Jastram Steering Control Amplifier
Jastram Steering Control Amplifier
Jastram Steering Control Amplifier
•/•*»
System Manual
Steering Control Amplifier
Model: SCA 300 & RFU 1300
467 Mountain Hwy, North Vancouver, B.C., Canada, V7J 2L3 TEL: 604-986-0714 FAX: 604-986-0334
Table of Contents ^engineering ltd.
Page 1 of 31
TABLE OF CONTENTS
INTRODUCTION 2
2.1 Mounting 11
2.2 General Instructions for Plug Assembly 11
2.3 Cabling and Wiring 11
SETUP AND TESTING 19
TROUBLESHOOTING 27
TABLE OF FIGURES
1 INTRODUCTION
Page 3 of 31
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An adjustment in the SCA 300 limits the maximum amount of current that
can be applied to the proportional solenoids. This adjustment sets the
maximum speed the rudder can achieve during a large change in the
rudder position.
The input device is where the command to the rudder is given. There are
two types of input devices that can be connected to the SCA. These are
full follow-up and non follow-up units. Electric wheels, lever controllers
and joysticks are examples of full follow-up devices. Jastram's full follow-
up input devices incorporate potentiometers in their design. The
potentiometer converts the position of the steering input device into a
signal for input to the SCA. This signal is called the rudder order signal.
A jog lever is an example of a non follow-up input device. With this type of
unit the steering gear turns as long as the device is held in either the port
or starboard position. When used with the SCA, Jastram has maintained
the simplicity of the non follow-up system by having the jog lever directly
operate the directional solenoid valve. Since the jog lever is a non follow-
up input device directly operating the directional solenoids, it does not
provide proportional control of the steering gear. Operating the jog lever
to port or starboard will immediately apply a fixed amount of current to the
directional valve solenoids. The fixed amount of current applied under
non follow-up operation, and therefore the fixed speed the steering gear
can achieve under non follow-up operation, is adjustable through a current
limiting, adjustable wire wound resistor in the SCA 300.
The rudder feedback unit (RFU) is mechanically tied to the ship's rudder
and converts the position of the rudder into an electronic signal. This
signal is called the rudder angle signal. The SCA is designed to be used
with the RFU 1300 but other types of rudder feedback units may be used.
Contact your Jastram representative for further information on connecting
other feedback units to the SCA.
Jastram's RFU 1300 operates in "stand alone" mode. This ensures that
all electronic circuitry necessary to drive the rudder angle indicators is
contained within the RFU 1300. This circuitry is simple and separating it
ensures constant rudder angle indication regardless of the status of the
amplifier unit. The RFU 1300 also contains limit switches which cut the
electric signals to the directional solenoid valve at the rudder's hard over
positions. This limits the travel of the steering gear to prevent possible
damage (see Figure 2).
Page 6 of 31
r min.
1. MECHANICAL HARDOVER
2. RFU LIMIT SWITCH
3. INTERNAL LIMIT (SCA OR AUTOPILOT ONLY)
4. ZERO DEGREES RUDDER
The SCA 300 is designed for use with DC powered hydraulic solenoid
valves.
The SCA is fully capable of either full follow-up or non follow-up operation.
Although Figure 1 shows the cabling layout for both, the non follow-up
components and cables can be considered as optional. All SCA's are
equipped with a relay which, when turned on, disconnects the non follow-
up jog lever from the hydraulic solenoids and connects the SCA's full
follow-up output.
During full follow-up steering, the SCA controls the 4-way directional
solenoid valve of the hydraulic power unit. The SCA does this by
comparing the rudder order signal from the full follow-up input device and
rudder angle signal from the rudder feedback unit. When these signals
are different, the SCA begins to apply current to the directional solenoid
valve, which turns the rudder to reduce the difference. The current
applied to the solenoid is proportional to the difference between the rudder
order and rudder angle signals. This results in the smooth acceleration
and deceleration of the rudder. The SCA continues to turn the rudder until
the rudder order and rudder angle signals are the same at which time the
SCA turns off the directional solenoid valve. The rudder is now at the
desired full follow-up angle. By adjusting the SCA 300 the following
performance parameters can be altered:
Internal Angle Limit - allows for electronic adjustment of the maximum full
follow-up rudder angle. This leaves the limit switches in Jastram's RFU
1300 as back up when the SCA is operating under full follow-up steering.
