18CI and 30CI Reversing Motor Pumpset

18CI and 30CI Reversing Motor Pumpset
ComNav Marine Autopilots
#15 - 13511 Crestwood Place
Richmond, BC
Canada V6V 2G1
Phone: 604-207-1600
Fax: 604-207-8008
In Canada or the USA
Toll Free Phone 1-800-428-0212
Toll Free Fax 1-800-470-9611
E-Mail: sales@comnav.com
Web Site: http://www.comnavmarine.com
18CI & 30CI Adjustable Reversing Motor Pump
Owner's Manual
Part Numbers: 20810016, 20810018, 20810031 & 20810035
Manual Part Number: 29010016
Revised: October 6, 2004
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29010016V1.0(18CI & 30CI Pump) .doc
***** IMPORTANT *****
The reversing motor pump you have purchased is a reliable, high quality product that will give
you many years of trouble-free service. To ensure that you get the most from your purchase,
read this installation and instruction manual carefully. By following the step-by-step procedure
and using only basic tools and materials, you will find the installation easy to do.
This Pump is not watertight and therefore is not covered under warranty against water
damage.
If you are installing this pump on a Capilano or Syten steering system, you probably have
a 3 line steering system. Read the 3 line steering installation instructions carefully.
TOOLS AND MATERIAL REQUIRED TO INSTALL PUMP
1.
Basic Tool Kit
2.
Pipe Cutter
3.
Funnel with Filter (a coffee filter will do)
4.
3/8" Electrical Drill
5.
2 Gallon Bucket (to catch excess oil)
6.
Rags or Paper Towels
*7.
Pipe Fittings (check with steering gear manufacturer for type and size)
*8.
Tubing (check with steering gear manufacturer for type and size)
9.
Hydraulic Oil (check with steering gear manufacturer for type)
10.
Teflon Based Thread Sealer (such as LOCKTITE P.S.T.)
11.
Miscellaneous Hardware (for mounting pump and securing lines)
*Consult with your steering system manufacturer to get detailed information regarding
factory authorized installation materials. Failure to do so could void your warrantee.
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18CI AND 30CI ADJUSTABLE REVERSING DC MOTOR PUMP
SPILL VALVE
ADJUSTMENT
OPTIONAL SPILL
VALVE
To adjust flow rates simply loosen the pump housing screws a small amount and
turn the pump housing. Turing the housing clockwise will decrease flow rate and
anti-clockwise will increase flow rate.
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29010016V1.0(18CI & 30CI Pump) .doc
the steering system. The first is to leave the
system completely filled and be careful not to
spill hydraulic fluid. The second is to drain
the system of fluid completely before cutting
or opening any lines.
PLANNING
Installation of the pump consists of:
•
Finding a mounting location for the pump.
•
Partially draining the steering system.
•
Mounting and connecting the pump to the
existing steering lines.
•
Filling and bleeding the steering system.
If you follow the first method, remember that
when you disconnect or cut the steering
lines, there will be a constant slow discharge
of oil due to gravity draining the system.
Have a container ready to catch all excess
oil. Do not reuse any oil reclaimed from your
system.
A suitable mounting location for the pump
MUST:
• Be dry
Draining your System
•
Be lower than at least one of the helm
pumps in the steering system.
If you wish to follow the second method and
drain the system, use the following simple
procedure.
•
Provide a solid mounting base.
•
Be at least 6 feet (2 meters) from the
vessel’s compass.
1. Have a large container, about 2 gallons,
ready.
2. Disconnect the delivery lines at a low
point, usually where the lines connect to
the steering cylinder.
A mounting location for the pump SHOULD:
•
Provide easy access to the pump.
•
Provide an easy connection point to the
steering system.
•
Minimize the length of the pump hoses.
•
Minimize the length of the wires to the
motor.
3. Turn the wheel of the highest helm pump
in both directions until no more fluid
comes out of the lines.
4. Repeat the previous step on each lower
helm pump in turn.
Types of Steering Systems
There are two general types of steering
systems, two line systems, and three line
systems. The pump connection to the
steering system is different for each type.
Separate instructions are supplied for both
types of steering systems.
A typical mounting location would be in the
engine compartment or the steering console.
The pump can be mounted in any orientation
except with Port C facing downward. If Port
C is facing downward then air will not be able
to rise out of the pump and the pump will not
have a supply of oil.
There are two ways to connect the pump to
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29010016V1.0(18CI & 30CI Pump) .doc
You have a three-line system if the helm pump is a Capilano Model 250 or 275 (Made by Teleflex),
or there is a Uniflow valve mounted close to the steering cylinder.
You have a two-line system if you do not have the above components in your system.
CAUTION
CLEANLINESS must be maintained while making hydraulic connections. Contamination
introduced into the steering system fluid can cause steering components to malfunction,
possibly resulting in a loss of steering.
Before beginning to connect the pump to the steering system, review the following installation
hints:
• Cap or cover the ends of hoses with a clean rag before pushing them between bulkheads.
