HYDRO POWER UNIT 3
Contents
1. Q103INVIN SSOH 9 OHQAH SNOIYVA 096S H co QT103INVIN 1510 OL 4S0H 9 0d H SNOIYVA 909 S H N MNVL ASOH OUGAH SNOIYVA 619 S H co SOHS 8 81 00 LX81 9 L 6 1S3 SS 8 81 89SS4H LC T d3HSVM 901 SS 91 6 SS cec SdH LeScS H lt 390 V9 13 31 LHOIS UIG 89809 SOHS 9I X Sc L X SIN SS 916 pY 9EESsH 19686 N ANYL OWGAH IN NIIN IV 02 dY Q3HSINI3 WANIAN IV LSVO 07v LG H T T 1335 V9 MNVL 107 OUCAH 0909 Hd 15 SS SC LX 6 01 6S S4H Z9ScS H Ave l HOLIMS GION3 10S L6LLS H OLLYIN TIH LdN FIVIN 0HQAH 99GcG H d314f109 INQNTINQTV 31VIN33 31VIA34 LdN v G9G66 H ui9 X 3IddlN 3dld TV 31VIA 3IVIN LdN Utp OHQAH v9S S H ASSV d3L 1l ANY HINA 86 LINN OHGAH SNOIYVA 80S S H ASSY 103INVIN NOILAGIYLSIG OHQAH SNOIYVA G0ScS H ASSY YOLOW dINAd OHQAH SNOIYVA GL60S H NYL XNV Id YEELS H GEElS H NOlLdId9S3 ON LaVd ON 9NIMV8Q CO OO lt co Joo Hydro 3 20 Exploded View Diagram SONLLLIA ANI ZL2. ISOH ZL 3SOH 3NI1 NYN1JY SONLLLIA ANI 5421 9 HLIM 3SOH 9 3S0H ANITA Tddns GIOSINVIV 3S0H 3NI1 GTOJINVMW OL dWNd NMOHS LON OF HOS 9NO1 8 3dld ut NYNLIY 3521 1 4 OF HOS DNO 6 3dld 8 dWNd N Hydro 3 3D Rendering 22 Hydro 3 Electrical Schematic 1 4 Customer Supplied Switches 24 VDC POWER x MOTOR 1 THERMAL SWITCH BLK PL1 TAS1 P lt lt CR1 L1 WHT MOTOR 1 THERMAL RELAY 15A CBO MICO 9000 41034 0100600 T _ ___ __ _ _ ll VALVE1 d A B COIL PB1A MOTOR 1 24 CONTROL POWER ON OFF TG1 CBt as 1215 e SOL1A e e BLK lt lt A gt gt BLE e VALVE 1 A COIL SW1A 4 4 2 2 wp 1N5400 D1 SOL1B AE ps VALVE 1 B COIL 24 1 MOTOR 2 GND CONTROL POWER ON OFF TG2 SW1B 4 4 1N5400 D1 VALVE2 A COIL B COIL PB2A 24B mee SOL2A PLK BLE e VALVE 2 COIL 1 1 2 2 wy N5400 i SOL2B WHT NEN aT VALVE 2 B COIL 24 4 MOTOR 3 2N CONTROL POWER ON OFF TG2 24C SW2B 1 VALVE3 1N5400 D1 le cad S gt BLE e VALVE COIL 24 3 2A SOL3B VALVE 3 B COIL 4 135400 D1 VALVE4 A COIL B COIL 4A CB4 P S gt BLE e VALVE 4 A COIL 24 4
3. L4B uy VALVE 4 B COIL SWAB 4 4 1N5400 D1 MOTOR 1 THERMAL RELAY M1 R1 A O GRN CONTACTOR COIL v HARKEN Hydro 3 23 Electrical Schematic 5 9 Customer Supplied Switches 24 MOTOR 2 THERMAL RELAY 24B GND CR2 LT2 GND yi SET 12 THERMAL SWITCH TRIPPED THERMAL BY PASS SWITCH TG2 OFF ON e O o MOTOR 2 THERMAL SWITCH BLK PL2 TAS2 PL WHT A lt gt ies MOTOR 2 THERMAL RELAY MICO 9000 41034 0100600 VALVE5 A colL B COIL e D1 M ASA BLK SOLSA BLUE A Du c e c lt lt VALVE 5 ACOIL 4A PB5B Ws D2 rM SOL5B VALVE 5 B COIL _ SW5B A 1 VALVE6 Y N5400 A col B COIL ial SOL6A e c c BLK lt BLUE VALVE 6 A COIL S 1 1 2 2A PB6B 15400 BENE SOL6B un 5 en M VALVE 6 B COIL VALVE7 1N5400 e e D2 A colL B COIL iai 3 SOL7A E CIEN c c BLK e BLUE VALVE 7 A COIL 1 1 2 2 7 SW7A 715400 ES SOL7B ue c M e VALVE 7 B COIL 1 1 VALVE8 va e e D2 A B COIL un ES SOL8A e c c c BLK BLUE VALVE 8 A COIL
4. Mailing address Harken Sweden AB Box 64 SE 440 30 Marstrand Web harken se Email harken harken se Harken UK Ltd Bearing House Ampress Lane Lymington Hampshire 041 8LW England Telephone 44 01590 6891 22 Fax 44 01590 610274 Web harken co uk Email enquiries harken co uk Please visit http Awww harken com locator aspx to locate Harken dealers and distributors H 51330 H 58031 Printed in USA 08 13 Version
5. 67 4 mm 0000 AWG 108 mm 12 Hydro 3 Electrical Installation Connect Deck Switches to the ECB Install the deck switches in a convenient location By design two 2 deck switches are used per function Generally one switch would actuate the function motor in a forward direction and the other in the reverse Example for a furler the A switch would furl and the B would unfurl Follow these steps to connect deck switches to ECB 1 Select moisture barrier gland insert 2 Pass switch wires through gland into the ECB case 3 Connect deck switch wires per Switch Wiring Table below Switch wires connect to terminal strip labeled 24 X and SWXX See photo Note For wire gauge information refer to pg SWIA 24 Switch Wiring Table Valve Switch Wire 1 1 A 424 1 B 424 1 2 424 2 B 424 2 3 A 24 3 B 424 3 4 A 424 4 B 424 4 5 424 5 B 424 5 6 A 24 6 B 24 6 7 A 24 7 B 24 7 12 1 SW1B Wire 2 SW1A SW1B SW2A SW2B SW3A SW3B SW4A SW4B SW5A SW5B SW6A SW6B SW7A SW7B Note Polarity is not an issue with 2 wire deck switches Connect ECB to Power Supply Follow these steps to connect power to ECB Valve 9 10 11 12 13 14 15 Switch A B A B A B A B A B A B A B Wire 1 24 9 24 9 24 10 24 10 24 11 24 11 24 12 24 12 24 13 24 13 24 14 24 14 24 15 24 15 Wire 2
6. oil Important guidelines to remember are e Follow proper procedures when changing oil Improper cleaning procedures may contaminate hydraulic system e Perform oil changes in a warm operating environment e Drain old oil before adding new Reservoir may be emptied via one of two methods 1 Place basin near HPU beneath drain plug Remove plug and let oil drain into basin until reservoir is empty 2 Use siphon oil pump method to pull oil up through hose in filler tube Use a basin to collect oil e Once oil is drained use lint free rags to clean reservoir Remove debris prior to refilling e Filter oil prior to filling reservoir Never fill a reservoir through a filler breather without filtering it prior to or during the filling process e care to not introduce contaminates from the filter housing when removing filter Note Always dispose of oil properly Contact your local waste authority and follow guidelines for recycling and or disposal CAUTION Filter oil prior to filling the reservoir Cleanliness of oil directly from barrel is not sufficient for system operation Contact local hydraulic service company for filter carts or pre filtered oil Problems occurring during oil change result from e Use of unsuitable hydraulic oil e Use of oil which was contaminated due to faulty storage e Failure to clean reservoir e nadequate cleanliness when filling i e dirty drums or containers e Filling to improper levels 18 Hydro 3 L
7. product warranty IMPORTANT Identifies condition or task requiring special attention Hydro 3 Safety Safety Requirements The instructions provided with this manual are for installation and use only The HARKEN Power Unit must only be serviced by a qualified hydraulic technician For repair service contact HARKEN to find the repair site nearest you See www harken com manuals for additional safety information WARNING Strictly follow all instructions to avoid an accident damage to your vessel personal injury or death e Always wear eye protection e Make sure all components are rated for the maximum system pressure Hose and fittings generally have a 4 1 safety factor In static applications these safety factors are normally reduced to 2 1 Special care should be used in selecting the proper products for these systems There is a correlation between cost of components and their quality e Do not exceed equipment ratings Overloading causes equipment failure and possible personal injury e Never set the relief valve pressure higher than the maximum rated pump pressure Doing so may result in equipment damage and or personal injury e System operating pressure must not exceed the pressure rating of the lowest rated component in the system If in question install pressure gauges in the system to monitor operating pressure They are your window to what is happening in the system e Keep hydraulic equipment away from f
