HRP Series Pump Installation Manual

HRP Series Pump Installation Manual
REVERSING PUMPSET
HRPtHRPtHRP17
TABLE OF CONTENTS
1. GENERAL INFORMATION ............................................... p. 01
2. TECHNICAL SPECIFICATIONS and APPLICATION ........ p. 02
3. DESCRIPTION ................................................................. p. 03
3.1
3.2
3.3
3.4
General
Motor
Pump
Valve Block and Valves
4. INSTALLATION ................................................................ p. 05
4.1 Mechanical
4.2 Hydraulic
4.3 Electrical
5. PREPARATION and TESTING ......................................... p. 07
5.1 Hydraulic Filling and Testing
5.2 Testing
6. NOTES ............................................................................. p. 08
7. DRAWINGS ..................................................................... p. 09
7.1 HRPtHRPtHRP17 — Assembly Schematic
7.2 HRPtHRPtHRP17 — System Connection Schematic
8. CYLINDER — PUMP REFERENCE GUIDE ..................... p. 11
i
1. GENERAL INFORMATION
A hydraulic steering system consists of a hydraulic actuator (normally a
cylinder) and one or more steering wheel pumps (helm pumps). As the
steering wheel (helm pump) is turned in the port direction, hydraulic oil is
pumped into the port hydraulic steering line. This oil is directed into the
port side of the steering cylinder. As the cylinder moves to port, oil from
the starboard side of the cylinder returns to the helm pump through the
starboard hydraulic lines.
One end of the cylinder is fixed and the other end is connected to a tiller
arm, which is connected to a rudder shaft. With this connection to a tiller arm the linear movement of the cylinder to port is changed to rotary
movement, which turns the rudder and steers the vessel to port.
Moving the steering wheel to starboard produces the same re-action with
oil being pumped out of the starboard line and returning through the port
line. If more the one helm pump is used, a return/fill line must be installed
to connect the cases of all the helm pumps together.
If an autopilot is to be installed, the hydraulic reversing pumpset is connected in the same manner as a helm pump with a port, starboard and a
return/fill line.
The Accu-Steer HRP05, HRP11 and HRP17 are reversing pump units
designed to interface a hydraulic steering system with electric or autopilot
control. The output flow rate of the pumpset determines the speed of the
steering cylinder. The HRP05 pumpset outputs 0.5 cu in/sec or 8.2 cubic
centimeters per second. The HRP11 pumpset outputs 1.0 cu in/sec or
16.4 cc’s/sec. The HRP17 outputs 1.6 cu in/sec or 26.3 cc’s/sec.
Most steering cylinders are balanced, which means the volume of oil
on both sides of the cylinder is equal. A steering cylinder is balanced
when the piston rod of the cylinder protrudes from both ends. Some cylinders are unbalanced in which the piston rod protrudes from one end
only. These are common on some in-board and out-board drives and are
usually referred to as side drives or simply unbalanced cylinders. These
Accu-Steer HRP pumpsets are capable of working with both balanced
and unbalanced cylinders. When unbalanced cylinders are used it is recommended that a vented header tank is used to allow for the expansion
and contraction from the unbalanced cylinder.
p01
2. TECHNICAL SPECIFICATIONS and APPLICATION
MODEL
HRP
05-12
HRP
11-12
HRP
17-12
HRP
05-24
HRP
11-24
HRP
17-24
VOLTAGE
12 VDC
12 VDC
12 VDC
24 VDC
24 VDC
24 VDC
OUTPUT/SEC
0.5 cu in 1.0 cu in 1.6 cu in 0.5 cu in 1.0 cu in 1.6 cu in
AVERAGE AMP
WEIGHT (lbs/kgs)
3-5
4-6
5-8
2-4
3-5
3-5
10/4.5
10/4.5
10/4.5
10/4.5
10/4.5
10/4.5
The output flow rate of an electric pumpset determines the maximum speed of the rudder. Under normal conditions a rudder speed
of 10 to 16 seconds will provide the best steering results for most
autopilot systems. It is therefore important to select the proper
pumpset to optimize your autopilot operation.
