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Marine Propulsion Systems

1

TECHNICAL MANUAL

-INTRODUCTION -

FOR

CONTROLLABLE PITCH PROPELLERSYSTEM

MODEL CPP KH-850Niveko

DORA

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A- Section

CONTENTS

A- INTRODUCTION ............................................................................................................5

A.1 - Storage Instructions...............................................................................................................5

A.2- Responsibility and Warranty...................................................................................................6A.3- Customer and ZF Reference Data...........................................................................................7A.4- Main Technical Data ................................................................................................................8

A.5.1- Mechanical System ...................................................................................................9A.5.2- Hydraulic System ......................................................................................................10A.5.3- Electric and Electronic System ..................................................................................12

B MECHANICAL INSTALLATION.......................................................................................15

B.1- General recommendations......................................................................................................15B.1.1- Assembly drawing .....................................................................................................17

B.2- Propeller Shaft Installation Procedure ..................................................................................18B.2.1- Shaft seal installation Type IHC..............................................................................22

B.2.1.1- Rear end shaft seal ................................................................................................22B.2.1.2- Front end shaft seal................................................................................................25B.2.1.3- Checks on mounted SUPREME

seals...................................................................27

B.2.1.4- Seal Lubrication......................................................................................................28B.2.1.5- Stern tube seal - Start-up instructions.....................................................................29B.2.2- Coupling flange installation Hydraulic press-fit ........................................................30

B.3- Propeller blade installation .....................................................................................................32B.4- Shaft-to-gearbox connection ..................................................................................................35B.5- OD-box installation..................................................................................................................39

C - HYDRAULICS INSTALLATION ........................................................................................43

C.1- Hydraulic control system - Type KH-850 / PVT ......................................................................44

C.2- Stern tube tank installation.....................................................................................................50

D ELECTRICAL INSTALLATION RECOMMENDATIONS .........................................................53

D.1- General recommendations......................................................................................................53D.2- Power devices .........................................................................................................................54D.3- Control devices........................................................................................................................59

E REFERENCE VALUES, SPECIFICATIONS AND REQUIREMENTS..........................................61

E.1- General engineering units.......................................................................................................61E.2- Setting data, torque values and electrical specifications......................................................63E.3- Hydraulic operating data.........................................................................................................66

E.4- Lubrication specifications.......................................................................................................67E.4.1- Propeller system specifications..................................................................................67E.4.2- Stern tube specifications............................................................................................70E.4.3- Shaft seal lubrication .................................................................................................71

E.5- Gap and sag specifications.....................................................................................................72

F- ELECTRONIC CONTROL SYSTEM MRCS 08/90............................................................89

Terminology: .......................................................................................................................89List of Abbreviations ............................................................................................................90Safety Instructions...............................................................................................................91F.1.1- General Description of the Scope of Supply..............................................................93F.1.1.1- Power supply..........................................................................................................94

F.1.1.2- Failure....................................................................................................................95F.1.2- CPP Control System MRCS 08/90.............................................................................96F.1.3- Technical Specification for the installed equipment : .................................................. 97F.1.4- Operating Instructions................................................................................................107F.1.5- Commissioning Instructions .......................................................................................110F.1.5.1- Parameter Input......................................................................................................111

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F.1.5.2- Input Procedure......................................................................................................112F.1.5.3- Parameter of Control Transmitters and Feedback Transmitters...............................113

F.2- MRCS 08/90 Electronic Unit - General Information ................................................................114F.2.1- General Description of the System.............................................................................114F.2.2- Basic Description.......................................................................................................117F.2.3- Technical Specifications ............................................................................................121F.2.4- Construction..............................................................................................................122

F.2.4.A- Mechanical Construction ........................................................................................122F.2.4.B- Electrical Construction............................................................................................125F.2.4.C- Power Supply.........................................................................................................126F.2.4.D- Main-CU ................................................................................................................132F.2.4.E- Shaft Speed-CU .....................................................................................................140F.2.4.F- Amplifier-CU...........................................................................................................148F.2.4.G- Parameter Setting PCB..........................................................................................155F.2.5- Parameter In/Output..................................................................................................158F.2.6- Parameter List...........................................................................................................161F.2.7- Error List - Error message and treatment ...................................................................168

