Junction Box
W158 2x2x0,75 2 Local Control Unit Alarm System

HYDRAULI & ALARM CONNECTIONS

W302 2x2x0,75 2 Hydraulic Junction Box PumpStarter Unit 1
W303 4x2x0,75 8 Hydraulic Junction Box Alarm System
W304 4x2x0,75 4 Pump Starter Unit 1 Alarm System

7634M
W401 4G10 4 External Power Supply 3x400VAC/32A Pump Starter Unit 1
W402 3G1,5 3 External Power Supply 230VAC/10A Pump Starter Unit 1
W403 4G10 4 Pump Starter Unit 1 Pump Motor 1
W404 3G1,5 3 Pump Starter Unit 1 Pump Motor 1 Stand Still Heater

CABLE LIST
LGG
LGG
LeA

All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG
7634M

LAYOUT AND CABLE PLAN

HYDRAULI & ALARM CONNECTIONS
6 of 10
MPP620F

------

62715
A
2022-09-27
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG

TERMINAL DIAGRAM
7634M

HYDRAULI & ALARM CONNECTIONS

7 of 10
MPP620F

------

62715
A
2022-09-27
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG

TERMINAL DIAGRAM
7634M

HYDRAULI & ALARM CONNECTIONS

8 of 10
MPP620F

------

62715
A
2022-09-27
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
LeA
LGG
LGG

TERMINAL DIAGRAM
7634M

HYDRAULI & ALARM CONNECTIONS

9 of 10
MPP620F

------

62715
A
2022-09-27
 2022-09-27

A
62715
-
-----
MPP620F
W231 4x2x0,75 5 Central Unit Hydraulic Junction Box

10 of 10
W245 10x2x0,75 16 Central Unit Alarm System
W256 2x2,5 2 Local Control Unit Hydraulic Junction Box
W257 2x2,5 2 Local Control Unit Hydraulic Junction Box
W258 2x2x0,75 2 Local Control Unit Alarm System

HYDRAULI & ALARM CONNECTIONS

W501 2x2x0,75 2 Hydraulic Junction Box PumpStarter Unit 2
W503 4x2x0,75 8 Hydraulic Junction Box Alarm System
W505 4x2x0,75 4 Pump Starter Unit 2 Alarm System

7634M
W601 4G10 4 External Power Supply 3x400VAC/32A Pump Starter Unit 2
W602 3G1,5 3 External Power Supply 230VAC/10A Pump Starter Unit 2
W603 4G10 4 Pump Starter Unit 2 Pump Motor 2
W604 3G1,5 3 Pump Starter Unit 2 Pump Motor 2 Stand Still Heater

CABLE LIST
LGG
LGG
LeA

All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. BERG: GREEN Confidential ® BERG Propulsion AB
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
 asj
B UPDATED BOM LIST. 2022-11-18 UcV - -
A BERG logotype and text 2020-09-01 LGG - -
Rev. Revision Comprises Date Sign. Check Appr.
 HPU 06
C380-28CC, C500-55CC, S650 - 80CC, S1000 - 80CC, S1000 - 112CC, S1000 - 140CC

ELECTRICAL SCHEME
®
YELLOW

Snm Lgg Ucv

CONNECTION GP-BOX 1 of 16 2022-01-21

(HPU 06) EF62608 1:1

Cover page 62608 A

 Revision Description Created by Creation date Validated by Validation date Verified by Verified on

0 First release Snm 2022-01-21

A Added relays and terminals for TS1 and LS1 Dry contact output. EC DOC. NO.307563 LeA 2023-06-28
®
YELLOW

Snm Lgg Ucv

CONNECTION GP-BOX 2 of 16 2022-01-21

(HPU 06) EF62608 1:1

Book revisions 62608 A

 1-Document book

Drawing Description Function Location Revision Date Created by Folder Folder description

01 Cover page =F1 +L1 0 2022-01-21 Snm

02 Book revisions =F1 +L1 0 2022-01-21 Snm

03 Drawings list =F1 +L1 0 2022-01-21 Snm

04 Wiring line diagram =F1 +L1 0 2022-01-21 Snm

05 Connection Box =F1 +L1 0 2022-01-21 Snm

06 Electrical scheme =F1 +L1 0 2022-01-21 Snm

07 Electrical scheme =F1 +L1 0 2022-01-21 Snm

08 Electrical scheme =F1 +L1 0 2022-01-21 Snm

1-Document book

Drawing Description Function Location Revision Date Created by Folder Folder description

