Volvo IPS - Steering Fault

[jkhbay]

Volvo Penta: D4 300D-E; IPS-F; EVC D PCU

Lost all steering with the boat in an outing yesterday. Was positioning the boat on anchor using the helm joystick and the EVC unit went into alarm highlighting the Port IPS Unit in red. The two fault codes that were displayed are below:

Battery Voltage Low - "Low supply voltage to steering actuator" - MID: 250 PSID: 2 FMI: 4 OCC: 1 STATUS: Active
Battery Voltage Low - "Limited or no steering" - MID: 250 PSID: 168 FMI: 1 OCC: 1 STATUS: Active

Both alarms were acknowledged on the EVC but did not reset. Also tried to reset the alarms using an engine stop/start, master batteries off/on and a reset of the EVC using the throttle button and there was no change to fault status. As soon is the ignition is turned on (and whilst the EVC display is booting up), the audible alarm is active. Start battery banks for both engines are new and were fully charged.

Can not find any reference to the fault codes or fault type in the IPS Group 40 and D4/D6 Group 30 Workshop Manuals.

Can anyone provide any assistance to what the fault codes mean (and where to find a listing of them) and what the probable causes of the fault/s are? Any assistance greatly appreciated.

 

[SeaKiwi]

AI is your friend. Gemini provides the following on the first error:

That "Battery Voltage Low - 'Low supply voltage to steering actuator' - MID: 250 PSID: 2 FMI: 4 OCC: 1 STATUS: Active" error on your Volvo IPS system strongly indicates a problem with the electrical power supply specifically to the steering actuator. While the message mentions "Battery Voltage Low," the FMI code (Failure Mode Indicator) of 4 points to an issue with the voltage being below normal or low source.

Here's a breakdown of what each part of the error message likely means and the potential causes:

• MID: 250: This likely identifies the specific electronic control unit (ECU) reporting the fault. In Volvo Penta systems, MID 250 often relates to the Electronic Vessel Control (EVC) system, which manages various functions including steering.
• PSID: 2: This is a Parameter Specific Identifier. For EVC systems, PSID 2 commonly refers to the steering system.
• FMI: 4: This is the Failure Mode Indicator. FMI 4 means "Voltage below normal or low source." This is the most crucial part of the message, indicating an insufficient voltage supply.
• OCC: 1: This indicates the number of times this fault has occurred.
• STATUS: Active: The fault is currently present.

Likely Causes:

Given the FMI 4 code, the issue is most likely related to the power supply to the steering actuator itself, rather than a general low battery voltage across the entire system (although that could be a contributing factor). Here are the most probable causes, ranging from simple to more complex:

1. Poor Connection at the Steering Actuator:
   • Loose or corroded electrical connectors at the steering actuator. This is a very common cause of voltage drops.
   • Damaged wiring or terminals at the actuator.
2. Faulty Wiring Between the EVC/Power Distribution and the Steering Actuator:
   • A break or short in the wiring harness supplying power to the actuator can cause a voltage drop.
   • Chafed or damaged insulation leading to resistance in the circuit.
3. Issues with Relays or Fuses:
   • A faulty relay responsible for supplying power to the steering actuator might be failing to provide sufficient voltage.
   • A partially blown or corroded fuse in the steering actuator's power circuit could be restricting current flow and causing a voltage drop.
4. Low General Battery Voltage (Less Likely as the Primary Cause but a Contributor):
   • While the FMI points to a local voltage issue, a significantly low overall battery voltage can exacerbate any existing resistance in the steering actuator's power circuit, leading to this error. Check the main battery voltage with a multimeter. It should be within the specified range for your Volvo Penta system.
5. Faulty Steering Actuator:
   • In some cases, an internal fault within the steering actuator itself could be drawing excessive current, leading to a voltage drop in its power supply. This is less common but possible.
6. Problem with the EVC System or Power Distribution Module:
   • Although less likely given the specific FMI code, a fault within the EVC unit or a power distribution module supplying the steering actuator could be the source of the low voltage.

Troubleshooting Steps:

It's recommended to have a qualified marine technician diagnose this issue, but here are some initial checks you or they might perform:

1. Check Battery Voltage: Verify the overall battery voltage with a multimeter to rule out a simple low battery issue.
2. Inspect Connections at the Steering Actuator: Carefully examine the electrical connectors at the steering actuator for any signs of looseness, corrosion, or damage. Clean and tighten them as needed.
3. Trace Wiring: Inspect the wiring harness leading to the steering actuator for any visible signs of damage, chafing, or breaks.
4. Check Fuses and Relays: Locate the fuses and relays associated with the steering system (refer to your Volvo Penta documentation) and check their condition.
5. Voltage Drop Test: A technician can perform a voltage drop test along the power supply circuit to the steering actuator to pinpoint areas of high resistance.
6. Actuator Test: A Volvo Penta diagnostic tool can be used to test the functionality of the steering actuator and its current draw.

In summary, the "Battery Voltage Low - 'Low supply voltage to steering actuator' - MID: 250 PSID: 2 FMI: 4" error strongly suggests a localized issue with the power supply to the steering actuator, most likely due to a poor connection, faulty wiring, or a problem with a related fuse or relay. While low overall battery voltage could contribute, it's unlikely to be the sole cause given the specific FMI code.

It's crucial to address this issue promptly as it directly affects the vessel's steering capabilities and safety. Contacting a certified Volvo Penta service technician is highly recommended for accurate diagnosis and repair.

 

[jkhbay]

Thankyou SeaKiwi. A great tip to use Google AI! Problem resolved. The 50A circuit breaker mounted on the motor feeding the power supply cables for the Power Steering Unit (PSU) was open circuit and wouldn't reset. On removal of the circuit breaker, I tested the cables prior to installing a new circuit breaker and found a short circuit. The positive cable from the circuit breaker to the PSU had chafed between the fuel cooler and the block causing a short circuit. The power cable to the circuit breaker was sheathed in a tube but the cable from the circuit breaker was not sheathed. I checked the starboard motor, and the cable was also not sheathed. Both cables will now be sheathed.