Kobelt HPU400 Series Instruction Manual

Kobelt Manufacturing Co. Ltd.
HPU400
Accu-Steer Hydraulic Power Unit
Owner’s Operation, Installation &
Maintenance Manual
June 2019

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NOTES:
RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE
Model #:
Serial #:
Date of Purchase:
Date of Installation:

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TABLE OF CONTENTS
1Introduction ............................................................................................................ 4
1.1 Contact .................................................................................................................... 4
1.2 Safety....................................................................................................................... 4
2Product Description ................................................................................................. 6
2.1 Components ............................................................................................................ 6
2.2 Technical Specifications ........................................................................................... 8
3Installation ............................................................................................................ 11
3.1 Mechanical ............................................................................................................ 11
3.2 Hydraulic................................................................................................................ 11
3.3 Electrical ................................................................................................................ 13
4Commissioning ...................................................................................................... 16
4.1 Hydraulic Fill & Bleed ............................................................................................. 16
4.2 Electrical Check...................................................................................................... 16
4.3 Functional Test ...................................................................................................... 17
5Operation.............................................................................................................. 18
6Maintenance ......................................................................................................... 19
6.1 Preventative Maintenance..................................................................................... 19
6.2 Recommended Spare Parts.................................................................................... 20
7Troubleshooting .................................................................................................... 21
8Warranty............................................................................................................... 22
9Appendix A: Installation Dimensions...................................................................... 23
10 Appendix B: Parts List ............................................................................................ 24
11 Appendix C: Manifold Assembly Parts.................................................................... 29
12 Appendix D: Typical System Arrangement.............................................................. 31

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1INTRODUCTION
1.1 CONTACT
Kobelt Manufacturing Co. Ltd.
8238 129th Street
Surrey, British Columbia
Canada, V3W 0A6
Sales Tel:
Fax:
Email:
Website:
[phone]
[phone]
[e-mail]
www.kobelt.com
This document is intended to clearly present comprehensive product data and provide
technical information to assist the end user in design applications. 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.
Kobelt recommends that customers visit our website to check for updates to this Manual.
Once a product has been selected for use, it should be tested by the user to ensure proper
function in all possible applications. For further instructions, please contact our distributors or
visit our website.
1.2 SAFETY
1.2.1 Safety Alerts
Throughout this manual, the following symbols, and their accompanying explanation, are
used to alert the user to special instructions concerning a service or operation that may be
hazardous if performed incorrectly or carelessly. The associated risk levels are stated below.
This symbol indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
This symbol indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
This symbol indicates a hazardous situation, which if not avoided,
could result in minor or moderate injury.
This symbol informs the reader of events not related to personal
injury but which there is a risk of damage to property or equipment.
This symbol informs the reader of safety-related instructions or
procedures.

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1.2.2 Notice to Installer
Disregarding the following safety measures can result in an accident causing severe injury to
personnel and damage to material assets.
•Only use the product as directed in this manual.
•Never put the product into service if there is evidence of visible damage.
•Never put the product into service before fully completing installation and
commissioning.
•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. (For the purpose of this manual, qualified personnel are persons
who are familiar with the assembly, installation, commissioning, and operation of the
product and who have the qualifications necessary for their occupation.)
•Observe all specifications in this manual. If these guidelines are not followed and
damage occurs, the warranty will be voided.
1.2.3 Product Hazards
High Pressure Operation: This HPU unit generates high pressure
hydraulics. Ensure all power sources are locked out prior to
performing work.
Equipment Starts Automatically: HPU units are controlled remotely
and may activate suddenly causing bodily harm. Ensure all power
sources are locked out prior to performing work.
Disconnect Power: Turn off power at distribution panel before
beginning installation to protect installer from electrical hazards.
Voltage and Current Compatibility: Confirm that the power source
is compatible with the maximum voltage and current ratings of is
product variant. Failure to do so could result in damage or fire.