09 X1-(1/3) =F1 +L1 0 2022-01-21 Snm 1 Terminal drawing

10 X1-(2/3) =F1 +L1 0 2022-01-21 Snm 1 Terminal drawing

11 X1-(3/3) =F1 +L1 0 2022-01-21 Snm 1 Terminal drawing

12 X2-(1/2) =F1 +L1 0 2022-01-21 Snm 1 Terminal drawing

®

13 X2-(2/2) =F1 +L1 0 2022-01-21 Snm 1 Terminal drawing

1-Document book
YELLOW

Drawing Description Function Location Revision Date Created by Folder Folder description

14 Bill Of Materials =F1 +L1 0 2022-01-21 Snm

15 Bill Of Materials =F1 +L1 0 2022-01-21 Snm

16 List of wires by line style =F1 +L1 0 2022-01-21 Snm

NOTE:

JUNCTION BOX IS POWERED BY 24VDC

THE ENCLOSURE SHOULD BE MOUNTED WITH FOUR BOLTS AND WASHERS.

RECOMMENDED MAXIMUM OPERATING TEMPERATURE 50 deg C / 122 deg F.

THE LID MUST REMAIN CLOSED WHEN THE SYSTEM IS IN OPERATION

PROTECTION: IP55 IEC 60529

COLOUR: RAL 7035

USE RITTAL KONFIGURATION FILE FOR CUT OUTS.

INTERNAL WIRES ARE 0,75mm2 BETATHERM 145 UNLESS OTHER IS SPECIFIED. Snm Lgg Ucv
SEE HARNESS DRAWING FOR SENSOR CABLES.
CONNECTION GP-BOX 3 of 16 2022-01-21
SEE DOCUMENT 285387 FOR SENSOR OVERVIEW, TYPE AND
CABLE RECOMMENDATION FOR SHIP YARD. (HPU 06) EF62608 1:1

Drawings list 62608 A

 +L1 - Connection Box

-PE1 -X1 -X2 -P1

Cl = Range =

+L2 - HPU Unit

-B1 -B2 -B3 -B4 -B5 -B6 -B7

®

Range = Range = Range = Range = Range = Range = Range =

YELLOW

TS 1 LS 1 AS 1 PSP CI 1 CI 2 CI 3
Analog 4-20mA Analog 4-20mA Analog 4-20mA Analog 4-20mA Switch Switch Switch
& switch & switch

-B8 -B9 -B10 -V1

Range = Range = Range = Range =

PSP 1 PSP 2 PSP 3 V1 5-a / V1 5-b

Switch Switch Switch PWM

Snm Lgg Ucv

CONNECTION GP-BOX 4 of 16 2022-01-21

(HPU 06) EF62608 1:1

Wiring line diagram 62608 A

 o
®
YELLOW

Snm Lgg Ucv

CONNECTION GP-BOX 5 of 16 2022-01-21

(HPU 06) EF62608 5:1

Connection Box 62608 A

 YELLOW ®

-PE1
2
1
PE

1
-X1
2
1
+24 V DC

Wire
0V

2
1
2

Wire
-PE1
W5\4 W6\4 W7\4 PE

2
1
2
-X1 24V
2
1
3

0V
3
4
4

+L2-X4
Phoenix Contact
1424656
-X1

1
24V
1

W1\1
2
5

2
W1\2 Ai
4
3
6

TS 1
W1\4
2
1
7

3
W1\3
4
3
8

0V
Wire
Wire

M12 SOCKET CONNECTOR 4P ANGLE

EM1806
ALARM SYSTEM

+L2-X5
JUMPER BAR, 5-Pol

Phoenix Contact
1424656
JUMPER BAR, 12-Pol +3-Pol
-X1

1
W2\1
24V
2
1
9

2
W2\2
Ai
4
3

LS 1
W2\4
2
1

3
W2\3
3
4

0V
10 11 12
Wire
Wire

M12 SOCKET CONNECTOR 4P ANGLE

EM1806
-X1

W101/ WIRE (WHITE)

2
1

Di (TS 1)
W102/ WIRE (WHITE)
4
3
37 38

Snm
-X1

W103/ WIRE (WHITE)

2
1

Di (LS 1)
W104/ WIRE (WHITE)
4
3
39 40

Lgg

+L2-X6
Phoenix Contact
1424655
-X1

1
24V
(HPU 06)

