R Raytheon Marine GmbH

High Seas Products

Postfach 1166
D – 24100 Kiel
Germany
Tel +49–4 31–30 19–0
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www.raymarine.com

Feedback Unit
Rud Angle Transmitter Unit

Type 101 – 528 NG024 - NG029

SERVICE MANUAL

1 Installation and First Putting into Operation

2 Maintenance, Repair, Spare Parts Catalogue
3 Construction, Principle of Operation, Technical Data

3701E/101–528.DOC032 Edition: 28.AUG.2003

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 Feedback Unit
Technical
Service Manual Documentation

CONTENTS Page

1 Installation and First Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.1 Lever Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.2 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.3 Kit for Spark Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1.1.4 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

1.2 First Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

1.2.1 Prerequisite for Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.2.2 Adjusting the Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.2.3 Zeroing of the Potentiometer R1 and R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.2.4 Adjusting the Micro Switch (Midship Indicator) (optional for all Versions) . . . . . . . 1–5

2 Maintenance, Shipboard Repair, Spare Parts Catalogue . . . . . . . . . . . . . . . . . 2–1

2.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.2 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.2.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.3 Repair – Exchanging of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.3.1 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.3.2 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.3.3 Microswitch (Mid Ship Indicator) (optional for all Versions) . . . . . . . . . . . . . . . . . . . 2–4

2.4 Spare Parts Catalogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

2.4.1 Notes on Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

3 Construction and Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.1 Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.2 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6

Annexes

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 Feedback Unit Technical
Service Manual Documentation

1 Installation and First Putting into Operation

1.1 Installation
Drilling scheme refers to Dimensional Diagram 101 D 528.HP005, Sheet 1 to 3.
For suggestions for attachment of one and two feedback units, see the overview table in
the annex. In any case of application, the consoles are to be supplied by the shipyard!

1.1.1 Lever Drive

(Refer to Dimensional Diagram 101 D 528.HP005, Sheet 2 and Fig. A to C in the annex).
The transmission ratio from the lever drive ist 1 : 1.
The lever system consists of two driving levers, the connecting tube and two ball–and–
socket joints.
After the lever system has carefully been adjusted, the connecting tube between the two
driving levers is to be shortened to the required length and jointly to be bored with the
shafts of the ball–and–socket joints applied to both sides, e.g. dia. 4H11.
Into these bores, the spiral pins supplied (DIN 7344) are to be pressed. Subsequently, the
spiral pins must mechanically be secured on both sides (top and bottom) by punch–mark-
ing.

Note:
Systems of up to 2 feedback units require two lever systems, accordingly (see Fig. B in the
annex).

1.1.2 Chain Drive

(Refer to Dimensional Diagram 101 D 528.HP005, Sheet 3 and Fig. E and F in the annex).
For rudder angles of max. +90°, the drive of the feedback unit should be via chain wheels
and chain. The transmission ratio from the chain drive is 2 : 1.
The tapholes (e.g. M6, depth 20 mm) required for fastening the chain wheel to the rudder
stock are to be centered on the plane surface of the rudder stock. Then the chain wheel is
to be screwed on and to be pinned by means of cylindrical pins. To ensure automatic chain
tension, a chain tightener is to be mounted and to be placed in accordance with space
conditions (chain tightener included in the scope of delivery).

Note:
For systems of 2 feedback units, two chain wheels – arranged in parallel – are to be cen-
tered and screwed on the plane surface of the rudder stock, and pinned (see Fig. F in the
annex).

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Service Manual

1.1.3 Kit for Spark Suppression

Preliminary remark
On switching inductively acting components such as transformers or magnet coils of any
type (contactors, solenoid valves), dangerous high voltage peaks are generated not only in
the circuit concerned but also in the neighbouring cables. There is danger that semiconduc-
tor elements within the equipment might be destroyed by these high voltage peaks. Fur-
thermore, heavy wear may occur on the electrical switching contacts.

These effects and the resulting disturbances on the devices concerned may be avoided by
installing varistors in the equipment.
A package of three varistors and an instruction are attached to the device for different volt-
age ranges:
NB03–923.01: for circuits of up to 28V DC
NB03–923.02: for circuits from 110V to 115V AC or DC
NB03–923.03: for circuits from 220V to 230V AC.