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2PRODUCT DESCRIPTION
The Accu-Steer Electric Pumpset is designed to interface hydraulic steering with
electric/autopilot control. Its compact and rugged construction provides ease of installation
along with long life operation. This unit is available in a wide range of voltages and flows for
both standard and custom requirements.
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: HPU400 Overview Diagram
2.1 COMPONENTS
The Accu-Steer Pumpset is a complete assembly consisting of an electric motor with control
box, gear pump, hydraulic control manifold and heavy-duty adapter mount. As the pump unit

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is self-contained, installation involves connecting the pump to the steering lines and the
electrical control and adjusting the unit to the requirements of the vessel.
2.1.1 Electric Motor
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. These motors are available in a wide range of voltages and
horsepower’s.
The electric control box on DC motors provides for remote start and thermal protection along
with large terminals for easy connection.
2.1.2 Gear Pump
The gear pump is a compact rugged unit which features a cast iron case, hardened steel gears
and a high-pressure shaft seal. The suction side of the gear pump is connected to a suction
drop manifold. This manifold has oversized porting for low velocity oil flow and air/oil
separation.
2.1.3 Hydraulic Steer Valve Manifold
The hydraulic manifold features the following;
•high pressure reusable filter
•pressure relief cartridge
•adjustable high and low flow control cartridges
•high speed solenoid valve
•pressure gauge
•4-way soft shift solenoid valve (HPU 200-300 optional, HPU400 standard)
•valve housing anodized aluminum with oversized porting
•bleed fitting for air extraction
2.1.4 Motor/Pump Housing
This coupling interfaces all components of the pumpset as well as provides a stable foot
mount. The unit is machined to ensure accurate coupling of the motor and pump. It houses
the flexible drive coupling, which transfers energy from the motor to the pump. The flexible
drive coupling provides quiet vibration-free alignment. It is constructed of anodized
aluminum.

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2.2 TECHNICAL SPECIFICATIONS
Table 1: HPU400 Technical Specifications –DC Configurations
MODEL
HPU400-24
HPU400S-24
KOBELT P/N:
600-160
600-160SS
NOMINAL MOTOR VOLTAGE
24 VDC
MAXIMUM MOTOR CURRENT
29 A
NOMINAL SOLENOID VOLTAGE
24 VDC
SOLENOID MAX. CURRENT
Direction: 1.3 A
Speed: 0.9 A
MAX. OUTPUT
4 GPM [15.1 Lit. /min.]
MAXIMUM ALLOWABLE
PRESSURE
•A & B PORTS
•T PORT
1000 PSI [70 bar]
50 PSI [3.4 bar]
RELIEF PRESSURE
750 PSI [51.7 bar]
VALVE WITH SOFT SHIFT
NO
YES
SERVICE DUTY
Intermittent: 20% ON / 80% OFF
RECOMMENDED FLUID
ISO VG 32, VI 60 Hydraulic Oil
PORT SIZE AT MANIFOLD BODY
-06 SAE ORB
PORT ADAPTERS
-06 SAE ORB TO 1/4” NPT
OPERATING TEMPERATURE
-14… 122oF [-10… 50oC]
PRODUCT WEIGHT
85 lbs [39 kg]
Table 2: HPU400 Technical Specifications –AC Configurations
MODEL
HPU400-
115/230-12
HPU400S-
115/230-12
HPU400-
115/230-24
HPU400S-
115/230-24
KOBELT P/N:
600-161
600-161SS
600-162
600-162SS
NOMINAL MOTOR VOLTAGE
115/208-230 VAC
MAXIMUM MOTOR CURRENT
10.8A /5.4 A
NOMINAL SOLENOID VOLTAGE
12 VDC
24 VDC
SOLENOID MAX. CURRENT
Direction: 2.5 A
Speed: 1.7 A
Direction: 1.3 A
Speed: 0.9 A
MAX. OUTPUT
4 GPM [15.1 Lit. /min.]
MAXIMUM ALLOWABLE
PRESSURE
•A & B PORTS
•T PORT
1000 PSI [70 bar]
50 PSI [3.4 bar]
RELIEF PRESSURE
750 PSI [51.7 bar]
VALVE WITH SOFT SHIFT
NO
YES
NO
YES
SERVICE DUTY
Intermittent: 20% ON / 80% OFF
RECOMMENDED FLUID
ISO VG 32, VI 60 Hydraulic Oil
PORT SIZE AT MANIFOLD BODY
-06 SAE ORB
PORT ADAPTERS
-06 SAE ORB TO 1/4” NPT
OPERATING TEMPERATURE
-14… 122oF [-10… 50oC]
PRODUCT WEIGHT
75 lbs [34 kg]

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2.2.1 Temperature Limits
The motor temperature has a maximum limit of 248oF [120oC]. Allowing the temperature to
exceed this limit will permanently damage the motor windings. The maximum oil
temperature limit is 149oF [65oC].
Observe the operating temperature range limits as presented in Table 1. Do not operate the
unit if the ambient temperature where the unit is located exceeds these limits.
Exceeding these temperatures may result in reduced operational life
or damage to the product.
2.2.2 Pressure Range
The normal operating pressure of the unit is 0 to 750 psi. Avoid operating the unit against the
rudder stops for prolonged periods of time.