F.3- Terminal Connecting Plan.......................................................................................................172X1 Terminal strip W/H Panel................................................................................................173X2 Terminal strip ECR Panel ...............................................................................................174

X3 Terminal strip Wing Panel STB.......................................................................................175X4 Terminal strip Wing Panel PORT....................................................................................176X5 Terminal strip ECR .........................................................................................................177X6 Terminal strip ECR .........................................................................................................181X7 Terminal strip ECR .........................................................................................................183X9 Terminal strip ER Control Box ........................................................................................183X10 Terminal strip ER Control Box ......................................................................................184X11 Terminal strip ER Control Box ......................................................................................185List of Cable-b .....................................................................................................................187

G- START-UP AND COMMISSIONING...................................................................................219

G.1- Start-up....................................................................................................................................219

G.2- Special start-up instructions ..................................................................................................221G.2.1- Special instructions: electronic control system...........................................................221G.2.2- Special instructions: hydraulic control unit .................................................................221G.2.3- Sepcial instructions: shaft seal assemblies................................................................222

G.3- Start-up check list ...................................................................................................................223G.4- Sea Trials and Commissioning...............................................................................................224

H- OPERATING INSTRUCTIONS ..........................................................................................228

H.1- Responsibility and Warranty...................................................................................................229H.2- Storage instructions................................................................................................................230H.3- Operating instructions ............................................................................................................231

H.3.1- Control panel operation.............................................................................................231H.4- Emergency operation (Come-home procedure).....................................................................237H.5- Regular maintenance ..............................................................................................................238

H.5.1- Propeller system maintenance schedule....................................................................238H.5.2- Special maintenance instructions: Hydraulic control unit ............................................240H.5.3- Special maintenance instructions: Shaft seal boxes...................................................241H.5.4- Hydraulic control unit / Fluid specifications.................................................................243H.5.4- Stern tube oil specifications.......................................................................................245H.5.6- Stern tube fore end seal / Lubrication specifications .................................................. 245

H.6- Spare parts ..............................................................................................................................246H.7- ZF Worldwide...........................................................................................................................255

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release date comments

00 04.2004 initial version DORA

01 04.2004 updating information: hydraulic control unit KH-850; Gap/Sag calculation (06-5-2004)

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A- INTRODUCTION

A.1 - Storage Instructions

1. The material has been shipped in good condition,protected against mechanical damage andcorrosion by appropriate packaging. The

consignee/shipyard shall inspect the materialupon delivery and make sure that:

- all items have been delivered as shown on thetransport documents

- no item has suffered any damage duringtransportation and handling

- all parts are free of corrosion.

Once the consignee/shipyard has accepted thedelivery of the goods, the consignee/shipyard willhave to make sure the goods are stored in goodconditions to prevent mechanical damage to and/orcorrosion of the goods. No dirt, dust, humidity or any

other matter must be allowed to penetrate into themechanical devices and/or electric or electroniccomponents.

2. Hydraulic machinery:Hydraulic devices (pumps, servos, valves, etc.)have been tested before delivery. Therefore, they

benefit from a natural internal oil film protection.However, this protection will last no more than 3months in a dry and sheltered environment. If thehydraulic units have been stored for more than 3months, they will have to be run under no-loadconditions, with fresh oil, to flush the entire systembefore the actual start-up. Oil and oil filter will thenbe changed before start-up!

3. If the hydraulic machinery is laid up for anextended period of more than 1 month, an anti-corrosion compound, such as Rust Veto Concen-trateby E.F.Hougton & Co. of Philadelphia, USA,

(or equivalent additive) should be added to thetank oil, and the system run without load for somelength of time, sufficient to circulate the added oilthrough the entire system.

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A.2- Responsibility and Warranty

Purpose of this manual

The following manual contains the information re-quired for installers and users of ZF Marine PropulsionSystems equipment. These include, but are not

limited to, ships staff, shipping company super-intendents, land based support staff, shipbuilders anddry-dock supervisory staff.