First determine the volume of your steering cylinder. This is usually indicated in the instruction manual of your steering system.
Enclosed at the back of this manual are lists of various steering
cylinder manufacturers with their cylinder models and volumes.
If you have to calculate the volume of your cylinder manually you
can use the following formula:
Volume = L(D2-d2)π÷4
Where:
L = length of stroke of cylinder
D = internal diameter of cylinder
d = diameter of piston rod
π = 3.14 (Pi)
The rudder speed, hard over to hard over (HOH), is determined
by dividing the volume (cu in) of the cylinder by the output of the
pumpset (cu in/sec). For example: a 15 cu in cylinder speed would
be approximately 14 seconds HOH using an HRP11 or approximately 9 seconds using and HRP17.
p02
3. DESCRIPTION
3.1 GENERAL
The Accu-Steer HRP05, HRP11 and HRP17 are complete
pump assemblies each consisting of a reversing gerotor gear
pump, hydraulic lock valves, suction make-up check valves,
a valve housing manifold and an electric permanent magnet
motor.
FIGURE 3.1 HYDRAULIC SCHEMATIC
7
8
9
5
6
3
4
“A”
“B”
2
DC
MOTOR
1
Lines A and B are the output (port and starboard) lines, which
are connected to steering lines on the vessel. Line T is the tank
suction make-up or return line. These lines are clearly marked
on the valve housing. Do not connect the output lines to the
tank (T) port.
The HRP (Hydraulic Reversing Pumpset) operates as follows:
t As the motor (1) rotates CCW, oil from the gear pump (2) is
pumped towards output “A”.
t This oil passes through the check valve (5) and goes to the
line output (7).
t The pressure at output “A” ensures the check valve (3)
stays closed and manually opens check valve (6).
p03
t Opening check valve (6) allows the returning oil from the
steering cylinder to flow back to the pump.
t If the pressure at the pump suction “B” is less than the
pressure in the make-up line, oil from the make up line will
pass by the check valve (4). This prevents cavitation due to
any air that may be in the steering line.
t When the pump stops turning all spring-loaded check
valves return to the normally closed position.
t When the motor (1) rotates (CW) the reverse movement of
the oil and valves takes place.
3.2 MOTOR
A list of features:
t Ignition protected (UL 1500 and SAE-1171).
t Ball bearing shaft supports both ends.
t Extended motor shafting eliminating the pump/motor coupling.
t Machined pilot bore ensuring aligned pump/motor adapter
mounting.
t Cushioned foot mounts for quiet operation.
t Opposite end shaft mount for tachometer/encoder.
3.3 PUMP
A list of features:
t The reversing gear pumps (HRP’s) use gerotor style pump
unit. The gerotor gear was used because of its quiet operation and its efficient pumping capabilities.
t The gears are driven directly from the extended motor shaft
which eliminate the need for a pump/motor shaft coupling.
t The shaft is supported by the motor ball bearing on one
side and a hard anodized aluminum end plate on the other
side.
t The gerotor pump is a two-piece gear assembly with an eccentric ring. Proper clearances and alignments are maintained through CNC precision machining.
t Valve block sealing is accomplished using O-ring style
seals.
p04
t The shaft seal is accomplished using a rubber shaft seal
rated at 50 psi. This shaft seal is connected to the tank/return line pump chamber. If this tank port is connected to a
steering line or is over pressurized, it may cause this seal to
fail. See the installation instructions for more details.