W3\1
2
1

Ucv

2
W3\2 Ai
4
3

4
Ai
AS 1

W3\4
1
2

3
W3\3 0V
4
3

Electrical scheme
13 14 15 16

M12 SOCKET CONNECTOR 4P STRAIGHT

CONNECTION GP-BOX

EM1805

+L2-X7
Hirschmann
JUMPER BAR, 3-Pol
CENTRAL UNIT

1215302
-X1

1
W4\1
2
1

W4\2 24V
2
W4\2
4
3

W4\1 Ai
3
PSP

W4\3
2
1

4
3
4

EF62608
17 18 19 20

DIN Contact 3P+PE (DIN 43650)

1:1
W5\4 W6\4 W7\4

EM1797
07-1

62608 A
6 of 16 2022-01-21
 YELLOW ®

06-11
+L2-X8
Hirschmann
1215302

W5\4 W6\4 W7\4

-X1
1

2
1
W5\1
2

4
3
W5\2 Di

CI 1
3

2
1
W5\3
4
W5\4
3
4
21 22 23 24

DIN Contact 3P+PE (DIN 43650)

EM1797

+L2-X9
Hirschmann
1215302
-X1

1
2
1

W6\1
2
Di
4
3

W6\2
3

CI 2
1
2

W6\3
4
W6\4
4
3
25 26 27 28
ALARM SYSTEM

DIN Contact 3P+PE (DIN 43650)

EM1797

+L2-X10
Hirschmann

NUMBER OF SENSORS DEPEND ON CONFIGURATION

1215302
-X1

1
2
1

W7\1
2
Di
4
3

W7\2
3
CI 3
1
2

W7\3
4
W7\4
4
3
29 30 31 32

DIN Contact 3P+PE (DIN 43650)

EM1797

Snm
-P1

Lgg
EI95438
-X1

+24V
2
1

0V
4
3
33 34

(HPU 06)

4-20mA (CW) Ao +
Ucv
1
2

Gnd Ao -
Pitch Indicator
4
3
35 36

4-20mA (CCW)
6

Illumination +
ECR CONTROL PANEL

Electrical scheme
7

Gnd
8

N/A
CONNECTION GP-BOX

EF62608
1:1

62608 A
7 of 16 2022-01-21
 YELLOW ®

-PE1
W8\4 W9\4

1
2
3
PE

2
1
4

2
1
5
+L2-X11
Phoenix Contact
1527906

-X2
1
W8\1
1 PWM
2
1

2
W8\2 PWM
4
3
2

V1 5-a
W8\3
2
1
3

4
4
3

W8\4
4

DIN Contact 2P + PE (with diod)

EM1807

+L2-X12
Phoenix Contact
1527906
LOCAL UNIT

-X2

1
W9\1
PWM
1
2
5

2
W9\2 PWM
4
3
6

V1 5-b
W9\3
2
1
7

4
4
3
8

W9\4

DIN Contact 2P + PE (with diod)

EM1807

+L2-X13
Hirschmann
1215302
-X2

1
W10\1
2
1
9

2
W10\2
4
3

3
PSP 1

W10\3
1
2

4
4
3

W10\4
10 11 12

DIN Contact 3P+PE (DIN 43650)

EM1797

Snm +L2-X14
Hirschmann
1215302
-X2

1
Lgg

W11\1
2
1

2
W11\2
3
4

3
PSP 2

W11\3
2
1

4
4
3

W11\4
13 14 15 16

(HPU 06)
STARTER UNIT 1, 2 AND 3

Ucv

DIN Contact 3P+PE (DIN 43650)

EM1797
Electrical scheme

+L2-X15
Hirschmann
NUMBER OF SENSORS DEPEND ON CONFIGURATION

1215302
CONNECTION GP-BOX
-X2

1
W12\1
2
1

2
W12\2
3
4

3
W12\3
2
1

PSP 3

4
4
3

W12\4
17 18 19 20

DIN Contact 3P+PE (DIN 43650)

EM1797
-PE1
PE

EF62608
2
1
6

W10\4 W11\4 W12\4

1:1

62608 A
8 of 16 2022-01-21
 -X1

1 1 2
=F1+L1-X1-3:2

1 2 2
=F1+L1-X1-4:4

2002-1691 Wago

1 3 2
=F1+L1-X1-1:2

3 4 4
=F1+L1-X1-2:2
+L2 HPU Unit
+L2-X4 Main function
Phoenix Contact
1424656
1 1
1 5 2
=F1+L2-X4:1
1 M12 SOCKET CONNECTOR 4P ANGLE

2 2
3 6 4
=F1+L2-X4:2 =F1
2
W1
0279630
CABLE 4P with shield
®

:7.7 L :1.94538
4 4
1 7 2
=F1+L2-X4:4
4

3 3
3 8 4
=F1+L2-X4:3
3
YELLOW

+L2 HPU Unit

+L2-X5 Main function
Phoenix Contact
1424656
1 1
1 9 2
=F1+L2-X5:1
1 M12 SOCKET CONNECTOR 4P ANGLE

