Final drawing
Customer : HYUNDAI HEAVY INDUSTRIES CO., LTD.
Hull No. : 8052
Type : AOC−300 (HIGH DAMPING On/Off)
6 x 300 Cylinder
with air supply
Control Air 5~9bar
It is changeable depends on ship’s condition.
G
Home−page : http://www.gc−tech.com
Tel : +82 52 268 ~ 5656 Fax : +82 52 265 ~ 7887
page 2
INDEX
NO. DESCRIPTION PAGE
1. General specification 3
2. Technical description 4
3. Function description 5~6
4. Installation 7~9
5. Top bracing operating procedure 10
6. Top bracing off setting procedure 10
7. Maintenance 11
8. Assembly & Allowable Misalignment 12
9. Drawings 13
Lay-out of top bracing 14
Air connection diagram for top bracing 15
Electric diagram for top bracing 15A~C
Control panel for top bracing 15D~E
Diaphragm hydropneumatic accumulator 16
Top bracing(GC-981116) 17
Top bracing(GC-981113) 18
Top bracing(GC-981112) 19
Manifold (GC-981118-4) 20
10. Spares list for hydraulic top bracing 21
11. Tools for hydraulic top bracing 22
12. Accumulator N2 GAS check & charging procedure 23~24
13. Alignment setting procedure 25~28
14. Panel rpm setting procedure 29~30
Green & Clean Technology Co., Ltd. AOC-300
page 3
General specification
1. Type : AOC-300.
2. Assembly drawing : refer to drawing GC-981112.
3. Dimension drawing with part list : GC-981116.
4. AOC-300 function description : GC-981113.
5. Air connection diagram : GC-981115-4.
6. Force to a air cushion at 5 ~ 9 bar : 35.3 KN ~ 63.5 KN
7. Max. force at relieving pressure (26 bar) : 183.8 KN (18.7 Ton).
8. Air connection port : Φ10 copper pipe or Φ10 steel pipe connector.
9. Foundation bolts : 10 pcs Hex-bolts (M16 x 45L).
10. Valve block : Consists of with 1 relief valve,
1 test coupling and 1 accumulator with stop valve.
11. Type of hydraulic oil : Standard hydraulic oil, ISO VG 32.
* Recommend oil chart
- MOBIL:MOBIL DTE 10 EXCEL 32
- SHELL:SHELL TELLUS OIL S32
- CASTROL:HYSPIN AWS 32
- BP:ENERGOL SHF 32
- TOTAL:AZOLLA ZS 32
(Top-Bracing is deliverd with oil filled condition)
12. Volume of oil : 6 liter per cylinder.
13. Size of air supply pipe : Φ10 steel pipe.
14. Weight : Approximately 220 kg/cyl (with oil).
15. Operating temperature : Max. 75℃.
16. Installation tolerance : Max. +15 mm.
17. Accumulator set pressure : 15 bar. (1.5 MPa)
18. Relief valve set pressure : 26 bar. (2.6 MPa)
19. Air set pressure : 5~9 bar. (0.5~0.9 MPa) changeable depends on ship's condition.
20. Paint color : LT313 - 7.5BG 7/2
Green & Clean Technology Co., Ltd. AOC-300
page 4
Technical description
By means of top bracing the main engine, it will in most cases be possible to
obtain such a high natural frequency of the system "engine - ship's side -
ship's bottom" that annoying vibrations of the engine top or ship's hull will be
eliminated.
The so-called guide force moments are caused by the transverse reaction
forces acting on the crossheads due to the connecting rod/crankshaft
mechanism. When the piston of a cylinder is not exactly in its top or bottom
position, the gas force from the combustion, transferred through the connecting
rod will have a component acting on the crosshead and the crankshaft perpen-
dicularly to the axis of the cylinder. Its resultant is acting on the guide shoe
(or piston skirt in the case of a trunk engine), and together they form a guide
force moment.