This manual is intended to provide the informationnecessary for the safeinstallation, onboard operationand routine ships maintenance. The manual alsocontains spare parts ordering information.

ZF Marine Propulsion Systems provide this manual asa guide only, it is not intended to, nor does it, replace

all, or in part, any directives from a customer, or enduser, or their appointed third party representative(s). Itis appreciated by ZF Marine Propulsion Systems thatregional law, insurance, shipping company andshipyard regulations as well as ships design specificconsiderations, etc, may result in the necessity tomodify, or change the techniques, practices andprocedures described herein. Please be advised,however, that any modification, or change oftechniques, practices and/or procedures mayinvalidate the manufacturer warranty, unless priorwritten agreement has been received, in writing, fromZF Masson. Limitations of liability, end user customer

and manufacturer responsibility

The following statements do not take precedence overany existing contractual obligations, real or implied.

REPAIR WORKDue to continuing development of our products,manufacturing technology and procedures futurerepair work may require the application of workpractices, test or adjustment data that are not coveredby this manual at the time of issue. We thereforerecommend that repair work carried out on your ZFproduct is performed only by skilled technicians who

have undergone practical and theoretical skills

training, (ZF training includes refresher andassessment courses), and is conducted at approvedZF training centres.

The ZF group has installed a network of fully staffedSales and Service Organisation Centres, (SSOCs), atstrategic locations throughout the world so that ourcustomers receive field support close to their geogra-phical location. Repair work carried out at ZF SSOCswill be guaranteed in accordance with the prevailingcontractual conditions.

Note :Damage resulting from work performed by non-ZF personnel and which is deemed by ZF to havebeen conducted in an improper manner, including allfollow-on remedial work, the costs thereof, loss of

vessel operational time and any associated loss ofrevenue including any and all third party liabilities,(consequential damages) are, in their entirety,excluded from the ZF contractual guarantee.

WARNING

Installation and Operation of the equipment, includingunauthorised modification, that is outwith theparameters described in this manual, (plus anypertinent ZF Marine Propulsion Systems technicaldata and the sales contract , including any relevantamendments/revisions), may result in irreparabledamage to, and/or malfunction of the equipment. Such

actions may result in invalidation and rejection ofexisting warranty and any warranty claims, solely atthe manufacturers discretion.

ADVISORY

Should any installation, operation, maintenanceand/or modification work be considered by end users,or any third party then ZF Marine Propulsion Systemsstrongly recommends that such work only beundertaken in full agreement with the expresspermission, in writing, of the manufacturer, ZFMasson S.A.

ZF Marine Propulsion Systems, Division ZF Masson may be contacted per the below :

Postal addressZF Masson S.A.B.P 716F89107 SENS Cedex (FRANCE)

Office addressZF Masson S.A.5, rue Henri-Cavallier89107 St. Denis les Sens (FRANCE)

Telephone : (33) 386 95 62 33Telefax : (33) 386 95 62 96

Website : www.zf-marine.com

- - - - - Service department - - - - -ZF Masson S.A.Service department

F-89100 Sens (France)

0033 386 956233

0033 386 951378services.zfmasson@zf.com

guy.geoffroy@zf.com

mailto:info.commercialcraft@zf.commailto:info.commercialcraft@zf.commailto:info.commercialcraft@zf.commailto:info.commercialcraft@zf.comhttp://zf-marine.com/mailto:services.zfmasson@zf.commailto:services.zfmasson@zf.commailto:info.commercialcraft@zf.commailto:services.zfmasson@zf.comhttp://zf-marine.com/

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A.3- Customer and ZF Reference Data

Client: NIVEKO

Vessel name:

ZF reference number: 98567

ZF serial number: CPP00027

Classification society (CPP system): BV-AUT-UMS-1D

Propeller type: KH-850

Propeller rotation: Right hand

Scope of supply (ZF)