8. switch should be in OFF position This deactivates deck switches For long term storage in addition to placing isolation switch in OFF position remove the fuse or circuit breaker between HPU motor and battery Oil Level Maintain an oil level of 2 3 3 4 full as viewed through Oil Level Electronic Control Indicator Always inspect oil level before use If necessary to Box ECB maintain proper level add more filtered oil to tank Motor Thermal Protection HARKEN standard Hydro Power Units feature a 4KW 24VDC series wound motor 12VDC motor available by special order Motors are specified to provide years of service under standard operating conditions Due to high current draw these motors will generate excessive amounts of heat after extended periods of operation at load To avoid motor damage the motor is equipped with an internal thermal monitor and switch The motor is sized to run a minimum of five 5 minutes without tripping the thermal switch If overheating occurs and the thermal switch is tripped an indicator light on ECB will illuminate After this occurrence the motor requires a variable cooling period based Internal Thermal Switch Override Oil Level ambient conditions indicator IMPORTANT In case of emergency thermal switch override is located inside the ECB Flip toggle switch to engage override Once thermal switch override is engaged motor will operate until it stalls If thermal switch over
9. 0 15 VALVE CONNECTOR Customer Supplied Switches M12 PLUG M12 FEMALE INTERFACE CABLE Y PB10A VALVE 10 BLUE GND COILA GND Bi BLACK 1 NOT 1 24 VDC SW10A 24 10 VALVE 10 SW10A VALVE 10 A B USED 2 SOL A GREEN YELLOW GND COILB 24 VDC 2 SOLA 10 3 COMMON NO CONNECTION ca 22 WATTS 3 COMMON 4 SOL B BROWN 24 VDC 4 SOL B 5 PE NO CONNECTION SW10B pas WHITE Son PB10B PB11A BLUE GND VALVE 11 IL A GND Ed 1 NOT 1 24 VDC BLACK SW11A 24 11 NS SW41A VALVE 11 USED 2 SOL A GE ENZVEITORTEND VALVE 11 24 VDC a COILB 2 SOLA 11 3 COMMON NO CONNECTION d 22 WATTS 3 COMMON 4 SOLB BROWN 24 VDC 4SOLB 5 PE NO CONNECTION re SW11B 5 PE WHITE SW11B VALVE 12 BLUE GND COIL A 1 24 VDC BLACK o 24 12 VALVE 12 A B IMMER in VALVE 12 iilis USED 2 SOLA GREEN YELLOW GND 24 VDC 2 SOLA 12 NO CONNECTION 22 WATTS 3 COMMON 4 SOL B BROWN 24 VDC EE 4 SOL B 5 PE NO CONNECTION SW12B 5 PE WHITE we PB12B PB13A GND ee 1 NO
10. 1 1 2 2A PB8B SWBA h SOL8B mm 0 MEME T VALVE 8 B COIL e GND VALVE8 115400 COIL COIL e PB9A L SOL9A Es c BLK BLUE VALVE 9 A COIL 24 1 1 2 PB9B SW9A LP Yu SOL9B c n WHT VALVE 9 B COIL vum 1 1 Boe e o M2 ids Reo 2 PL2 GER e ELA CONTACTOR COIL MOTOR 2 THERMAL 1 1 2 ale RELAY b 4 b 4 D1 D2 Hydro 3 Electrical Schematic 10 15 Customer Supplied Switches MOTOR 3 THERMAL RELAY 24C GND oe 6 GND u THERMAGE pace cua 24C 1 THERMAL SWITCH TRIPPED 163 OFF ON MOTOR 3 THERMAL SWITCH BLK lt PL3 TAS3 dicas WHT 24 2 MOTOR 3 THERMAL RELAY MICO 9000 41034 0100600 VALVE10 AcoiL BcoiL 01 D2 03 CES PB10A a A A series ho euo E 8 BLK lt lt gt gt BLUE q VALVE 10 A COIL I SW10A 2A x PB10B 15400 EO SOL10B VALVE 10 B COIL o uere c WHT VALVE11 vas L col B COIL e D3 ES SOL11A amp P BLK gt gt ELE e VALVE 11 A COIL 24 11 SW4A 1 1 2 2 PB11B wy 1N5400 EN ps SOL11B en vius p US VALVE 11 B COIL A COILIB COIL a D3 ven db B
11. 5A SW15B Ground IMPORTANT Align key and keyway on connector 1 White N C Port A or B 9 1 Black N C Port B or A Blue S e 5 j Green Yellow Not Used all Brown Not Used Female preme sss Connect HPU to Battery Follow these steps to connect HPU to Battery 1 A 250 3004 circuit breaker or fuse not supplied must be installed between HPU motor and battery Prior to making connection remove fuse element or verify circuit break is in OFF position 2 Connect positive lead from fuse to open 8 mm terminal stud contactor on solenoid switch 3 Connect from fuse to battery 4 Connect negative lead from 10 mm stud on motor case to common terminal or battery terminal A CAUTION DO NOT close the circuit with the fuse or circuit breaker until the Commissioning phase 14 Hydro 3 Commissioning When commissioning hydraulic equipment it is extremely important to carefully follow each procedure to avoid premature system damage and or failure Secure connections ensure cleanliness confirm proper fluid levels and perform all recommended tests The following are instructions to ensure proper commissioning of your Hydro 3 Filling Reservoir Pump hydraulic oil through an adequate filter into reservoir Fill until oil level indicator is 2 3 3 4 full Inspect for leaks Reservoir capacit
12. Cables per motor to connect power unit motor to ECB 1 Cable per valve to connect power unit to ECB Pressure Reducing Valves If Required See pg 9 4 Remote Manifold Pressure Relief Valves If Required See pg 9 4 Hydro 3 Flow Control Valves If Required See pg 9 Safety Important Safety Information Read all instructions carefully and follow all safety precautions to avoid personal injury or property damage during system operation Harken is not responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Contact Harken with questions regarding safety precautions and operations If you lack training on hydraulic safety consult a hydraulic distribution or service center for a hydraulic safety course Failure to comply with the following cautions and warnings could result in equipment damage and personal injury Symbols and Safety Statements Used in this Manual oymbols and safety statements have been placed throughout this text to call attention to special information that may affect the equipment and or the equipment operator Following is an explanation for your reference DANGER This symbol alerts you to hazards that cause death or serious injury WARNING This symbol alerts you to potential hazards that may kill or hurt you and others if you don t follow instructions CAUTION This symbol alerts you to potential hazards that may damage equipment or void
