PR 9000 DW - CB Adj&Chk (E) (CSA CK2084E - 20161108)

PR-9000-DW CONTROL BOX Adjustment Procedure & Check Sheet Issued: 8-Nov-2016
0. Reference
0-1. Layout of DW-DRVR pwb
* Remarks “N” = “NOR” position of the test switch
* Remarks = “No.1 pin” of the jumper
XF4(5A)
R901
DS104 K16 K17 1
J5
2
3 2 1
K10
K11
TP107
DS310
TP201 DS309
TP401
K12
DS201
K8
K9
DS306
K22
DS305 TP402
K5 K7 DS303 DS304
TP202 VR405 VR403 VR404
DS308 DS401
K4 DS307
DS302 DS311 JP401
TP101 VR301 TP404 L1
DS301
XF3(1A) VR402
TP102 TP405
TP104 TP302 DS312 VR401
TP301 TP403 JP602
DS101
J1 DS502 DS501
L2
DS102
TP103 VR601 TP604
DS103 TP601 TP605
TP106 JP704 JP601 TP603
TP505
JP201 K6 VR602 FL1
TP105 VR503
K1
J4 TP602 TP606 TP504
J3 TP210
TP503
VR502 VR505
DS708 VR704
VR501 K18
J2 DS707 N
VR508 S1 TP501
K2 K15 DS709
DS710 TP703 TP502
K13
K20 K19 K14 S2 VR504
TP701 VR702 N
JP705 VR507
S3(MS) S5(LP)
DS706 DS705 DS703
N N DS701 VR701 VR506
XF1(2A)
K3 DS702
XF2(2A)
TP702 DS704
N N JP702 JP703 VR703
2ERR1
2ERR2
AUX_+
AUX_P
AUX_S
2AL1
2AL2
ATX+
ATX-
ARX+
ARX-
TM1
TM2
TM0
NFU
SG
S4(FU) S6(LS)
TB3 TB8 TB6
TB1 TB7
TB2
1ERR1
1ERR2
MRAC1
MRAC2
1RR1
1RR2
1RC1
1RC2
2RR1
2RR2
2RC1
2RC2
3RR1
3RR2
3RC1
3RC2
ISO1
ISO2
1AL1
1AL2
AC1
AC2
RL1
RL2
PD
FB
F0
FU
LP
LS
CC
TB4 JP701 TB9

TB5
LMP1C
LMP2C
LMS1C
LMS2C
LMP1
LMP2
LMS1
LMS2
JLN1
JLN1
JLN2
JLN2
JLN3
JLN3
JLN4
JLN4
JAL0
JAL0
JAL1
JAL1
JAL2
JAL2
JCOM
JCOM
MS1
MS2
UL1
UL2
FG1
FG2
FT1
FT2
FT0
TKS FORM CSA-CK2084E 1/20

0-2. Description of the TEST SWITCH
Switch Description Position Test function
[NOR] VR501 CW:([+] as Port) / CCW:([-] as Stbd)
S1 Polarity of test signal (TP502)
[INV] VR501 CW:([-] as Stbd) / CCW:([+] as Port)
[NOR] Normal operation
S2 Operation mode of control box Simulate the autopilot order signal (TP502) by VR501
[TEST]
[!!] The autopilot cannot control torque motor in this mode
S3(MS) Simulate steering pump
[TEST] Make the running condition (=shorted MS1-MS2 terminal)
S4(FU) Simulate autopilot mode
[TEST] FU mode (=shorted FU-CC terminal)
Simulate autopilot NFU lever
S5(LP) The torque motor lever will turn to Port-max in NFU mode
for Port [TEST]
(=shorted LP-CC terminal)
Simulate autopilot NFU lever
S6(LS) The torque motor lever will turn to Stbd-max in NFU mode
for Stbd [TEST]
(=shorted LS-CC terminal)
[!!] The above all test switches must be returned to “NOR” position after testing/adjustment
0-3. Description of major VR and MEASURING POINT
Measuring
VR Specification Description
Point
---- POWER LED(White) [*] Pilot lamp of control box [*] This LED looks yellow during ON
---- UNLOAD LED(Orange) Operation indicator of unload valve
---- RUN LED(Green) Running indicator of control box
---- AC1/AC2 110VAC Source of autopilot
---- RL1/RL2 100VAC Driving signal of control box (=running steering pump)
---- UL1/UL2 100 or 110VAC Source of unload valve
Approx. 12VDC
---- TM1/TM2 Control signal of torque motor
[+]: Port / [-]: Stbd
5.5±0.1VDC
R901 2/3(R901) Control signal of torque motor for NFU mode
[+]: Port / [-]: Stbd
---- TP102/TP401 (+)24±3.6VDC
---- TP103/TP401 (-)24±3.6VDC
---- TP104/TP401 (+)15±0.6VDC
Power supply for FU circuit
---- TP105/TP401 (-)15±0.6VDC
---- TP106/TP401 (+)5±0.12VDC
---- TP107/TP401 (+)12±1.8VDC
---- TP606/TP401 Approx. 60Hz Frequency of the dither signal
VR602 TP602/TP401 Approx. 0.8VAC Voltage of the dither signal
7±0.35VAV
---- FG1/FG2 Source of LVDT
2.7±0.27kHz
VR401 TP403/TP401 0±0.02VDC@neutral Torque motor angle F/B-zero adjustment
Approx. ±10VDC Autopilot order signal/”Test Signal”(=simulate autopilot order signal)
VR501 TP502/TP401
[+]: CW / [-]: CCW [*] [*] The polarity of test signal can be changed by test switch S1
VR502 TP504/TP401 Approx. ±9.0VDC Order signal that adjusted Gain and Parallel running gain
Approx. 9~10VDC
VR402 TP404/TP401 Torque motor angle F/B-span common adjustment
[+]: Port / [-]: Stbd
VR403 TP404/TP401 Approx. (-)9.5~10.5VDC Torque motor angle F/B-span independent adjustment for Port direction
VR404 TP404/TP401 Approx. (+)9.5~10.5VDC Torque motor angle F/B-span independent adjustment for Stbd direction
Approx. ±13VDC Torque motor angle F/B-span adjustment for indication of autopilot P/S
VR405 TP405/TP401
[+]: Port / [-]: Stbd [*] lamp [*] The polarity of this signal can be changed by jumper JP401
Approx. 1 sec when 0 to
VR508 ---- Speed adjustment for torque motor lever
max position
Approx. 60% of single To reduce order signal gain for parallel running
VR504 TP404/TP401
running mode (Use this adjustment when TB7 1RR1/1RR2 terminal shorted)
VR505 TP404/TP401
VR506 TP404/TP401
Approx. 60% of single To reduce order signal gain when operating isolation system
VR507 TP404/TP401
running mode (Use this adjustment when TB7 ISO1/ISO2 terminal shorted)
LED(Red)
DS705(Port)
VR703 Approx. 75% of max torque Output threshold of order signal contact for HLA
DS706(Stbd)
motor lever angle
---- TB8-7/TB8-5 Short Shorted when DS705(Port) turns on for HLA
---- TB8-8/TB8-5 Short Shorted when DS706(Stbd) turns on for HLA
---- TB8-6/TB8-5 Short Shorted when NFU mode for HLA