The moments may excite engine vibrations moving the engine top athwartships
and causing a rocking (excited by H-moment) or twisting (excited by X-moment)
movement of the engine.
For engines with fewer than seven cylinders, this guide force moment tends to
rock the engine in transverse direction, and for engines with seven cylinders
or more, it tends to twist the engine. The guide force moments are harmless
to the engine, however, they may cause annoying vibrations in the superstruc-
ture and /or engine room, if proper countermeasures are not taken.
(The guide force moments are harmless except when resonance vibrations
occur in the engine/double bottom system.)
The hydraulic top bracing is designed as an adjustable connection which allows
adjustment in accordance with the loading conditions of the ship.
Green & Clean Technology Co., Ltd. AOC-300
page 5
TOP-BRACING ON/OFF
Such the preceding reasons, the top bracing is installed to solve vibrations casued by
several problems during sailing. However, sometimes in one particular area to cause
resonance vibration produces greater due to top bracing. (see the picture below.)
This is causing a bigger problem to solve is stop the operation of top bracing in the range.
Function Description (In case of TOP-BRACING ON)
(see Dwg. GC-981113 )
The top bracing can be installed :
On one side (exhaust side or camshaft side)
Both side of engine.
On one side with fore or aft and both side with fore or aft.
depending on the circumstances & requirements.
When the force from engine and/or hull is less than 35.3~63.5 KN,top bracing keeps
preadjusted condition.
But, the force is between 35.3~63.5 KN and 183.8 KN, oil pressure in primary chamber
will increase.
In this case, accumulator absorbs the force.
Green & Clean Technology Co., Ltd. AOC-300
page 6
When the force from engine and/or hull is higher than setting
pressure of relief valve(force : 183.8 KN), the relief valve is open.
At the same time, oil in primary chamber flows to secondary chamber.
During the oil in primary chamber flows to secondary chamber,
the secondary piston move backward until the pressure of secondary
and air chamber is equal.
So, air chamber absorbs the force.
When engine and hull moves away from each other(negative force)
the oil pressure in primary chamber is decreased.
At the same time, compressed air in air chamber push the
secondary piston forward and the oil in secondary chamber flows
back to primary chamber through the check valve until the pressure
in primary, secondary and air chamber is equal.
Ship's M/E starting air to be fed to all the top bracing installed parallely
through a pressure regulating valve.
*Do not feed the moisture-laden air which may cause a rust occurrence.
Function Description (In case of TOP-BRACING OFF)
Using the 3-way valve and solenoid valve, the supplied air and oil pressure of top bracing
must be turned off to stop operation.
And then, they are working through E.C.R is controlled by signals.
T/B(1)
T/B(2)
T/B(3)
E.C.R J/B (oil pressure release)
T/B(4)
(air release) T/B(5)
T/B(6)
MANI FOLD
Green & Clean Technology Co., Ltd. AOC-300
page 7
Installation.
1. It is recommended to study this installation manual before commencing
the installation work.
2. Review the drawing of scope of supply with the parts supplied.
Check if they are identical and there are any missing parts.
3. Measure the distance between beam of hull and gallery beam of engine.
The distance should be within NO.1,2,4,5,6-965±30 NO.3-665±30 mm.
(To adjust the length of top bracing using the transfer barrier after loosening fixing bolt)
a) In case of the distance is too short.
It is recommended to cut the gallery beam to meet the required distance.
b) In case of the distance is too long.
It is recommended to apply a adaptable plate on to gallery beam.
4. The supporters must be removed after installation top bracing.
Green & Clean Technology Co., Ltd. AOC-300
page 8
5. Check the leveling of vertical & horizontal direction by using level
gauge and weld the plates.
6. Do final treatment about welding spartters and painting.
7. Install the top bracing according to the following guide.
a) Between center line of cylinder and barrier should be kept as below.
1) Tighten the bolts of welding plates. Adjust the transfer barrier and lock nut.
Then tighten the fixing bolt(pos. no. 30) on transfer barrier.
2) Install the pipe as shown on the pipe diagram.