2 2
3 10 4
=F1+L2-X5:2 =F1
2
W2
0279630
CABLE 4P with shield
:7.7 L :1.91069
4 4
1 11 2
=F1+L2-X5:4
4

3 3
3 12 4
=F1+L2-X5:3
3
+L2 HPU Unit
+L2-X6 Main function
Phoenix Contact
1424655
1 1
1 13 2
=F1+L2-X6:1
1 M12 SOCKET CONNECTOR 4P STRAIGHT

2 2
3 14 4
=F1+L2-X6:2 =F1
2
W3
0279630
CABLE 4P with shield
:7.7 L :2.24406
4 4
1 15 2
=F1+L2-X6:4
4

3 3
3 16 4
=F1+L2-X6:3
3

Snm Lgg Ucv

CONNECTION GP-BOX 9 of 16 2022-01-21

(HPU 06) EF62608 1:1

X1-(1/3) 62608 A
 -X1
+L2 HPU Unit
+L2-X7 Main function
Hirschmann
1215302
2 2
1 17 2
=F1+L2-X7:2
2 DIN Contact 3P+PE (DIN 43650)

=F1
1 W4 1
3 18 4
=F1+L2-X7:1
0279630
CABLE 4P with shield
1
:7.7 L :2.18917

3 3
1 19 2
=F1+L2-X7:3
3

3 20 4

+L2 HPU Unit

+L2-X8 Main function
Hirschmann
1215302
1 1
1 21 2
=F1+L2-X8:1
1 DIN Contact 3P+PE (DIN 43650)

=F1
2 W5 2
3 22 4
=F1+L2-X8:2
0279630
CABLE 4P with shield
2
:7.7 L :3.01248

3 3
1 23 2
=F1+L2-X8:3
3
®

3 24 4

+L2 HPU Unit

+L2-X9 Main function
YELLOW

Hirschmann
1215302
1 1
1 25 2
=F1+L2-X9:1
1 DIN Contact 3P+PE (DIN 43650)

=F1
2 W6 2
3 26 4
=F1+L2-X9:2
0279630
CABLE 4P with shield
2
:7.7 L :3.42828

3 3
1 27 2
=F1+L2-X9:3
3

3 28 4

+L2 HPU Unit

+L2-X10 Main function
Hirschmann
1215302
1 1
1 29 2
=F1+L2-X10:1
1 DIN Contact 3P+PE (DIN 43650)

=F1
2 W7 2
3 30 4
=F1+L2-X10:2
0279630
CABLE 4P with shield
2
:7.7 L :2.36135

3 3
1 31 2
=F1+L2-X10:3
3

3 32 4

Snm Lgg Ucv

CONNECTION GP-BOX 10 of 16 2022-01-21

(HPU 06) EF62608 1:1

X1-(2/3) 62608 A
 -X1

1 33 2
=F1+L1-P1

3 34 4
=F1+L1-P1

1 35 2
=F1+L1-P1

3 36 4
=F1+L1-P1

1 37 2
=F1+L2

3 38 4
=F1+L2

1 39 2
=F1+L2
®

3 40 4
=F1+L2

2002-2291 Wago
YELLOW

Snm Lgg Ucv

CONNECTION GP-BOX 11 of 16 2022-01-21

(HPU 06) EF62608 1:1

X1-(3/3) 62608 A
 -X2
+L2 HPU Unit
+L2-X11 Main function
Phoenix Contact
1527906
1 1
1 1 2
=F1+L2-X11:1
1 DIN Contact 2P + PE (with diod)

=F1
2 W8 2
3 2 4
=F1+L2-X11:2
0279630
CABLE 4P with shield
2
:7.7 L :2.92893

3 3
1 3 2
=F1+L2-X11:3
3

3 4 4

+L2 HPU Unit

+L2-X12 Main function
Phoenix Contact
1527906
1 1
1 5 2
=F1+L2-X12:1
1 DIN Contact 2P + PE (with diod)

=F1
2 W9 2
3 6 4
=F1+L2-X12:2
0279630
CABLE 4P with shield
2
:7.7 L :2.49214

3 3
1 7 2
=F1+L2-X12:3
3
®

3 8 4

+L2 HPU Unit

+L2-X13 Main function
Hirschmann
YELLOW

1215302
1 1
1 9 2
=F1+L2-X13:1
1 DIN Contact 3P+PE (DIN 43650)