3.4 VALVE BLOCK and VALVES
A list of features:
t The valve block is an aluminum block, precision machined
to house the valves, direct the oil and serve as the endplate
for the gear pump. The pump end plate is referenced to the
valve block with locator pins to ensure the proper alignment.
t The suction make-up valves are located between the return
line port and the pump output internal ports. These allow
the pump to “breathe” properly in the event of air from the
steering lines entering the pumpset.
t The output check valves are part of what is called a lockvalve assembly. The lockvalve assembly consists of two
output check valves and a lockvalve spool. In the nonrunning position the spring operated check valves remain
closed, isolating the pump from the steering system. The
spring action of the check valves holds the lockvalve spool
in the mid-closed position.
t The end plate houses the pump shaft guide and aligns the
pump.
4. INSTALLATION
4.1 MECHANICAL
The pumpset should be placed on a horizontal shelf or bracket
with a solid foundation. The pump can be bolted or screwed
down with the motor foot bracket. The foot bracket is fitted
with anti-vibration mounts to maintain the quiet operation of
the pumpset. The pumpset should be close to and below the
steering lines for ease of connections and bleeding.
4.2 HYDRAULIC
Before connection to the hydraulic lines, ensure all hydraulic
lines in the steering system are clean and free of contaminating
particles, which could enter the pump and cause it to fail.
p05
Most steering manufacturers have recommended hydraulic
oils to be used in their systems. The HRP pumpsets are compatible with these oils. Most manufacturers use an ISO #32 or
ISO #10 type of oil.
Three hydraulic connections are required to the pumpset. Two
lines connect the pump (outputs A and B) to the main steering
(port and starboard) lines.
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. For older autopilots the motor leads can be reversed to change the pumps
direction. The third line, which is the interconnect or fill line,
connects the pumpset to the header tank or helm pump case.
This third line is critical, as it provides make up oil and allows
the pumpset to vent any air, which may enter the pumpset
from the steering lines. It is recommended that flex hose be
used for all three lines to prevent any pump noise from being transmitted to the steering system. The port and starboard
steering lines should have a pressure rating of 1000 psi minimum; where the third fill/interconnect line is a non-pressurized
line. Shut-off or isolation valves for all three lines are recommended. If the pumpset fails, the isolation valves can be shut
off and manual steering maintained.
The three hydraulic connections on the valve block are 9/16”18 UNF (ORB -06) threads and are fitted with adapter to 1/4”
NPT (National Pipe Thread). If installers prefer the adapters
can be removed and connections can be made directly to the
valve block. When installing the hydraulic fitting in the 1/4”
NPT connection a pipe thread sealant such as Teflon paste or
tape must be used.
NOTE OF CAUTION: It is important that the port or starboard
line does not become crossed with the fill/interconnect line as
this could cause high pressure to be introduced into the pumps
tank cavity. In steering systems where the fill/interconnect line
is pressurized (e.g. - Hynautics or Teleflex) the recommended
operating pressure is approximately 20 to 25 psi. The shaft seal
on the HRP pumpsets is rated at 50 psi and is well within the
pressure range of these steering systems. Over-pressurizing
these steering systems and causing a shaft seal failure will void
the warranty of the pumpset.
p06
4.3 ELECTRICAL
The motor is a permanent magnet style motor. There are two
leads, which connect to the autopilot pump driver junction
box (processor). As mentioned previously the direction of the
pumpset can be reversed by simply reversing the polarity of
these two leads.
To test the operation of the HRP pumpset, touch the two leads
from the motor to the supply voltage (12 VDC or 24 VDC) to jog
the motor in one direction and then reverse the leads to jog the
pumpset in the other direction. Use caution not to perform this
operation where any combustible fumes exist.
The motors used on the HRP05, HRP11, and HRP17 pumpsets are ignition protected, built to conform to UL-1500 and
SAE-1171 standards.
5. PREPARATION and TESTING
5.1 HYDRAULIC FILLING and TESTING
When installing a pumpset it is recommended that the system
be flushed to ensure that the oil is clean and free of contamination through out the hydraulic steering system.
