Berg Propulsion CPP System BCP/HDX Operation & Service Manual – ERC3000 Propeller Control

Description

Berg Propulsion CPP System BCP/HDX Operation & Service Manual

This is the Berg Propulsion operation and service manual for the BCP controllable pitch propeller system and the HDX hydraulic pitch control unit, written for the vessels GMS110 and GMS111 and covering propeller sizes across the BCP range. The document brings together the full service book: the propeller and shafting, the hub design, the OMC oil pressure coupling, the oil pipe assemblies running through the shaft and gear, the OD box and oil distributor, the hydraulic pressure and lubrication oil system, the ERC3000 remote control system, the propeller system alarm scheme, spare parts and special tools.

Everything a chief engineer, superintendent or yard service technician needs to install, operate, commission, adjust and repair the CPP installation is contained in these pages — not a general textbook on controllable pitch propellers but the Berg Propulsion service book for this specific machinery.

File Details

• Manual type: Operation and Service Manual (service book)
• Brand: Berg Propulsion AB (Öckerö, Sweden)
• Equipment: Controllable Pitch Propeller system, type BCP with HDX pitch control unit
• Control system: ERC3000 electronic remote control
• Language: English
• Format: PDF
• Length: 290 pages
• Document reference: P3-32267 (ERC3000 remote control system drawing set), P4-31976 (shaft speed sensor), P3-31843 (sensor arrangement), P4-32227 / ASL32227 (propeller system alarms)
• Vessels referenced: GMS110, GMS111 (Berg order no. 5719, 5720)
• Publication date shown on drawings: 2008

Chapters Covered

• 1 Technical Specification — propeller and hub, tail shaft, hydraulic system data
• 2 Propeller and Shafting
  • Type of delivery, installation of blade, installation of propeller shaft
  • Oil filling of hub, locking of screws and plugs before launching
  • Check of correct mounting of blade
• 2.2 Hub Design — exploded hub assembly and parts list
• 2.3 Oil Pressure Coupling Type OMC
  • Introduction, scope of supply
  • Mounting instruction, dismounting instruction
• 2.4 Oil Pipes
  • Pipe in shaft, installing OD-box male coupling into pipe assembly
  • Installing the gear shaft pipes, examples of different possible combinations
• 2.5 OD Box
  • Description and design of the OD box, pipe connections
  • Installation by the yard, installation by the Berg representative
• 2.6 Lubrication and Hydraulic Oil
  • Recommended oil types, oil filling from main tank
  • Oil drainage of hub, locking of plug
• 2.7 Oil Circulation — separated lubrication and pitch setting circuits
• 2.8 Appendix — drawings and part lists
• 3 Accessories
  • Sterntube seals — IHC Supreme type STA-300-D (aft) and STF-280 (forward)
  • Sterntube and sterntube bearings — Cedervall instruction manual
  • Rope guard, shaft earthing device (BAC), net cutter
• 4 Hydraulic System Type BCP with Hub Lubrication System
  • General description, pitch control unit oil distributor
  • Pressure oil system, propeller hub lubrication oil system
  • Water saturation measuring, hub lubrication oil filter, shut off valve, flow sensor, header tank
  • Hub lubrication system fault alarm, oil recommendations
  • Emergency control and pitch blocking (take home device)
  • Hydraulic pumps, water sensor and flow switch, routine service
• 5 Remote Control System ERC3000
  • General description, system configuration
  • Operation of controls — bridge main panel, bridge aux panels, engine room
  • Operation, activating the system, pitch and engine speed control, emergency pitch control
  • Command transfer system, manoeuvring, backup control and pitch indicating system
  • Load control system, additional functions
  • System configuration and technical data, interfacing of components
  • Parameter setting and fault diagnosis, ERC3000 internal alarm list
  • Clutch control and shaft speed indication
• 6 Supervising System — propeller system alarm drawings and alarm setting list
• 7 Spare Parts — ordering information, filter inserts FV2011, FV2025
• 8 Special Tools — blade screw spanner VA1040, mounting equipment for OMC coupling VA90871, spanner for shaft nut VA16567-1

Read end to end, the manual walks through the whole life of the CPP: from the sea trial data stamped on the tail shaft and hub, through the OMC coupling drive-up procedure with its 20 mm marking line, into the oil pipe cassette inside the hollow-bored shaft, then out through the OD box on the front of the gearbox where the feedback arm drives the potentiometers and micro-switches that feed the ERC3000. Separate chapters handle the IHC Supreme sterntube seals with their lip-seal overhaul, liner machining and spring-shortening tables, the Cedervall sterntube bearing chockfast installation, and the BAC shaft earthing device with its millivoltmeter readings and silver graphite brush maintenance. The ERC3000 section is fully documented — bridge main, bridge wing and engine room panels, combinator curve and constant speed mode, load control, command transfer, backup control, and the complete internal alarm list with fault diagnosis codes for the PLC, expansion boards and field wiring.

Technical Data at a Glance

• Propeller: Type BCP 850, 4 blades, diameter 3500 mm, material Cu Ni Al Bronze, rotation CCW, BV Ice Class, rated power 2610 kW, max shaft speed 183 RPM
• Tail shaft: Length 5783 mm, diameter 270/260/250 mm, hollow bore 105 mm
• Hydraulic system: Denison PV29 pump, VEM 3-phase 4-pole motor, calculated pressure 38 bar, working pressure 45 bar
• Hub lubrication: Header tank 35 L, circulation flow approx. 1 L/min, main system feed approx. 3 L/min, hub lubrication system alarm at flow 2 hours, saturation > 80% for > 1 hour
• Shaft speed sensor: Inductive proximity switch, 10–30 VDC, DC NPN, IP67, flange coupling bolt count entered in PLC
• Sterntube bearings: Aft bearing shaft dia. 240 mm / outer dia. 310 mm / length 588 mm; Fwd bearing shaft dia. 230 mm / outer dia. 300 mm / length 290 mm

What This Manual Lets You Do

With this Berg Propulsion service book in hand you can commission the OMC coupling correctly with the hydraulic jack and injectors, torque the blade screws and lock the plugs before launch, fill and drain the hub, and set up the oil circulation and header tank so the blade seals see their correct pressure. It supports the full sterntube seal overhaul — measuring liner run-out, machining the running surface to 0.2–0.8 µm Ra, shortening the lip seal springs by the table values when the diameter is reduced, and re-doing the zero wear down measurement at each docking. It lets you calibrate the ERC3000 parameter pages for lever signals, zero pitch and load limit, tune the combinator curve and delay programs, and read the internal alarm list to trace a control failure to a specific PLC module or field device.

These are the procedures that sit behind the specific torque and pressure numbers on the vessel, and they are not something to substitute from a generic hydraulic handbook. The ERC3000 parameter settings in particular are the ones that prevent overshoot, hunting and pitch feedback alarms — using the values printed here is what keeps the propeller on the combinator curve through a manoeuvre.

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Instant PDF Delivery

The file is a PDF download, delivered straight after checkout — no shipping, no waiting on a courier. Open it on any PC, laptop, tablet or phone, search the chapter you need on the bridge laptop or print the drawing pages for the engine room file. Whether you are troubleshooting an OD box feedback fault, planning a sterntube seal renewal in the next docking, or just want the Berg alarm setting list to hand when the CPP control failure lamp comes on, this is the document.