0-4. Description of the LED on PWB
LED Descriptions Conditions
DS101 [Power] +15V_SENCE (TP104) “On” when operate
DS102 [Power] -15V_SENCE (TP105) “On” when operate
DS103 [Power] +5V (TP106) “On” when operate
DS104 [Power] 12V for FU mode (TP107) “On” when operate
DS201 [Power] 12V for NFU mode (TP202-TP201) “On” when operate
DS301 [Power] SEQ_5V (TP302-TP301) “On” when operate
DS302 MS (Steering pump running signal from starter) input “On” when input MS
DS303 RL (Steering pump running signal to autopilot) output “On” 3sec after DS302 turned “on”
DS304 LP (NFU order contact for Port) input “On” when input LP
DS305 LS (NFU order contact for Stbd) input “On” when input LS
DS306 FU (FU mode contact) input “On” when NFU mode
DS307 LMP (Limit-switch contact for Port) input “On” when input LMP
DS308 LMS (Limit-switch contact for Stbd) input “On” when input LMS
DS309 Output TM control signal for Port in NFU mode “On” when output TM signal for Port
DS310 Output TM control signal for Stbd in NFU mode “On” when output TM signal for Stbd
DS311 Unloading in NFU mode “On” when unloading
DS312 [HLA] Mode contact signal “On” when FU mode
DS401 [Power] FG1/FG2 LVDT Excite signal generator “On” when signal was generated
DS501 Limit function for Port in FU mode “On” when limit for Port
DS502 Limit function for Stbd in FU mode “On” when limit for Stbd
DS701 CMF(Control Motor Fail) “On” when detect much deviation
DS702 CMF(Control Motor Fail) “On” 5sec after DS701 turned “on”
DS703 [HLA] Order contact for Port in NFU mode “On” when output contact
DS704 [HLA] Order contact for Stbd in NFU mode “On” when output contact
DS705 [HLA] Order contact for Port in FU mode “On” when output contact
DS706 [HLA] Order contact for Stbd in FU mode “On” when output contact
DS707 PD signal for Port input “On” when input PD signal for Port
DS708 PD signal for Stbd input “On” when input PD signal for Stbd
DS709 [Loopback] TM control signal voltage or current for Port “On” when command to TM for Port
DS710 [Loopback] TM control signal voltage or current for Stbd “On” when command to TM for Stbd

Ship Name IMO: Tokyo Keiki Order No
Location Date: Ser. No No.1/3: No.2/4:
Adjusted by Company/Engineer(TKID):
Items and Check Points Result No.1/3 Result No.2/4
1. Preparation
(1) Turn off the power supply of the control box.
Turn off the ship’s power supply for control box, and then confirm that the voltage at terminal
TB101 U/V is 0VAC.
OK NG OK NG
(2) When install the control box, all wiring must be checked with work drawings. The following
wires must be connected and checked carefully in any specification of the steering gear.
Own control box “crosswise” Another control box
*RC1 *RC1
Running Running
*RC2 *RC2
+15V *RR1 *RR1 +15V
0V *RR2 *RR2 0V
OK NG OK NG
(3) Check TB of transformer which is placed on left upside corner of the control box.
These wiring and spec should be as following figures depending on the input power source.
440VAC 380VAC 220VAC

Orange line Jumper
[Trans wires] [Trans wires]
Pink line Input power from Ship’s power source
OK NG OK NG
(4) Turn on the ship’s power supply for control box.
[Input] [Input]
Measure the supplied voltage at the terminal TB101 U/V and then confirm that the setting of
transformer is proper for the supplied voltage.
VAC VAC

2. Jumper setting
(1) Check and verify the following jumper settings and put the circle mark on the applicable.
[!!] Typical settings are mentioned in “Standard” columns of below table, but the specifications may be
changed for each vessel. Therefore, especially for the highlighted with thick-frame and [!!] marked items,
should be checked carefully before actually supplying power.
Standa Results
Item Description Note rd No.1/3 No.2/4
JP201 Un-load valve voltage The drive voltage of un-load valve can be selected by this
[1-2]: 100VAC jumper. When supplying the voltage, the un-load valve 1-2 1-2
1-2
[2-3]: 110VAC should release the hydraulic circuit from unloading 2-3 2-3
condtion.
JP401 F/B Output signal polarity In FU mode, the control box output the Feed Back signal
[1-2]: (-)=Port, (+)=Stbd (=torque motor angle) from FB terminal for indication of
1-2 1-2
[2-3]: (+)=Port, (-)=Stbd autopilot. It can change the polarity of above signal. 2-3
2-3 2-3
In case of connecting with Tokyo Keiki autopilot,
[2-3] should be shorted.
JP601 PWM minimum pulse This is only for factory.
width adjustment [!!] Keep [open] this jumper in normal operation. Open Open
Open
[Open]: Normal operation Short Short
[Short]: For adjustment
JP602 PWM watch dog test This is only for factory.
Open Open
[Open]: Normal operation [!!] Keep [open] this jumper in normal operation. Open
Short Short
[Short]: For test
JP701 Transfer alarm to When short these jumpers, the internal CPU of control All Open All Open
Autopilot box transferes these alarm statuses which were input
[1-2]: JAL0 from each terminal to autopilot. All 1-2 1-2
[3-4]: JAL1 This function is disabled. Open 3-4 3-4
[5-6]: JAL2 [!!] Keep [open] this jumper. 5-6 5-6
[7-8]: JCOM 7-8 7-8
JP702 Transfer method for It can select the type of method which is used for All Open All Open
autopilot transfering the status of control box from the internal 1-2 1-2
[All open]: Depends on CPU of control box to autopilot. All 3-4 3-4
JP703 This function is disabled. Open 5-6 5-6
[All short]: Serial signal [!!] Don’t short these jumpers when JP703 are shorted. 7-8 7-8
[!!] Keep [open] this jumper. 9-10 9-10
JP703 Transfer method for It can select the type of method which is used for All Open All Open
autopilot transfering the status of control box from the internal 1-2 1-2
[All open]: Depends on CPU of control box to autopilot. All 3-4 3-4
JP702 This function is disabled. Short 5-6 5-6
[All short]: Dry contact [!!] Don’t short these jumpers when JP702 are shorted. 7-8 7-8
signal [!!] Keep [short] this jumper. 9-10 9-10
JP704 +5V power supply of The internal CPU of control box shares +5V power with
internal CPU and DRVR DW-DRVR pwb when this jumper is shorted.
Open Open
PWB [!!] Keep [Short] this jumper. Short
Short Short
[Open]: Independent
[Short]: Share
JP705 Transfer status It can select the status for transfering to autopilot.
[1-2]: Current of TM It is enabled only when JP703 [5-6] is shorted.
1-2 1-2
control signal This function is disabled. 3-4
3-4 3-4
[3-4]: Order voltage in [!!] Keep [3-4] this jumper.
FU mode

