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HPU200 Hydraulic Power Units

Kobelt Manufacturing Co. Ltd.

Rev B

MNL-HPU200

13 of 36

Figure 4: Connections in Top Face of Hydraulic Manifold

(4) four hydraulic connections are required:

•

Connect ports ‘

CYLINDER

’

to the (2) two steering cylinder ports. It is not critical to

identify which of the steering lines is Port or Starboard as most new autopilots will
determine the pump direction and program the drive outputs to suit.

•

Connect the ‘T

ANK

’ port to the

to pump suction line with recommended in line filter.

•

Connect the ‘PRES

S

URE’ to the pump.

3.3

E

LECTRICAL

The pump unit is manufactured for operation from 12VDC, 24VDC, or 115/208-230VAC supply
voltages. Ensure that the unit has been ordered for the required operating voltage. The
electrical junction box contains a terminal strip with connections to the port, starboard, and
speed control solenoids located on the manifold.

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Содержание Accu-Steer HPU200

Страница 1: ...Kobelt Manufacturing Co Ltd HPU200 Accu Steer Hydraulic Power Unit Owner s Operation Installation Maintenance Manual January 2020 ...

Страница 2: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 2 of 36 NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model Serial Date of Purchase Date of Installation ...

Страница 3: ...11 3 1 Mechanical 11 3 2 Hydraulic 11 3 3 Electrical 13 4 Commissioning 18 4 1 Hydraulic Fill Bleed 18 4 2 Electrical Check 18 4 3 Functional Test 19 5 Operation 20 6 Maintenance 21 6 1 Preventative Maintenance 21 6 2 Recommended Spare Parts 22 7 Troubleshooting 23 8 Warranty 24 9 Appendix A Installation Dimensions 25 10 Appendix B Parts List 26 11 Appendix C Manifold Assembly Parts 31 12 Appendix...

Страница 4: ...cted for use it should be tested by the user to ensure proper function in all possible applications For further instructions please contact our distributors or visit our website 1 2 SAFETY 1 2 1 Safety Alerts Throughout this manual the following symbols and their accompanying explanation are used to alert the user to special instructions concerning a service or operation that may be hazardous if p...

Страница 5: ...lified personnel are persons who are familiar with the assembly installation commissioning and operation of the product and who have the qualifications necessary for their occupation Observe all specifications in this manual If these guidelines are not followed and damage occurs the warranty will be voided 1 2 3 Product Hazards High Pressure Operation This HPU unit generates high pressure hydrauli...

Страница 6: ...ion This unit is available in a wide range of voltages and flows for both standard and custom requirements HPU series are suitable for vessels from 30 to 150 in length depending on the vessels steering characteristics Proper pump selection is very important to optimize performance Figure 1 HPU200 Overview Diagram 2 1 COMPONENTS The Accu Steer Hydraulic Power Unit is a complete assembly consisting ...

Страница 7: ...el gears and a high pressure shaft seal The suction side of the gear pump is connected to a suction drop manifold This manifold has oversized porting for low velocity oil flow and air oil separation 2 1 3 Hydraulic Steer Valve Manifold The hydraulic manifold features the following high pressure reusable filter pressure relief cartridge adjustable high and low flow control cartridges high speed sol...

Страница 8: ...ODY 06 SAE ORB PORT ADAPTERS 06 SAE ORB TO 1 4 NPT OPERATING TEMPERATURE 14o F 122o F 10o C 50o C PRODUCT WEIGHT 66 lbs 30 kg 60 lbs 27 kg Table 2 HPU200 Technical Specifications AC Configurations MODEL HPU200 115 230 12 HPU200S 115 230 12 HPU200 115 230 24 HPU200S 115 230 24 KOBELT P N 600 142 600 142SS 600 143 600 143SS NOMINAL MOTOR VOLTAGE 115 208 230 VAC MAXIMUM MOTOR CURRENT 10 8 A 115 VAC 5...

Страница 9: ...imum oil temperature limit is 149oF 65oC Observe the operating temperature range limits as presented in Table 1 Do not operate the unit if the ambient temperature where the unit is located exceeds these limits Exceeding these temperatures may result in reduced operational life or damage to the product 2 2 2 Pressure Range The normal operating pressure of the unit is 0 to 750 psi Avoid operating th...

Страница 10: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 10 of 36 Figure 2 Hydraulic Schematic ...

Страница 11: ...that the unit is securely fastened to a suitable foundation Figure 3 HPU Mounting Pattern 3 2 HYDRAULIC Three hydraulic connections are required to the pump set Two lines connect the main steering lines and the third line to the header tank of interconnect line which compensates for thermal expansion of the oil and self bleeds air from the system Flexible hose with a pressure rating of minimum 150...