After the hydraulic and electrical connection have been made,
open all valves if installed, and allow sufficient time for the
pump and lines to fill with oil. Operate the pumpset and note
the HOH time. This time varies with the type of steering system
and autopilot used
5.2 TESTING
Set the autopilot to the manual mode and operate the pumpset
to determine if the port and starboard directions are correct.
If the rudder goes the opposite way, reverse the two electrical
leads to the motor.
Most new autopilot systems will perform this test during their
dockside set-up procedures.
p07
6. NOTES
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p08
7. DRAWINGS
7.1 HRPtHRPtHRP17
ASSEMBLY SCHEMATIC
4”
SIDE VIEW
8”
A
3.25”
T
TOP VIEW
4”
B
2.25”
p09
7.2 HRPtHRPtHRP17
SYSTEM CONNECTION SCHEMATIC
HELM
PUMP
STARBOARD LINE
STEERING
CYLINDER
PORT LINE
T
A
B
p10
8. CYLINDER-PUMP REFERENCE GUIDE
Please read the following:
t The Accu-Steer HRP series of pumps are recommended for medium
duty applications (<100 hours/month).
t The Accu-Steer HPU100 and up are recommended for heavy duty and
work boat applications.
t The Accu-Steer HM series of hydraulic manifolds require an electric
driven or engine driven pump unit.
t When 2 cylinders are used double the displacement volumes.
STEERING
MFR.
CYLINDER
MODEL
HYNAUTIC
PSK-10
BORE/
STROKE
CU IN
DSPLT
ACCU-STEER
PUMP “A”
6.0
HRP05
ACCU-STEER
PUMP “B”
Power Steering
K-1
1.50” x 9.00”
12.1
HRP11
K-2
1.75” x 9.00”
17.6
HRP11
HRP17
K-3
2.00” x 9.00”
23.1
HRP17
HRP75
K-4
2.00” x 12.0”
30.5
HRP75
K-5
2 x CYL’S
25.5
HRP17
HRP75
K-6
CTR MNT
9.0
HRP05
HRP11
K-7
1.50” x 9.50”
12.6
HRP11
K-8
2.50” x 9.50”
39.2
HRP75
K-9
2.50” x 14.25”
54.0
HRP75
K-10
1.25” x 9.50”
7.5
HRP05
K-11
1.25” x 9.00”
11.0
HRP11
K-12
1.25” x 7.00”
8.6
HRP05
K-13
1.25” x 9.00”
11.0
HRP11
K-14
1.25” x 7.00”
8.6
HRP05
K-16
1.25” x 9.00”
11.0
HRP11
K-18
1.25” x 7.00”
7.0
HRP05
K-19
1.25” x 9.00”
9.0
HRP05
K-21
1.50” x 9.00”
12.1
HRP11
K-22
1.50” x 10.00”
13.3
HRP11
K-24
1.50” x 6.00”
6.6
HRP05
K-25
1.50” x 10.00”
13.3
HRP11
K-26
1.50” x 12.00”
16.0
HRP11
p11
COMMENTS
HRP11
HRP17
STEERING
MFR.
CYLINDER
MODEL
BORE/
STROKE
CU IN
DSPLT
ACCU-STEER
PUMP “A”
HYNAUTIC
K-27
1.50” x 10.00”
13.3
HRP11
JASTRAM
MAROL
ACCU-STEER
PUMP “B”
COMMENTS
K-28
1.50” x 12.00”
16.0
HRP11
HRP17
K-29
1.50” x 12.00”
16.0
HRP11
HRP17
K-31
2.00” x 10.0”
25.5
HRP17
HRP75
K-32
2.00” x 8.00”
20.0
HRP17
HRP75
K-33
2.00” x 9.00”
23.1
HRP17
HRP75
K-51
1.50” x 7.00”
10.2
HRP11
B-125-7
1.25” x 7.00”
6.4
HRP05
INBOARD/OUTBOARD
B-125-9
1.25” x 9.00”
8.2
HRP05
INBOARD/OUTBOARD
B-125-7
1.25” x 7.00”
6.4
HRP05
B-125-9
1.25” x 9.00”
8.2
HRP05
B-150-7
1.50” x 7.00”
10.2
HRP11
B-150-9
1.50” x 9.00”
13.1
HRP11
B-200-12
2.00” x 12.00”
31.9
HRP75
B-200-15
2.00” x 15.00”
39.1
HRP75
HPU100
B-300-9
3.00” x 9.00”
52.4
HRP75
HPU100
B-300-12
3.00” x 12.00”
69.9
HPU200
B-300-16
3.00” x 16.00”
93.2
HPU200
B-300-20
3.00” x 20.00”
116.6
HPU200
K-1
N/A
10.0
HRP75
HPU100
HEAVY DUTY APPLIC.