=F1
2 W10 2
3 10 4
=F1+L2-X13:2
0279630
CABLE 4P with shield
2
:7.7 L :2.10738

3 3
1 11 2
=F1+L2-X13:3
3

3 12 4

+L2 HPU Unit

+L2-X14 Main function
Hirschmann
1215302
1 1
1 13 2
=F1+L2-X14:1
1 DIN Contact 3P+PE (DIN 43650)

=F1
2 W11 2
3 14 4
=F1+L2-X14:2
0279630
CABLE 4P with shield
2
:7.7 L :2.5925

3 3
1 15 2
=F1+L2-X14:3
3

3 16 4

Snm Lgg Ucv

CONNECTION GP-BOX 12 of 16 2022-01-21

(HPU 06) EF62608 1:1

X2-(1/2) 62608 A
 -X2
+L2 HPU Unit
+L2-X15 Main function
Hirschmann
1215302
1 1
1 17 2
=F1+L2-X15:1
1 DIN Contact 3P+PE (DIN 43650)

=F1
2 W12 2
3 18 4
=F1+L2-X15:2
0279630
CABLE 4P with shield
2
:7.7 L :0

3 3
1 19 2
=F1+L2-X15:3
3

3 20 4

2002-2291 Wago
®
YELLOW

Snm Lgg Ucv

CONNECTION GP-BOX 13 of 16 2022-01-21

(HPU 06) EF62608 1:1

X2-(2/2) 62608 A
 ABB

Mark Description Reference Article number Quantity

1 -A1 MOUNTING RAIL TS35 X 15FH 2929643 EM2160 1

Deif

Mark Description Reference Article number Quantity

1 -P1 PITCH INDICATOR XL72 XL72 m/IP66 EI95438 1

Lapp

Mark Description Reference Article number Quantity

155-12-843, 155-12-843,
1 -A2, -A3, -A22 CABLE GLAND M16x1,5 EM3340 3
155-12-843

52103340, 52103340,
2 -A13, -A14, -A15, -A16, -A17 CHECK NUT M32x1,5 52103340, 52103340, EM3374 5
52103340

3 -A29, -A30 BLIND PLUG 8x14 53100008, 53100008 EM3393 2

53112040, 53112040,
®

4 -A5, -A6, -A7, -A8, -A9 CABLE GLAND M32x1,5 53112040, 53112040, EM3373 5
53112040

53332380, 53332380,
5 -A18, -A19, -A20, -A21 CABLE GLAND INSERT M32 3x8 EM3392 4
53332380, 53332380
YELLOW

54113010, 54113010,
6 -A26, -A27, -A28 BLIND PLUG M16 EM3390 3
54113010

7 -A24 BLIND PLUG M25 54113030 EM3368 1

8 -A25 BLIND PLUG M32 54113040 EM3399 1

9 -A4 CABLE GLAND M25x1,5 1772230000 EM3357 1

KM16ME, KM16ME,
10 -A10, -A11, -A23 CHECK NUT M16x1,5 EM3350 3
KM16ME

11 -A12 CHECK NUT M25x1,5 KM25ME EM3351 1

Snm Lgg Ucv

CONNECTION GP-BOX 14 of 16 2022-01-21

(HPU 06) EF62608 1:1

Bill Of Materials 62608 A

 Rittal

Mark Description Reference Article number Quantity

KX 1508.000 + Cut Out

1 -J1 W:400 H:300 D:120 EM1654-1 1
HPU06

Wago

Mark Description Reference Article number Quantity

1 -X3 END STOP TS35 249-117 EL2262 2

2 -X18, -X19 JUMPER BAR 2,5 3-pol 2002-473, 2002-473 EL6083 2

3 -X16 JUMPER BAR 2,5 5-pol 2002-475 EL6063 1

4 -X17 JUMPER BAR 2,5 12-pol 2002-482 EL6098 1

5 -X1-1, -X1-2 TERMINAL SINGLE SWITCH OFF 2,5-4 2002-1671, 2002-1671 EL6011 2

6 -X1- END PLATE FOR EL6011 2002-1691 EL6017 1

-X1-7
8, -X1-5
6, -X1-11
12, -X1-9
10, -X1-13
14, -X1-15
16, -X1-17
18, -X1-19 2002-2201, 2002-2201,
®

20, -X1-21 2002-2201, 2002-2201,

22, -X1-23 2002-2201, 2002-2201,
24, -X1-25 2002-2201, 2002-2201,
26, -X1-27 2002-2201, 2002-2201,
28, -X1-29 2002-2201, 2002-2201,
30, -X1-31 2002-2201, 2002-2201,
YELLOW