13. ED 2 SOLA 3 COMMON 4 SOL B 5 PE 1 NOT USED 2 SOLA 3 COMMON 4 SOL B 5 PE M12 FEMALE INTERFACE CABLE Y PB5A BLUE GND VALVE 5 GND COILA a BLACK 424 5 4 SW5A i e SW5A E GREEN YELLOW GND VALVE 5 3 COMMON A COLE 4 SOL B NO CONNECTION T 5 PE 2 1 BROWN 24 VDC NO CONNECTION SW5B WHITE PBSB SW5B PB6A BLUE GND VALVE 6 GND COILA _ _ 1 24 VDC 24 60 o 6 2 SOL A SW6A SW6A GREEN YELLOW GND VALVE 6 6 3 COMMON A COND 4 SOL B NO CONNECTION MB 5 PE BROWN 24 VDC NO CONNECTION MN SW6B WHITE _ PB6B SW6B PB7A BLUE GND VALVE 7 GND COILA EN BLACK B T ee 3 SOLA SW7A SW7A GREEN YELLOW GND VALVE 7 7 3 COMMON ONE 4 SOL B NO CONNECTION T BROWN 24 VDC NO CONNECTION une SWT7B WHITE PB7B SW7B PB8A BLUE GND VALVE 8 GND COILA EN BLACK oe SW8A 24 8 SW8A GREEN YELLOW GND VALVE 8 8 3 COMMON COND 4 SOL B NO CONNECTION a eee BROWN 24 m N NO CONNECTION PB8B SW8B WHITE SW8B PB9A BLUE GND VALVE 9 GND COILA _ _ 1 24 VDC BLACK o 24 9 o 2 SOLA SW9A SW9A I GREEN YELLOW GND VALVE 9 9 3 COMMON 5 CORE 4 SOL B NO CONNECTION M Bes BROWN 24 E o NO CONNECTION PB9B SW9B WHITE SW9B Hydro 3 27 Valve and Switch Wiring Schematic 1
14. ERATE FEED WIRES CUSTOMER SUPPLIED Hydro 3 Control Box Mounting Dimensions Note Allow 1 25 mm clearance for toggle switch and indicator light 444 75 4254 439 67 17 510 16 750 310 89 39 1 299 30 Hydro 3 Control Box Interior Layout JO O Olu Lie 40 LO Ol j LE TO Ol X E TJ CAELI BI Lh ET T TF eI i X ESSI ESSI TI RI Er ea a 168 BYPASS ON MOTOR 1 MOTOR 2 MOTOR3 GREEN ON RED OFF PRESS TO RESET JO O p TO TO TED 15 TEM OT 1L pe PE ILL EST PE HIT E T Ez LL E TL IL 2 7 eters TO Olmi TO 9 eoo JO Ol io JO Olm Eee Hydro 3 TESTO TO T OE T To LOL Ole T poto oka 2218 I WI EID e L HT ETE L fee TT B Pr IT EDD EL TL EL wl e H bee P ima HARKEN 31 Warranty Harken warrants that each Harken product when properly used and maintained will be free from defects in material and workman ship from the date of receipt of the product by the final customer Harken products are covered by two different kinds of warranties on the basis of the purchaser and use made of them For complete warranty or for information r
15. HITE e gt SW4B 55 26 Hydro 3 Valve and Switch Wiring Schematic 5 9 Customer Supplied Switches VALVE CONNECTOR Y Y PL5 2 e VALVE 5 A B A 24 VDC o og 22 WATTS i Y i Y PN fA EN e 3 3 x 55 PL6 2 4 VALVE 6 A B A v A 24 VDC 4 2 E 22 WATTS l Y i Y d gt 5 55 PL7 2 4 VALVE 7 gt 4 24 VDC E 2 22 WATTS L T L P FTN TN e e e 3 3 55 PL8 2 22 d VALVE 8 s gt 4 Ae cos 24 VDC 2 22 WATTS Y e Y FTN TN T o e 373 55 9 2 275 VALVE 9 A B x A v v A 24 VDC 22 WATTS I Y Y L T LIN amp gt 5 55 M12 PLUG 1 NOT USED 2 SOLA 3 COMMON 4 SOL B 5 PE 1 NOT USED 2 SOLA 3 COMMON 4 SOL B 5 PE 1 NOT USED 2 SOLA 3 COMMON 4 SOL B 5 PE 1 NOT US
16. HYDRO POWER UNIT 3 Installation and Operation Manual Intended for specialized personnel or expert users Please read these instructions carefully before installing servicing or operating the equipment This manual may be modified without notice See www harken com manuals for updated versions PLEASE SAVE THESE INSTRUCTIONS The Hydro Power Unit pictured above is for display purposes only Actual system purchased may vary Table of Contents INTRODUC m M 3 UNIT SELECTION AND PARTS EIS DNA cane Fus UE 4 SAFET INFORMATION eX M M 9 6 POWER UNITINSTALLATION UU Ul nS 1 8 Planning installation Location in boat Secure power unit Mount control box HYDRAULIC 9 11 Hose and fitting selection recommendation Hose shortening End fittings Fitting instructions Port identification Configuration Function assignment Manifold blanking plates Flushing hoses Connecting hoses Case drains Mounting clamp hose support Protect hoses from sunlight Individual function protection ELEGIRICAL INS TALLA FION 12 14 Wire selection Connect deck switches to ECB Connect ECB to power supply Connect HPU motor and valves to ECB Connect H
17. LK PELA BLUE CO a P ME VALVE 12 A COIL 7 2432 PB12B F 1N5400 R ZEE Yos SOL12B c LERE VALVE 12 B COIL VALVE13 1 L A COIL B COIL e D3 ES SOL13A HAI c TE oe 6 lt S gt BE VALVE 13 A COIL PB13B SE Ur E MENS D3 SOL13B s A e VALVE 13 B COIL Ww 5 13 1 1 1N5400 VALVE14 D3 A COIL B COIL E HM l A 15400 M 7 SOL14A BLUE ora 2 80 2405 VALVE 14 A COIL m PB14B 715400 SWI4A a SOL14B o o Ce tet C VALVE 14 COIL VALVE15 wigs COIL e e D2 CB12 T3 US T 7 T lt SOL15A 32445 4 SE T1072 VALVE 15 A COIL 6A ee ss ae us iN p wi SOL15B s i i x A VALVE 15 B COIL IN5400 IN5400 b ND MOTOR3THERMAL o M3 RELAY a e 5 e _ CONTACTOR COIL Hydro 3 25 Valve and Switch Wiring Schematic 1 4 Customer Supplied Switches
18. PU to battery ONMMISINND 2 c 15 16 Fill reservoir Hydraulic fluid Closed circuit Leak check One way function flush System validation Function pressure check Oil level and filter OPERA MON M P 17 Power up power down Oil level Motor thermal protection single and multiple function operation Filter element replacement schedule Hydraulic oil change schedule MAINIPNIND u 18 19 How to change oil Leakage inspection Cleanliness inspection Oil level inspection Additional maintenance points TROUBLESHOOTING UNI YET x Oa TOS Sas DERIG REIS ERES TOPUE FEST GU NON E FF P 19 DRAWINGS AND SEPHEMBATIDS uu u 20 31 Bill of Materials Exploded View Diagram 3D Rendering Electrical Schematics Motor Thermal Relay Schematic Suggested Wiring Schematics Control Box Mounting Dimensions Control Box Interior Diagram S u Back Cover 2 Hydro 3 Introduction HARKEN Hydraulic Power Units HPU are the complete power solution Offered in three sizes Hydro 1 2 and 3 the HPU can power functions including winches furlers sail t
19. SW9A SW9B SW10A SW10B SW11A SW11B SW12A SW12B SW13A SW13B SW14A SW14B SW15A SW15B 1 Prior to making any connection verify internal 5A circuit breaker is in OFF position and system isolation switch on ECB cover is in OFF position 2 Pass power supply wires through gland into the ECB case 3 Connect power supply positive lead to the circuit breaker terminal labeled OCB 4 Connect power supply common lead to any GND terminal Hydro 3 13 Electrical Installation Connect HPU Motor and Valves to ECB Valve Wiring Table Each valve operates using a three wire cable bundle with an M12 Valve Black White Blue connector 1 SW1A SW1B Ground 2 oW2A oW2B G d Note Valve wires supplied are 5M These can be extended with a 3 SW3A CW3B TT 16 gauge wire if needed Refer to Wire Sizing Table pg 12 4 SW4A SW4B Ground Follow these steps to connect HPU motors and valves to ECB 9 SW5A SW5B Ground 6 SW6A SW6B Ground 1 Join mating ends of Deutsch Connector to connect the ECB 7 SW7A SW7B round to the HPU motor 8 SW8A SW8B Ground 2 Pass valve wires through gland into the ECB case 9 SW9A SW9B Ground M 10 SW10A SW10B Ground 3 Connect valve wires per Valve Wiring Table at right Valve wire 11 SW11A SW11B Ground sets connect to terminal strip labeled SWXA SWXB and GND 12 SW12A SW12B Ground See photo pg 13 13 SW13A SW13B Ground 14 SW14A oW14B Ground 4 Connect valve cable to M12 connector on valve 15 SW1
