Harken Tensioner CT0 Operating instructions

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Tensioner CT0
USER AND MAINTENANCE MANUAL

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INDEX
1. Glossary....................................................................................................................................... 4
2. Symbols ....................................................................................................................................... 4
3. Safety information....................................................................................................................... 5
4. General advice............................................................................................................................. 6
5. Harken®limited worldwide warranty.......................................................................................... 6
6. Product information.................................................................................................................... 7
7. Product identification.................................................................................................................. 8
8. Maximum Loads .......................................................................................................................... 8
9. Weights........................................................................................................................................ 9
10. Product composition................................................................................................................... 9
11. Rope diameter........................................................................................................................... 10
8. Installation procedure............................................................................................................... 11
8.1 Electric Tensioner Outline ......................................................................................................... 11
8.2 Hydraulic Tensioner Outline...................................................................................................... 12
8.4 Installation - Technical info ....................................................................................................... 13
8.5 Tensioner Mounting Template.................................................................................................. 14
9 Motorized use ........................................................................................................................... 16
9.1 Hydraulic equipment (HY) ......................................................................................................... 16
9.1.1 Motor................................................................................................................................. 16
9.1.2 Manifold ............................................................................................................................ 16
9.1.2 Manifold performance data .............................................................................................. 16
9.1.3 Hydraulic motor installation procedure................................................................................... 17
9.1.3 Tensioner manifold installation procedure.............................................................................. 17
9.1.4 PLC Control requirements........................................................................................................ 17
9.1.5 Tensioner Manifold structure .................................................................................................. 18
9.1.6 Hydraulic Motor connections................................................................................................... 19
9.2 Hydraulic performance graph ................................................................................................... 21
9.3 Electric equipment (EL) ............................................................................................................. 22
9.3.1 Electric motor.................................................................................................................... 23
9.3.2 Electric unit wirings ........................................................................................................... 24
9.3.3 Electric unit equipment use............................................................................................... 24
9.3.2 Performance data.............................................................................................................. 25
9.3.3 Electric performance graph............................................................................................... 25

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10. Installation procedure............................................................................................................... 26
10.1 Cleaning and maintenance........................................................................................................ 26
10.2 Internal maintenance procedure .............................................................................................. 27
10.2.1 Maintenance product........................................................................................................ 27
10.2.2 Tools .................................................................................................................................. 28
10.2.3 Disassemble procedure.......................................................................................................... 29
11. Assembly ................................................................................................................................... 33
11.1 Lipped rings ............................................................................................................................... 34
11.2 Torque ....................................................................................................................................... 34
11.3 Marking ..................................................................................................................................... 34
12. Troubleshooting ........................................................................................................................ 35
13. Ordering spare parts ................................................................................................................. 36
14. Contact us.................................................................................................................................. 36

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1. Glossary
-Intended use: specific and proper use of the tensioner for which it is designed
-Improper use: use of the device in a different way from that indicated in the instructions
for use specified in this manual
-Qualified operator: person who has attended specialisation and training about the use of
the tensioner
-User: person who uses the winch and the tensioner regularly
-Maximum working load (MWL): maximum value of the load the tensioner can bear
2. Symbols
WARNING!
This denotes the existence of the potential danger, which could cause injury or
damage if the information or instructions are not followed
NOTE!
This denotes important information concerning the device