(See Figure 2)
Deadband - provides a region about a rudder and helm set position for
which a small change in position of the helm will not cause movement at
the rudder. The size of the helms "dead" region is adjustable.
Gain - sets the rate of acceleration and deceleration of the rudder. The
most visible effect of this adjustment is that it changes the angular
difference between rudder order and rudder angle, at which the rudder
begins to decelerate.
Full Follow-up Speed - adjusts the hard over to hard over time of the
steering gear in full follow-up mode.
Non Follow-up Speed - adjusts the hard over to hard over time of the
steering gear in non follow-up mode. ^
The SCA 300 can output to rudder angle indicators (RAI) as well as rudder
order indicators (ROI).
The SCA contains two rudder angle indicator outputs, CRAI (constant
rudder angle indication) and RAI. The CRAI signal is the rudder angle
indicator signal output from the RFU 1300 rudder feedback unit operating
in "stand alone" mode. This signal is simply routed through the SCA. The
RAI signal is the rudder angle indicatorsignal output from the SCA. This
RAI signal is used when a rudder feedback unit other than the RFU 1300
is used with the SCA.
The SCA also outputs a rudder order indicator signal. The rudder order
indicator gives the present position of the full follow-up steering input
device and therefore the full follow-up rudder command at the SCA.
Page 9 of 31
1.4 Specifications
Enclosure
Resistance 40 ± 1 % kOhm
Resistance 10±1%kOhm
Resistance 10 ± 1 % kOhm
General Functions
Environmental
2 INSTALLATION
2.1 Mounting
The SCA 300 should be mounted in the wheelhouse if possible. This will
result in shorter cable lengths and ease in the tuning procedure.
CAUTION: Do not install the O-ring seals or heat-shrink the strain relief until the
system is tested and performs satisfactorily. :
a) Refer to Figures 5 and 6. Lay out the terminal blocks and label the
required terminals. If optional non follow-up input device is not required
terminal block TB2 may be omitted.
- RECEPTACLE NUMBER
TB# - TERMINAL BLOCK NUMBER
SCA - STEERING CONTROL AMPLIFIER (SCA 300)
RFU - RUDDER FEEDBACK UNIT (RFU 1300)
NFU - NON FOLLOW UP INPUT DEVICE (JOG LEVER)
FFU - FULL FOLLOW-UP INPUT DEVICE
RAI - RUDDER ANGLE INDICATOR
ROI - RUDDER ORDER INDICATOR
Page 15 of 31
WIRING DIAGRAM
TERMINAL FROM CABLE No. TERMINAL TO
CABLE 1
20 AWG/6/SHIELDED — RFU-R1
SCA-R1 —
e
CABLE 2
2 (+V)
SCA-R2 — 20 AWG/3/SHIELDED
3 (+ros; — FFU
9 (-V)
1 •-
2 *•
3 •- CABLE 3
SCA-R3 — 6 •- 20 AWG/6/SHIELDED TB1
7 •-
8 •-
e e
9 •-
Page 16 of 31
WIRING DIAGRAM
TERMINAL FROM CABLE No. TERMINAL TO
1 •-
2 •- CABLE 3A -• +VDC
TB1 — 7 •- 20 AWG/4/SHIELDED -• +RAI
8 •-
9 •-
0 -• -RAI
-• -VDC
— RAI
1 •-
2 •- CABLE 3B •+ +VDC
TB1 3 •- 20 AWG/4/SHIELDED -• +ROI
6 •-
9 •-
e -• -ROI
-• -VDC
ROI
1 •- CABLE 4 -• 1
3 •- 16 AWG/4/N0T SHIELDED -• 3
SCA-R4 — — TB2
7 •- -• 7
9 •- -• 9
WIRING DIAGRAM
TERMINAL FROM CABLE No. TERMINAL TO
CABLE 4A
3 •-
16 AWG/3/N0T SHIELDED
TB2 — 7 •- -• port(blk; NFU
9 •- -• stbd(wht;
CABLE 4B
1 •- 16 AWG/2/N0T SHIELDED NFU NFU/FFU
TB2 —V SWITCH
— VJ
FFU^ —'
NOTES: IF OPTIONAL NON FOLLOW-UP INPUT DEVICE \$ NOT REQUIRED THEN
CABLE 4B MAY feE OMITTED.