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Figure 2: Hydraulic Schematic

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3INSTALLATION
3.1 MECHANICAL
The pumpset 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.
The HPU is equipped with (2) two clearance holes for 3/8”bolts and (4) four holes for 5/16”
bolts through the mounting feet. Ensure that the unit is securely fastened to a suitable
foundation.
Figure 3: HPU Mounting Pattern
3.2 HYDRAULIC
Three hydraulic connections are required to the pumpset. Two lines connect the main
steering lines, and the third line to the header tank of interconnect line which compensates
for thermal expansion of the oil and self bleeds air from the system.
Flexible hose with a pressure rating of minimum 1500 psi working pressure is recommended
for the steering line connections. Flexible hose (min. 250 psi pressure rating) is
recommended for the fill/interconnect line. The hose should be minimum 3/8” inner
diameter.
A shut-off, or isolation, valves are strongly recommended for all three lines to provide
isolation in case of pumpset failure.
Ensure the plugs remain in place until the unit is ready for
connection.

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All piping and hoses must be flushed prior to connection. Failure to
do so can result in damaged components and seals.
The two hydraulic ports on the valve block are fitted with 3/8” NPT (National Pipe Thread)
adapters. If preferred, the adapters can be removed, and connections can be made directly
to the valve blocks -06 SAE ORB ports. When installing the hydraulic fitting in the 3/8” NPT
port a pipe thread sealant such as Teflon paste must be used.
All hoses and piping must also be plugged or capped until ready for
connection.
The piping to the steering cylinder should be 3/8” nominal size and no more than 1/2” with a
suitable wall thickness to safely withstand the operating pressure. The Port and Starboard
steering lines should have a pressure rating of 1000 psi minimum. Secure the piping against
vibration with pipe clamps spaced every 3 feet [1 m].
The connections to the hydraulic manifold must be made by hoses of suitable rating to
accommodate any movements, vibration or thermal strain.

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Figure 4: Connections in Top Face of Hydraulic Manifold
(4) four hydraulic connections are required:
•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.
•Connect the ‘TANK’ port to the to pump suction line with recommended in line filter.
•Connect the ‘PRESSURE’ to the pump.
3.3 ELECTRICAL
The pump unit is manufactured for operation from 12VDC, 24VDC, or 115/208-230VAC supply
voltages. For DC motor configurations the electrical junction box contains a remote starter
relay, a thermal breaker, and a terminal strip. The DC start relay may be activated with a

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positive or negative switched signal. The terminal strip contains connections to the port,
starboard, and speed control solenoids located on the manifold.
For AC motor configurations the electrical junction box contains a terminal strip with
connections to the port, starboard, and speed control solenoids located on the manifold. The
junction box does not contain any AC termination, these connections are to be made directly
to the junction box located on the side of the motor.
When AC drive motors or large DC drive motors are used, the customer should ensure that
their motor protection and starting circuits conform to ABYC recommendations or other
applicable local electrical codes. Ensure that the electrical cable used to supply the motor and
control connections are sized properly to prevent unreasonable voltage drop.
The solenoids use a common connection (Terminal 5) and can be activated by a positive or a
negative pulse signal. The port and starboard manifold coils are connected to terminals 6 and
7. The high-speed coil is connected to terminal 5 and 8. The high-speed coil uses the same
polarity pulse as the 4-way solenoids.
DO NOT energize the coil detached from the valves.
Figure 5: Electrical Connection Locations
The (3) three locations of the solenoid connection wires are shown in Figure 5 above. The
corresponding wiring Pair #, wiring size, colour, and arrangement is defined in Table 3 and
Figure 6.

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Table 3: HM450 Wiring Connections
HM450
Pair #
Wire Name
Colour
Gauge
Function
1
HS-A
White
18AWG
High-Speed Coil connection A.
1
HS-B
White
18AWG
High-Speed Coil connection B.
2
CYL1-A
Black
18AWG
Cylinder Port 1 Coil connection A.
2
CYL1-B
Black
18AWG
Cylinder Port 1 Coil connection B.
3
CYL2-A
Black
18AWG
Cylinder Port 2 Coil connection A.
3
CYL2-B
Black
18AWG
Cylinder Port 2 Coil connection B.
Figure 6: HPU400 Electrical Wiring Diagram

