Summary of Contents for Kobelt HPU400 Series
- Page 1 HPU400 Accu-Steer Hydraulic Power Unit Owner’s Operation, Installation & Maintenance Manual June 2019 Kobelt Manufacturing Co. Ltd.
- Page 2 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model #: Serial #: Date of Purchase: Date of Installation: Rev A MNL_HPU400 2 of 33...
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Page 3: Table Of Contents
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ABLE OF ONTENTS Introduction ......................4 Contact ........................4 Safety ........................4 Product Description ....................6 Components ......................6 Technical Specifications ................... 8 Installation ......................11 Mechanical ......................11 Hydraulic ........................ 11 Electrical ........................ -
Page 4: Introduction
Kobelt reserves the right, without notice, to change the design, or construction, of any products and to discontinue or limit distribution of any products. Kobelt also reserves the right to change, or update, without notice, any technical information contained within this document. - Page 5 • Do not carry out any modifications to the product. • Only use authentic Kobelt spare parts. • Observe all local regulations, directives and laws during the installation of this product. • All installation, commissioning, and maintenance work must only be conducted by qualified personnel.
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Page 6: Product Description
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. RODUCT ESCRIPTION The Accu-Steer Electric Pumpset is designed to interface hydraulic steering with electric/autopilot control. Its compact and rugged construction provides ease of installation along with long life operation. This unit is available in a wide range of voltages and flows for both standard and custom requirements. - Page 7 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. is self-contained, installation involves connecting the pump to the steering lines and the electrical control and adjusting the unit to the requirements of the vessel. 2.1.1 Electric Motor The electric motor is a heavy-duty totally enclosed, fan-cooled unit featuring high efficiency permanent magnet construction, oversized brush gear with easy access, and standard foot and face mountings.
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Page 8: Technical Specifications
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ECHNICAL PECIFICATIONS Table 1: HPU400 Technical Specifications – DC Configurations MODEL HPU400-24 HPU400S-24 KOBELT P/N: 600-160 600-160SS NOMINAL MOTOR VOLTAGE 24 VDC MAXIMUM MOTOR CURRENT 29 A NOMINAL SOLENOID VOLTAGE 24 VDC Direction: 1.3 A... - Page 9 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 2.2.1 Temperature Limits The motor temperature has a maximum limit of 248 F [120 C]. Allowing the temperature to exceed this limit will permanently damage the motor windings. The maximum oil temperature limit is 149 F [65 Observe the operating temperature range limits as presented in Table 1.
- Page 10 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 2: Hydraulic Schematic Rev A MNL_HPU400 10 of 33...
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Page 11: Installation
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NSTALLATION ECHANICAL The pumpset must be placed on a horizontal bracket with a solid foundation. It should be close to and below the steering lines for ease of connections and bleeding. The HPU is equipped with (2) two clearance holes for 3/8” bolts and (4) four holes for 5/16”... - Page 12 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. All piping and hoses must be flushed prior to connection. Failure to do so can result in damaged components and seals. The two hydraulic ports on the valve block are fitted with 3/8” NPT (National Pipe Thread) adapters.
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Page 13: Electrical
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 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. - Page 14 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. positive or negative switched signal. The terminal strip contains connections to the port, starboard, and speed control solenoids located on the manifold. For AC motor configurations the electrical junction box contains a terminal strip with connections to the port, starboard, and speed control solenoids located on the manifold.
- Page 15 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 3: HM450 Wiring Connections HM450 Pair # Wire Name Colour Gauge Function HS-A White 18AWG High-Speed Coil connection A. HS-B White 18AWG High-Speed Coil connection B. CYL1-A Black 18AWG Cylinder Port 1 Coil connection A.