Mounting the varistors

1) Select the varistors that are appropriate to the operating voltage of the corresponding
circuit.
2) Install a varistor in parallel and as close as possible to the inductive component con-
cerned.
3) In case the connections cannot be made directly on the coil or transformer in question,
the varistors are to be installed in the nearest junction box where the cables or adequate
terminals can be reached.
4) Please keep remaining packages with varistors for a future extension where additional
varistors might be required.
5) After installation, check all circuits for correct functioning.

1.1.4 Cabling
See system–specific Cable Diagram as well as Wiring Diagram
101–528.HP050 for version NG024
101–528.HP053 for version NG027
101–528.HP054 for version NG029

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Service Manual Documentation

1.2 First Putting into Operation

For putting into operation, a multimeter (internal resistance >20kOhm/V) is required.

1.2.1 Prerequisite for Putting into Operation

The parts of the equipment are connected ready for operation according to the system
cable and connection diagrams (see Section 1.1).

Caution!
On performing work on the Feedback Unit, observe the electrical
safety regulations!
The following works are to be performed by authorized trained per-
sonnel only.

The following versions should be taken into consideration when carrying out adjustment work:
Version Limit switch Potentiometer Midships indication Application
(optional)
NG029 1 set 45° 1x x FU or RIA
NG024 – 1x (x) RIA
NG027 **) 2 set 45° 2x (x) FU, RIA, NFU *)

*) for secondary steering system (e. g. steering failure)

**) for rudder limitation units

1.2.2 Adjusting the Limit Switches

Adjustment of the limit switches B2 and B4 (for large rudder angles with small speed) and
B1 and B3 (for small rudder angles) is to be made in the feedback unit according to the
ship–specific limit position of the particular rudder. The equipment must be switched on in
order that the limit switches can correctly be adjusted.

– Take off the protective hood of the feedback unit.

– Release the fastening screws of the cams (see Fig. 1–1)
– Set the cams so that they switch off before the mechanical limit position of the rudder is
reached.
– Screw down the headless pin in the cam disk.
– Feedback unit is to be closed by the protective hood again.

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Service Manual

Earthing screw

Terminal strip
Angle
Micro switch

Limit Switches

Cam disk

Gear for B2 B4 Potentiometer

potentiometer

Cams

Fig. 1–1: Feedback Unit – opened Divice

1.2.3 Zeroing of the Potentiometer R1 and R2

– Take off the protective hood of the feedback unit. With the rudder position exactly mid-
ships, disconnect the electrical connections of potentiometer R1 or R2 from the terminal
strip (see Wiring Diagram 101 E 528.HP050, HP053, HP054).
– Loosen the fastening of the potentiometer concerned.
– Connect the multimeter to the respective connections 1 and 2 or 2 and 3 of the poten-
tiometer to be zeroed.
– Turn the casing of the potentiometer until the resistance between the connections 1 and
2 becomes the same as it is between the connections 2 and 3.

Total resistance of the potentiometer: 5 kΩ +20%,

– After zeroing, the potentiometer R1 or R2 is immediately to be re–fastened and its con-
nections are to be re–established on the terminal strip L1.
– Subsequently, the fastening screws are to be secured by means of varnish.

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Service Manual Documentation

Note:
Slight tolerance–limit deviations in the mid–position of the potentiometer R1 can later be
compensated by an offset compensation of the feedback input amplifier on the follow–up
steering control amplifier PCB of the follow–up steering control amplifier by means of the
potentiometer R15 ”RUDDER OFFSET”.
For cases of application, where the feedback unit does not operate in conjunction with the
follow–up steering control amplifier zeroing of the rudder feedback potentiometer should be
performed according to the information given in the description of device or system descrip-
tion concerned!

1.2.4 Adjusting the Micro Switch (Midship Indicator),standard in NG029

(optional for all Versions)

Pre–conditions:
– Feedback unit must electrically be isolated.
– Connect multimeter to the terminals L1.11 and L1.12.
– Disconnected a possibly installed lamp circuit.
– Set the rudder exactly to midship position.
– Displace the shaft of the feedback unit no longer!
– In this position, loosen the cam wheel (refer to Fig. 1–1) and turn it on the shaft in such a
way that the probe roller of the microswitch is exactly positioned in the v–shaped notch
of the cam wheel.
– Then fix the cam wheel with its two headless socket screws, M4x8.
– Adjust the angle of the probe in such a way that it switches on or off when turning the
cam wheel within the area of the slopes of the v–shaped notch (when doing this, ob-
serve the overlap of the microswitch!)
Permissible deviation from the rudder zero position: +2°.
Monitor the switching function at the multimeter.
– Once more fix the position of the angle.
– After the adjustments have been made, re–establish all electrical connections.
– Carefully cover the fixing screws of the angle, the microswitch and the headless socket
screws at the cam wheel with glyptal.
– Re–attach the protective hood.
– Observe correct earth connection!