Connect the pipe to air connection port.
(refer to drawing GC-981115-4)
3) Supply air and adjust to 5∼9 bar.
Green & Clean Technology Co., Ltd. AOC-300
page 9
b) Piston setting and air venting
Standard position
Standard line Plug Test coupling
Cyl' stroke indicator
Position mark Air chamber
Primary chamber
air oil oil
Red band Secondary chamber
Green band
Indicator on ram
Fig - A
Air connector Oil filling coupling
1) Stop air supply.
Ram out position 2) Connect hyd' hose to test coupling.
3) Tighten up the transfer barrier and lock nut
until the green band meet position mark.
Adjust bolt During this work, air will be come out first
then oil will be come out through hyd' hose.
(primary chamber air venting)
Lock nut 4) Disconnect the hyd' hose from test coupling
when 3) is done.
5) Check the position of secondary piston
air oil oil byy cyl'
y stroke indicator.
6) Loosen up the plug a little on the valve
block for secondary chamber air venting.
Transfer 7) If cyl' stroke indicator is shorter than the
barrier Drain oil
end of position mark, fill oil to secondary
chamber until cyl' stroke indicator meet
the end of position mark.
Fig - B If cyl' stroke indicator is longer than the
top of position mark, supply air to air
chamber over 4bar. Do 2) to secondary oil
filling coupling then oil will be come out.
Drain oil until cyl' stroke indicator meet
the end of position mark.
Ram in position 1) Connect hyd' hose to primary oil filling
coupling and drain off until oil is not
coming out.
2) Loosen up stoppper and transfer barrier
enough.
3) Supply air over 4bar, until the green
air oil oil band meet the end of position mark.
Then stop air supply.
4) Do 3) In order of Fig-B.
5) Do 4), 5) In order of Fig-B.
Fill oil
Fig - C
Green & Clean Technology Co., Ltd. AOC-300
page 10
Top bracing operating procedure
1. Before top-bracing operating, confirm the following works which should be
completed to activate top-bracing.
1) Pipes for air supply are connected to top-bracing.
2) Ready to use control air(5~9bar).
3) Piston position setting is completed.
(Refer to piston setting and air venting)
2. Loosen up the transfer barrier and lock nut by using torque bar until they are tight
each other.(Make the position of key way and fixing bolt hole to fix the distance
of the transfer barrier and lock nut)
3. Tighten up the fixing bolt.
4. Set the air supply pressure 5~9 bar.
5. Check the piston position.
(If the position of piston are on standard line after air venting , top-bracing activation
is finished. But, if there is a change in position of pistons, refer to piston
setting and air venting to adjust piston position)
Top bracing off setting procedure
1. Close the stop valve in supply line from control air line.
2. Open the stop valve(air drain) side the manifold.
3. Close the stop valve below the accumulator.
4. If you want to activate top-bracing again, set the air pressure 5~9 bar. Then open the
stop valve below the accumulator.
5. Check the piston position.
(If there is a change in piston position, refer to piston setting and venting to adjust
piston position)
Green & Clean Technology Co., Ltd. AOC-300
page 11
Maintenance (Refer to as following before any action.)
Service in shop
Step 1 To remove the top bracing from place of installation
a) Open the air-port on the side of the top bracing. This release the
top bracing air pressure and prevent the elongation of the top bracing
cylinder when taken off the flange. Loose the adjustment nut.
b) Secure the barrier flange jig(Tool No.1-2) between cylinder cover &
bearing cover. And sling on eye bolt & hoist it away.
NOTE: The top bracing weight approximately 220kg.
The top bracing should be taken to avoid a drop. Do not lift the
transfer barrier & lock nut when pulling the top bracing away from
the flange.
Step 2 Opening the top bracing cover.
a) Open all oil filling & bleeder ports and drain for oil and fit
a compressed air hose to the air inlet and pressurize to approxi-
mately over 1bar, as this will push the secondary piston down/squeezing
any remaining oil out of the cylinder.