K-3
N/A
20.0
HRP75
HPU100
HEAVY DUTY APPLIC.
K-4
N/A
31.0
HRP75
HPU100
HEAVY DUTY APPLIC.
K-5
N/A
42.0
HPU100
HEAVY DUTY APPLIC.
K-6
N/A
54.0
HPU200
HEAVY DUTY APPLIC.
K-7
N/A
54.0
HPU200
HEAVY DUTY APPLIC.
MCS-26
N/A
3.9
HRP05
MCS-26T
N/A
3.9
HRP05
MCS-28
N/A
5.5
HRP05
MCS-28T
N/A
5.5
HRP05
MCB-35F
N/A
8.5
HRP05
MCB-42L
N/A
17.4
HRP11
MRB-50
N/A
2.6
HRP05
p12
HPU300
HRP17
LEVER RATIO =
0.74 : 1.00
STEERING
MFR.
CYLINDER
MODEL
BORE/
STROKE
CU IN
DSPLT
ACCU-STEER
PUMP “A”
MAROL
MRB-50
N/A
3.7
HRP05
LEVER RATIO =
0.74 : 1.00
MRB-50
N/A
4.8
HRP05
LEVER RATIO =
1.00 : 1.00
MRB-63
N/A
5.1
HRP05
LEVER RATIO =
1.23 : 1.00
MRB-63
N/A
7.1
HRP05
LEVER RATIO =
1.00 : 1.00
MRB-63
N/A
9.3
HRP05
MRB-75
N/A
10.6
HRP11
LEVER RATIO =
0.74 : 1.00
MRB-75
N/A
14.7
HRP11
LEVER RATIO =
1.00 : 1.00
MRB-75
N/A
19.2
HRP17
LEVER RATIO =
1.23 : 1.00
MRB-80
N/A
18.7
HRP17
LEVER RATIO =
1.00 : 1.00
MRB-80
N/A
24.2
HRP17
HRP75
LEVER RATIO =
1.23 : 1.00
MRB-100
N/A
20.9
HRP17
HRP75
LEVER RATIO =
0.74 : 1.00
MRB-100
N/A
29.3
HRP75
LEVER RATIO =
1.00 : 1.00
MRB-100
N/A
37.7
HRP75
LEVER RATIO =
1.23 : 1.00
HS3000
1.25” x 7.00”
6.55
HRP05
INBOARD CYLINDER
HS4000
1.57” x 7.00”
11.48
HRP11
INBOARD CYLINDER
HS5000
1.77” x 6.70”
13.53
HRP11
INBOARD CYLINDER
MORSE
T-TRQUE
ACCU-STEER
PUMP “B”
HRP11
COMMENTS
LEVER RATIO =
1.23 : 1.00
HS SINGLE
N/A
8.0
HRP05
OUTBOARD CYLINDER
HS DOUBLE
N/A
16.0
HRP11
OUTBOARD CYLINDER
TTDS-175
N/A
16.0
HRP17
HRP75
TTDS-200
N/A
16.0
HRP17
HRP75
TTDS-250
N/A
32.0
HRP75
TTDS-300
N/A
32.0
HRP75
TTDS-400
N/A
32.0
HRP75
p13
STEERING
MFR.