CPP assembly -

Propeller shaft assembly -

Stern tube assembly -

Stern tube seal assy., fore -

Stern tube seal assy., aft -

Stern tube gravity tank 80L

Od-box with pitch indicator

Hydraulic power pack

Hydraulic control accessories -

CPP electronic control unit -

DORA

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A.4- Main Technical Data

Propeller data

Propeller type: KH 850

Number of blades: 4

Propeller hub size: 850 mm = 33,5 inch

propeller diameter: 3500 mm = 137,8 inch

Propeller hub material: G-CuAl 10 Ni

Propeller blade material: G-CuAl 10 Ni

Propeller weight:

hub + shaft: 5151 kg = 11355,8 lbs

one blade: 659 kg = 1452,8 lbs

total inertia ( in air ): 3012 kgm

Propeller shaft dataPropeller shaft length:

coupling flange to axis of blade

rotation: 5833 mm = 229,6 inch

Propeller shaft diameter:

Aft bearing dia: 320 mm = 12,6 inch

Fwd bearing dia: 300 mm = 11,8 inch

Dia at coupling flange: 280 mm = 11,0 inch

Propeller shaft coupling type OMC

Stern tube data

Stern tube mounting: chockfast

Stern tube length: 2505 mm = 98,6 inch

Stern tube oil tank capacity: 80 litres = 17,6 gal (GB)= 21,1 gal (US)

Stern tube temperature transducer,

type: PT100

AFT stern tube seal : IHC size: 355 =

FWD stern tube seal : IHC size: 330 =

Miscellaneous

none

DORA

semi split with 4 th ring

std supreme - non split

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A.5.1- Mechanical System

The KH type propeller system includes a hydraulically operated controllable pitch propeller and hollow propellershaft or "line shaft", through which it is mechanically linked to a propulsion gearbox.

The gearbox output shaft is rigidly linked to the line shaft, which is a monoblock part running all the way throughthe stern tube to the propeller hub. The propeller hub (i.e. the propeller) is bolted to the propeller shaft.A hydraulic actuator piston inside the propeller hub moves back and forth to swivel the propeller blades so as to

change the propeller pitch, through a yoke and crank assembly.The line shaft and gearbox shaft are hollow to allow oil pressure for propeller pitch adjustment to run through theshafts, from the OD box at the front end of the propulsion gearbox to the actuator cylinder located inside thepropeller hub. The central feeding pipe moves fore and aft with the actuator piston, so that, at the same time, itprovides an accurate indication of the propeller pitch.

OD-box

gearbox

coupling flange

shaft

pitch controloil piping

stern tubeshaft seal, fore

stern tube flange(hydraulicconnection)

stern tubebearing, fore

stern tube

stern tubebearing, aft

stern tubeshaft seal, aft

propeller blades

propeller hub

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A.5.2- Hydraulic System

Propeller actuation is provided through hydraulic pressure acting on the piston inside the propeller hub.

A main oil tank containing the hydraulic fluid supplies the operating fluid to the system. Operating pressure issupplied by an independent, electrically driven variable displacement oil pump (P1) fitted as a part of thehydraulic control unit. An identical stand-by oil pump assembly (P2) is installed in parallel with the mainoperating pump and is controlled through a pressure switch connected to the CPP main hydraulic control block.

Emergency actuation is possible by means of a hand pump (PM).

A pressure regulator (LP1) placed parallel to the oil filter (FLT) sets the maximum operating pressure limit. Oilexiting from the oil filter passes through a flow control valve (LD1) before it reaches the distributor solenoidvalves (D1). The flow control valve determines the speed of the propeller adjustment. It has been set in ourfactory.

The distributor solenoid valves are energised with 24 V DC to direct oil under operating pressure throughpressure outlets (A) or (B) to the propeller pitch servo, as requested by the operator, until the desired propellerpitch is reached.

Hydraulic pressure is carried to the servo chambers through the propeller shaft, where two concentric channelsare formed in the centre of the shaft. Both channels open at the front end of the propulsion gearbox output shaft,into the manifold or O.D. box. In this way, oil under pressure can be supplied from the engine room to either of

the servo chambers in the propeller hub.