Страница 12: ...ved and connections can be made directly to the valve blocks 06 SAE ORB ports When installing the hydraulic fitting in the 3 8 NPT port a pipe thread sealant such as Teflon paste must be used All hoses and piping must also be plugged or capped until ready for connection The piping to the steering cylinder should be 3 8 nominal size and no more than 1 2 with a suitable wall thickness to safely with...

Страница 13: ...new autopilots will determine the pump direction and program the drive outputs to suit Connect the TANK port to the to pump suction line with recommended in line filter Connect the PRESSURE to the pump 3 3 ELECTRICAL The pump unit is manufactured for operation from 12VDC 24VDC or 115 208 230VAC supply voltages Ensure that the unit has been ordered for the required operating voltage The electrical ...

Страница 14: ...d 7 respectively The high speed coil is connected between Terminal 5 and 8 The high speed coil uses the same polarity control signal as the port and starboard solenoids DO NOT energize the coil detached from the valves It may cause them to heat up beyond normal operating temperatures Table 3 HPU200 Wiring Connections HPU200 Terminal Wire Name Wire Colour Function 1 N C No Connection N C 2 N C No C...

Страница 15: ... Motor Wiring The following section details the motor wiring for either 12 VDC or 24 VDC motor operation Figure 6 HPU200 DC Motor Wiring Diagram 3 3 2 AC Motor Wiring The following section details the motor wiring for either 115 VAC or 230 VAC operation Figure 7 HPU200 AC Motor Wiring Diagram ...

Страница 16: ...C CCW T1 T4 T5 T2 T3 T8 CW T1 T4 T8 T2 T3 T5 3 3 3 Example Connection Diagrams The following section contains various example methods for connection of the HPU It is recommended that installation work is carried out by a Kobelt Partner authorized service representative or trained installation technician Please contact the nearest Kobelt authorized distributor for assistance Figure 8 HPU200 Jog Con...

Страница 17: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 17 of 36 Figure 9 HPU200 Autopilot Wiring Diagram Common Positive ...

Страница 18: ...7 Check the hard over to hard over speed of the rudder and adjust the low speed adjustment for the appropriate speed Clockwise to decrease and counter clockwise to increase Once the low speed adjustment is complete activate the high speed valve and check the hard over to hard over speed Adjust the high speed valve to obtain the desired speed If after the high speed adjustment is complete you adjus...

Страница 19: ... Verify that the rudder position has changed 5 Set the autopilot to manual mode and operate the pump set to determine if the Port and Starboard directions are correct 6 If the rudder goes the opposite way than expected a Reverse the two electrical connections between the solenoids and the autopilot or electronic jog lever Most new autopilot systems will perform this test during their dockside set ...

Страница 20: ... open the opposite side check valve and allows flow comeback When there is no pressure in lines directional valve is in center both check valves are close and holding the load in position By energizing related solenoid on directional valve flow will be sent to port or starboard Hydraulic in line filter provides protection for small high pressure systems up to 3 000 PSI By using this filter at the ...

Страница 21: ...e the filter cap and change or clean the filter Return the pump to normal operation If the filter becomes plugged on a regular basis the steering system should be flushed out and the hydraulic oil replaced The brushes on the electric DC motor can be easily checked by removing the access plate and visually inspecting the brushes Replace the carbon brushes as required and check the internal conditio...

Страница 22: ...r Repair kit Pump Repair Kit Manifold Repair Kit 600 141 RK 7070 0020 RK 7061 0005 RK 600 013 RK 1 HPU200 300 400 REPAIR KIT 115 230 VAC Pump Repair Kit Manifold Repair Kit 600 142 RK 7061 0005 RK 600 013 RK Select appropriate kit to match voltage of model purchased When purchasing spare parts refer to Appendix B Parts List at the back of this manual for Kobelt component Part Numbers It is recomme...

Страница 23: ...ing gear goes hard over Short circuit in electrical wiring to solenoid Test wiring and solenoid valve coils Solenoid valve contaminated Isolate lines clean and or repair the solenoid valve as required Steering gear does not respond Solenoid not being energized Manually operate the solenoid valve Pump filter plugged due to contaminated Clean or replace filter No pressure on gauge Bypass open 1 Chec...

Страница 24: ...dentification of a potential issue or defect with a Kobelt Product or Part the Warranty Applicant Applicant must immediately contact Kobelt and describe the issue in writing by letter fax email or other electronic conveyance Kobelt will then assess the cause of the defect and determine warranty applicability and appropriate remediation If any part is found to be defective Kobelt will replace said ...

Страница 25: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 25 of 36 9 APPENDIX A INSTALLATION DIMENSIONS Figure 10 HPU200 Installation Dimensions ...