CYLINDER
MODEL
TELEFLEX
WAGNER
BORE/
STROKE
CU IN
DSPLT
ACCU-STEER
PUMP “A”
ACCU-STEER
PUMP “B”
COMMENTS
125-8EM
8.4 /
9.8
HRP05
HRP11
UNBALANCED
CYLINDER
125-8VEM
8.4 /
9.8
HRP05
HRP11
UNBALANCED
CYLINDER
92-VPS
9.8 /
11.6
HRP05
HRP11
UNBALANCED
CYLINDER
BA125-7
1.25” x 7.00”
7.2
HRP05
BA125-8
1.25” x 8.00”
9.0
HRP05
BA135-7
1.35” x 7.00”
8.2
HRP05
BA135-8
1.35” x 8.00”
9.4
HRP05
BA150-7
1.50” x 7.00”
10.2
HRP11
BA175-7
1.75” x 7.00”
13.7
HRP11
BA200-7
2.00” x 7.00”
18.9
HRP17
BA200-11
2.00” x 11.00”
HRP11
HRP11
29.7
HRP17
HC5342
8.1
HRP05
HRP75
OUTBOARD CYLINDER
HC5345
8.1
HRP05
OUTBOARD CYLINDER
HC5345
6.8
HRP05
OUTBOARD CYLINDER
HC5370
8.1 /
9.7
HRP05
HRP11
UNBALANCED
CYLINDER
HC5380
9.4 /
11
HRP05
HRP11
UNBALANCED
CYLINDER
HPU100
HEAVY DUTY APPLIC.
N50-190
50 x 190 mm
19.1
HRP17
N50-300
50 x 300 mm
30.2
HRP75
N80-190
80 x 190 mm
49.0
HRP75
N80-300
80 x 300 mm
77.3
HPU200
HEAVY DUTY APPLIC.
N80-400
80 x 400 mm
103.0
HPU200
HEAVY DUTY APPLIC.
N65
2.00” x 11.00”
6.0
HRP05
N85
2.00” x 11.00”
7.8
HRP05
N175-750
1.75” x 7.50”
14.8
HRP11
N175-1000
1.75” x 10.00”
19.7
HRP17
N250-800
2.50” x 8.00”
33.0
HRP85
N250-1000
2.50” x 10.00”
41.2
HRP75
HPU100
HEAVY DUTY APPLIC.
N250-1300
2.50” x 13.00”
53.6
HRP75
HPU100
HEAVY DUTY APPLIC.
N350-1200
3.50” x 12.00”
94.2
HPU200
N350-1600
3.50” x 16.00”
125.6
HPU300
p14
HEAVY DUTY APPLIC.
HM250
HEAVY DUTY APPLIC.
STEERING
MFR.
CYLINDER
MODEL
BORE/
STROKE
CU IN
DSPLT
ACCU-STEER
PUMP “A”
ACCU-STEER
PUMP “B”
COMMENTS
WAGNER
N400-1500
4.00” x 15.00”
152.4
HPU300
HM250
HEAVY DUTY APPLIC.
N400-2000
4.00” x 20.00”
203.2
HM400
T2
N/A
16.0
HRP75
HPU100
HEAVY DUTY APPLIC.
T3
N/A
20.4
HRP75
HPU100
HEAVY DUTY APPLIC.
T4
N/A
30.5
HRP75
HPU100
HEAVY DUTY APPLIC.
T5
N/A
41.6
HPU100
T10
N/A
54.2
HPU100
HPU200
HEAVY DUTY APPLIC.
T11
N/A
54.2
HPU100
HPU200
HEAVY DUTY APPLIC.
T12
N/A
77.1
HPU200
p15
HEAVY DUTY APPLIC.
HEAVY DUTY APPLIC.
HEAVY DUTY APPLIC.
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