S2 TEST TB6
3. Actuation Check
(1) Turn off the power supply of the control box. NOR None Discon
nect
Remove external wires from TB6. (TB6 connector must be kept on the pwb) only
Set the S1, S2, S3(MS), S4(FU), S5(LP) and S6(LS) to “NOR”. wires
Turn on the power supply of the control box.
OK NG OK NG
(2) Confirm that POWER ON lamp (Yellowish white) turns on.
OK NG OK NG
(3) Confirm that UNLOAD indication lamp (Orange) turns on.
OK NG OK NG
(4) Confirm the power supply for autopilot as below.
[AC/AP-Pow] [AC/AP-Pow]
TB1 AC1/AC2 approx. 110VAC (not adjustable)
VAC VAC
(5) Set the S3(MS) to “TEST”, then the DS302 will turn on. S3(MS)
Confirm that the DS303 turns on in 3sec after DS302 turned on.
OK NG OK NG
(6) Confirm that RUN Lamp (Green) turns on.
OK NG OK NG
(7) Confirm the running signal for autopilot as below.
[RL/Running] [RL/Running]
TB1 RL1/RL2 approx. 100VAC (not adjustable)
VAC VAC
(8) Confirm that the UNLOAD indication lamp (Orange) turns off.
[!!] If the lamp does not turn off, you should check below items.
a. Connection of limit-switch
b. Deactivating limit-switch (not over limit condition)
c. Contact logic of the limit-switches (should open at over limit)
Terminal: TB4 LMPx/LMPxC(for Port) , TB4 LMxS/LMSxC(for Stbd)
OK NG OK NG
4. NFU mode check

4-1. Check the operation for Port direction S2 TEST TB6
(1) Set the S5(LP) to “TEST”. NOR S3(MS) Discon
S5(LP) nect
(2) Confirm that UNLOAD indication lamp (Orange) turns off. only
wires OK NG OK NG
(3) Confirm the drive voltage of unload valve as below.
[UL/Port] [UL/Port]
TB4 UL1/UL2 approx. 100VAC or 110VAC (not adjustable)
VAC VAC
(4) Confirm the drive voltage of torque motor as below. [TM/Port] [TM/Port]
(+) (+)
TB6 TM1(+)/TM2 approx. (+)12VDC (not adjustable)
VDC VDC
(5) Keep activating the limit-switch for Port direction at the steering gear side.
OK NG OK NG
[UL/Port] [UL/Port]
TB4 UL1/UL2 approx. 0VAC (not adjustable)
VAC VAC
(8) Confirm the drive voltage of torque motor as below.

[TM/Port] [TM/Port]
TB6 TM1(+)/TM2 approx. 0VDC (not adjustable)
VDC VDC
(9) Deactivate the limit-switch.

(10) Set the S5(LP) to “NOR”. S3(MS)

4-2. Check the operation for Stbd direction S2 TEST TB6
(1) Set the S6(LS) to “TEST”. NOR S3(MS) Discon
S6(LS) nect
(2) Confirm that UNLOAD indication lamp (Orange) turns off. only
wires OK NG OK NG
[UL/Stbd] [UL/Stbd]
TB4 UL1/UL2 approx. 100VAC or 110VAC (not adjustable)
VAC VAC
(4) Confirm the drive voltage of torque motor as below. [TM/Stbd] [TM/Stbd]
(-) (-)
TB6 TM1(+)/TM2 approx. (-)12VDC (not adjustable)
VDC VDC
(5) Keep activating the limit-switch for Stbd direction at the steering gear side.
OK NG OK NG
[UL/Stbd] [UL/Stbd]
TB4 UL1/UL2 approx. 0VAC (not adjustable)
VAC VAC
(8) Confirm the drive voltage of torque motor as below.

[TM/Stbd] [TM/Stbd]
TB6 TM1(+)/TM2 approx. 0VDC (not adjustable)
VDC VDC
(9) Deactivate the limit-switch.

(10) Set the S6(LS) to “NOR”. S3(MS)
4-3. Check the torque motor drive voltage for NFU mode S2 TEST TB6
(1) Turn off the power supply of the control box. NOR S3(MS) Conn
Re-connect external wires of TB6 connector.
(2) When set the S5(LP)/ S6(LS) to ”TEST”, some voltage will appear S3(MS)
on the terminal of resister R901. S5(LP)
Adjust the voltage (current of torque motor for NFU mode) as below.
between 2(+)/3 terminal of resister R901
S6(LS)
When set S5(LP) to “TEST”: (+) 5.5 ± 0.1VDC
When set S6(LS) to “TEST”: (-) 5.5 ± 0.1VDC
by sliding the adjusting lever of R901
[!!] When adjusting the resister R901, the power supply of control box
must be turned off.
Top view Side view
To be decreased To be increased Contactor
[S5(LP)] [S5(LP)]
J5 (+) (+)
R901 Slide the lever to
adjust voltage
VDC VDC
1 2 [!!] Do not tilt the lever!
3 2(+) 1 [S6(LS)] [S6(LS)]
(-) (-)
VDC VDC
(3) Set the S3(MS), S5(LP) and S6(LS) to “NOR”. None
4-4. Check the torque motor operation S2 TEST TB6

(1) Run only one steering gear pump which should be tested. NOR None Conn
(2) Set the S5(LP) to “TEST”. S5(LP)
(3) Confirm that the rudder moves to Port direction.

[!!] If the rudder moves to Stbd direction, turn off the power supply and
then swap the external wires at TB6 TM1 and TM2 terminals.
OK NG OK NG
(4) Set the S5(LP) to “NOR”. S6(LS)
Set the S6(LS) to “TEST”.
(5) Confirm that the rudder moves to Stbd direction.
OK NG OK NG
(6) Set the S6(LS) to “NOR”. None

4-5. Check the limit-switch S2 TEST TB6
(1) Confirm that angle of limit switch activated and rudder stopped as below. NOR S5(LP) Conn 1 Limit angle 1 Limit angle
Confirmation procedure (control the rudder by S5(LP) and S6(LS)) [Narrow-Port] [Narrow-Port]
deg deg
1 Limit angle (limit switch activated) S6(LS)
Once put the rudder approx 1~2deg less from maximum angle, turn the [Narrow-Stbd] [Narrow-Stbd]
rudder little by little, and confirm the rudder angle at rudder was deg deg
stopped by activating limit switch.

[Wide-Port] [Wide-Port]
2 Rudder stopped angle deg deg
Once put the rudder more than 20deg less from maximum angle, turn
[Wide-Stbd] [Wide-Stbd]
the rudder to maximum in one stroke, and then confirm that the rudder
angle at rudder stopped completely. deg deg
2 Stopped angle 2 Stopped angle

[!!] The rudder must be turned to more than 35 deg certainly in any [Narrow-Port] [Narrow-Port]
slow moving. deg deg
[!!] The limit-switches of steering gear side should be adjusted by [Narrow-Stbd] [Narrow-Stbd]
steering gear maker.
deg deg
[!!] If the activated angle of the limit-switch is too small, the rudder
[Wide-Port] [Wide-Port]
will not reach 35deg in FU mode. Therefore, the limit-switch
should be activated at around 36deg or more. deg deg
[!!] If you found activating the safety relief valve or any abnormality, you [Wide-Stbd] [Wide-Stbd]
should report to steering gear maker through shipyard/ship’s owner. deg deg
4-6. Check the rudder speed S2 TEST TB6