NFU/FFU SWITCH CONTACT MUST BE OPEN IN THE "NFU" POSITION
AND CLOSED IN THE "FFU" POSITION.
CABLE 5
-• 1
16 AWG/3/N0T SHIELDED
SCA-R5 -• 2 — RFU-R2
-• 3
Page 18 of 31
WIRING DIAGRAM
TERMINAL FROM CABLE No. TERMINAL TO
CABLE 6 BREAKER —
16 AWG/3/SHIELDED -*"VX/« +VDC
SCA-R6—
-• -VDC
-• -VDC
TO SHIP'S DC
POWER SUPPLY
FOR STEERING"
CONTROL
CABLE 8
+COMM 4-WAY
16 AWG/3/N0T SHIELDED DIRECTIONAL
RFU-R3— PORT
SOLENOID
STBD
Adjustments to the SCA 300 are made at the trimmer potentiometers (trim pots) located
on the amplifier's circuit board. Each trim-pot can be located by reading the labels on
the SCA 300's circuit board or by referring to Figure 12.
Factory Pre-settings
NOTE: These trim pot positions should be used before proceeding with amplifier
calibration. Multi-turn trim pots do not have hard stops at the end of their
25 turns of travel. They do, however, emit a ••clicking" noise when the end
of screw travel is reached.
WARNING: DO NOT LET THE STEERING GEAR GO ALL THE WAY HARD
OVER TO ITS MECHANICAL STOPS. READ THE FOLLOWING
INSTRUCTIONS BEFORE ATTEMPTING ADJUSTMENTS.
Page 20 of 31
RECEPTACLE 6
RAI GAIN
ROI GAIN
GAIN
• i r~a
FDBK t* I DEAD BAND
GAIN BAL ULAUtlANU
FASTER
SPEED
RECEPTACLE
2 NFU SPEED
ADJUSTMENT
RECEPTACLE
SLOWER
1
NFU/FFU.
RELAY
WIRE WOUND
RESISTOR
RECEPTACLE 4 RECEPTACLE 5 TAP AND
SET SCREW
NOTE: Jastram's input and output devices use plugs wherever possible in order
to eliminate a reversed polarity condition (e.g. indicators displaying
incorrect rudder direction). However, this condition may still occur where
plugs are not used. This section attempts to assist in identifying and
correcting a reversed polarity condition. If this condition exists, steps for
correction will be described later in the procedure.
a) Ensure all trim pots and jumpers are at the factory pre-set position.
b) Manually center the steering gear.
c) Place NFU/FFU switch in the NFU position. If optional NFU input device
is not installed, temporarily disconnect cable 5 at the SCA.
2. Application of Power
g) Slowly turn the FFU input device towards hard over while observing the
rudder movement; take care not to allow the rudder to reach its
mechanical hard over limit.
h) Adjust the FDBK GAIN trim pot in the SCA clockwise (CW) to reduce
rudder angle or counter-clockwise (CCW) to increase rudder angle. This
is to achieve a condition where the FFU input device is at hard over and
the rudder is a few degrees inside the desired internal limit angle (see
Fig. 2).
i) If oscillations continue turn the DEADBAND trim pot CW until oscillations
cease.
j) Carefully turn the FFU input device to the opposite hard over position and
ensure that the rudder stops a few degrees inside the desired internal
limit angle. Adjust FDBK GAIN trim pot CW as necessary to ensure
rudder does not reach its mechanical hard over limit.
k) Return FFU input device to center.
I) Place NFU/FFU switch in NFU position. If optional NFU input device is
not installed then turn off HPU.
a) With HPU on and NFU/FFU switch in FFU position confirm that port and
starboard operations of the FFU input device correspond to port and
starboard turns of the rudder. If this is not the case a reverse polarity
condition exists at the FFU input device. To correct for reverse polarity,
turn off HPU and DC power supply then refer to the FFU input device
owner's manual and reverse +V and -V connections.
b) Place NFU/FFU switch in NFU position. If optional NFU input device is
not installed then turn off HPU.
c) If Rudder Order Indicator (ROI) is not installed then proceed to step 8.
d) Turn FFU input device to hard over port and record angle displayed on
ROI.
e) Turn FFU input device to hard over starboard and record angle displayed
on ROI.
f) If the two recorded angles are acceptably balanced proceed to step 7.
g) Calculate the average of the two recorded angles.
h) Refer to FFU input device owner's manual and adjust potentiometer so
that the ROI displays the average angle,
i) Swing the input device to its hard over positions and confirm that the ROI
angles now match. If the ROI angles are still unacceptably unbalanced
repeat the above procedure from step (d).
