Hydraulic Projects PC45 Quick guide

Hydraulic Projects Ltd
PC45
Constant Running Marine Autopilot Hydraulic
Pump Installation and Service Instructions
Serial Number
FORM_PC45 ISS.4
Released\11 Data Sheets & Manuals\Manuals\Customer Documentation\FORM_PC45.PDF
“Engineering Excellence”

The information in this manual was, to the best of our knowledge,
correct when it went to press and Hydraulic Projects Ltd cannot be liable
for any inaccuracies or omissions. There may also be differences
between the specifications in the manual and the product as a result of
ongoing development for which we accept no liability.
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• Important Safety Information
• Description
• Pump Size
• Location
• Hydraulic Connections
• Hydraulic Fluid
• Commissioning
• Trouble Shooting
• Service
• Filters
• Brushes
• Installation Details
• Technical Data
• Typical Performance
• Wiring details
• Typical Arrangements
• General Information
• End of Life Disposal
• Contact details
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IMPORTANT SAFETY INFORMATION
Failure to install and maintain this equipment in accordance with the in-
structions contained in this Manual could result in damage or injury.
This equipment must be installed and maintained by a person who is
qualified to do so. This equipment is only for use with marine
Auto pilots within the limitations stated in the following pages.
Auto pilot steering systems are navigational aids and the user must still
maintain a permanent watch.
This equipment meets the latest EMC (Electromagnetic Compatibility)
standards required for use in the recreational marine environment. In or-
der to ensure conformance and to prevent interference with electronic
systems the unit must be properly bonded to earth and the
supply cables screened.
DO NOT FLASH TEST
Beware of hot motor and solenoid components and the risk of
entrapment from moving parts.
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DESCRIPTION
"PC45" constant running type gear pumps are driven by 12 or 24 volt dc
permanent magnet fan cooled motors. Flow reversal is achieved by
switching a double acting solenoid valve. Incorporated in the design are
pilot operated check valves that prevent the pump being back driven by
the manual steering system.
Other features include compatibility with balanced or unbalanced cylin-
ders and they can also be used with pressurised reservoir systems
(max 3.5 bar).
A relief valve, variable speed control and an integral reservoir with filter
are fitted as standard.
PUMP SIZE
Maximum flow output at no load is indicated on the rating plate. Check
the voltage shown is correct for the output of your auto pilot.
LOCATION
These pumps are designed for 'under deck' installations only.
Excessive temperature, vibration and fumes in the atmosphere can
drastically reduce motor brush life.
Mounting the unit on a flimsy surface can transmit and amplify undesir-
able noise.
As in common with other electrical equipment, contact with water and
excessive humidity must be avoided.
Keep the cable and pipe work runs as short as practically possible.
Units must be mounted either horizontally, foot down or vertically, tank
down (refer page 10)
This unit should not be positioned in a confined area where there are in-
flammable gases.
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HYDRAULIC CONNECTIONS
The 'A' and 'B' ports are G1/4(BSP) parallel threaded, the 'R' port is
G3/8 (BSP) parallel threaded.
Use only bonded rubber/metal washers to seal the fittings. Do not use
tapered adapters, sealing compound or P.T.F.E tape.
Ports marked 'A' and 'B' are the service line connections to the ram,
the pipe work and connections must be suitable for a 100 bar working
pressure minimum rating.
The port marked 'R' is the reservoir or balance line. If used as a bal-
ance line it must be connected, through a continuous rise to the helm
pump bottom connection.
Do not plug this port – damage and steering failure could result.
If used with pressurised reservoir type systems the pipe must be suit-
able for at least 7 bar.
Ensure that no dirt enters the system during the installation, be certain
that all pipes and fittings are cleaned before connecting up.
HYDRAULIC FLUID
Good quality ISO VG10 to ISO VG42 hydraulic mineral oil is recom-
mended, check the compatibility with the helm pump and ram manu-
facturers specifications and if it is suitable for use with nitrile rubber hy-
draulic seals.
Refer ‘Recommended Oils’.

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COMMISSIONING
CAUTION! Be aware of the danger of moving linkages and the risk of
entrapment during this procedure.
Bleed the system according to the Helm Pump Manufacturers instruc-
tions. To aid clearing air from the electric pump please note the orienta-
tion of the hydraulic/electrical connections -See installation data.
The pump must not be run without oil.
Set the speed control to achieve the desired hard-over time (nominally
12 seconds). Screw in to reduce speed.
The relief valve is set at 58 Bar and should not be adjusted unless the
steering gear is designed to operate at a lower pressure.
TROUBLE SHOOTING
1) Motor does not run
: check electrical connections.
: check auto pilot output.
: check motor brushes.
: check fuse / trip rating (Ref. page 10)
2) Motor runs, but no ram movement.
: check that the solenoid is operating.
: check motor rotation direction.
: check for air in system.
: check for incorrect hydraulic connections.
: check there is sufficient fluid in the system.
: check that the flow control is open.
: check that the relief is set correctly.
: check the drive coupling between pump and motor.
: check if the pump has been dismantled and incorrectly assembled.
3) Excessive noise
: check for air in system.
: check the motor for damage.