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3. Safety information
WARNING! Read this manual carefully and fully understood before using the
system to avoid personal injury or property damage during system operation.
-This manual is an integral part of the device and aims to provide all the
information needed for its safe and correct use and for proper maintenance.
-This manual gives technical information on installation and maintenance.
-This information is destined exclusively for qualified operators.
-Installation of the device by personnel who are not experts may cause serious
damage to users and those in the proximity product.
-Install and use the tensioner only as described in the technical information
supplied.
-Improper use can cause severe harms to users, equipment and the boat.
-Never substitute any tensioner part with one that is not original. Even though they
look similar and are both made by Harken®, the non-original part may not be
suitable and the warranty will be invalidated.
-Modifications carried out by the user, without explicit written authorization from
the manufacturer, will invalidate the warranty and relieve the manufacturer of any
responsibility for damage caused by the defective product.
-Failure to install the tensioner will void the warranty of the device itself and the
Harken®product to which it is connected.
-Refer to the warranty on the web site www.harken.com
-Do not apply to the tensioner loads greater than the MWL (Maximum Working
Load).
-If the tensioner is powered by a hydraulic motor:
•Do not operate the hydraulic motor during installation or maintenance
•Do not let the oil in the system come into contact with your eyes or skin. Harken
cannot be responsible for damage or injury resulting from unsafe product use,
lack of maintenance or incorrect product and /or system installation or operation.
-Wear suitable clothing when using the tensioner, to avoid loose ends of fabric
becoming entangled in the tensioner.
-Periodical maintenance must be carried out regularly as specified in the chapter
on Maintenance. In case of doubt, contact Harken Tech Service.
-This manual is available only in English. If you do not fully understand the English
language, do not carry out the operations described in this Manual. For any
doubts, questions or comments contact the Harken distributors nearest to you,
Special Project assistance, or contact the Harken Italy Technical Service by e-
mail: [e-mail]
-See www.harken.com for additional safety information.

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4. General advice
Intended use
The Harken devices are designed and manufactured for a use on sailing boats to control
ropes, halyards and related sail and rig systems. For any other usage, contact the Harken
Italy Technical Service by e-mail: [e-mail]
Improper use
- The Harken device must not be used for purposes different from those outlined in ‘Intended
use’ chapter, or for purposes not mentioned in this manual or different from those mentioned.
- The Harken device must not be used if unauthorized modifications or interventions have
been carried out.
- Do not use the tensioner for hauling, mooring the boat or weighing the anchor.
- Do not use the tensioner to divert a line (cross-sheeting).
5. Harken®limited worldwide warranty
The Harken product is covered by a warranty: if during the warranty period the tensioner
proves defective or suffers breakages, as indicated in the warranty, the manufacturer, after
checking the device, will repair or replace the defective components.
NOTE!
Refer to the Harken®Limited Worldwide Warranty in the Harken Catalogue and
on the website www.harken.com

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6. Product information
Harken Tensioner CT0 is needed to a double purpose:
1. Avoid slack and the entanglement of the rope on the Captive drum.
2. Keep tension on the rope wrapped on the Captive drum.
The Tensioner removes the slack when loading and unloading line on the spool.
Two independently low friction rollers guide the rope along the entry line direction for
constant and reliable tension.
Tensioner CT0 can be used with a maximum dynamic load of 3T.
One unit has two possible motor assemblies for flexible installation:
-by an electric motor
-by a hydraulic motor
Tensioner CT0 is used both for Hydraulic Captive Winch and for Electric Captive Winch.
As regards the differences, refer to:
- the installation procedures in the ‘Installation’ chapters of the Hydraulic Tensioner CT0 and
of the Electric Tensioner CT0 of this manual;
- the performance graphs in the relative chapters of the electric and of the hydraulic versions
of this manual.

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Legend
Rope diameter:
Ø10-12mm
Ø14-16mm
Motorization type:
EL = Electric motor
HY = Hydraulic motor
Voltage
EL →24V
HY →50cc
7. Product identification
The product identification is based on its composition and technical functions:
8. Maximum Loads
Loads associated to Tensioner CT0 are:
- Maximum tensioning load: 12Kg
- Maximum working load (MWL) on the rope: 3000 Kg (Maximum dynamic load)
- Maximum static load on the rope: 5000Kg
Tensioner
CT0
Maximum working
load (MWL)
Maximum static load
Maximum tensioning
load
lb
Kg
lb
Kg
lb
Kg
6600
3000
11000
5000
26,5
12
WARNING!
Subjecting the tensioner to loads above the Maximum Working Load can cause
the winch to fail or pull off the deck suddenly and unexpectedly during high loads
causing severe injury or death.
Product
Size
Rope diameter
Motorization
type
Voltage/displacement
Tensioner
CT0
XX
EL/HY
XXX

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9. Weights
NOTE!
Weights refer to the tensioner with the motorization.
10. Product composition
Tensioner CT0 is composed by the following groups:
Version
Weight [Kg]
EL
3.8
HY
6.8

