Related Manuals for Kobelt HPU300
Summary of Contents for Kobelt HPU300
- Page 1 HPU300 Accu-Steer Hydraulic Power Unit Owner’s Operation, Installation & Maintenance Manual June 2019 Kobelt Manufacturing Co. Ltd.
- Page 2 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model #: Serial #: Date of Purchase: Date of Installation: Rev D MNL_HPU300 2 of 44...
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Page 3: Table Of Contents
HPU300 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
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: HPU300 Overview Diagram OMPONENTS The Accu-Steer Pump set is a complete assembly consisting of an electric motor with control box, gear pump, hydraulic control manifold and heavy-duty adapter mount. - Page 7 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. The HPU300 is available with 12VDC, 24VDC or 115/230VAC motors. The electrical junction box provides remote start and protected connections for the solenoid values for port, starboard, and two-speed operation.
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Page 8: Technical Specifications
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ECHNICAL PECIFICATIONS Table 1: HPU300 Technical Specifications – DC Configurations MODEL HPU300-12 HPU300S-12 HPU300-24 HPU300S-24 KOBELT P/N: 600-150 600-150SS 600-151 600-151SS NOMINAL MOTOR VOLTAGE 12 VDC 24 VDC MOTOR POWER 1.0 HP 1.0 HP... - Page 9 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 2: HPU300 Technical Specifications – AC Configurations MODEL HPU300- HPU300S- HPU300- HPU300S- 115/230-12 115/230-12 115/230-24 115/230-24 KOBELT P/N: 600-155 600-155SS 600-156 600-156SS NOMINAL MOTOR VOLTAGE 115/208-230 VAC MOTOR POWER 1.0 HP...
- Page 10 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 2: Hydraulic Schematic Rev D MNL_HPU300 10 of 44...
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Page 11: Installation
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NSTALLATION ECHANICAL The pump set 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. - Page 12 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. A shut-off, or isolation, valves are strongly recommended for all three lines to provide isolation in case of pump set failure. Ensure the plugs remain in place until the unit is ready for connection.
- Page 13 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 4: Connections in Top Face of Hydraulic Manifold (3) three hydraulic connections are required for close loop: • 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.
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Page 14: Electrical
DO NOT energize the coil detached from the valves. It may cause them to heat up beyond normal operating temperatures. Table 3: HPU300 Wiring Connections – DC Motors HPU300 Terminal... - Page 15 Kobelt Manufacturing Co. Ltd. Figure 5: HPU300-DC Terminal Block Diagram 3.3.1 DC Motor Wiring The following section details the motor wiring for either 12 VDC or 24 VDC motor operation. Figure 6: HPU300 DC Motor Wiring Diagram Rev D MNL_HPU300 15 of 44...
- Page 16 3.3.2 AC Motor Wiring Motors for AC versions of the HPU300 pump set are not prewired to the terminal box. The installer must make the connections in the motor’s terminal box. The following section details the motor wiring for either 115 VAC or 230 VAC operation.
- Page 17 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.
- Page 18 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 10: HPU300 Autopilot Wiring Diagram, Common Positive Rev D MNL_HPU300 18 of 44...
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Page 19: Commissioning
HPU300. Confirm that the electrical connections to the HPU300 pump-set have been made correctly and correspond to the requirements of your system installation. Rev D... -
Page 20: Functional Test
HPU300 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 21: Operation
HPU300 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 22: Maintenance
HPU300 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 23: Recommended Spare Parts
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ECOMMENDED PARE ARTS As a minimum Kobelt recommends the following spare parts are on-hand: Table 5: Recommended Spares ITEM KOBELT PART # HPU300 REPAIR KIT (12 VDC) 600-150-RK • 7070-0021-RK Motor Repair kit •... -
Page 24: 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. -
Page 25: 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 26: Revisions History
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. EVISIONS ISTORY Table 7: Table of revision changes Document Release Date Author Revision Summary Revision • 2024-03-19 Revised description of item 6 page 38 to reflect 24VDC Rev D MNL_HPU300 26 of 44... -
Page 27: Appendix A: Installation Dimensions
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. A: I PPENDIX NSTALLATION IMENSIONS Figure 11: HPU300 Installation Dimensions Rev D MNL_HPU300 27 of 44... -
Page 28: Appendix B: Parts List
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. B: P PPENDIX ARTS Figure 12: HPU300-DC Parts Diagram Rev D MNL_HPU300 28 of 44... - Page 29 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 8: HPU300 Parts List for DC Configurations HPU300-12 HPU300-24 Model No.: HPU300S-12 HPU300S-24 ITEM DESCRIPTION HPU MOTOR/ PUMP ADAPTOR 7001-0030 MANIFOLD 502-406 HPU200 TUBE 201-050 FLARELESS TUBE NUT, 1/2 7039-0630 FLARELESS TUBE FERRULE, 1/2...