(1) Confirm that the rudder speed (from Stbd 35 deg to Port 30 deg and NOR S5(LP) Conn
from Port 35 deg to Stbd 30 deg) by using the S5(LP) and S6(LS) is
within the specifications of the steering system.
S6(LS)
[!!] The rudder must move from 35 deg to opposite 30 deg (=65 deg) within [Stbd->Port] [Stbd->Port]
28 sec with full power of the steering gear. In some cases, it needs two
pumps running to make the full power. The power of each steering
sec sec
gear pump will depend on the specifications of each vessel.
[!!] In this procedure, the power of steering pump is called as below. [Port->Stbd] [Port->Stbd]
Case-[1] ... Slower than 65deg/28sec : “Power of one pump is 50%”
sec sec
Case-[2] ... Faster than 65deg/28sec : “Power of one pump is 100%”
[!!] The rudder speed in NFU mode is not adjustable by the control box. When [Power of pump] [Power of pump]
the speed is slower than the specified time, you should report actual
condition to steering gear maker through shipyard/ship’s owner.
50%/100% 50%/100%
4-7. Check the rudder stability S2 TEST TB6
(1) Set the actual rudder to 0deg. NOR None Conn
(2) Set the S5(LP) and S6(LS) to “NOR”.

Turn off the power supply of the control box.
(3) Keep the running of steering gear pump, and then leaves for 2 minutes.
Check the actual rudder angle and confirm the rudder moved from original
angle less than 1.0deg.
[!!] Steering gear maker accepts the above mentioned specification. If you [From origin] [From origin]
notice the rudder out of specification, you should report actual condition
to steering gear maker through shipyard/ship’s owner.
deg deg
(4) Stop the steering gear pump.

5. FU mode adjustment
5-1. Check the power supply for FU circuit S2 TEST TB6
(1) Confirm that the power supply of the control box is off. NOR S3(MS) Remv
S4(FU)
Remove TB6 connector from pwb.
Confirm that the S1 and S2 are in “NOR” position.
Set the S3(MS) and S4(FU) to “TEST”.
(2) Confirm the power supply voltage as below
TP102(+)/TP401 (+)24 ± 3.6VDC (not adjustable) [TP102/+24] [TP102/+24]
(+) (+)
VDC VDC
TP103(+)/TP401 (-)24 ± 3.6VDC (not adjustable) [TP103/-24] [TP103/-24]

(-) (-)
VDC VDC

(+) (+)
VDC VDC
TP105(+)/TP401 (-)15 ± 0.6VDC (not adjustable) [TP105/-15] [TP105/-15]

(-) (-)
VDC VDC
TP106(+)/TP401 (+) 5 ± 0.12VDC (not adjustable) [TP106/+5] [TP106/+5]

(+) (+)
VDC VDC

(+) (+)
VDC VDC
5-2. Check the power supply for LVDT* S2 TEST TB6

(*Linear Variable Differential Transformer=Feedback transmitter of torque motor)
(1) Confirm the voltage and frequency of exciting signal for LVDT as below. NOR S3(MS) Remv [FG/Exciter] [FG/Exciter]
S4(FU)
TB5 FG1/FG2 7.0 ± 0.35VAC (not adjustable) VAC VAC
2.7 ± 0.27kHz (not adjustable)

kHz kHz
5-3. Adjust the zero of torque motor feedback for control box S2 TEST TB6
(1) Confirm the torque motor lever is in neutral position. NOR S3(MS) Remv
S4(FU)
Neutral position
Angle Scale
Lever
(2) In above 5-3-(1) condition, adjust the feedback-zero as below.
[TP403/Zero] [TP403/Zero]
TP403(+)/TP401 minimum value by VR401
mVDC mVDC
(3) In above 5-3-(1) condition, measure the LVDT-out as below.

[FT/Zero] [FT/Zero]
TB5 FT1/FT2 Only measure
VAC VAC
5-4. Adjust the dither signal S2 TEST TB6

(1) Confirm the frequency and adjust the voltage of the dither signal. NOR S3(MS) Remv [TP606/Freq.] [TP606/Freq.]
S4(FU)
Hz Hz
TP606/TP401 approx. 60Hz (not adjustable)
TP602/TP401 approx. 0.8VAC by VR602 [TP602/Volt.] [TP602/Volt.]
VAC VAC

5-5. Check the maximum order voltage S2 TEST TB6
(1) Set the S2 to “TEST”. TEST S3(MS) Remv
S4(FU)
(2) Set the VR502 to approx. middle position.
(3) Set the VR503 to CW-max position.
(4) Set the test voltage as below. [TP502/Port] [TP502/Port]
(+) (+)
TP502(+)/TP401 exactly (+)10.00VDC by VR501 VDC VDC
(5) In above 5-5-(4) condition, measure the Act-Order as below. [TP505/Port] [TP505/Port]
(-) (-)
TP505(+)/TP401 approx. (-)10VDC Only measure VDC VDC
(6) Set the test voltage as below. [TP502/Stbd] [TP502/Stbd]

(-) (-)
TP502(+)/TP401 exactly (-)10.00VDC by VR501 VDC VDC
(7) In above 5-5-(6) condition, measure the order voltage as below. [TP505/Stbd] [TP505/Stbd]
(+) (+)
TP505(+)/TP401 approx. (+)10VDC Only measure VDC VDC
5-6. Adjust the gain of torque motor S2 TEST TB6

(1) Set the test voltage as below. TEST S3(MS) Remv [TP502/Port] [TP502/Port]
S4(FU) (+) (+)
TP502(+)/TP401 exactly (+)3.00VDC by VR501 VDC VDC
(2) Switch the S2 : “TEST” “NOR” (wait 1sec) “TEST” NOR

Adjust the order gain as below. [TP504/Port] [TP504/Port]
TEST (+) (+)
TP504(+)/TP401 (+)9.00±0.1VDC by VR502 VDC VDC
(3) Set the test voltage as below. [TP502/Stbd] [TP502/Stbd]

(-) (-)
TP502(+)/TP401 exactly (-)3.00VDC by VR501 VDC VDC

Adjust the order gain as below. TEST
TP504(+)/TP401 (-)9.00±0.1VDC by VR502
[TP504/Stbd] [TP504/Stbd]
[!!] If the VR502 was adjusted at 5-6-(4), re-check (measuring (-) (-)
voltage) above item from 5-6-(1) to 5-6-(2). VDC VDC
5-7. Check the operation of torque motor S2 TEST TB6

(1) Set the VR501 to its approx. middle position. TEST S3(MS) Remv
S4(FU)
(2) Turn off the power supply of the control box. Conn
Re-connect TB6 connector to pwb.
(3) When turning the VR501 from middle to CW-max and CCW-max
position slowly (do not turn quickly), confirm that the torque motor lever
follows smoothly to the movement of the VR501.
VR501 turns to CW: Torque motor turns to Port direction
VR501 turns to CCW: Torque motor turns to Stbd direction
[!!] If the torque motor lever turns to its maximum position quickly
even if VR501 was not turned to CW-max and CCW-max
position, turn off the power supply and then swap the external
wires at TB5 FT1 and FT2 terminals. OK NG OK NG
5-8. Adjust the speed of torque motor lever S2 TEST TB6
(1) Set the VR501 to CW-max or CCW-max. TEST S3(MS) Conn
S4(FU)
(2) Set the S2 to “NOR”. NOR
The torque motor lever will return to neutral position.
(3) When set the S2 to “TEST”, the torque motor lever should start moving TEST
to maximum position.
Adjust the VR508 so that the speed of torque motor lever turns from
NOR
neutral to maximum position in approx. 1sec.
VR508 (CW): to be slower / (CCW): to be faster
[!!] The speed (=“1sec”) is required by steering gear maker. sec sec
(4) Set the S2 to “TEST”. TEST