20. T 5 i 9SW13A VALVE 13 2 SOL A VALVE 13 iini USED 18 GREEN YELLOW GND L 2 SOL A NO CONNECTION COIL B 22 WATTS 3 COMMON 4 SOL B BROWN 24 VDC 9 4 SOL B 5 PE NO CONNECTION SW13B 5 PE WHITE Cowan PB13B PB14A BLUE GND VALVE 14 GND GOLA 1 NOT 4 24 VDC 5 24 14 VALVE 14 4 SW14A SW14A ede USED 14 SOME S GREEN YELLOW GND VALVE 14 2 SOL A NO CONNECTION COIL B 22 WATTS 3 COMMON 4 SOL B BROWN 24 VDC 4 501 B 5 PE NO CONNECTION SW14B 5 PE WHITE PB14B SW14B VALVE 15 GND in BLACK 1 NOT 1 24 VDC SW15A 24 15 9SW15A VALVE 15 USED 2 SOL A GREEN YELLOW GND VALVE 15 24 VDC 2 SOL A 15 CONNECTION 22 5 3 4 SOL B BROWN 24 VDC L 4 SOL B 5 PE NO CONNECTION 5 9SW15B eee WHITE PB15B SW15B HARKEN 28 Hydro 3 Suggested Wiring Practice for Motors CUSTOMER SUPPLIED BATTERIES DISCONNECT AND FUSES PRIMARY DISCONNECT Power Supply 24 Volts DS1 m 900A Time Delay Fuse M1 1M l 24V oe 250 24VDC 4KW 210 FLA i Time Delay Fuse M2 2M GND 250 24VDC 4KW 210 FLA Time Delay Fuse M3 3M P l 250A 24VDC 4KW 210 FLA E M SEP
21. VALVE CONNECTOR M12 PLUG M12 FEMALE INTERFACE CABLE PB1A BLUE GND VALVE 1 GND N 1 NOT USED 1 24 VDC SEDE 9SW1A SW1A VALVE 1 A B 2 SOLA 4 2 SOLA GREEN YELLOW GND VALVE 1 24 VDC 3 COMMON 3 COMMON ONO CONNECTION COIL B 22 WATTS nm B E B BROWN 24 VDC i CONNECTION sw1B WHITE PB1B SW1B PB2A BLUE GND VALVE 2 GND a i i 1 NOT USED 1 24 VDC SLASK SW2A e SW2A VALVE 2 A B v v v v 2 SOL A 2 2 SOL A GREEN YELLOW GND VALVE 2 24 VDC 2 D 3 COMMON 3 COMMON COIL B 22 WATTS 4 SOL B 4 SOL B Y e Y pas E BROWN 24 VDC ONO CONNECTION 9 sw2B e TN o 373 WHITE PB2B 5 S sw2B 5 5 PL3 2 PB3A e gt BLUE GND VALVE 3 2 COILA e GND 44 BLACK LL 1 i 1 NOT USED 1 24 VDC SW3A 24 3 o owa VALVE 3 A B v v v v ahi 2 SOLA 2 SOLA GREEN YELLOW GND VALVE 3 24 VDC 3 COMMON 3 3 COMMON COIL B 22 WATTS 4 SOL B 4 SOL B EN Y Y pis BROWN 24 VDC L A i NO CONNECTION PB3B sw3B e e gt WHITE 3 gt SW3B 55 PL4 2 e j BLUE GND VALVE 4 lt GND COILA 44 BLACK LL i 1 1 NOT USED 1 24 VDC 24 4 9 S sw4A 4 AIB di 2 SOLA 2 SOLA GREEN YELLOW GND VALVE 4 C 2 3 COMMON 4 3 COMMON COIL B 22WATTS 4 SOL B 4 SOL B De MESH EN Y Y pes EISE BROWN 24 VDC lt NO CONNECTION PB4B SW4B FTN e e 35 W
22. eakage Inspection After commissioning visually inspect system for leaks Perform visual leak inspection at regular intervals It is good practice to visually inspect for leaks prior to every use A CAUTION If leak is present decrease system pressure to 0 psi before tightening fittings Cleanliness Inspection Maintain a dirt free system This is very important in applications in environment with a high degree of airborne contaminants Leak detection is easier and quicker on clean system Oil Level Inspection Check oil level every 2 to 4 hours during the first day of use Check oil level twice a day during first week and once a week thereafter CAUTION If necessary top off oil reservoir using proper fluid type Do not mix oil types Refer to Oil Equivalent Table pg 15 Additional Maintenance Points e Always power down HPU prior to performing maintenance e Place a label or tag on HPU indicating type of fluid that is installed e Replace any hoses that appear to be worn or chafed Troubleshooting Problem None of the functions are working Single function is not working Functions are running slow Function load reduced Possible Cause No electrical power Motor is not operating Motor is stalling Pump is not operating correctly Function is turned off owitch is not working Valve is not working System leak present Reduced motor speed Relief valve is opening Pump flow is reduced Filters are plugged Sy
23. elating to a specific warranty concern please refer to the following Harken Catalog Harken Website www Harken com Call or Email the nearest Harken Distributor Harken Corporate Headquarters HARKEN Corporate Headquarters N15W24983 Bluemound Rd Pewaukee WI 53072 USA Telephone 262 691 3320 Fax 262 701 5780 Web www harken com e Online Catalog www harkenstore com Email harken harken com Harken Australia Ply Ltd 1B Green Street Brookvale N S W 2100 Australia Telephone 61 2 8978 8666 Fax 61 2 8978 8667 Web harken com au Email info harken com au Harken France ZA Port des Minimes BP 3064 17032 La Rochelle Cedex 1 France Telephone 33 05 46 44 51 20 Fax 33 05 46 44 25 70 Web harken fr Email info harken fr Harken Italy S p A Via Marco Biagi 14 22070 Limido Comasco CO Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web harken it e Email info harken it Harken New Zealand Ltd 30 36 Fanshawe Street PO Box 1951 Auckland 1001 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web harken co nz Email harken harken co nz Harken Polska SP ZOO ul Rydygiera 8 budynek 3A lokal 101 pietro 01 793 Warszawa Poland Tel 48 22 561 93 93 Fax 48 22 839 22 75 Web harken pl Email polska harken p Harken Sweden AB Main Office and Harken Brandstore Vastmannagatan 81B SE 113 26 Stockholm Sweden Telephone 46 0303 61875 Fax 46 0303 61876
24. en pressurized Protect Hydraulic Hose from Sunlight Sunlight leaches out elastomers causing the cover to weather check or develop cracks deep enough to allow moisture penetration of reinforcement Use protective hose covers and or store under protective cover when not in use Individual Function Protection Some equipment may require lower max flow or lower max pressure than the hydro unit can deliver Use a flow control valve pressure reducing valve and or pressure relief valve to reduce maximum flow and or maximum pressure These valves are not included with the Hydro 3 unit They should be purchased as required by the original equipment manufacturer Hydro 3 11 Electrical Installation HARKEN Hydro Units include 24 volt DC motors standard 12 VDC motors are available by special order Electrical installation is intended to be straight forward For instance connections internal to the ECB are prewired At the time of installation the user is only required to make the necessary connections between the switches valves ECB HPU and power supply battery To ease installation the ECB terminals for switches valves 24V power and ground are labeled For quick reference terminal and valve port labeling follows a corresponding numbering scheme For the wires routing from switches on the deck or valves on the manifold waterproof integrity is maintained by passage through a sealed gland Electrical installation is divided into five basic steps 1 Connect