- Page 30 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. HPU SUCTION DROP MANIFOLD 7001-0021 RARE EARTH MAGNET 119-205 PLUG, HEX HEAD, 16 ORB 7039-0679 ADAPTER, STR, 10 MORB X 10 FJIC 7039-0157 HPU FOOT MOUNT PLATE 7057-0011 SCREW, FLAT SKT HD, 5/16-18 UNC X 3/4...
- Page 31 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 13: HPU300-AC Parts Diagram Rev D MNL_HPU300 31 of 44...
- Page 32 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 9: HPU300 Parts List for AC Configuration HPU300- HPU300- 115/230-12 115/230-24 Model No.: HPU300S- HPU300S- 115/230-12 115/230-24 ITEM DESCRIPTION HPU MOTOR/ PUMP ADAPTOR 7001-0030 MANIFOLD 502-406 HPU200 TUBE 201-050 FLARELESS TUBE NUT, 1/2...
- Page 33 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ELECTRICAL BOX 503-026 HPU SUCTION DROP MANIFOLD 7001-0021 RARE EARTH MAGNET 119-205 PLUG, HEX HEAD, 16 ORB 7039-0679 ADAPTER, STR, 10 MORB X 10 FJIC 7039-0157 ROLLER 2543-0009 HPU FOOT MOUNT PLATE...
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Page 34: Appendix C: Manifold Assembly Parts
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. C: M PPENDIX ANIFOLD SSEMBLY ARTS Figure 7: 502-406 Manifold Parts Diagram Rev D MNL_HPU300 34 of 44... - Page 35 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 10: 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 36: Appendix D: Electrical Box Assembly Parts
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. D: E PPENDIX LECTRICAL SSEMBLY ARTS Figure 8: 503-023 ELECTRICAL BOX Table 11: Electrical Box HPU 300-12VDC Parts Table Part No.: 503-023 ITEM DESCRIPTION JUNCTION BOX; HPU 300 300-010-1 FILLER PLUG 7/8”... - Page 37 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NUT, HEX, #10-24, 18-8 SS 1022-0108 WASHER FLAT 1/4IN 18-8 1023-0110 CABLE GLAND, 1/2 NPT, .27 - .48 CORD, 6009-7840 NYLON TERM FORK INS VYL #8 18-22AWG RED 6009-6452 NUT, CABLE GLAND, 1/2NPT 302-064 CAP SCREW - BH SKT;...
- Page 38 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 9: 503-024 ELECTRICAL BOX Rev D MNL_HPU300 38 of 44...
- Page 39 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 12: Electrical Box HPU 300-24VDC Parts Table Part No.: 503-024 ITEM DESCRIPTION JUNCTION BOX; HPU 300 300-010-2 FILLER PLUG 7/8” 200-263 SCREW, PAN HEAD, #10 UNC X ½, GR 18-8 1012-0808...
- Page 40 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 17: AC ELECTRICAL BOX Table 13: Electrical Box HPU 300-AC Parts Table Part No.: 503-026 ITEM DESCRIPTION JUNCTION BOX; HPU 300 300-010-4 SCREW, PAN HEAD, #10 UNC X 1/2, GR 18-8...
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Page 41: Appendix E: Typical System Arrangement
HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. E: T PPENDIX YPICAL YSTEM RRANGEMENT Figure 10: Typical System Arrangement, Closed Loop Rev D MNL_HPU300 41 of 44... - Page 42 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 11: Typical System Arrangement, Open Loop In this arrangement suction block must be removed. Rev D MNL_HPU300 42 of 44...
- Page 43 HPU300 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Rev D MNL_HPU300 43 of 44...
- Page 44 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 Digitally signed Keivan by Keivan Ashouei Ashouei Date: 2024.03.19 10:27:41 -07'00'...