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SERVICE
With a minimum of moving parts and top quality precision engineering
the pump will give many years of trouble free service. Should service re-
placement seals be required, a kit is available from your nearest dealer
under the following part code: PC45-sk
During disassembly carefully note the order of the components and
keep everything scrupulously clean, especially the
pump faces with the plastic shim gasket or o-ring. When re-assembling,
lubricate the check valve piston and gears with
hydraulic fluid and ensure that all parts move freely. A smear of grease
on the o-rings will aid assembly without damage.
Evenly torque tighten the four M6 pump socket head cap screws to 10
Ibs/lft (13.5 Nm). The gears must turn easily at this stage.
FILTERS
Constant running pumps are equipped with internal return-line filters
which must be changed after the first 50 hours and then annually. Spare
filters can be ordered under the part code: R2690
To access the filter first drain the tank then undo and remove the clamp
ring. Carefully withdraw the tank taking great care not to distort the tank
or damage the O ring seal or tank lip. The filter is secured with a single
nylock nut. Once the filter is replaced tighten the nylock nut until the fil-
ter is secure then fit the new O ring and re-fit the tank. A smear of gen-
eral purpose grease will aid assembly.
BRUSHES
Inspect the motor brushes every 500 hours, or annually, for wear.
Replacement motor brushes are available from your dealer. State the
serial number of your unit when ordering.
Be sure to clean out all loose carbon before fitting new brushes.
If fluid has entered the motor, degrease the brush gear and commutator
before running the unit, otherwise arcing will reduce brush life.

Clamp ring Brush holder
Tank O ring sealFilter
9/16” A/F
Nylock nut
9
7/16” A/F Clamp ring nut
torque to 6 lbs/ft (8.1 Nm)

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TECHNICAL DATA
Max Pressure: 70 Bar
Amb. Temp: -20 to +55 deg C
(ref. ‘Recommended oils)
Supply Voltage: 12 / 24 VDC
Current Limitation: Must be fitted with current overload.
Minimum fuse/trip rating :
PC45FCU24=40A
PC45FCU12=50A
Performance: Refer to graphs
Installation: Under deck, horizontal or vertical
(tank down) Horizontal only if fitted
with isolation mounts.
Pipework: Suitable for 70 Bar
working pressure (100 max)
Rec. Oils: From -20 to +10 deg C
useISOVG10.
From +10 to +55 deg C
useISOVG40

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Filtration: Replacable internal element. Return
line 15 micron
Motor Rating: 25% Duty Cycle: 30A
(PC45 FCU 24) 50% Duty Cycle: 25 A
100% Duty Cycle: 20 A
550W,IP54
Reservoir: 4.0 L Capacity
3.5BARMax.
Relief Valve: Pre-set 57 Bar
Speed Control: Screw in to reduce speed
Adjustable Pressure compensated
Solenoid Coils: 12V 2.5A
24V1.3A
Relay: 12V 1.0A
24V0.5A
Reservoir Port 'R': G3/8 (BSP) Parallel
Cylinder Ports 'A' & 'B': G1/4 (BSP) Parallel
EMC Protection: BS EN 60945:2002 (DC)
Ignition protection: BS EN 28846:1993
Part Nos: PC45 FCU 24 (550W)
PC45FCU12(405W)
Weight: 12kg

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Control
R
Cylinder Port B
Cylinder Port A
190mm
Ø193mm
25.4mm
50.8mm
360mm
Oil Filler / Breather
Or Connection
to Helm Pump
Speed
Relief
Valve
INSTALLATION DETAILS

WIRING DETAILS
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TYPICAL PERFORMANCE
(WITH FLOW CONTROL SET TO MAXIMUM)
12VAMPS
24VAMPS
24VFLOW
12VFLOW
Coil Wiring
Diagram
Attach leads to contactor as shown
Solenoid Coil B
Autopilot
C A B
Battery
Use wire guage - 2.5mm Min
2
Fuse - 35A
A & B - Course output
C - Pump engage (Clutch) output
+- -++-
RED motor lead
BLACK motor lead
Motor
rotation
+
Contactor

TYPICAL ARRANGEMENTS
Helm pump with Integral check valve
Steering Cylinder
Steering Cylinder
Unloader valve (order R2345-O)
filler/breather
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Secondary Steering
Primary Steering

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Keep this manual in safe place.
Quote the model and serial numbers in all correspondence.
Model Number: _____________________________________
Serial Number:: _____________________________________
Date of Purchase: _____________________________________
Dealer:: _____________________________________
_____________________________________
_____________________________________
_____________________________________
GENERAL INFORMATION
END OF LIFE DISPOSAL
Please dispose of End of Life items responsibly.
In the event that you are unable to use your nearest local authority
civic amenity sites to recycle, units can be returned to us at the
address on the back cover.

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Hydraulic Projects Limited
Dawlish Business Park
Dawlish
Devon
EX7 0NH
United Kingdom
Telephone [phone]
Fax [phone]
Email [email protected]
Web www.hypro.co.uk
CONTACT DETAILS