PVT-oilpump

pumpcoupling

bellhousing

electricmotor

handpump

hydrauliccontrol

unit

electric

junction

box

filler

plug

mainoil

tank

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CPP hydraulic circuit diagram:

P1

XP1

P2

XP2

PM

T

G1 LD1

D1

SC1

CP1

PPB

B

PPA

A

C3

C1

C2

LP1 CP2

CaP

M1

FLT

VV

FA

NV

M1

M2

NE

TH1

PV1

PV2

P1

PM

P2

75b

75b

100b

T

A

X

P

Y

B

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A.5.3- Electric and Electronic System

The main cabinet and switchboard is supplied with alternating current. All control and monitoring devices (suchas solenoid valves, pressure switches and so forth) are connected to a 24V direct current source, preferablyincluding an independent back-up source (such as a 24V battery).

For a detailed description and data concerning the electric and electronic propeller pitch control system, refer tothe manufacturer's documentation in sections Dand Fin this manual.

Electronic Pitch Control System - Block Diagram

Hydr.Unit

W/ HWING PORT

Alarm Monit. System

24 VDC Supply

8

X4 Term . X1 Term . X3 Term .

X2 Term.

1 2 3

7

W H

EC R

ER

24 VDC Supply4

5

21

WING STB

21

PITCHSHAFTRPM

21

PITCHSHAFTRPM

EC R

S08/90

CABINET

Em .

Contr. Box

10SafetySystem

Main Switchboard

6

9

Terminals X5,X6,X7

Terminals X9,X10

PITCH

SHAFT RPM

(OPTION)

PITCH

(OPTION)SHAFT RPM

8a

15

X5 1

mA

76*** *

2213** *

8* ***

mA

10

** *129

** *mA

** *11** *

21*

X3

12

X1 5

13

X5 5

14

19*

21

**

mA

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ote:

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able:

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one

side

of

the

**ZF Supply* EH Supply

*** Engine Maker Supply

2.l imit pick up zero

4.l imit pick up ahead

Sensor/Actuator

5.l imit pick up astern

3.valve group

1.value pitch

Propulsion

8.fuel rack position9.engine speed signal10:load reduction 40%

12.overload

6.local/remote switch engine7.speed setting to governor

11.em stop/pitch to zero

13.engine rpm control

21selection switch ECR W/H to engine19.pick up shaft rpm

22accept remote to engine

CPP Control System MRCS 08/90 General description

The Manual Control of CPP is possible from the local side. Automatic control is possible from the ECR Panel,from Wheelhouse Panels as well as from the WING via a Control Lever.

Change-over from ECR to the Wheelhouse is made by a selector switch LOCAL/REMOTE on the Engine. Thechange over between ECR, W/H Panel and Wings is made by pushbuttons incorporated in the control panels.

This change over is interlocked by the control lever positions UP / DOWN, which must be in similar positions.

The CPP control is possible only if the engine is running (system without clutch), indicated by a lamp installed inthe control panels. Zero position of the CPP is indicated in the panels and will interlock Engine start.

The Electronic Unit is to be installed in the Engine Control Room Console and contains all electronic PCBs forthe CPP Control System MRCS 08/90 .

The Microprocessor controlled System will activate the Hydraulic Solenoid Valves for AHEAD and ASTERNmovement of the CPP. The feedback from the CPP position transmitter is supplied to the control system andregulates the position of the CPP.

The control of CPP is monitored by an incorporated overload detection with Automatic Slow Down.

In the wheelhouse panels a Back-Up control of the CPP is provided by Joystick, which can be activated by a

covered switch.

Indicators for Shaft RPM and CPP angle are installed in or near the Control Panels.

The Engines are to be started locally. After Starting of the Hydraulic System for the CPP, the Engine and CPPcan be operated manually in the Engine Room.

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CPP KH-850

DORA - 01/2004 - 13

After changing the LOCAL/REMOTE Switch to Remote, the Control can be taken over by one of the ControlPanels or the Wings, provided that the relevant Control Lever is at Zero Position, the Engine is running and theCPP Hydraulic Pressure is available. Take Over is executed by pressing the relevant pushbutton ECR, W/H orWING.

For exact values, please refer to section A.4- Technical Data and relevant information in section E.1- Assembly

values and setting data! For lubricants and oil specifications, please refer to section E.2- Lubricationspecifications!