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11. Rope diameter
WARNING!
For safety and correct performances, use ropes of the diameters indicated below.
NOTE!
For safety and for correct performance of the Tensioner use only rope of the best
brands.
The rope diameter when is not stretched cannot exceed the 5% of the nominal
value specified at the Captive order.
Two configurations of Tensioner CT0 are available in function of the rope diameter:
Ø10-12mm and Ø14-16mm.
Every Tensioner is assembled considering the specific rope diameter defined at the order.
The parts that change between the two configurations are the hubs and the lipped rings:
Tensioner description
Ø rope
Hub code
Lipped ring code
min
max
in
mm
in
mm
Tensioner CT0 10-12
0.39
10
0.47
12
S734630052
S737290080
Tensioner CT0 16-18
0.55
14
0.63
16
S734620052
S737300080

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8. Installation procedure
To install the device, please follow the steps shown below of the installation procedure,
taking into account the outline, the mounting template and several technical info needed.
8.1 Electric Tensioner Outline
Harken supplies to the customer the outline drawing of the product and the minimum space
around necessary for making the inspection and maintenance of the product.
NOTE!
The following dimensions refer to electric motorized Tensioner (all
configurations).
All dimensions are in [mm]

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8.2 Hydraulic Tensioner Outline

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8.4 Installation - Technical info
WARNING! - The mounting surface requires a flat area of 0.5mm tolerance under
the Tensioner base plate.
WARNING! -The Tensioner must be aligned with the Captive Winch and/or
turning block respecting the entry/exit angle (see outline, on the base of the
Tensioner are marked with engraved line) and the height of the line (24,6mm
from the fixing surface to the centre of the rope).
It is installer's responsibility to carry out all structural tests needed to ensure that the deck
can bear the load.
To install the Tensioner CT0 to the deck, use 4xM10bolts, steel class A4 70:
NOTE! Harken does not supply the fasteners needed to install the Tensioner
since these may vary depending on the deck on which it is to be installed. It is the
installer's responsibility to choose the correct fasteners taking account of the
loads they will have to bear.
Harken assumes no responsibility for incorrect installation of its devices or for an incorrect
choice of mounting fasteners.
WARNING! - Use only the bolt size and number specified in the outline drawings.
Failure to use the correct number and size of mounting fasteners or failure to
ensure the correct deck strength can cause damages or severe injury during high
loads.
WARNING! - Incorrect installation of the Tensioner may cause severe injury.
The mounting bolts must be isolated with anti-corrosive lubricants (i.e. DURALAC or
TEFGEL). It is mandatory to prevent any direct contact between the aluminum Tensioner
frame from other conductive materials such as carbon fiber (deck or hull); in that case a
fiberglass lamination is required to avoid any galvanic corrosion.

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8.5 Tensioner Mounting Template
To operate the installation, follow the steps below (alphabetic indexes):
A. Place the drilling cut-out template over the point chosen for installation.
The template in DWG format and 1:1 scaled is available on request from the Harken Italy
Tech Service at [e-mail].
Small-scaled mounting template for Tensioner CT0 is shown below.
B. Mark the position of the holes to be drilled in the deck.
C. Drill the holes.
D. Seal the external part of the main holes and all the fixing holes with a suitable marine
adhesive sealant as shown in the following image (green lines).
To apply the adhesive sealant: clean and remove all grease from the bottom surface and
apply the sealant.

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NOTE!
Make sure the drainage holes in the base of the tensioner are not obstructed by
the sealant.
E. Remove excess marine sealant.
SEALING TEMPLATE

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9 Motorized use
9.1 Hydraulic equipment (HY)
9.1.1 Motor
Hydraulically operated, Tensioners have a load capacity proportional to the pressure set up
on the manifold, while the recovery speed of the Tensioner is proportional to the oil flow.
The hydraulic motor oil must reflect the ISO VG 46 characteristics. It must be filtered with a
maximum grade of 10 micron and with a contamination level equal to or inferior to class
(according to NAS 1638 or 22/18/15 according ISO/DIN 4406), the temperature range of the
hydraulic oil during operation have to be within 25°C and 90°C.
Motor ports that have to be connected to the manifold are 2 main ports:
-Size: G 3/8”
-Depth: 12mm
Motor displacement is 50cc.
9.1.2 Manifold
The Tensioner manifold is plumbed independently and does not rely on the winch for oil flow.
The manifold includes a solenoid valve that should be energized while paying-out (easing
out). The independence of this valve from the Captive winch directional valve, allows to
optimize timing between winch and Tensioner.
The Pay-out circuit includes a pressure-reducing valve, allowing the users to adjust
Tensioner pull force.
During pay-in (trimming in) the Tensioner motor is allowed to freewheel. The pay-in circuit
includes a low-pressure relief valve so the user can adjust drag while trimming in. This is
important when there is no sheet load to help prevent overrides on the winch drum.
All work ports are BSPP type (ISO/DIS1179-1).
All components and work ports are clearly marked with engraved labels.
9.1.2 Manifold performance data
Specifications of the hydraulic motors used to power the hydraulic Tensioner CT0:
Tensioner CT0
recommended pressure range
Max recommended
flow
PSI
bar
gal/min
l/min
From 725 to 2030
From 50 to 140
3,73
14