Step 3 Open the cylinder as following instruction and check with the drawing.
a) Remove the cylinder cover
b) Apply over 1 bar air into primary chamber to lift up complete inner
construction.
c) The secondary piston can be removed by hand lifting.
d) Remove all bearing and seals and fit new ones from the seal kits.
e) Check for damage to all chromium coated surfaces and report if any
surface looks worn but usable if scratches look too deep, the part
should be replaced.
Maintenance Period
HOW TO CHECK
ITEM CHECK POINT CHECK PERIOD
Cyl.stroke The end of two
OIL LEAKAGE indicators have
indicator & to be between Every one
SEAL CONDITION Position mark the red bands month
Top of the the manual for
N2 CONDITION accumulator ‘GAS-FILLING Every six months
Green & Clean Technology Co., Ltd. AOC-300
page 12
Assembly
a) Assemble secondary piston into ram.
b) Insert complete inner construction into cylinder.
Use the jig provided to insert the inner complete construction
specially when the wear ring are renewed.
c) Close the cylinder cover and tighten hex bolts.
Allowable Misalignment :
Top Bracing Length Allow. Misalignment
575 ± 15 mm +/- 20 mm
610~999 ± 50 mm +/- 30 mm
1000 ± 50 mm +/- 50 mm
Green & Clean Technology Co., Ltd. AOC-300
page 13
DRAWINGS
DRAWINGS
DRAWING NO. TITLE REV.
GC-981114 Lay-out of Top-bracing 0
GC-981115-4 Air connection diagram for Top-bracing 1
GC-981115A Electric diagram for Top-bracing 4
GC-981115B Electric diagram for Top-bracing 1
GC-981115D Electric diagram for Top-bracing 1
GC-091110A Control panel for Top-bracing 0
GC-091110B Control panel for Top-bracing 0
GC-981117 Diaphragm hydropneumatic accumulator 1
GC-981116 Top-bracing (Part List) 3
GC-981113 Top-bracing (Function Description) 0
GC-981112 Top-bracing (Dismantling Drawing) 0
GC-981118-4 Manifold 0
Green & Clean Technology Co., Ltd. AOC-300
VIEW "A" Welding plate
Oblong mounting holes
for vertical alignment.
"A" Adjustment of length:
Unscrew fixing bolt(pos. no. 30)
Bearing adjust the lock nut and
(spherical axial) transfer barrier with torque bar.
Retighten fixing bolt.
Torque bar
Transfer barrier
Indicator on ram Lock nut
Green band
Cylinder stroke indicator
Red band
Position mark
Valve block with
Secondary piston
relief valve
Air port
Primary piston
Oil port
"B" Accumulator
with valve
Welding plate
Oblong holes for horizontal alignment.
VIEW "B"
G
G
Max allowable
alignment difference
G
pic.1 pic.2 pic.3
pic.4 pic.5 pic.6
1. Open the cap of accumulator. (pic.1)
(Accumulator의 Cap을 제거한다.)
2. Loosen the half a degree off by using 6mm wrench. (pic.2)
(6mm L-렌츠을 이용하여 꽉 조여있는 Bolt를 살짝만 풀어준다.)
3. Take out N2 gas regulator from kit, install after checking left side
valve close. (pic.3,4)
(측면밸브를 반드시 잠근 후 N2 gas regulator를 Accumulator 상단에 조
립한다.)
4. Open upper valve of N2 gas regulator. (pic.5)
(N2 gas regulator 상단의 밸브를 열어준다.)
5. Can be checked the valve gauge bar, opening upper valve. (pic.6)
(질소가스 확인)
* Disassemble is reverse.
6. Close the upper valve of N2 gas regulator. (pic.5)
(N2 gas regulator 상단의 밸브를 잠근다.)
7. Take off N2 gas regulator. (pic.4)
(N2 gas regulator를 분리한다.)
8. Close the by using 6mm wrench. (pic.2)
(6mm L-렌츠를 이용하여 볼트를 꽉 잠근다.)