5-9. Adjust the common span of torque motor feedback for control box S2 TEST TB6
(1) Set the VR403 and VR404 to CCW-max position. TEST S3(MS) Conn
S4(FU)
(2) Set the S4(FU) to “NOR”. S3(MS)

S5(LP)
Set the S5(LP) to “TEST”.
The torque motor should turn to mechanical maximum position for Port direction.
(4) Adjust the feedback-span [Common-Port] as below. [TP404/Port] [TP404/Port]
(+) (+)
TP404(+)/TP401 approx.(+)9~10VDC by VR402
VDC VDC

S6(LS)
The torque motor should turn to mechanical maximum position for Stbd direction.
(6) Adjust the feedback-span [Common-Stbd] as below.
TP404(+)/TP401 approx.(-)9~10VDC by VR402 [TP404/Stbd] [TP404/Stbd]
(-) (-)
[!!] If VR402 was adjusted at 5-9-(6), re-check from 5-9-(3) to 5-9-(4).
VDC VDC
(7) Set the S5(LP) and S6(LS) to “NOR”. S3(MS)
5-10. Initial adjust the span of torque motor feedback for control box S2 TEST TB6
(1) Calculate target voltage of feedback-span [Port] as below. TEST S3(MS) Conn
Target voltage of TP404[Port]

Example In case that item 5-5-(5) voltage is ... (-)9.3VDC
The polarity [Calc./Port] [Calc./Port]
must be inverted Subtract 0.5 (+) (+)
Target TP404 = -(-9.3-0.5) = -(-9.8) = (+)9.8VDC

VDC VDC
(2) Calculate target voltage of feedback-span [Stbd] as below.

Target voltage of TP404[Stbd]
Example In case that item 5-5-(7) voltage is ... (+)9.4VDC
The polarity [Calc./Stbd] [Calc./Stbd]
must be inverted Add 0.5 (-) (-)
Target TP404 = -(+9.4+0.5) = -(9.9) = (-)9.9VDC

VDC VDC
(3) Set the VR403 and VR404 to approx. middle position.

S5(LP)
Set the S5(LP) to “TEST”.
The torque motor should turn to mechanical maximum position for Port direction.
(5) Adjust the feedback-span [Port] as below.
TP404(+)/TP401 same as above 5-8-(1) by VR403
[!!] If you can’t adjust above voltage, re-adjust with below procedure.
1) Set the VR403 to middle position.
[TP404/Port] [TP404/Port]
2) Turn slightly the VR402. (CW: Increase voltage/ CCW: Decrease voltage) (+) (+)
3) Re-try item 5-10-(5).

VDC VDC

S6(LS)
The torque motor should turn to mechanical maximum position for Stbd direction.
(7) Adjust the feedback-span [Stbd] as below.
TP404(+)/TP401 same as above 5-8-(2) by VR404
[!!] If you can’t adjust above voltage, re-adjust with below procedure.
1) Set the VR404 to middle position.
2) Turn slightly the VR402. (CW: Increase voltage/ CCW: Decrease voltage) (-) (-)
3) Re-try item from 5-10-(4) to 5-10-(7).

VDC VDC
(8) Set the S5(LP) and S6(LS) to “NOR”. S3(MS)

5-11. Confirm the torque motor angle S2 TEST TB6
(1) Set the S4(FU) to “TEST”. TEST S3(MS) Conn
S4(FU)
Set the test voltage as below.
TP502(+)/TP401 exactly (+)10.00VDC by VR501
(2) Confirm that the S1 is in “NOR” position.
Confirm the test voltage as below.
The torque motor lever turns to its maximum Port.
(3) Confirm that the torque motor lever does not
touch the stopper by turning the torque motor
lever furthermore Port direction by hand as
shown right picture.
[!!] There is possibility that the torque motor
inside mechanism is touching with its
stopper even if the torque motor lever
does not touch to stopper bolt. herefore,
you must turn the torque motor lever by
hand to confirm the gap with stopper.
[!!] If the torque motor lever touches the stopper, or there is too much
gap, re-adjust with below procedure.
1) Turn slightly the VR403. VR403 (Span-Port)
CCW CW
2) Switch the S2 :
“TEST” “NOR” (wait 1sec) “TEST”
Increase Decrease [Gap/Port] [Gap/Port]
3) Confirm the gap with stopper, repeat 1)~3) TM angle TM angle
adjustment until the gap becomes properly.
OK NG OK NG
(4) Set the S1 to “INV”.
Confirm the test voltage as below.
TP502(+)/TP401 exactly (-)10.00VDC by VR501
The torque motor lever turns to its maximum Stbd.
(5) Confirm the gap with the stopper for Stbd direction as above item
5-11-(3).
[!!]If the torque motor lever touches the stopper, or there is too much
gap, re-adjust with below procedure.
1) Turn slightly the VR404. VR404 (Span-Stbd)
CCW CW
2) Switch the S2 :
“TEST” “NOR” (wait 1sec) “TEST” Increase Decrease [Gap/Stbd] [Gap/Stbd]
3) Confirm the gap with stopper, repeat 1)~3) TM angle TM angle
adjustment until the gap becomes properly.
OK NG OK NG
(6) Set the S1 to “NOR”.
5-12. Confirm the rudder speed(1/2) S2 TEST TB6
(1) Confirm that the S1 is “NOR” position. TEST S3(MS) Conn
S4(FU)
Set the test voltage as below.
(2) Set the S3(MS) to “NOR”. S4(FU)
Run only one steering gear pump which should be tested.