25. ent manifold than mainsheet Example 2 Run primary winches on different manifold than headsail furler Refer to this information when connecting the electric switches For easy reference label the hydraulic hoses in accordance with the valve For example label Valve Station 1 hoses for your attached manifold VS1A and VS1B Function Assignment Table Function Valve Attached Remote Name Station Number Manifold Number Manifold Number Motor VS1 Al 1 52 1 1 VS3 A1 1 54 1 1 55 D VS6 A2 2 VS7 A2 2 VS8 A2 2 VS9 A2 2 VS10 R1 3 VS11 R1 3 VS12 R1 3 VS13 R1 3 VS14 1 2 515 1 2 9 VS1 R1 1 52 R1 1 VS3 R1 1 VS4 R1 1 VS5 1 2 56 R2 2 VS7 R2 2 VS8 R2 2 VS9 R2 2 VS10 R3 3 VS11 R3 3 VS12 R3 3 VS13 R3 3 VS14 1 2 VS15 1 2 3 10 Hydro 3 Hydraulic Installation Manifold Blanking Plates All manifold stations must have either blanking plates or valves Once all functions have been assigned attach blanking plates to stations not in use Tighten 10 24 bolts to 4 1 ft lb 5 6 N m torque The unit is shipped with the number of valves ordered Additional valves may be added if blanking plates are present Flushing Hoses Flush hoses prior to connecting to HPU if not done when purchased Use an external filtration pump not included to remove all debris Connecting Hoses Install hos
26. er unit may have been exposed to many unusual conditions If irregularities appear document details and contact shipper and HARKEN distributor Plan Installation Mounting is required for both the HPU and the ECB Because this installation is on a boat the following are some points to consider when choosing the installation location Location in Boat Filter status indicator Dry and well ventilated typically near the engine room HPU and ECB to be mounted within close mutual proximity recommended maximum 5 m wire run See Electrical Installation pg 12 Provide necessary clearance for HPU HPU in close proximity to battery and power supply to reduce voltage drop See Electrical Installation pg 12 Provide access for maintenance and servicing Make access available to filler tube filter filter status indicator and site gauge Central to the system as illustrated in Typical System diagram Provide routing for hydraulic hoses from HPU to functions Hoses attach to manifold horizontally Case Drain Port Nearest boat s centerline in an upright position to reduce the heeling extremes Attached manifold Choose an area close to the plumbing center of the system Typical System Electronic Control Box ECB BATTERY Hydraulic Power Unit HPU Hydro 3 7 Installation Securing Hydraulic Power Unit of the tank lid or the HPU components Introduction of contaminants can cause operatio
27. es per predetermined route e f hose end fittings differ verify mating fittings prior to running the hose e Remove plugs from the HPU manifold and function ports to connect A and B hoses To prevent filled hoses from draining connect the lower of the two ends first This is typically the HPU e Attach the other hose end at the higher connection e f case drain hoses are required continue with the same procedure used on A and B hoses e Plug all unused A and B ports to prevent contamination Any unused A and B ports with a valve must be plugged with ORB plugs as well IMPORTANT ORB BSPP and JIC connections do not need PTFE tape or other sealing Case Drains Function motors with drain ports must be routed to a common case drain on the HPU during the installation T fittings may be used to connect multiple drain port hoses to one common hose that leads to the case drain Line sizing should be based on maximum flow in order to prevent flow restriction and back pressure Example The 3 unit is sized to fully power either three functions or two double flow functions at a time To allow for free flow back to the HPU the common case drain hose that combines flow from all drain port hoses must be up sized The recommended minimum hose size for function drain ports should be 14 inner diameter ID Mounting Clamp Hose Support Support hoses using mounting clamps to prevent chafing and premature failure Remember to allow for 2 to 4 shortening wh
28. for 10 micron or better Oil Filter Status Indicator IMPORTANT Oil filter status indicator functions only when unit is powered and when motor and pump are running In operating conditions with high levels of airborne particles inspect breather at frequent intervals CAUTION If necessary top off oil reservoir using proper fluid type Do not mix oil types Refer to Oil Equivalent Table pg 15 Only use filter elements capable of meeting or exceeding the oil cleanliness level requirements Hydraulic 011 Change Schedule e After first 500 operating hours e Every 1000 operating hours or biannually regardless of accumulated operating hours e 011 change interval lengths can be adjusted longer or shorter if results of laboratory fluid sampling and oil analysis reveal oil is cleaner or more contaminated than expected at 1000 operating hours IMPORTANT Conduct recommended oil change schedule in accordance with fluid type aging and oil contamination level Oil condition depends on moisture content and additive level In operating conditions with high levels of airborne particles and or elevated thermal loads reduce intervals between oil changes should be reduced accordingly How to Change Oil Oil change intervals are recommended based on various factors such as the type of fluid the degree of aging and the contamination of the oil Water content and the levels of additives are also significant factors in determining the condition of the
29. ion of intended function 2 Inspect each fitting for leakage A CAUTION If leak is present decrease system pressure to 0 psi before tightening fittings 3 Tighten fitting as necessary 4 Repeat procedure for all functions IMPORTANT If installation was completed with empty hoses check the oil level indicator after each function and add oil as necessary Run Time Table One Way Function Flush Hose size Run time per 10 3 m of Hose Flush the function motor through the system filter by running each function in a single T am A direction Run in same direction as previous step This process helps ensure system 1 5 125 75 cleanliness by depositing any contaminates into the system filter Refer to Run Time 5 3 16 10 Table Total length is sum of A and B hose Repeat procedure for all functions 3 4 19 15 1 25 25 System Validation Verify proper function performance and correct switch wiring by running one function at a time first in one direction and then in the other direction Single direction functions i e single speed winch are operated by one deck switch If function does not operate per specific user manual switch wiring may be incorrect or A and B hoses may be reversed If this is the case refer to the Hydraulic and Electrical Installation sections and verify each step Two direction functions i e furlers two and three speed winches are operated by two deck switches Each switch operates one direction Verify each sw