7 TERMINAL TWIN 2,5-4 EL6000 29

32, -X1-33 2002-2201, 2002-2201,
34, -X1-35 2002-2201, 2002-2201,
36, -X2-1 2002-2201, 2002-2201,
2, -X2-3 2002-2201, 2002-2201,
4, -X2-5 2002-2201, 2002-2201,
6, -X2-7 2002-2201, 2002-2201,
8, -X2-9 2002-2201
10, -X2-11
12, -X2-13
14, -X2-15
16, -X2-17
18, -X2-19
20, -X1-3
4

8 -X2- , -X1- END PLATE TWIN 2002-2291, 2002-2291 EL6005 2

2002-2407, 2002-2407,
9 -PE1-3, -PE1-4, -PE1-5 TERMINAL GROUND 8P EL6073 3
2002-2407

10 -X20 END PLATE 8P GROUND 2002-2491 EL6071 1

11 K1,K2 RELAY 1 POLE 24VDC EL2500 2

Weidmüller

Mark Description Reference Article number Quantity

104250000, 104250000,
1 -PE1-1, -PE1-2, -PE1-6 TERMINAL WPE 10/ZR EL2226 3
104250000

Snm Lgg Ucv

CONNECTION GP-BOX 15 of 16 2022-01-21

(HPU 06) EF62608 1:1

Bill Of Materials 62608 A

 BETAtherm 145 BLACK

Origin Destination Wire number Section Length (mm) Reference Article number

=F1+L1-P1 =F1+L1-X1-36:4 0.75 (mm²) 249 BETAtherm 145 - 83087041 EM2250

=F1+L1-X1-2:2 =F1+L1-X1-4:4 0.75 (mm²) 66 BETAtherm 145 - 83087041 EM2250

=F1+L1-X1-34:4 =F1+L1-P1 0.75 (mm²) 288 BETAtherm 145 - 83087041 EM2250

603

BETAtherm 145 RED

Origin Destination Wire number Section Length (mm) Reference Article number

=F1+L1-X1-1:2 =F1+L1-X1-3:2 0.75 (mm²) 79 BETAtherm 145 - 83087042 EM2255

=F1+L1-P1 =F1+L1-X1-33:2 0.75 (mm²) 262 BETAtherm 145 - 83087042 EM2255

341

BETAtherm 145 WHITE

Origin Destination Wire number Section Length (mm) Reference Article number

=F1+L1-P1 =F1+L1-X1-35:2 0.75 (mm²) 218 BETAtherm 145 - 83087040 EM2245

218
®
YELLOW

Snm Lgg Ucv

CONNECTION GP-BOX 16 of 16 2022-01-21

(HPU 06) EF62608 1:1

List of wires by line style 62608 A

 12 12 12 12 12

11 11 11 11 11

14 14 14 14 14
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

6-24 6-24 6-24 6-24 6-24

V= V= V= V= V=

A1 A1 A1 A1 A1

A2 A2 A2 A2 A2
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

M TOOK AWAY MISSPLACED TERMINALS 31-MAR-2023 Mna

L FIXED NUMBERS FOR QS1 31-OCT-2022 Mna
K UPDATED QF1, AUX. CON, ADDED SIDE AUX. CON. 13-JUL-2022 Mna Order No. Drawn Checked Approved Sheet
I CHANGED KF1 TO QF1+C1, REMOVED K1 12-APR-2022 Mna UtV LGG - B.J. T.H. - 1 of 7
I CHANGED CAT-LOGO TO BERG-LOGO, MAX 60°C. 12-APR-2022 Mna UtV LGG Part No. Date
D.O.L. STARTER UNIT, PUMP
H AUX POLES QS1, X1/7-10, H5, K4, K5, F3 22-NOV-2018 B.J. F.K. T.H. 400VAC...690VAC/ 22-32A EB61333 22-NOV-2018
Rev.
400V/ 12,1-17,7kW, 690V/ 21-30,5kW
F
Rev.
TRIP CLASSSETTING: 10E & TR1 SETTING: 8s
Revision Comprises
15-NOV-2016
Date
B.J.
Sign.
T.H.
Check
-
Appr. - 61333 M
 Item Description Type Art. No. Qty.
AS1 CABINET RAL 7035 500x500x300mm EM95201 1
DOOR STOP, WALL MOUNT BRACKETS A4 EM95210, EM95208 1
MOUNTING RAIL TS35 X 15FH EM2160 1
QS1 MAIN SWITCH, 3 POLE 63A EB3120 1
DOOR SWITCH IP 54 FOR EB3120 EB3121 1
SHAFT FOR EB3120 EB3122 1
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.