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Page 16: Commissioning
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. OMMISSIONING & B YDRAULIC LEED After the hydraulic and the electrical connections have been completed, open all isolating valves and allow enough time for the pump and lines to fill with oil. Start the pump and observe the pressure gauge. -
Page 17: Functional Test
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. UNCTIONAL The Function Test should be carried out while the vessel is still at dock and before it is taken out to sea after installation has been completed. After installation and filling has been completed, perform the following function tests: Power ON the HPU Power ON the autopilot (or electronic jog lever). -
Page 18: Operation
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. PERATION The HPU operates as follows: • Manifold receives oil from pump, and outputs to steering lines. Output flow determining the speed of the rudder. • Output flow is controlled by flow control valves. -
Page 19: Maintenance
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. AINTENANCE REVENTATIVE AINTENANCE During normal operation of the pump, the high-pressure filter should be checked periodically and changed or washed out if contaminated. If the speed of the steering system begins to gradually slow down. It is an indication that the filter is plugging. -
Page 20: Recommended Spare Parts
• 600-013-RK Manifold Repair Kit When purchasing spare parts refer to Appendix B: Parts List for Kobelt Part Numbers. It is recommended that any required service work on an Accu-Steer unit be performed by a factory authorized service representative. Please contact the nearest Kobelt authorized distributor for assistance. -
Page 21: Troubleshooting
If you encounter problems with the operation of your product, please refer to the trouble- shooting suggestions before contacting Kobelt for assistance. If the steps below do not resolve your issue, please reach out either Kobelt directly or our Dealers in your area. Table 5: Common Solutions... -
Page 22: Warranty
If any part is found to be defective, Kobelt will replace said part FOB the Kobelt factory provided that any such defective part is returned by the Buyer with freight and applicable forwarding charges prepaid by the Buyer. -
Page 23: Appendix A: Installation Dimensions
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. A: I PPENDIX NSTALLATION IMENSIONS Figure 7: HPU400 Installation Dimensions Rev A MNL_HPU400 23 of 33... -
Page 24: Appendix B: Parts List
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 10 A B: P PPENDIX ARTS Figure 8: HPU400 Parts Diagram Rev A MNL_HPU400 24 of 33... - Page 25 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 6: HPU400 Parts List for DC Configurations HPU400-24 Model No.: HPU400S-24 ITEM DESCRIPTION HPU MOTOR/ PUMP ADAPTOR 7001-0030 MANIFOLD 502-406 HPU200 TUBE 7056-0071 FLARELESS TUBE NUT, 1/2 7039-0630 FLARELESS TUBE FERRULE, 1/2...
- Page 26 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. LOCK WASHER HIGH COLLAR, #8, 1023-0407 SCREW, FLAT SKT HD, #10 UNC X 1/2 1015-0808 PLUG, HEX HEAD, 16 ORB 7039-0679 ADAPTER, STR, 10 MORB X 10 FJIC 7039-0157 HPU FOOT MOUNT PLATE...
- Page 27 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 7: HPU400 Parts List for AC Configuration HPU400- HPU400- 115/230-12 115/230-24 Model No.: HPU400S- HPU400S- 115/230-12 115/230-24 ITEM DESCRIPTION HPU MOTOR/ PUMP ADAPTOR 7001-0030 MANIFOLD 502-406 HPU200 TUBE 7056-0071 FLARELESS TUBE NUT, 1/2...
- Page 28 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. LOCK WASHER HIGH COLLAR, #8, 1023-0407 SCREW, FLAT SKT HD, #10 UNC X 1/2 1015-0808 PLUG, HEX HEAD, 16 ORB 7039-0679 ADAPTER, STR, 10 MORB X 10 FJIC 7039-0157 HPU FOOT MOUNT PLATE...
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Page 29: Appendix C: Manifold Assembly Parts
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 11 A C: M PPENDIX ANIFOLD SSEMBLY ARTS Figure 9: 502-406 Manifold Parts Diagram Rev A MNL_HPU400 29 of 33... - Page 30 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 8: HM450 Manifold Parts Table Part No.: 502-406 ITEM DESCRIPTION HM450 MANIFOLD BODY 7001-0046 FLOW CONTROL NEEDLE SIZE 07 7044-0012 PRESSURE GAUGE, 1450 PSI, 04 ORB 7088-0025 PLUG, HEX SKT, 04 ORB, PLATED STEEL...
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Page 31: Appendix D: Typical System Arrangement
HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 12 A D: T PPENDIX YPICAL YSTEM RRANGEMENT Figure 10: Typical System Arrangement, Closed Loop Rev A MNL_HPU400 31 of 33... - Page 32 HPU400 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 11: Typical System Arrangement, Open Loop In this arrangement suction block must be removed. Rev A MNL_HPU400 32 of 33...
- Page 33 Kobelt 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...