The feedback unit can now be put into operation.

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 Feedback Unit Technical
Service Manual Documentation

2 Maintenance, Shipboard Repair, Spare Parts Catalogue

2.1 Safety Precautions

Warning!
Use care during maintenance and repair to avoid contact
with energized electrical conductors. Applicable safety
regulations must be followed, such as VDE, VBG 4,
OSHA 1919, and other consensus safety standards.

Caution!
Maintenance and repair must be performed by trained
and qualified personnel who are knowledgeable in
equipment national safety requirements!

Device may be damaged!

Exchange of spare parts only with the supply voltage
switched off.

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 Feedback Unit
Service Manual

2.2 Care and Maintenance

The feedback unit is an important component within the

steering control. In view of the ship’s safety, particular atten-
tion must therefore be given to its care and maintenance.

2.2.1 Maintenance Schedule

Con. Maintenance Intervall Reference

No.
1 – check the tight fitting of the fixing screws of the compo- every 2 years
nents in the feedback unit and re–tighten when neces-
sary and cover with glyptal
– carefully grease the toothed sides of the toothed wheels,
e.g. with MOLYKOTER
– check for exact alignment and correct switching function 1.2.2
of the limit switch
2 – check the shafts and the toothed wheels for mechanical every 3 years
loosening
– check the correct function of the potentiometer 1.2.3

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Service Manual Documentation

2.3 Repair – Exchanging of Parts

Pre–conditions:
– Rudder is in midship position
– Rudder equipment is electrically isolated
– Driving element removed from the feedback unit
– Protective hood removed.

2.3.1 Limit Switches

– Mark the electrical connections
– Loosen the electric terminal connections
– Screw off the two fastening screws of the limit switch
– Exchange the defective limit switch
– Re–assembly in the revers order
– Check the adjusting of the appertaining cam (refer to Section 1.2.2)

2.3.2 Potentiometer
– Remove the trigger cam on the feedback unit shaft.
– Carefully remove the PCB together with all its components (unscrew four fixing screws),
observing cable connections!
– Mark the electrical connections of the potentiometer and remove them at the terminal
strip.
– Loosen the toothed–wheel fixing at the potentiometer shaft and remove the toothed
wheel.
– Unscrew the fixing screws at the potentiometer.
– Replace the defective potentiometer.
– Re–assemble in reverse order.
– Align and set zero point in accordance with section 1.2.2 and 1.2.3.

2.3.3 Microswitch (Mid Ship Indicator) (optional for all Versions)

– Screw off the two fastening screws of the microswitch
– Draw off the electrical plug connections of the switch
Do not pull at the electrical wires!
– Exchange the defective microswitch
– Re–assembly in the revers order
– Check the adjusting of the microswitch (refer to Section 1.2.4)

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Service Manual

2.4 Spare Parts Catalogue

2.4.1 Notes on Ordering

To ensure fast processing of replacement parts orders and to make sure that the correct re-
placement part is delivered, the following details are required:

1. Name of the ship

2. Raytheon Anschütz order number:
e.g.: 610 0 61637
3. Device type (refer to type label) that the replacement part is required for:
e.g.: Feedback Unit, Type 101–528 NG029.
4. Exact designation of the replacement part from the specifications given in the
replacement parts catalogue

Example:

Stock No. Designation Drawing No.