PLATE "MAIN SWITCH" NS3525 1

ELECTRICITY HAZARD SIGN NS7175 1
RAW MATERIAL NAME PLATE EL6132 1
T1 TRANSFORMER 350<690//<240VAC, 200VA EM2110 1
TV1 AC/DC CONVERTER 85<277VAC//24VDC 3A EM3151 1
F1 TRANSFORMER PROTECTION 0.45...0.63A EB3210 1
F2 AUTOMATIC FUSE MCB - 1P C 1A EL1079 1
QF1 MOTOR PROTECTION 23-28A EB3190 1
AUX CONTACT FOR QF1 EB3217 1
C1 CONTACTOR 18,5KW EB3199 1
SIDE AUX CONT. FOR 3RT2 1NO+1NC EB3219 1
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

LINK MODULE EB3228 1

K2, K3, K4, K5 RELAY 1 POLE 24VDC EL2500 4
MR1 UNDER VOLTAGE MONITORING RELAY EM3163 1
TR1 TIME RELAY, ON-DELAY, 2C ER2441 1
H1 LED-LAMP, "POWER ON", WHITE 24V AC/DC EB2331, NS3521 1
H2 LED-LAMP, "FAULT", RED 24V AC/DC EB2333, NS3523 1
H3 LED-LAMP, "STANDBY" YELLOW 24V AC/DC EB2334, NS3524 1
H4 LED-LAMP, "RUN" GREEN 24V AC/DC EB2332, NS3522 1
S1 SELECTOR SWITCH "LOCAL/ON-OFF-REMOTE" EB2173, EB2036, NS3134 1
S2 SELECTOR SWITCH, "MAN-AUTO" EB2035, EB2056, NS3361 1
PLATE HOLDER FOR ZB4 EB2031 6
TA1 TIME COUNT. 48X48MM DC 10-80V EK1301 1
RUST PREVENTING EMITTER FM3620 1
SCREW SELF DRILL 4,2X14 PHILLIP 2 SM3626 25
X1/, X2/ TERMINAL TWIN 2,5 EL6000 12
ENDPLATE TWIN EL6005 1
PE TERMINAL PE EL2226 3
END BRACKET EL2262 7
TERMINAL MARKING EL6049 12
T2 CURRENT TRANSFORMER 60/5A EI96100 1
H K4, K5 22-NOV-2018 B.J. F.K. T.H.
F S1 TEXT CHANGED TO "LOCAL/ON - OFF - AUTO" 07-NOV-2016 B.J. - - Order No. Drawn Checked Approved Sheet
F CHANGED F1, F2. TERM. X1/1...6 & F101 REMOVED 07-NOV-2016 B.J. - - - B.J. T.H. - 2 of 7
F ADDED TV1, T2, A1, TA1, K3. TWIN TERM. 07-NOV-2016 B.J. - - Part No. Date
D.O.L. STARTER UNIT, PUMP
D ADDED EB3206 03-JUL-2015 B.J. - - 400VAC...690VAC/ 22-32A EB61333 22-NOV-2018
Rev.
400V/ 12,1-17,7kW, 690V/ 21-30,5kW
B, C
Rev.
MR1 NEW TYPE, DOOR STAY
Revision Comprises
26-NOV-2014
Date
B.J.
Sign.
-
Check
-
Appr. - 61333 M
 Item Description Type Art. No. Qty.
A1 AMMETER, PANEL 5A 2XIN EI96091 1
H5 LED-LAMP BLUE 230V AC EB2335 1
H5 LABEL "HEATER ON" PLASTIC, BLACK LETTERS NS3526 1
F3 AUTOMATIC FUSE MCB - 2P C 6A EL1090 1
AUX POLE FOR EB3120 EB3119 2
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

Order No. Drawn Checked Approved Sheet

- B.J. T.H. - 3 of 7
Part No. Date
D.O.L. STARTER UNIT, PUMP
400VAC...690VAC/ 22-32A EB61333 22-NOV-2018
Rev.
400V/ 12,1-17,7kW, 690V/ 21-30,5kW
H
Rev.
NEW SHEET, H5, F3, AUX POLE FOR EB3120
Revision Comprises
22-NOV-2018
Date
B.J.
Sign.
F.K.
Check
T.H.
Appr. - 61333 M
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

F
H

Rev.
Revision Comprises
STANDSTILL HEATER, H5, F3, X1/7-10
TV1, F1, F2, TERMINAL X1/1...6 & F101 REMOVED
Date
07-NOV-2016
22-NOV-2018

Sign.
B.J.
B.J.
-
F.K.