• Do not blow copper filings off freshly cut and reamed copper tube. Wipe the filings off instead
• Do not use a tape type thread sealer. These can shred and enter the steering system fluid. A
Teflon based thread sealer, such as 'LOCTITE P.S.T.' must be used on all male pipe threads.
Do not place thread sealer on the first two threads.
• Do not place thread sealer on female pipe threads.
• When tightening fittings into the pump lockvalve, hold the lockvalve, not the motor. That way,
the lockvalve will not twist out of alignment with the rest of the pump.
• Connection of the pump lines is most easily made at existing breaks in the steering system
lines. For example: valves, t-joints and other fittings.
Opening your hydraulic steering system will allow air to enter the pipes and pumps. This air must
be expelled when the steering system is bled after you refill your system and during the "Set-up
Routine" when you can use the Autopilot to expel it.
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HYDRAULIC CONNECTIONS FOR TWO LINE STEERING SYSTEMS
A simple schematic of the pump installation is shown in Figure 2.
2 Line Steering System Installation
Delivery Lines:
Ports A and B in the diagram above are the input/output ports of the pump and must be
connected to the steering lines coming from the steering cylinder. It does not matter which
pump port is connected to which steering line.
Compensating Line:
In the above diagram Port C is the compensating or bleed line, and must be connected to the
steering system's reservoir. This connection can be made at a helm pump, remote reservoir
(if there is one), the compensating line connecting two helm pumps, or the compensating line
connecting a helm pump to the remote reservoir. If the connection is being made directly to
the helm pump, ensure that the bleed line is connected to the LOWER helm bleed port. The
compensating line MUST have a gradual rise from the pump to the connection to the steering
system. This allows air to rise out of the pump, ensuring a constant supply of oil to the pump.
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29010016V1.0(18CI & 30CI Pump) .doc
HYDRAULIC CONNECTIONS FOR THREE LINE STEERING SYSTEMS
A simple schematic of the pump installation is shown in Figure 3.
Delivery Lines:
In the above diagram, Ports A and B are the input/output ports of the pump and must be
connected to the steering lines between the steering cylinder and the Uniflow valve. The
simplest method of doing this is to install a tee in each of the cylinder ports of the uniflow
valve itself and connect to these tees. It does not matter which pump port is connected to
which steering line.
Compensating Line:
Port C is the compensating or bleed line and must be connected to the steering system’s
reservoir. This connection can be made at: a helm pump; a remote reservoir (if there is one); the
return line connecting two helm pumps; or the return line between a pump and the Uniflow
valve. If the connection is being made directly to the helm pump, ensure that the bleed line is
connected to the LOWER helm bleed port.
The connection MUST be at least six feet (2 M) from the Uniflow valve as shown above. If the
connection is too close to the Uniflow valve, the manual steering system may not work well.
The compensating line MUST have a gradual rise from the pump to the connection to the
steering system. This allows air to rise out of the pump, ensuring a constant supply of oil to
the pump.
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29010016V1.0(18CI & 30CI Pump) .doc
REFILL AND BLEED
After you have installed your pump, refill and bleed your manual steering system according to
the manufacturer's directions. Any air, which is in the pump, will be expelled in a separate
bleeding routine after you connect the Pump to the autopilot.
TECHNICAL SPECIFICATIONS
Part Number:
20810016
20810018
20810031
20810035
Model Number:
18CI
18CI
30CI
30CI
Operating Voltage:
12VDC
24VDC
12VDC
24VDC
Max Displacement @ 200PSI:
73 in3
73 in3
122 in3
122 in3
Current @ 200 PSI:
4.5 Amps
3.0 Amps
6.0 Amps
3.0 Amps
Max Pressure:
800 PSI
800 PSI
500PSI
500PSI
ALL PUMPS
Port Sizes:
Displacement (18CI):
Displacement (30CI):
Min Stall Pressure:
Oil Type:
Operating Temperature:
Lockvalve:
Lockvalve Leakage:
Unbalanced Cylinder:
Weight:
Size:
Size (metric):
Shaft Seal:
- 3/8 inch compression fittings supplied
- Adjustable, from 36in3 (600cm3) to 73in3 (1200cm3)
- Adjustable, from 61in3 (1000cm3) to 122in3 (2000cm3)
- 1200 PSI (84.0 Bar) (8,268 kPa)
- Any approved hydraulic steering fluid
- 0 to 50 Degrees Celsius (32 to 122 Fahrenheit)
- Yes
- Negligible
- Yes, up to 3/4 (1.9cm) diameter rod
- 5.0 lbs (2.27 kg) including wire
- 10 inches x 3.75 inches x 4.75 inches
- 254mm x 95mm x 121mm
- 100 PSI (6.89 Bar) (689 kPa) minimum
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29010016V1.0(18CI & 30CI Pump) .doc
18CI & 30CI ELECTRICAL CONNECTIONS
The drawing above shows how to connect the two wires from the 18CI and 30CI pump to the
various motor drive controller units. The electrical connections shown apply to several ComNav
products. These products are as follows:
1) ComNav CT2 (part #20350001) Reversing DC Motor Drive Box - 1001 & 2001 Autopilots
2) ComNav 1420 Processor (part #20070003) - 1420 Autopilots
3) ComNav 1440 Processor (part #20080003) - 1440 Autopilots (Not available in North America)
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29010016V1.0(18CI & 30CI Pump) .doc
PUMP BLEEDING INSTRUCTIONS
1.