30. itch operates the intended function direction If not either reverse switch wiring at terminal strip inside the ECB or reverse A and B hoses For more specific operational instructions refer to specific function user manual Function Pressure Check Refer to each function s user manual for maximum flow maximum pressure and function working load before operation under stated condition A CAUTION To avoid equipment damage DO NOT exceed function s maximum pressure or maximum flow DO NOT exceed the safe working load of any function Carefully load system and verify function operates per specific user manual During function operation inspect hoses for chafing or binding With pressure at zero inspect fittings for leaks Ensure proper safety precautions are practiced to avoid personal injury due to pressurized oil A CAUTION If leak is present decrease system pressure to 0 psi before tightening fittings Oil Level and Filter Maintain an oil level of 2 3 3 4 full as viewed through tank fill indicator Most foreign particles flush into the return filters after first few hours of operation If system was exposed at any time to possible contamination replace filter element If you have any questions contact your HARKEN Tech Service Representative 16 Hydro 3 Operation Power Up Power Down HARKEN Hydro Power Units have system isolation switches on the electronic control box During short term inactive periods the system isolation
31. lames and heat Excessive heat will soften packings and seals resulting in oil leaks Heat also weakens hose materials and packings For optimum performance do not expose equipment to temperatures of 65 C 150 F or higher Use caution when searching for leaks cracks kinks or other damage Serious injury can occur to hands or face from pressure build up or heated fluids Do not handle pressurized hoses Escaping oil under pressure can penetrate the skin causing serious injury If oil is injected under the skin seek immediate medical attention e Relieve system pressure before servicing or replacing hose lines e Never remove a hose line from a pressurized motor or cylinder e Avoid hydraulic hose damage Avoid sharp bends and kinks when routing hydraulic hoses Using a bent or kinked hose will cause severe back pressure Sharp bends and kinks will internally damage the hose leading to premature hose failure e Route hose assemblies so that all bends are directed away from the operator Do not drop heavy objects on hose A sharp impact may cause internal damage to hose wire strands e Applying pressure to a damaged hose may cause it to rupture Do not lift hydraulic equipment by the hoses or swivel couplers Use the carrying handle or other means of safe transport 6 Hydro 3 Installation While unpacking the hydraulic power unit HPU and electronic control box ECB inspect for irregularities During transport the pow
32. llips Petroleum Corp Filler Tube Brand Name Gulf 46AW Mobil DTE 20 Series 25 Mobil DTE 10 Series 19 Pennzol Magnus A 315 Tellus 46 Shell Tellus T46 Shell Po SUNTAC WR 150 WR Texaco Rando HD 46 Union Hydraulic Oil Unax AW 215 Registered trademarks Amoco Amoco Oil Company Ashland Valvoline Ashland Inc Atlantic Richfield Atlantic Richfield Co BP9 BP p l c Chevron USA Chevron Intellectual Property LLC Citgo Petroleum Corp Citgo Petroleum Corp Conoco Continental ConocoPhillips Esso and Exxon ExxonMobil Gulf GULF Oil International Mobil ExxonMobil Pennzoil SOPUS Products Phillips Petroleum Corp Phillips 66 Shell SOPUS Products Texaco Chevron Intellectual Property LLC Union Phillips 66 15 Commissioning Closing Circuit Verify the system installation after completing hydraulic and electrical installation and filling the reservoir To begin closing the electrical circuit 1 Hip internal ECB circuit breaker to ON position 2 Install fuse element between HPU motor and battery cable or flip circuit breaker to ON position 3 Hip system isolation switch on ECB cover to ON position Leak Check To perform leak check run one function at a time in a single direction for 5 10 seconds If installation was completed with empty hoses increase the run time to 10 30 seconds Perform the following 1 Confirm hose run is correct by verifying operat
33. nal problems and possibly CAUTION The HPU was shipped cleaned and tested HARKEN strongly recommends against disassembly or removal void warranty A mounting pad with tie downs will be required for securing the HPU to the boat Every installation is unique Considerations for the mounting pad and tie downs follow e The mounting pad not supplied may be a tray platform or bridge that securely attaches to the boat and supports the HPU Consider total weight and overall dimensions See Technical Data pg 20 The HPU is fastened using four 4 M10 1 5 x 15 mm bolts which thread into the underside of the HPU tank Underside access must be available for fastening Additional tie down supports not supplied are required These may be similar to battery box tie downs and fabricated from nylon or polyester webbing Tie downs should attach 2 to the mounting pad and be lashed over the HPU tank as illustrated DP ake wey K ou J Approximate clearance required for installation g 200 mm Mount Control Box Choose a suitable location for the electronic control box ECB as described in the planning section The ECB is L 16 75 425 mm x W 12 305 mm x H 6 7 169 mm and is externally mounted using four 4 M6 14 fasteners The ECB is water resistant to IP67 however its location should be dry and within a 5 m wire run to the HPU Power supply cable
34. p Motor Functi 4 15 Supply Ye 10 When ordering specify that all hoses are flushed filled with clean nO Noe EON IUO Retun 1 2 125 oil and capped at point of purchase In most conditions HARKEN Double Pump Motor Function 3 Supply 2 12 5 recommends ISO 46 grade oil See Oil Equivalent Table pg 15 Return 28 16 If hoses are shipped they may not contain oil HARKEN can Triple Pump Motor Function 12 45 upp E us supply flushed clean empty hoses if ordered when purchased exception noted in Hydraulic Oil section pg 15 IMPORTANT Always ensure pressure rating for selected hose is equal to or greater than 2000 psi 140 bar Hose Shortening Hydraulic hoses typically shorten 2 to 4 of total length when pressurized When routing and measuring hose lines ensure extra hose length is added to compensate for the hose shortening under pressure End Fittings Hydraulic fittings vary widely HPU manifold A and B ports are 8 SAE female P and T ports are 10 SAE female The case drain is 8 JIC male Hose end fittings may be selected to fit existing function fittings or function fitting may be replaced Refer to individual function manuals for specific A amp B and drain port sizes Fitting Instructions End fittings must be installed using proper tools by qualified persons Fittings should be stainless steel whenever possible A CAUTION Cadmium plated fittings rust in saltwater environment Replacement costs outweigh initial cost advan