9. Close the cap of accumulator. (pic.1)
(Cap을 다시 조립한다.)
pic.1 pic.2 pic.3
pic.4 pic.5 pic.6
pic.7 pic.8 pic.9
1. Open the cap of Accumulator. (pic.1)
2. Loosen the half a degree off by using 6mm wrench. (pic.2)
3. Take out N2 gas regulator from kit, install after checking left side valve close.
(pic.3,4)
4. Open the upper valve of N2 gas regulator. (pic.5)
5. Take out the hose from the kit, connector to N2 gas bottle by using 27mm
spanner. (pic.3,6)
6. Connect the hose to the right connector of N2 gas regulator by using 17mm
spanner. (pic.7)
7. Charge N2 gas more than 15bar by adjusting N2 GAS bottle valve. (pic.8)
8. When opening the left side valve of N2 gas regulator, n2 gas deflate when
setting up at 15bar with adjusting valve. The setting is finished. (pic.9)
* Disassemble is reverse.
9. Close the left side valve of N2 gas regulator. (pic.9)
10. Close the upper side valve of N2 gas regulator. (pic.5)
11. Take off N2 gas regulator. (pic.4)
12. Close the by using 6mm wrench. (pic.2)
13. Close the cap of accumulator. (pic.1)
HYD.TOP BRACING SETTING MANUAL
1. BEFORE ALIGNMENT SETTING In case of On/Off type
Select Manual mode and then, Off mode
PIC.1 PIC.2 PIC.3
PIC.4 PIC.5 PIC.6
1) To stop the supply air to the Top bracing, set the air pressure at '0' bar. (PIC.1)
2) Relief valve pressure release
- Even the supply air is stopped, the internal pressure in 'Top bracing' is still remained by 'Relief valve'.
To release the internal pressure, first use the 25mm spanner to detach the Locker. (PIC.2)
- Before opening the Adjust bolt fully, you must check the remaining numbers of thread to reset the
Relief valve pressure. (PIC.3)
- Open the Adjust bolt fully by using the 6mm spanner. (PIC.4)
3) Loosen the Fixing bolt by using the 6mm wrench. (PIC.5)
4) Loosening Lock nut & Transfer barrier.
- It is possible to adjust the Top bracing alignment after loosening the Lock nut & Transfer barrier
which transfer the Main engine force to Top bracing. To carry out this work, you need 'Tool No.1-3
Torque bar'. Turn the transfer barrier clockwise direction. When you can move the Lock nut &
Transfer barrier by hands
hands, it is well enough loosen
loosen. (PIC
(PIC.6)
6)
2. ALIGNMENT ADJUSTMENT & MEASUREMENT METHOD
:
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# MEASUREMENT METHOD
: TO GET THE ALIGNMENT DATA USE THE STEEL RULER ACCORDING TO ABOVE FIGURE. THE 'A' IS THE
DIFFERENCE BETWEEN THE O.D OF RAM & O.D OF BEARING COVER. 'A' SHOULD BE 2.5mm, IF THE
ALIGNMENT IS ON THE CENTER LINE. SO, CHECK THE 'A' DATA, THEN SUBTRACT 2.5mm FROM THE
CHECKED DATA. IT WILL BE THE ALIGNMENT DIFFERENCE.