1.721059 Switch 1C65ZN

5. Required number of parts

3701E/101–528.DOC032 2–4 Edition: 28.AUG.2003

Rückmelder
FEEDBACK UNIT Ersatzteilkatalog
SPARE PARTS
Type 101–528 NG024–NG029 CATALOGUE

6 5 4

14.614 1
Rückmelder
FEEDBACK UNIT Ersatzteilkatalog
Type 101–528 NG024–NG029 SPARE PARTS
CATALOGUE

POS. Lager-Nr. Benennung Zeichnungs-Nr. Stck. in NG... Hersteller-Code

STOCK-NO. DESIGNATION PART-NO. QTY. in NG... MFRC
024 027 029 Versorgungs-Nr.
NATO-STOCK-NO.
1 1.504 178 Mikroschalter NB 14-230.00-061 0 0 1 D 2865
MICRO SWITCH 5930-12-307-9339
2 1.721 059 Schalter 1 C 65 ZN 0 2 4 D 2865
SWITCH
3 3.500 814 Nocken 101-528.00-038 2 2 4 D 2865
CAM SET

4 1.508 706 Zahnrad z = 152 101-528.00-017 1 1 1 D 2865

GEAR WHEEL z = 152 3020-12-349-2741
5 3.601 012 Sensorpotentiometer 101-528.14 1 2 1 D 2865
POTENTIOMETER
6 1.500 313 Zahnrad z = 76 101-528.00-034 1 2 1 D 2865
GEAR WHEEL z = 76

All depicted items which are not mentioned in the text are not applicable for this unit. Since further development may necessitate making modifications to
existing equipment, its conformity with the relevant illustrations and drawings is not always ensured. RAYTHEON MARINE will be under no liability
whatever that may arise from any such differences.

14.614 RA/S–SU 0308 EDITION 01 2

 Feedback Unit Technical
Service Manual Documentation

3 Construction and Principle of Operation

3.1 General
The feedback unit is a part of the control loop of a steering control system. Limit switches
switch the steering gear off after the end position of the rudder has been reached, and a
microswitch (optional) signalises the midship position of the rudder. With some types of the
feedback unit, an electrical signal proportional to the rudder angle is also delivered. This
signal is required for the follow up (FU) via an autopilot and for the display at an actual
rudder position indicating unit (RIA).
The feedback unit can be directly attached at the shaft of the rudder or at a regulating unit
of the steering gear by means of corresponding attachment assemblies.

Fig. 3– 1: Feedback Unit with Lever Drive System

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Service Manual

3.2 Construction
Fig. 3– 2 shows the construction of the feedback unit.
For the equipping of the individual variants, refer to the ’Technical Data’.
The following components are mounted on a PCB:
– Limit switches B1 and B4
– Potentiometer R1 and R2
– Microswitch B5 (optional for all versions) and
– Terminal strip
The PCB is fixed in the casing with four screws. The casing has six bore holes on its
topside for cable bushings and an earthing screw. The feedback unit shaft carries cams for
activating the limit switch and a toothed wheel for adjusting the potentiometer, which has a
corresponding toothed wheel on its shafts. The casing is sealed with a protective hood
against environmental influences.

Earthing screw

Casing

Terminal strip Angle

Micro switch

Limit Switches

Plate

Feedback gear
with gear

Gear for Potentiometer

potentiometer

Fig. 3– 2: Construction of the Feedback Unit

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3.3 Principle of Operation

A lever support or chain drive transfers the movement of the rudder to the shaft of the feedback
unit. Thus, the cams are turned with the feedback unit shaft. When a pre–determined rudder
position is reached, the cams then switch off the solenoid valves of the steering gear via the limit
switches. Some versions of the rudder feedback unit comprise 2 sets of limit switches, to switch
off respectively the solenoid valves on exceeding a large rudder angle (for small speed e. g. in
confined waters) and on exceeding a small rudder angle (during normal speed); with this, the
switching off is controlled by the rudder limit unit, Type 105–108.
With some types of feedback unit, the rudder movement is transmitted to the potentiometers
R1 and R2 via toothed–wheel gears with a transmission ratio of 1:2. These generate an
independent voltage from the rudder position, which is then redirected as a rudder position
signal to, e.g. an autopilot or a actual rudder position indicator.
Option for all versions:
A microswitch is activated via a cam wheel on the shaft of the feedback unit; the microswitch
probes the rudder zero position (midship indicator). By closing or opening a circuit with the
microswitch, a status report can be transmitted.