5-12. Confirm the rudder speed(2/2) S2 TEST TB6
(3) Measure the rudder speed at actual rudder moves from Stbd 35 deg to TEST S4(FU) Conn
Port 30 deg and from Port 35 deg to Stbd 30 deg by switching the S1
“NOR” / “INV” positions.
[!!] The rudder speed in this item will slightly slower than item 4-6.
[!!] If the rudder speeds as below case, re-adjust the torque motor
lever angle as below.
[Gap/Port] [Gap/Port]
Case-a: Slower than 65deg/28sec (65deg/56sec)
Case-b: Differ more than 1sec (2sec) on both directions
OK NG OK NG
[( ) values for “power of pump is 50%”]
1) Adjust the feedback-span as below. [Stbd->Port] [Stbd->Port]
VR403 (for Port) / VR404 (for Stbd)
sec sec
CCW CW
[Gap/Stbd] [Gap/Stbd]
Rudder speed=“Faster” Rudder speed=“Slower”
(Lever angle=Increase) (Lever angle=Decrease) OK NG OK NG
2) Confirm the gap between torque motor lever and its stoppers (as
[Port->Stbd] [Port->Stbd]
same as item 5-11-(3) and 5-11-(5).), and measure the rudder
speed.
sec sec
(4) Set the actual rudder to approx. 0deg. S3(MS)

S4(FU)
Stop the steering gear pump.
Set the S1 to “NOR”.
Set the S3(MS) to “TEST”.
5-13. Confirm the gap of torque motor and stopper (1/2)
[!!] There is possibility that the torque motor inside mechanism is
touching with its stopper even if the torque motor lever does not
touch to stopper bolt. Therefore you must turn the torque motor
lever by hand to confirm the gap. S2 TEST TB6
(1) Set the test voltage as below. TEST S3(MS) Conn
S4(FU)
Measure the feedback-span [Port] as below. (+) (+)
TP404(+)/TP401 approx. (+)10VDC Only measure TEST

VDC VDC

[FT/Port] [FT/Port]
VAC VAC
(4) Hold the torque motor lever in mechanical maximum position of Port
direction by hand.
Measure the feedback-span [Port] as below and confirm that the voltage
value was increased from above item 5-13-(2).
TP404(+)/TP401 more than 5-13-(2) Only measure
[!!] If the torque motor lever does not move by hand (=already touched
to stopper) or TP404(+)/TP401 voltage does not change,
re-adjust item from 5-11-(2) and 5-11-(3).
(+) (+)
VDC VDC

[FT/Port] [FT/Port]
VAC VAC

5-13. Confirm the gap of torque motor and stopper (2/2) S2 TEST TB6
S4(FU)
Measure the feedback-span [Stbd] as below. (-) (-)
TP404(+)/TP401 approx. (-)10VDC Only measure TEST

VDC VDC

[FT/Stbd] [FT/Stbd]
VAC VAC
(9) Hold the torque motor lever in mechanical maximum position of Stbd
direction by hand.
Measure the feedback-span [Stbd] as below and confirm that the
voltage value was increased from above item 5-13-(7).
TP404(+)/TP401 more than 5-13-(7) Only measure
[!!] If the torque motor lever does not move by hand (=already touched
to stopper) or TP404(+)/TP401 voltage does not change,
re-adjust item from 5-11-(4) and 5-11-(5).
(-) (-)
VDC VDC

[FT/Stbd] [FT/Stbd]
VAC VAC
5-14. Confirm the maximum torque motor feedback S2 TEST TB6

S4(FU)
Measure the feedback-span [Port] as below. TEST [TP404/Port] [TP404/Port]
(+) (+)
TP404(+)/TP401 approx. (+)9VDC Only measure
VDC VDC
(3) Set the test voltage as below.

Measure the feedback-span [Stbd] as below. TEST [TP404/Stbd] [TP404/Stbd]
(-) (-)
TP404(+)/TP401 approx. (-)9VDC Only measure
VDC VDC

5-15. Confirm the maximum deviation voltage S2 TEST TB6
Confirm that the maximum deviation voltage is less than the threshold of TEST S3(MS) Conn
S4(FU)
control motor fail while in turning the rudder by below procedure.
(1) Set the S3(MS) to ”NOR”. S4(FU)
Run only one steering gear pump which should be tested.
(2) Set the VR501 to CW or CCW max position.
Turn the rudder from Stbd-max to Port-max by switching the S1 “NOR”
/ “INV” positions. During the rudder moving, confirm the condition of
deviation voltage (max value) and LED as below.
TP702(+)/TP401 Less than 2.8VDC Only measure
DS701 Does not keep on
[!!] DS701 may blink at the beginning and end of turning the rudder.
[!!] If the DS701 turns on continuously at item 5-15-(2) and 5-15-(3), it
is suspected that the torque motor lever does not move smoothly [Stbd->Port] [Stbd->Port]
or touches to mechanical stopper. However, if the condition was (+) (+)
not corrected by re-check/re-adjust the item from 5-11 to 5-14, there VDC VDC
is possibility that the DW-DRVR pwb, Torque-motor, LVDT or etc [DS701] [DS701]
has been faulty.
OK NG OK NG
(3) Turn the rudder from Port-max to Stbd-max by switching the S1 “NOR” [Port->Stbd] [Port->Stbd]
(-) (-)
/ “INV” positions. During the rudder moving, confirm the condition of
VDC VDC
deviation voltage (max value) and LED as same as above item
5-15-(2). [DS701] [DS701]
OK NG OK NG
(4) Set the actual rudder to 0deg. S3(MS)
S4(FU)
Stop the steering gear pump.
Set the S1 to ”NOR”.
Set the S3(MS) to ”TEST”.
5-16. Adjust drive signal for P/S lamp of autopilot S2 TEST TB6
S4(FU)
Adjust the feedback-span for autopilot as below. TEST (+) (+)
TP405(+)/TP401 approx. (+)13.0VDC by VR405

VDC VDC

Adjust the feedback-span for autopilot as below. TEST
TP405(+)/TP401 approx. (-)13.0VDC by VR405 [TP405/Stbd] [TP405/Stbd]
(-) (-)
[!!] If the VR405 was adjusted at 5-16-(4), re-check (measuring
voltage) above item from 5-16-(1) to 5-16-(2).
VDC VDC

5-17. Adjust the gain for parallel running-1
[!!] This adjustment is required in case of the steering gear equipped with S2 TEST TB6
“two”, “three” or “four” pumps.
(1) Calculate the 60% of 5-14-(2) voltage for Port direction. TEST S3(MS) Conn [Calc./Port] [Calc./Port]
S4(FU) (+) (+)
VDC VDC
(2) Calculate the 60% of 5-14-(4) voltage for Stbd direction. [Calc./Stbd] [Calc./Stbd]
(-) (-)
VDC VDC

Make short circuit between the TB7 1RR1/1RR2 terminals with jumper wire.
(5) Switch the S2 : “TEST” “NOR” (wait 1sec) “TEST” NOR [TP404/Port] [TP404/Port]
(+) (+)
Measure the feedback-span [Port] and then calculate the error from TEST
VDC VDC
5-17-(1) voltage as below.
[Error/Port] [Error/Port]

(7) Switch the S2 : “TEST” “NOR” (wait 1sec) “TEST” NOR [TP404/Stbd] [TP404/Stbd]
(-) (-)
Measure the feedback-span [Stbd] and then calculate the error from TEST
VDC VDC
5-17-(2) voltage as below.
[Error/Stbd] [Error/Stbd]
(8) Adjust the feedback-span so that each errors of 5-17-(5) and 5-17-(7) to [TP404/Port] [TP404/Port]
be minimum as below. (+) (+)
TP404(+)/TP401 error to be minimum by VR504 VDC VDC
After adjustment, re-check above item 5-17-(4)~(7) and then record the [TP404/Stbd] [TP404/Stbd]
(-) (-)
TP404(+)/TP401 voltage for both directions to right column. VDC VDC

Remove the jumper wire between the TB7 1RR1/1RR2 terminals.
“three” or “four” pumps.
(1) Confirm that the power supply of the control box is off. TEST S3(MS) Conn
Make short circuit between the TB7 2RR1/2RR2 terminals with jumper wire. S4(FU)
(+) (+)
VDC VDC
5-17-(1) voltage.