Doc No.: MAN01502, 27-02-01 SCA 300 Manual
Setup and Testing ^engineering ltd.
Page 23 of 31
a) Confirm that port and starboard operations of the FFU input device
correspond to port and starboard indication on the ROI. If this is not the
case, a reverse polarity condition exists at the indicator. To correct for
reverse polarity, turn off HPU and DC power supply, then refer to the
indicator owner's manual and reverse +ROI and -ROI connections.
b) With the FFU input device at hard over adjust the ROI GAIN trim pot in
the SCA until the ROI displays the desired internal limit angle.
a) To confirm that the FFU input device is accurately centered turn the FFU
input device to hard over port and record angle of the rudder.
b) Turn FFU input device to hard over starboard and record angle of the
rudder.
c) Ifthe two recorded angles are acceptably balanced proceed to step (g).
d) Calculate the average of the two recorded angles.
e) Refer to FFU input device owner's manual and carefully adjust
potentiometer so that the rudder turns to the average angle.
f) Swing the input device to its hard over positions and confirm that the
rudder angles now match. If the rudder angles are still unacceptably
unbalanced repeat the above procedure from step (a).
g) With the FFU input device at hard over carefully turn the FDBK GAIN trim
pot CCW until the rudder turns to the desired internal limiting angle.
Check that the opposite internal limit angle corresponds.
h) Turn FFU input device to port and starboard and observe the rudder
movement. Ensure that the same amount of deceleration occurs during
both port and starboard turns. If amount of deceleration is unequal, re
adjust the BALANCE trim pot as described in section 8.
i) Turn the FFU input device from one hard over to other and time how long
it takes for the steering gear to complete the turn. If a slower FFU rudder
speed is desired turn the SPEED trim pot CCW until the desired rudder
speed is reached, then repeat section 8.
a) Confirm that port and starboard turns of the rudder correspond to port
and starboard indication on the RAI. If this is not the case, a reverse
polarity condition exists at the indicator. To correct for reverse polarity,
turn off HPU and DC power supply, then refer to the indicator owner's
manual and reverse +RAI and -RAI connections.
b) With the rudder at hard over adjust the RAI GAIN trim pot in the SCA until
the RAI displays the actual rudder angle.
11. Finishing
a) When all SCA 300 adjustments have been made and the system
performs satisfactorily, replace lid and tighten hold down screws.
b) Confirm that all heat shrink tubing boots are threaded tightly against the
plugs then unplug the SCA 300's cables and carefully heat the shrink
tubing attached to the plugs. This can be done with a torch at a low
setting. Allow the tubing to cool and replace plugs.
The SCA 300 is virtually maintenance free. No parts require routine maintenance.
Once a year open the cover of the SCA 300 and visually check for signs of corrosion. If
corrosion is apparent, replace corroded part. Ensure the lid is put on tightly.
The PCB does not require replacement unless it has been damage by corrosion,
excessive voltage or a failed component. Its replacement is simple and no special
tools are required. Care must be taken to ensure the working environment is free of
excessive moisture and metal particles or chips. When installing the new PCB, place a
small amount of thermal compound on the bottom of the regulator and transistor heat
sinks protruding from the underside of the PCB. Ensure that the mica insulating
washer and plastic shouldered bushing are properly installed to isolate the heat sink
from the enclosure backing plate. The new PCB should be secured with a small
amount of locktight on its fastener's threads - avoid getting locktight on anything but the
screw threads. Using an ohmmeter, confirm that the heat sinks are properly isolated
from the enclosure backing plate.
Relay
The NFU/FFU relay (FFU) is rated for 30,000 cycles. If the performance of the
NFU/FFU switch becomes intermittent, check the wiring and switch and if necessary
replace the relay.
Page 26 of 31
Page 27 of 31
5 TROUBLESHOOTING
The table below gives some general solutions for simple problems, If a
problem cannot be solved, contact Jastram.