Страница 26: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 26 of 36 10 APPENDIX B PARTS LIST Figure 11 HPU200 Parts Diagram ...

Страница 27: ...10 LOCK WASHER 1023 0311 11 SCREW HEX HEAD 5 16 18 x 2 1 2 1001 1140 12 SOCKET HEAD CAP SCREW 10 12x 1 1 4 1002 0820 13 LOCK WASHER 1023 408 14 DIRECTIONAL VALVE 7036 0012 7036 0013 15 CABLE GLAND 1 2 NPT 6009 7840 16 ADAPTOR 10 MORB X 10 MJIC 7039 0126 17 COUPLING JAW L075 X 1 2 BORE 7056 0023 18 INSERT COUPLING L075 BUNA 7056 0025 19 COUPLING JAW L075 X 5 8 X 3 16 7056 0037 20 ELECTRIC MOTOR 3 4...

Страница 28: ...808 29 PLUG HEX HEAD 16 ORB 7039 0679 30 ADAPTER STR 10 MORB X 10 FJIC 7039 0157 31 HPU FOOT MOUNT PLATE 7057 0011 32 SCREW FLAT SKT HD 5 16 18 UNC X 3 4 1015 1112 33 LOCK WASHER 3 8 1023 0412 34 SCREW SKT HD 3 8 16 UNC x 3 1002 1248 35 ADAPTER STR 10 MJIC X 08 MORB 7039 0117 36 GEAR PUMP 7061 0006 37 SCREW HEX HEAD 5 16 18 x 3 4 1001 1112 38 ADAPTER STR 8 MJIC X 8 MORB 7039 0119 ...

Страница 29: ... x 3 8 NPT F 7039 0139 9 PLASTIC PLUG 3 8 NPT 7039 3043 10 LOCK WASHER 1023 0311 11 SCREW HEX HEAD 5 16 18 x 2 1 2 1001 1140 12 SOCKET HEAD CAP SCREW 10 12x 1 1 4 1002 0820 13 LOCK WASHER 1023 408 14 DIRECTIONAL VALVE 7036 0012 7036 0013 15 CABLE GLAND 1 2 NPT 6009 7840 16 ADAPTOR 10 MORB X 10 MJIC 7039 0126 17 COUPLING JAW L075 X 1 2 BORE 7056 0023 18 INSERT COUPLING L075 BUNA 7056 0025 19 COUPLI...

Страница 30: ...28 SCREW FLAT SKT HD 10 UNC X 1 2 1015 0808 29 PLUG HEX HEAD 16 ORB 7039 0679 30 ADAPTER STR 10 MORB X 10 FJIC 7039 0157 31 HPU FOOT MOUNT PLATE 7057 0011 32 SCREW FLAT SKT HD 5 16 18 UNC X 3 4 1015 1112 33 LOCK WASHER 3 8 1023 0412 34 SCREW SKT HD 3 8 16 UNC x 3 1002 1248 35 ADAPTER STR 10 MJIC X 08 MORB 7039 0117 36 GEAR PUMP 7061 0006 37 SCREW HEX HEAD 5 16 18 x 3 4 1001 1112 38 ADAPTER STR 8 M...

Страница 31: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 31 of 36 11 APPENDIX C MANIFOLD ASSEMBLY PARTS Figure 12 502 406 Manifold Parts Diagram ...

Страница 32: ...PLATED STEEL 7039 0661 5 1 EXPANSION PLUG CV173 218S 7039 3054 6 1 RELIEF VALVE 7043 0008 7 1 DIFFERENTIAL PRESSURE SENSE VALVE 80 PSI 7046 0001 8 1 PLUG HEX SKT 02 ORB PLATED STEEL 7039 0660 9 1 PLUG HEX SKT 08 ORB PLATED STEEL 7039 0663 10 1 PLUG HEX HEAD 16 ORB 7039 0679 11 1 REPAIR KIT 600 013 RK 12 1 SOL VALVE 2 WAY N C C 08 2 7048 0012 13 2 CHECK VALVE 7049 0017 14 1 HM LOCK VALVE SPOOL 7006...

Страница 33: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 33 of 36 12 APPENDIX D TYPICAL SYSTEM ARRANGEMENT Figure 13 Typical System Arrangement Closed Loop ...

Страница 34: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 34 of 36 Figure 14 Typical System Arrangement Open Loop In this arrangement the suction block must be removed ...

Страница 35: ...HPU200 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev B MNL HPU200 35 of 36 Page Intentionally Left Blank ...

Страница 36: ...elt Manufacturing Co Ltd 8238 129th Street Surrey British Columbia Canada V3W 0A6 Sales Tel 1 604 572 3935 Fax 1 604 590 8313 Email sales kobelt com Website www kobelt com Made in Canada Printed in Canada ...

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