(-) (-)
VDC VDC
5-17-(2) voltage.
(-) (-)


“four” pumps.
Make short circuit between the TB7 3RR1/3RR2 terminals with jumper wire. S4(FU)
(+) (+)
VDC VDC
5-17-(1) voltage.

(-) (-)
VDC VDC
5-17-(2) voltage.
(-) (-)

5-20. Adjust the gain for Isolation System
[!!] This adjustment is required only in case that the control box is connected S2 TEST TB6
with the isolation system of steering gear.
S4(FU) (+) (+)
VDC VDC
(-) (-)
VDC VDC

Make short circuit between the TB7 ISO1/ISO2 terminals with jumper wire.
(+) (+)
VDC VDC
5-20-(1) voltage.

(-) (-)
VDC VDC
5-20-(2) voltage.
(-) (-)

Remove the jumper wire between the TB7 ISO1/ISO2 terminals.

6. Adjust and Confirm the HLA (*HLA=Hydraulic Locking Alarm)

[!!] The PR-9000-DW control box output the contact signal that
demand order to the torque motor. The HLA system should sense
the motion of steering gear actuator or torque motor lever, compare
the motion and signal from the control box, and then generates the
alarm if it detects the difference.
[!!] This adjustment is required only in case that the control box is
connected with HLA system under the rule IACS UI SC94 rev.1.
S2 TEST TB6
[!!] The HLA system is supplied by steering gear maker.
S4(FU)
Remove external wires from TB8 -5,-6,-7 and -8. (TB8 connector must
be kept on the pwb)
[!!] Be careful not to short and touch wires when disconnecting and
reconnecting at TB8 connector, because signal/voltage may be
supplied on these wires from HLA system.
6-1. Adjust the output threshold S2 TEST TB6
S4(FU) (+) (+)
VDC VDC
(-) (-)
VDC VDC
(3) Set the VR703 to CW-max.

(4) Set the feedback [Port] as below.
TP404(+)/TP401 6-1-(1) ±0.1VDC by VR501
ADJUSTMENT PROCEDURE
Repeat the below items [1]~[3] until the voltage becomes target value.
[1] Measure the TP404(+)/TP401 voltage
[2] Turn the VR501 slightly if necessary (+) (+)
[3] Switch the S2 : “TEST” “NOR” (wait 1sec) “TEST”
VDC VDC
(5) Confirm that the contact of below terminals is in “Open” condition.

TB8 -5(AUX_+)/-7(AUX_P) and TB8 -5(AUX_+)/-8(AUX_S)
OK NG OK NG
(6) Turn gradually the VR703 to CCW direction until DS705 LED turns on.
(7) During DS705 LED is on, confirm that the TB8 -5(AUX_+)/-7(AUX_P)
terminals are shorted (=approx. 25ohms).
OK NG OK NG
(8) Set the feedback [Stbd] as below. (Refer to adjustment procedure of
above item 6-1-(4)) [TP404/Stbd] [TP404/Stbd]
(-) (-)
TP404(+)/TP401 6-1-(2) ±0.1VDC by VR501
VDC VDC
(9) If DS706 does not turn on, turn gradually the VR703 to CCW
direction until DS706 turns on.
(10) During DS706 LED is on, confirm that the TB8 -5(AUX_+)/-8(AUX_S)
terminals are shorted (=approx. 25ohms).
OK NG OK NG
6-2. Check the output of mode signal S2 TEST TB6
(1) Confirm that the contact condition of below terminals. TEST S3(MS) Conn
S4(FU)
FU mode: TB8 -5(AUX_+)/-6(NFU) “Open”
open / short open / short
(2) Set the S4(FU) to “NOR”. S3(MS)
(3) Confirm that the contact condition of below terminals.

It should be changed from above item 6-2-(1).
NFU mode: TB8 -5(AUX_+)/-6(NFU) “Short” (=approx. 25ohms)
open / short open / short
Re-connect external wires of TB8 -5,-6,-7 and -8.

S2 TEST TB6
7. Adjustment of Autopilot
(1) Confirm that the power supply of the control box is off. NOR None Conn
Set the all test switches to “NOR”.
Set the VR501 to middle position.
Confirm that all external wires and connectors are securely connected
to original terminals, and all connection cable/plug of voltage meter
are removed.
OK NG OK NG
(2) Adjust “rudder angle”, “limit angle” and “sensitivity” etc at autopilot.
S2 TEST TB6
8. Confirm the operation of Autopilot
(1) Set the system switch to “No.1” or “No.2” which should be tested. NOR None Conn
8-1. Confirm the pilot power fail S2 TEST TB6

(For system being equipped with 4 steering gear pumps) NOR None Conn
[!!] When you turn off the power of both no.1 and no.3 control box, the
light of “1-PWR” on the ANN unit turns off.
[!!] When you turn off the power of both no.2 and no.4 control box, the
light of “2-PWR” on the ANN unit turns off.
(2) At above 8-1-(1) condition, confirm that the indication of the “POWER” on
the ANN unit changes from “ON” to “OFF”.
OK NG OK NG
(3) Turn on the power supply of the control box.
(4) At above 8-1-(3) condition, confirm that the indication of the “POWER” on
the ANN unit changes from “OFF” to “ON”.
OK NG OK NG
(5) Test above items from 8-1-(1) to 8-1-(4) at all control boxes.
8-2. Confirm the CMF (*CMF=Control Motor Fail) and HLA S2 TEST TB6
[!!] The HLA system must be supplied and be adjusted by steering NOR None Conn
gear maker.
[!!] If HLA alarm could not be generated with below procedure, check
the output contact from the control box to HLA system and then
report its conditions to steering gear maker through
shipyard/ship’s owner to rectify this problem.
[!!] Do not touch the HLA system. It is not our products/supplies.
(1) Run only one steering gear pump which should be tested.
(2) Set the mode switch to “HAND”.
Set the steering wheel to 0deg position.
Confirm that the actual rudder is approx. 0deg.
(3) Turn off the power supply of all control boxes. Remv
Remove TB6 connector from pwb at all control boxes.
Turn on the power supply of all control boxes.
(4) Set the steering wheel to 10 degrees or more.
(5) Approx. 5 seconds after above 8-2-(4) condition, confirm that the “CONT.
MOTOR #(1~4)” is generated on the ANN unit.
[!!] The Servo Loop Fail (error: “FU STEERING”, “RUD. SPEED”) will
be generated at the same time.
OK NG OK NG
(6) Confirm that the “HYD. LOCK” is generated on the ANN unit and HLA
system/alarm panel.
OK NG OK NG
(7) Change the active steering gear pump to another one which should be
tested, and then test above item from 8-2-(4) to 8-2-(6).
Repeat the test for all steering gear pumps.
(8) Turn off the power supply of all control boxes. Conn
Re-connect TB6 connector to pwb at all control boxes.
Turn on the power supply of all control boxes.