Flange
Gear wheel z1 (z=152)

Gear wheel z2 (z=76)

Potentiometer R1 or R1 + R2

Mounting surface
Lever drive system

Fig. 3– 3: Drive by Means of a Lever Drive; Range of Rudder Angle: from ± 30° to ± 45°

Mounting surface

Flange

Chain wheel, large Chain wheel, small

Chain Rudder stock

Fig. 3– 4: Drive by Means of Chain and Chain Wheels; Range of Rudder Angle: from ± 45° to ± 90°

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3.4 Technical Data

3.4.1 Mechanical Data

Dimensions: see Dimensional Drawing 101 D 528.HP005
Weight: approx. 4 kg

Mounting position: optional

Keys (Limit switches): max. 4 peaces

Accuracy: < 1° (incl. hysteresis)

Absolute accuracy: < 1/3°

Resolution: < 0,1°

Air and creepage pathes acc. to VDE 110, insulation class C,

for limit switches: for voltage up to 220VDC

Midship switch group:

Switching range: approx. +2°, adjustable

Potentiometer: 5 kΩ + 20%,

3.4.2 Electrical Data

Input voltage: +15VDC

Output voltage: 0VDC ... approx. +10VDC (dependent on rudder posi-

tion)

Scaling of the scale factor:
Permissible switching power
via limit switches (e.g. for
solenoids):
Minimal switch current
in the follow–up steering control amplifier for +10VDC
max. rudder angle
< 50W inductive load
(with 24VDC /110VDC, 110 / 220VAC)
10mA / 24V DC

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3.4.3 Environmental Conditions

Ambient temperature
– storage: –35°C ... +70°C
– operation: –25°C ... +63°C

Shock resistance: acc. to BV 043 50m/s2

Resistance to vibration: acc. to GL and BV 044

(with 2 ... 25Hz: + 1,6 mm)
(with 10 ... 100Hz: + 4,0 g)

Type of enclosure: IP56

GL test number: 95 594 HH 1986

(not for modifications)

EMC: see Declaration of Conformity

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ANNEXES

Mounting Proposals for one and two feedback units,

Diagrams:

Dimensional Drawing: 101 D 528.HP005 Sheet 1 to 3

Hydraulic Unit: 115 D 430.HP005

Wiring Diagram: 101 E 528.HP050 (for NG024)

101 D 528.HP053 (for NG027)
101 D 528.HP053 (for NG029)

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1 1
FU 1 4 FU 2
1
FU 1 3 3
4
3
Legend for Fig. A, B and C FU 1 2 4
1 Feedback unit (FU) Legend for Fig. E and F
2 Lever drive 1 Feedback unit (FU)
3 Console (from shipyard) 2 Chain drive 1
4 Rudder stock FU 3 3 Console (from shipyard)
4 Rudder stock 3
FU = Feedback Unit 5 Chain tightener

3 5
4 3 4 3
3

+α –α 1 2
+α –α
2
2 2
Fig. A: Mounting Proposal for one Feedback Unit Fig. E: Mounting Proposal for one Feedback Unit
Drive from rudder stock via lever system, Type 148–442 Fig. C: Mounting Proposal for 3 Feedback Units Drive from rudder stock via chain and chain wheels, Type 148–341
Drive from rudder stock via lever system, Type 148–442
Rudder angle: +30° ... +45° Rudder angle: +60° ... +90° (and ...360° with rudder propeller)
Rudder angle: +30° ... +45°

1 FU 1 1
1
FU 1 4 FU 2 3 3
FU 1 2 2 FU 2
3 3 1
1 1
4
3
2 5 3

3 4 3 2 5 5
3
3

4
+α –α
Legend for Fig. D 1 1
2 1 Feedback unit (FU) 4 Console (from shipyard)
Fig. B: Mounting Proposal for 2 Feedback Units 2 2 Lever drive 5 Hydraulic cylinder Fig. F: Mounting Proposal for 2 Feedback Units
Drive from rudder stock via lever system, Type 148–340 3 Holder Drive from rudder stock via 2 chains and chain wheels, Type 148–342
Rudder angle: +30° ... +45° Rudder angle: +60° ... +90° (and ...360° with rudder propeller)

Fig. D: Mounting Proposal for one Feedback Unit

Drive from hydraulic cylinder via lever system, Type 148–442

Mounting Proposals for Feedback Units (Schematic Representation)

Edition: 28.AUG.2003 Annex 1 3701E/101–518.DOC031