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9.1.3 Hydraulic motor installation procedure
The pressure lines must be connected to the motor using the approved size and type
hydraulic hose.
WARNING! - Do not remove the plugs on the Tensioner motor connections until
absolutely necessary to prevent contamination.
Each 90° hose bend causes pressure loss and decreases performance - avoid where
possible. If a 90° bend is needed, use a 90° swept hose fitting not a 90°elbow. Do not exceed
the minimum bend radius specified by the hose manufacturer.
9.1.3 Tensioner manifold installation procedure
Manifold can be mounted near the Tensioner or in a remote location.
The various functions must be connected to the manifold using approved size and type
hydraulic hose.
Before connecting make sure insides of hoses tubes are clean and free of debris that can
damage valves.
WARNING! - Do not remove the plugs on the manifold hydraulic connections
until absolutely necessary to prevent contamination.
Each 90° bend causes pressure loss and decreases performance - avoid where possible. If a
90° bend is needed, use a 90° swept hose fitting not a 90°elbow. Do not exceed the
minimum bend radius specified by the hose manufacturer.
Manifolds drilled through for 2xM8 mounting fasteners.
The max pressure is set on the valve PR1 on the Tensioner manifold, during the
commissioning of the system, it should be verified that during the pay-out the sheave does
not slip on the rope: in this case, reduce the pressure.
The drag of the Tensioner during the pay-in is set by the valve RV1 on the manifold, to
increase the drag screw the valve (to reduce unscrew), also in this case verify that in all
conditions the sheave does not slip on the rope.
9.1.4 PLC Control requirements
•The Hydraulic Tensioner manifold needs to be connected to the PLC for the solenoid
valve control. In the pay-in direction the Tensioner motor is not powered, the
Tensioner is freewheeled by the pull of the Captive.
On the pay-out, the solenoid valve should be activated.
•Tensioner should be operated for a slightly longer period than the winch. It should be
switched on 0.5 seconds before releasing the winch brake and deactivated 0.5
second after the brake is engaged again.

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9.1.5 Tensioner Manifold structure

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9.1.6 Hydraulic Motor connections

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PORT ID TABLE
ID
DESCRIPTION
SIZE
P
Pressure IN
G1/2” BSPP
T
Tank OUT
G1/2” BSPP
TA
Pay IN, Tensioner motor
G1/2” BSPP
TB
Pay OUT, Tensioner motor
G1/2” BSPP
GTA
Gauge, Tensioner motor Pay IN
G1/4” BSPP
GTB
Gauge, Tensioner motor Pay OUT
G1/4” BSPP
GP
Gauge, pressure IN
G1/4” BSPP
LS
Load sense
G1/4” BSPP
CAVITY/DEVICE ID TABLE
HYD. ID
DESCRIPTION
SV1
Tensioner valve, Pay OUT
PR1
Tensioner reducing valve, Pay OUT
CV1
Check valve, Tensioner load sense
RV1
Tensioner Pay IN relief valve
WARNING! - Do not overdo with pressure at start-up operations.
Here below the suggested maximum pressures at first activation:
Start-up pressure
HYD. ID
DESCRIPTION
PSI
bar
PR1
Tensioner reducing valve, Pay OUT
870
60
CV1
Check valve, Tensioner load sense
218
15
NOTE!
The maximum flow and pressure must be in accordance to graphic performance.
Wrong dimensioning of components can void warranty.
For any other information, contact Harken Tech Service at [e-mail]