8-3. Confirm no alarm at maximum angle S2 TEST TB6
(1) Start all steering gear pump. NOR None Conn
Set the mode switch to “HAND”.
Set the system switch to “No.1” or “No.2” which should be tested.
(2) Turn the steering wheel to Port-max and Stbd-max. The actual rudder
will stop at its maximum angle.
Keep this condition while 10sec or more and confirm that the CMF“CONT.
MOTOR” and the Servo Loop Fail (error: “FU STEERING”, “RUD.
SPEED”) are not generated on the ANN unit.
Confirm for both (Port and Stbd) directions several times.
[!!] If the CMF is generated, it is suspected that the torque motor No.1 system No.2 system
touches its stoppers. Therefore, re-adjust (reduce) the maximum
angle of torque motor lever at item from 5-11 to 5-12.
[Port] [Port]
[!!] If the Servo Loop Fail(s) are generated, it is suspected that the
limit-switch angle is narrower than order limit angle. Therefore,
OK NG OK NG
extend the limit-switch angle or reduce the order limit angle of
autopilot by “Limit Over Angle” parameter at ANN service menu.
[Stbd] [Stbd]
[!!] After all re-adjustment, confirm that the rudder can be turned more
than 35deg certainly.
OK NG OK NG
(3) Change the system switch to another one.
Then test above item 8-3-(2).
8-4. Confirm the rudder speed S2 TEST TB6
(1) Run only one steering gear pump which should be tested. NOR None Conn
Set the mode switch to “HAND”.
Set the system switch to “No.1” or “No.2” which should be tested.
(2) Measure the rudder speed at actual rudder moves from Stbd 35 deg to
Port 30 deg and from Port 35 deg to Stbd 30 deg by turning the steering
wheel to maximum angle.
[!!] Refer to item 4-5 and 5-12.
[!!] If the rudder speeds as below case, re-adjust item 5-11 and then
re-check item 5-12.
[Stbd->Port] [Stbd->Port]
Case-a: Slower than 65deg/28sec (65deg/56sec)
Case-b: Differ more than 1sec (2sec) on both directions sec sec
[( ) values for “power of pump is 50%”]
[Port->Stbd] [Port->Stbd]
Speed to be “Slower” : The torque motor lever angle should be decreased.
Speed to be “Faster” : The torque motor lever angle should be increased.
sec sec
(3) Turn the steering wheel from Stbd-max to Port-max, and then while
moving the rudder, confirm that the torque motor lever can be turned [Stbd->Port] [Stbd->Port]
furthermore to Port direction by hand.
OK NG OK NG
(4) Turn the steering wheel from Port-max to Stbd-max, and then while
moving the rudder, confirm that the torque motor lever can be turned [Port->Stbd] [Port->Stbd]
furthermore to Stbd direction by hand.
OK NG OK NG
(5) Repeat the testing above item from 8-4-(2) to 8-4-(4) for all steering gear
pumps and the autopilot systems.
S2 TEST TB6
9. Finish the work
(1) Confirm that all external wires are securely connected to original terminals. NOR None Conn
OK NG OK NG
(2) Confirm that all test switches are in “NOR” position.
OK NG OK NG
(3) Set the VR501 to middle position.
OK NG OK NG
(4) Close the front cover of the control box.
OK NG OK NG
(5) Set the system switch of autopilot to “OFF”.
OK NG OK NG
(6) Stop all steering gear pumps.
OK NG OK NG

PR 9000 DW - CB Adj&Chk (E) (CSA CK2084E - 20161108)

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PR 9000 DW - CB Adj&Chk (E) (CSA CK2084E - 20161108)

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PR-9000-DW CONTROL BOX Adjustment Procedure & Check Sheet Issued: 8-Nov-2016

TB4 JP701 TB9

TKS FORM CSA-CK2084E 1/20

TKS FORM CSA-CK2084E 2/20

DS101 [Power] +15V_SENCE (TP104) “On” when operate

DS102 [Power] -15V_SENCE (TP105) “On” when operate

DS103 [Power] +5V (TP106) “On” when operate

DS104 [Power] 12V for FU mode (TP107) “On” when operate

DS301 [Power] SEQ_5V (TP302-TP301) “On” when operate

DS306 FU (FU mode contact) input “On” when NFU mode

DS311 Unloading in NFU mode “On” when unloading

DS312 [HLA] Mode contact signal “On” when FU mode

DS701 CMF(Control Motor Fail) “On” when detect much deviation

TKS FORM CSA-CK2084E 3/20

440VAC 380VAC 220VAC

TKS FORM CSA-CK2084E 4/20

TKS FORM CSA-CK2084E 5/20

4. NFU mode check

(8) Confirm the drive voltage of torque motor as below.

(9) Deactivate the limit-switch.

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(8) Confirm the drive voltage of torque motor as below.

(9) Deactivate the limit-switch.

(3) Set the S3(MS), S5(LP) and S6(LS) to “NOR”. None

4-4. Check the torque motor operation S2 TEST TB6

(2) Set the S5(LP) to “TEST”. S5(LP)

(3) Confirm that the rudder moves to Port direction.

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stopped by activating limit switch.

2 Stopped angle 2 Stopped angle

4-6. Check the rudder speed S2 TEST TB6

(2) Set the S5(LP) and S6(LS) to “NOR”.

(4) Stop the steering gear pump.

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TP103(+)/TP401 (-)24 ± 3.6VDC (not adjustable) [TP103/-24] [TP103/-24]

TP104(+)/TP401 (+)15 ± 0.6VDC (not adjustable) [TP104/+15] [TP104/+15]

TP105(+)/TP401 (-)15 ± 0.6VDC (not adjustable) [TP105/-15] [TP105/-15]

TP106(+)/TP401 (+) 5 ± 0.12VDC (not adjustable) [TP106/+5] [TP106/+5]

TP107(+)/TP401 (+)12 ± 1.8VDC (not adjustable) [TP107/+12] [TP107/+12]

5-2. Check the power supply for LVDT* S2 TEST TB6

2.7 ± 0.27kHz (not adjustable)

(3) In above 5-3-(1) condition, measure the LVDT-out as below.

5-4. Adjust the dither signal S2 TEST TB6

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(6) Set the test voltage as below. [TP502/Stbd] [TP502/Stbd]

5-6. Adjust the gain of torque motor S2 TEST TB6

(2) Switch the S2 : “TEST” “NOR” (wait 1sec) “TEST” NOR

(3) Set the test voltage as below. [TP502/Stbd] [TP502/Stbd]

(4) Switch the S2 : “TEST” “NOR” (wait 1sec) “TEST” NOR

5-7. Check the operation of torque motor S2 TEST TB6

(4) Set the S2 to “TEST”. TEST

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(3) Set the S6(LS) to “NOR”. S3(MS)

(5) Set the S5(LP) to “NOR”. S3(MS)

(7) Set the S5(LP) and S6(LS) to “NOR”. S3(MS)

Target voltage of TP404[Port]

Target TP404 = -(-9.3-0.5) = -(-9.8) = (+)9.8VDC

(2) Calculate target voltage of feedback-span [Stbd] as below.

Target TP404 = -(+9.4+0.5) = -(9.9) = (-)9.9VDC

(3) Set the VR403 and VR404 to approx. middle position.

3) Re-try item 5-10-(5).

(6) Set the S5(LP) to “NOR”. S3(MS)

3) Re-try item from 5-10-(4) to 5-10-(7).