Bleed your manual steering system
according to the manufacturer's
instructions. When you have completed
the bleeding, leave the equipment for
the bleeding procedure attached to your
hydraulic steering system.
2.
Fill your highest reservoir completely.
Turn the steering wheel just past the
stop to press as much oil as is possible
into the system.
3.
If you can, use a bottle of
recommended hydraulic oil and a piece
of plastic tubing to add extra capacity to
your highest reservoir.
The manufacturer of your system may
provide these items when you purchase a
bleeding kit for your system. If you have a
helper, have them watch the oil level in the
highest reservoir and refill it when necessary.
Adding Capacity
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29010016V1.0(18CI & 30CI Pump) .doc
4.
Your hydraulic cylinder rod is now fully
extended in one direction. To bleed the
Reversing Pump you will be extending
the cylinder rod in the other direction.
Open one and close the other bleeding
screw just as you did when bleeding the
manual part of your system and you
were extending the cylinder arm in this
direction. Generally, you close the
bleeding screw or nipple closest to the
rod which is now retracted. Open the
bleeding screw closest to the now
extended rod.
See diagram on
following page.
5.
If possible, position yourself so that you
can see your hydraulic steering cylinder
while operating the steering controls of
the autopilot.
6.
You will be able to move the steering
cylinder rod by pressing the Red Key or
the Green Key on the Autopilot. When
you press the key, the lights will stop
blinking and the red or green light will
turn on. Extend the rod as far as it will
travel in the other direction.
7.
The Autopilot will stop driving the
Reversing Pump shortly after the rod
reaches the end of its travel.
Bleeding cylinder, rod moving left
Bleeding cylinder, rod moving right.
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29010016V1.0(18CI & 30CI Pump) .doc
8.
Refill your steering system from the
highest reservoir.
9.
Adjust the bleeding screws so that the
cylinder will be bled when the rod is
extended in the original direction.
Generally, you close the bleeding screw
or nipple closest to the now retracted
rod. Open the bleeding screw closest to
the rod which is now extended.
13. Close all bleeding screw or nipples.
Clean up any spills of oil and wipe
fittings clean. Remove any buckets or
equipment a short distance from the
cylinders and fittings.
14. Use the Autopilot to extend the rod fully
in one direction and then the other.
15. Check for leaks by looking for spilled
hydraulic fluid near or on fittings and
cylinders.
10. Use the Autopilot to fully extend the
cylinder rod to the other side.
11. Refill the highest reservoir.
12. Repeat steps 6 to 10 at least 10 times.
****
IMPORTANT
****
If you have installed a ComNav Marine reversing motor pump, a constant running pump or an
engine driven pump, there are several checks that must be done during the first several weeks of
usage in order to prevent poor or dangerous steering performance.
Proper hydraulic pump speed
After you have filled and bled your hydraulic steering system and drive unit, it is important to check
that your drive unit can attain a hardover to hardover time of 10 to 15 seconds. This is the
optimum speed for proper autopilot operation.
Residual air in your steering system
Following the initial installation and bleeding of your ComNav pump, some residual air may remain
suspended in the hydraulic fluid. During the first few weeks, this air will gradually bleed out
through the header tank or the highest helm pump and the oil level may go down. Check several
times and add more oil as required.
Leaking fittings or equipment
Following the initial installation and bleeding of your ComNav pump continuously monitor the oil
level of the reservoir or the highest helm pump in your steering system and add oil as required. If
this condition persists, it may be an indication of leakage in your steering system. Check all
hydraulic steering fittings and equipment for leakage.
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MANUAL CHANGES
DECEMBER 31, 1996
1. PAGE 11 - A STERNER, MORE DETAILED WARNING WAS GIVEN REGARDING
RESIDUAL AIR AS WELL LEAKING FITTINGS AND EQUIPMENT.
2. PAGE 11 - WARNING ADDED ABOUT ATTAINING A 10 TO 15 SECOND H.O. TIME.
3.
Converted document to Word.
July 5, 1999
Added shut-off valves to hydraulic connection diagrams.
September 26, 2000
REMOVED:
"ComNav does not recommend the use of reversing motor pumps in most commercial
applications or in cases where the average duty cycle will exceed 200 hours per month"
CHANGED:
Address
October 6, 2004
CHANGED:
To New PartNumber
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29010016V1.0(18CI & 30CI Pump) .doc
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