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4COMMISSIONING
4.1 HYDRAULIC FILL &BLEED
After the hydraulic and the electrical connections have been completed, open all isolating
valves and allow enough time for the pump and lines to fill with oil. Start the pump and
observe the pressure gauge. There should be some pressure showing (approx. 40-80psi). If
not, check the rotation of the pump motor (clockwise as viewed from the motor end). If the
rotation is wrong check the polarity of the power connection to terminals 1 and 2. All pumps
are leak and run tested prior to shipment.
Check that the high-speed solenoid is not activated. Operate the 4-way solenoid valve to
check that the port and starboard directions are correct. If they are wrong, reverse
connections to Terminals 6 and 7. Check the hard over to hard over speed of the rudder and
adjust the low speed adjustment for the appropriate speed. Clockwise to decrease and
counter clockwise to increase. Once the low speed adjustment is complete activate the high-
speed valve and check the hard over to hard over speed. Adjust the high-speed valve to
obtain the desired speed. If after the high-speed adjustment is complete you adjust the low
speed, the high speed should be rechecked. The pressure relief is factory set (normally 750
psi) and should not require adjustment.
The pressure relief is factory set at 750 psi and should not require
adjustment.
4.2 ELECTRICAL CHECK
Ensure that the cover is installed and secured on the value junction
enclosure and all pigtail connections have been properly terminated
and enclosed before powering on the HM450.
Confirm that the electrical connections to the HPU200 pump-set have been made correctly
and correspond to the requirements of your system installation.

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4.3 FUNCTIONAL TEST
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:
1. Power ON the HPU
2. Power ON the autopilot (or electronic jog lever).
3. Active the autopilot (or electronic jog lever) to command motion of the HPU.
4. Verify that the rudder position has changed.
5. Set the autopilot to manual mode and operate the pump-set to determine if the
Port and Starboard directions are correct.
6. If the rudder goes the opposite way than expected.
a. Reverse the two electrical connections between the solenoids and the
autopilot (or electronic jog lever).
Most new autopilot systems will perform this test during their
dockside set-up procedures.
7. Operate the pump-set and note the “hard-over” to “hard-over” (HO to HO) time.
8. Verify that it is in the range of 10 to 16 seconds. Times outside of this range
indicate a mismatched pump-set for the steering system.
9. Confirm the unit develops rated pressure during operation.

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5OPERATION
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.
•Pressure relief valve is factory set to approximately 750 psi.
•Excess flow is returned to tank via differential bypass valve.
•pilot operated check valves allow free flow from the inlet port to outlet. Inlet pressure
open the opposite side check valve and allows flow comeback. When there is no
pressure in lines (directional valve is in center) both check valves are close and holding
the load in position.
•By energizing related solenoid on directional valve, flow will be sent to port or
starboard.
•Hydraulic in-line filter provides protection for small, high pressure systems up to 3,000
PSI. By using this filter at the pressure side of a pump, foreign particles 90 microns and
larger, such as those created by pump wear, are removed before damage can result to
the valving in the system. A sintered bronze element ensures protection against
crushing should dirt accumulate and increase pressure drop across the element.

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6MAINTENANCE
6.1 PREVENTATIVE MAINTENANCE
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.
Check the pressure gauge on the pump, a higher pressure indicates a plugged filter. Isolate
the pump hydraulically, remove the filter cap and change or clean the filter. Return the pump
to normal operation. If the filter becomes plugged on a regular basis, the steering system
should be flushed out and the hydraulic oil replaced.
The brushes on the electric DC motor can be easily checked by removing the access plate and
visually inspecting the brushes. Replace the carbon brushes as required and check the
internal condition of the motor.
•Monthly (12 times per year)
oInspect connections for leaks.
•Quarterly (4 times per year)
oVerify adequate oil level.
oVisually inspect wire and cable insulation for splits or damage.
•Every (2) two years
oSample and analyze the oil in the steering lines.
oDrain reservoir and clean out.

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6.2 RECOMMENDED SPARE PARTS
As a minimum Kobelt recommends the following spare parts are on-hand:
Table 4: Recommended Spares
QTY
ITEM
KOBELT PART #
1
HPU200 REPAIR KIT (24 VDC)
•Motor Repair kit
•Pump Repair Kit
•Manifold Repair Kit
600-160-RK
7070-0023-RK
7061-0005-RK
600-013-RK
1
HPU200/300/400 REPAIR KIT (115/230 VAC)
•Pump Repair Kit
•Manifold Repair Kit
600-142-RK
7061-0005-RK
600-013-RK
When purchasing spare parts refer to Appendix B: Parts List for Kobelt Part Numbers.
It is recommended that any required service work on an Accu-Steer
unit be performed by a factory authorized service representative.
Please contact the nearest Kobelt authorized distributor for
assistance.