35. ressure required for each piece to table below to select power unit HARKEN Hydro Power Units are available in three sizes Hydro 1 2 and 3 Each motor pump combination is rated at 4 GPM 15 LPM with a maximum operating pressure of 2000 PSI 140 BAR Hydraulic Power Units Max Maximum Tank Maximum Weight Power Number of simultaneous 24v DC current draw Capacity continuous output Without manifolds With attached manifolds unit functions functions Motor amps gal psi gpm _ bar l m Ib kg Ib kg Fasteners Hydro 1 4 1 1 x 4000 Watt 210 7 9 30 200094 1409015 89 40 5 102 46 1 M10 Hydro 2 9 2 2 x 4000 Watt 2 x 210 18 5 70 200098 140 30 182 82 6 194 88 2 M10 Hydro 3 15 3 3 x 4000 Watt 3x 210 185 70 2000912 140 Q9 45 233 105 9 246 111 4 M10 One function delivers double flow output 8 gpm using 2 motors This number is reduced by one when a double flow function is in use Wiring to Connect Valves to Electronic Control Box 1 Cable per Valve Hydraulic Power Unit HPU You must Supply Suitable Hydraulic Hoses See pg 9 owitches Battery Cable with Suitable Fuses Electronic Control HPU Mounting Bolts Four 4 M10 Depth of Threaded Holes in Tank Bottom 15 mm Included with Unit ECB Mounting Bolts Four 4 or 1 4 1 Hydraulic Power Unit HPU Mounting Pad to Secure Power Unit to Boat See pg 8 2 Electronic Control Box ECB Hydraulic Oil See pg 15 3 Electric Wiring Cables with Terminals 2
36. ride is engaged HPU warranty may be voided A CAUTION Motor operation beyond temperature limits will cause damage to motor and possibly other components Single and Multiple Function Operation The Hydro 3 is designed to operate either three single flow functions on different manifolds or two double flow functions at a time All functions are powered by either one or a combination of two motors If additional functions are operated simultaneously oil flow will be divided among all functions and performance across all operating functions will decrease Hydro 3 17 HARKEN Hydraulic Power Units will provide years trouble free operation with proper routine maintenance Adherence to a maintenance schedule will lengthen component life reduce downtime and minimize repair costs Typical maintenance includes regular oil changes replacing filter elements oil sampling and component inspection Under normal operating conditions the following maintenance schedules are suggested Filter Element Replacement Schedule e Within eight 8 operating hours after the initial commissioning e Every 500 operating hours or when Oil Filter Status Indicator signals a dirty filter e During any complete oil change Filter supplied with the unit is a drop in element HYFEH10 Ensure O rings are fitted into ends of filter prior to installation Contact HARKEN for replacement elements If using other manufacturer cross reference the filter and use element rated
37. rim cylinders windlasses and keel cylinders HPUs can include waterproof prewired electronic control boxes ECB or act as stand alone central or supplemental power units HARKEN HPU features a 4kW 24VDC motor which is sized alongside the pump to power a single function With additional pumps and motors multiple functions can run simultaneously or the built in double flow feature can supply more oil to power intensive functions Motors are fan cooled series wound and energy efficient at all speeds Factory installed manifolds and pumps are internally plumbed saving space installation time and additional hardware Valve manifolds are equipped with horizontal ports to provide ease with hose routing Elevated reservoir fill cap keeps oil from spilling filters air exchange and removes moisture from the tank to ensure a healthy hydraulic power unit Drop in return line filters with status gauge make maintenance fast and easy The prewired ECB features sealed passage for switch and valve wires The ECB is prewired internally and contacts are labeled The user is required to make electrical connections for supply power switches and valves Tank mounted electrical motor contactors meet the IP67 waterproof specification Use the built in double flow function to supply more oil to power intensive equipment Fan cooled series wound motors are energy efficient at all speeds TOR Its Drop in return line filters with Nt A stat
38. s and deck switches connect to ECB See Electrical Installation pg 13 hydraulic hoses contain manufacturing debris when purchased Attaching a dirty hose will contaminate the system I CAUTION Cleanliness is crucial for any hydraulic system Contamination is the primary cause of seal failure Most Always flush hoses thoroughly before use Failure to do so may void warranty Measure hydraulic hose runs after the HPU has been mounted Remember these important points when measuring runs e Short straight runs between HPU and function are best Avoid sharp edges which may chafe the hose e Minimize fittings connections throughout the run to avoid possible leak points Minimize 90 bends which increase system losses and decrease performance If unavoidable use a 90 swept fitting do not use a 90 elbow fitting Use a swept hose fitting for a 90 bend A CAUTION Do not exceed the manufacturer specified minimum bend radius Avoid using an elbow 8 Hydro 3 Hydraulic Installation Hose and Fitting Selection Recommendation Recommended Hose ID for Hose Lengths Under 40 12 m Return 3 4 19 Functions must be connected to the HPU manifold using proper gpm Ipm in mm hydraulic hose size and type Required hose type is SAE 100 R2 Single Flow Case Drain l4 6 3 or SAE 100 R8 Hose size is determined by flow and run length Double Flow Case Drain 38 10 between HPU and function Triple Flow Case Drain o O 125 Single Pum