PIC.1 PIC.2 PIC.3
PIC.4 PIC.5 PIC.6
1) Adjust the horizontal alignment
1-1) Measure the horizontal alignment by using the steel ruler. (PIC.1)
1-2) Loosen the all bolts to the hull side. (PIC.2)
1-3) Adjust the horizontal direction by using the driver. (PIC.3)
Remeasure the horizontal alignment by using the steel ruler
ruler. (PIC
(PIC.1)
1)
Tightening the all bolts. (PIC.2)
2) Adjust the vertical alignment
2-1) Measure the vertical alignment by using the steel ruler. (PIC.4)
2-2) Loosen the all bolts to the engine side. (PIC.5)
2-3) Adjust the vertical direction by using the driver. (PIC.3)
Remeasure the vertical alignment by using the steel ruler
ruler. (PIC
(PIC.4)
4)
Tightening the all bolts. (PIC.5)
3. PISTON SETTING AND AIR VENTING
RAM OUT POSITION PIC.1 PIC.2
RAM IN POSITION PIC.3 PIC.4
PIC.7 PIC.8
< RAM OUT POSITION >
1) Tighten up the Transfer barrier & Lock nut until the green band meet position mark. (PIC.8)
Turn the Transfer barrier anti-clockwise direction. (PIC.1)
< RAM IN POSITION >
1)) Loosen upp the Transfer barrier & Lock nut enough.
g
Turn the Transfer barrier clockwise direction. (PIC.3)
2) Supply air over '4' bar until the green band meet the end of position mark. (PIC.8)
3) Then stop air supply
4) If the position mark is not on the green band, please repeat this work procedure.
< OIL FILLING >
1)) To connect the fillingg hose with connector which was supplied
pp (p no.1-1)) to the test
in Tool box(part
coupling of secondary chamber. (PIC.2)
2) To fill oil into the secondary chamber until the end of the Cyl.stroke indicator meet to the green band.
< AIR VENTING >
1) To supply air over '4' bar and connect the pressure gauge hose(part no.1-8) to the test coupling of
the Valve block. (PIC.4) During this work, air will be come out first then oil will be come out through
the hose.
2) If the Cyl.stroke indicator position is not on the green band, please repeat this work procedure.
# The Cyl.stroke indicator position is normal between red bands.
4. AFTER ALIGNMENT SETTING In case of On/Off type
Select Manual mode and then, On mode
PIC.1 PIC.2 PIC.3
PIC.4 PIC.5 PIC.6
PIC.7
1) During the position setting, the key way & the Fixing bolt hole should be in line. (PIC.1)
2) Tightening the Fixing bolt by using the 6mm wrench. (PIC.2)
3) Setting the Relief valve by using the 6mm spanner. (PIC.3)
4) Relief valve for first time the thread of screw is the same. (PIC.4)
5) Assembly the Locker by using the 25mm spanner. (PIC.5)
6) Open the stop valve of accumulator fully. (PIC.7)
7)) To make the Top
p bracing
g normal working
g condition, supply
pp y the air at '5~9' bar. (PIC.6)
( )
*It is changeable depends on ship's condition.
Initial panel settings
1. LEVEL-Push for more than 3 seconds. 11. MODE-PUSH
2 SHIFT-PUSH
2. SHIFT PUSH 12 SHIFT-PUSH
12. SHIFT PUSH
N/A
3. MODE-PUSH 13. SHIFT-PUSH Push the UP button "00000"
4. SHIFT-PUSH 14. MODE-PUSH
5 MODE-PUSH
5. MODE PUSH 15 SHIFT-PUSH
15. SHIFT PUSH Push the UP button "HI-LO"
"HI LO"
6. SHIFT-PUSH Push the UP button
*This value changes according to the BMS 16. MODE-PUSH
output signal. EX) -100,
100, -120,
120, -150
150
7. MODE-PUSH 17. SHIFT-PUSH Push the UP button "HI"
8. SHIFT-PUSH 18. LEVEL-Push for more than 3 seconds.
Settings completed
9 MODE-PUSH
9.
10. SHIFT-PUSH Push the UP button
*This value changes according to the BMS
output signal. EX) 100, 120, 150
PROCEDURE OF RPM SETTING
EX)
BUTTON
1. TOP-BRACING OFF MODE(70~75RPM)
HIGH - 75 LOW - 70
2. ALWAYS TOP-BRACING ON MODE
BUTTON HIGH - 0 LOW - 0
BUTTON
(HIGH RPM SETTING)
BUTTON
BUTTON
BUTTON
(LOW RPM SETTING)
BUTTON
BUTTON