Check
-
Appr.
T.H.

-
-
Order No.

400VAC...690VAC/ 22-32A
D.O.L. STARTER UNIT, PUMP

400V/ 12,1-17,7kW, 690V/ 21-30,5kW

B.J.
Drawn

Part No.
EB61333

61333
T.H.
Checked
-
Date
Approved

M
Rev.
22-NOV-2018
Sheet
4 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

F
D
H

Rev.
Revision Comprises
REMOVED TEXT PSW3
STANDSTILL HEATER, K4, K5
CHANGED S1 PLATE, ADDED K3

Date
03-JUL-2015
15-NOV-2016
22-NOV-2018

Sign.
B.J.
B.J.
B.J.

-
-
F.K.

Check
-
-

Appr.
T.H.

-
-
Order No.

400VAC...690VAC/ 22-32A
D.O.L. STARTER UNIT, PUMP

400V/ 12,1-17,7kW, 690V/ 21-30,5kW

B.J.
Drawn

Part No.
EB61333

61333
T.H.
Checked
-
Date
Approved

M
Rev.
22-NOV-2018
Sheet
5 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

H
Rev.
NEW SHEET
Revision Comprises
Date
22-NOV-2018
Sign.
B.J.
F.K.
Check
Appr.
T.H.
-
-
Order No.

400VAC...690VAC/ 22-32A
D.O.L. STARTER UNIT, PUMP

400V/ 12,1-17,7kW, 690V/ 21-30,5kW

B.J.
Drawn

Part No.
EB61333

61333
T.H.
Checked
-
Date
Approved

M
Rev.
22-NOV-2018
Sheet
6 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Berg: GREEN Confidential ©Berg Propulsion AB

F
Rev.
Revision Comprises
ADDED K3, X2/120-122
Date
07-NOV-2016
Sign.
B.J.
-
Check
-
Appr.
-
-
Order No.

400VAC...690VAC/ 22-32A
D.O.L. STARTER UNIT, PUMP

400V/ 12,1-17,7kW, 690V/ 21-30,5kW

B.J.
Drawn

Part No.
EB61333

61333
T.H.
Checked
-
Date
Approved

M
Rev.
22-NOV-2018
Sheet
7 of 7
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. Berg: GREEN Confidential © Berg Propulsion AB
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

300
300

A
B

Rev
Date
2022-06-22
2022-06-27
1
1

Pages
210

Info
Removed end stops
Added measurment fo rails in cabinet
Mna
Mna

Sign
---
---

Checked
260
260

LOGGER AND
No connection
Connection
Unless otherwise noted

DIMENSIONS AND LAYOUT

REMOTE MONITORING UNIT
Resistance in

Induktance in mH
Capacitance in nF

100

200
Tolerance
SS-ISO 2768-1
Unless otherwise noted
Scale
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. Berg: GREEN Confidential © Berg Propulsion AB
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.

LOGGER AND
No connection
Connection
Unless otherwise noted

TERMINAL CONNECTIONS
REMOTE MONITORING UNIT
Resistance in

Induktance in mH
Capacitance in nF
Tolerance
SS-ISO 2768-1
Unless otherwise noted
Scale
 The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. Berg: GREEN Confidential © Berg Propulsion AB
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Item
Quantity
Article
Description

LOGGER AND
No connection
Data

Connection
Unless otherwise noted

TERMINAL CONNECTIONS
REMOTE MONITORING UNIT
Resistance in

Induktance in mH
Capacitance in nF
Tolerance
SS-ISO 2768-1
Unless otherwise noted
Scale
10. APPENDIX – MPP OIL REQUIREMENTS
10.1. GENERAL INFORMATION
The oil supplier must always ensure that the oil is suitable to its purpose and meets the Berg
Propulsion requirements.

10.2. OIL REQUIREMENTS – MINERAL OIL

All oil must pass ISO 11158 or DIN 51524-
3

ISO 3448 Viscosity Grade (HDX OD Box): ISO VG 32

ISO 3448 Viscosity Grade (BCX OD Box): ISO VG 46

Load Carrying Capability: Load stage 11 or better according to ISO14635-1

HDX=gear mounted oil distributor
BCX=shaft mounted oil distributor

NOTICE! Failure to follow the oil requirements can shorten the service life of the
propulsion equipment.
© 2023 Berg Propulsion. All rights reserved.