39. stem leak present Insufficient motor torque Relief valve is opening Pump is not operating correctly Hydro 3 How to Verify Check power to ECB Check motor switches on ECB Check wiring from ECB to motor Check main circuit breaker to ECB Check lights on micro circuit breaker If red reset circuit breaker Check thermal switch trip light on ECB Verify proper voltage at motor Verify operation of motor relay Pressure relief valve not working Not enough current going to motor Check oil level in reservoir Repair pump Check function breaker in ECB Check wiring from deck switch to ECB Check wiring from ECB to directional valve Check lights on micro circuit breakers If red reset circuit breaker Check operation of directional valve solenoids Perform manual override with hex wrench Check hose and fitting connections Verify adequate battery voltage to motor Hydraulic line is plugged Check oil level in reservoir Check filter status gauge Replace filter element if needed Check hose and fitting connections Verify batteries are fully charged Check relief valve opening pressure Check oil level in reservoir Check system pressure under load 19 Bill of Materials H31N39 SNI1V014 00 3ATVA 66006 cN cN LIM SNOIYVA GVSES H N dd 8 19 SS 9019 GAH 55 916 89SdZAH GOEES H cN ASSV NIVd 3SV9 SNOlYVA 9 5 H
40. tages Port Indentification Hydro 3 HPU has two 2 attached manifolds each with four 4 valve ports It also comes with a remote manifold containing up to four 4 valve ports HPU remote manifold attaches via hose to pressure ports on distribution manifold T3 Back Tank Ports Distribution manifold as a v Remote manifold Attached manifold on Hydro 3 HPU Hydro 3 9 Hydraulic Installation Configuration The stock configuration of Hydro 3 is internally plumbed such that valves are pre assigned to a manifold and motor This is illustrated in the Function Assignment Table Hydro 3 unit uses valves 1 4 with manifold 1 and motor 1and valves 6 9 with manifold 2 and motor 2 Valves 10 13 correspond with remote manifold and motor 3 Valve Station 5 is located on the distribution manifold and is used with motors 1 2 and 3 Valve Stations 14 and 15 can be used with remote manifolds when more multiflow valves are needed Function Assignment The Hydro 3 unit is equipped with two 2 attached manifolds and one 1 remote manifold per design specification Each manifold style has up to four 4 valve stations corresponding with four 4 ECB switches Assign each function to its own set of valve ports Record the function name in the Function Assignment Table below When assigning valves to functions be sure to separate functions that will run simultaneously to different manifolds Example 1 Run primary winches on differ
41. the deck switches to the ECB 2 Connect a ECB to power supply 3 Connect HPU motor to the ECB 4 Connect valves to the ECB 5 Connect the HPU to the battery IMPORTANT Adhere to electrical standards per the National Boatbuilding Regulatory Bureau A CAUTION DO NOT connect the cable from the battery to the HPU until all of the other steps are complete CAUTION Be extremely careful when connecting the battery cables Short circuiting the battery connections can damage the HPU and or motor and possibly cause damage to the boat a fire and or personal injury CAUTION Never run the HPU pump without oil This can cause serious damage to the pump and or motor and will void the HPU warranty Wire Selection Three types of wire cables are required for installation 1 Wires to connect switches to the ECB 2 Wires to connect the power supply to the ECB 3 Wires to connect the HPU to the battery Minimize voltage loss on battery and power supply cables by sizing wire gauge for a length of wire Refer to the Wire Sizing Table below for a given length of wire At the HPU motor contactor the positive terminal is an 8 mm stud and the common ground terminal is a 10 mm stud Install end terminals using proper crimping tool Wire Sizing Table 16 ft 5 m 33 ft 10 m 49 ft 15 m Switch or Valve to ECB 16 AWG 1 31 mm 14 AWG 2 08 mm 12 AWG 3 31 mm Power Supply to ECB 12 AWG 3 31 mm 10 AWG 5 26 mm 8 AWG 8 366 mm Battery to HPU Motor 00 AWG
42. us gauges provide a no mess alternative to typical spin on styles i Le Plumbing to manifolds is under reservoir top so there is no exposed plumbing not visable Hydro 3 HPU Coated aluminum tanks have hardcoat anodized 6061 16 aluminum top plates Manifolds are made with clear anodized aluminum VEA Z A S External shut off switches F oc Sealable penetrations nto S n e control box provided for deck switch wiring Deutsch receptacle and plug connects motor power cables to electronic control box _ Manifolds and pumps are preplumbed saving space installation time and additional hardware Prewired and waterproofed control boxes are molded from extremely tough Electronic polycarbonate Control Box ECB Remote Manifold Hydro 3 3 Power Unit Selection Parts Power Unit Selection Power unit selection must be based on the flow and pressure requirements for all hydraulic equipment that will operate at the same time Most HARKEN hydraulic equipment winches furlers etc requires a flow of 4GPM 15 LPM with a maximum operating pressure of 2000 PSI 140 BAR To select the correct power unit 1 Consult the manual for each piece of hydraulic equipment that will be driven by the power unit Note flow and pressure 2 Determine which pieces of hydraulic equipment or circuits will be used at the same time i e winch and furler 3 Compare total flow p
43. y is 70 liters 18 5 gal Approximately 55 liters 14 5 gal will be needed for the reservoir If installation is completed with empty hoses extra oil will be needed to meet the 2 3 3 4 tank fill indicator requirement Hydraulic Oil HARKEN recommends mineral based ISO 46 grade oil Refer to Oil Equivalent Table below If HPU is primarily used in an extreme cold weather environment ISO 32 is suitable Characteristics of good quality mineral based hydraulic oil are Note If the hydraulic installation was completed with empty hoses be sure to have extra oil on hand to top off the tank as the Good anti wear performance Resistance to oxidation depredation Protection against rust and corrosion Resistance to foaming Ability to separate water rapidly Suitable for widely varying temperature conditions Good low temperature flow properties Retains viscosity temperature characteristics while in service Universally available hoses are filled T gt Oil Level Indicator A CAUTION Never run the HPU pump without oil This will void warranty Oil Equivalent Table Manufacturer Amoco Ashland Valvoline Atlantic Richfield BP Chevron USA Citgo Petroleum Corp Citgo Petroleum Corp Conoco Continental Esso Exxon Brand Name Rykon 46 Evergol 46 Duro AW S 215 Energol HLP AW Hydraulic Oil 46 A W Pacemaker XD 46 ANN 46 ouper Hydraulic Oil 21 Nuto H46 Nuto H46 Manufacturer Phi
Download Pdf Manuals
Related Search