HYDRO POWER UNIT 2
Contents
1. VALVE 5 250 2 SOL A SWA ENSIS 5 GREEN YELLOW GND VALVE 5 24 VDC 3 COMMON 3 COMMON ONO CONNECTION COIL B 22 WATTS 4 SOLB 4 SOL B BROWN 24 VDC PE u CONNECTION id SW5B WHITE PBSB SW5B PB6A BLUE GND VALVE 6 GND i 1 NOT USED 1 24 VDC 24 6 VALVE 6 A B 2 SOL A omen omen 2 SOLA i GREEN YELLOW GND VALVE 6 24 VDC 3 COMMON 6 3 COMMON Ou CONNECTION COIL B 22 WATTS 4 SOL B 4 SOL B BROWN 24 VDC PE CONNECTION SW6B WHITE PB6B SW6B PB7A BLUE GND VALVE 7 GND n 1 NOT USED 1 24 VDC BERGA y 24 VALVE 7 A B 2 SOL A SENS PENA 2 SOL A GREEN YELLOW GND VALVE 7 24 VDC 3 COMMON 47 3 COMMON ONO CONNECTION COIL B 22 WATTS 4 SOL B 4 SOL B BROWN 24 VDC SE ds CONNECTION 9 sw7B WHITE PB7B SW7B PB8A BLUE GND VALVE 8 GND a BLACK 1 NOT USED 1 24 VDC 24 8 gt 3W8A VALVE 8 A B 2 SOL A 2 SOL A GREEN YELLOW GND VALVE 8 24 VDC 3 COMMON 3 COMMON ONO CONNECTION COIL B 22 WATTS a 8 250 8 BROWN 24 VDC 4 NO CONNECTION PBSB SW8B WHITE SW8B 55 PB9A 2 2 BLUE GND VALVE 9 GND COILA 24 BLACK 1 NOT USED 1 24 VDC a O SW9A 24 9 O W9A VALVE 9 A B v v v v 2 SOL A TOEA GREEN YELLOW GND VALVE 9 24 VDC u E 3 COMMON 3 COMMON NO CONNECTION COIL B 22 WATTS 2 4 SOLB 4 SOL B BROWN 24 VDC PE NO CONNECTION2. 1 VS4 1 1 VS5 D 1 amp 2 VS6 A2 2 VS7 A2 2 VS8 A2 2 VS9 A2 2 VS1 R1 1 VS2 R1 1 VS3 R1 1 VS4 R1 1 VS5 D 182 VS6 R2 2 VS7 R2 2 VS8 R2 2 VS9 R2 2 10 Hydro 2 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 hoses 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 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 and B ports with a valve must be plugged with ORB plugs IMPORTANT ORB BSPP and JIC connections do not need PTFE tape or other sealing Case Drains Fu
3. 3SOH SONILLIJ ANI 5421 9 ISOH 9 ANITA Tddns QTOJINVW ISOH FNIT OL ANNA NMOHS LON 21 2 3D Rendering _ O gm N Hydro 2 22 Motor Thermal Relay Schematic AV T38 TVINddH1 1 caver y y 1 lt lt Zld A Zld gt wa HOLIMS 0101 NO 330 291 HILIMS SSVd A8 12 344 1 HOLIMS 2 401011 Vi cu 0101 AV T38 TVINddH1 YOLOIN 394141 HILIMS TVIA3HL L 401011 AND G NVYo y y 9 1 lt lt 114 114 gt 119 HOLIMS 01011 NO 330 ISI HILIMS SSVd A8 581223 AV T38 0101 1 dvdr N 23 Hydro 2 Suggested Wiring Practice for Motors Customer Supplied Batteries and Disconnect 24 SUGGESTED WIRING PRACTICE FOR MOTORS CUSTOMER SUPPLIED BATTERIES DISCONNECT AND FUSES PRIMARY DISCONNECT Power Supply 24 Volts DS1 600A Time Delay Fuse a M1 1M N 250 24VDC 4KW 210 FLA _ Time Delay Fuse M2 2M GND PS j 1 250 A 24VDC 4KW 210 FLA SEPERATE FEED WIRES CUSTOMER SUPPLIED Hydro 2 Electrical Schematic GND 10
4. 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 System leak present Insufficient motor torque Relief valve is opening Pump is not operating correctly Hydro 2 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
5. 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 switch 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 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 011 Level and Filter Maintain an oil level of 2 3 3 4 full as viewed through tank fill
6. 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 2 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 capacity 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 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 Oil Level Indicator Retains viscosity temperature characteristics while in service Universally available Note If the hydraulic installation was completed with empty hoses be sure to have extra oil on hand to top
7. 14 6 3 Double Flow Case Drain 3 8 10 3 Single Pump Motor Function 4 Supp ut Return 12 125 1 30 supply 1 2 12 5 Double Pump Motor Function 8 Return 5 8 16 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 advantages Hydro 2 Hydraulic Installation Port Indentification Hydro 2 HPU has two 2 manifolds containing four 4 valve ports each HPU remote manifold attaches via hose to pressure ports on distribution manifold T3Batk Ports T24 P yn P Pressure Ports 3 E 1123 80 jg A U
8. Refer to Wire Sizing Table pg 12 4 SW4A SW4B Ground Follow these steps to connect HPU motors and valves to ECB 9 SWSA SWSB Ground 6 SW6A SW6B Ground 1 Join mating ends of Deutsch Connector to connect the ECB 7 SW7A SW7B Ground to the HPU motor 8 SW8A SW8B Ground 9 SW9A SW9B Ground 2 Pass valve wires through gland into the ECB case 3 Connect valve wires per Valve Wiring Table at right Valve wire sets connect to terminal strip labeled SWXA SWXB and GND See photo pg 13 4 Connect valve cable to M12 connector on valve a Brown Not Used White Port A or B A 1 Black N C Port B or A l Blue 3 ue 5 Green Yellow Not Used E m Note Align key and keyway on connector Female pm s ae s Pl 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 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 2 Commissioning
9. 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 HYFEH 10 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 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 conten
10. Sob swoB 3 WHITE 3 SW9B e 23 99 28 Hydro 2 HARKEN 2 29 Control Box Mounting Dimensions 50339 298 83 11 765 280 16 11 030 4 s 1 Note Allow 1 25 mm clearance for toggle switch and indicator light 1 398 78 38011 O E 440 71 45938 15 700 14 965 d 17 351 18 086 1 TAIRIAISIN 5 AN N x 2 ERE 9 8 _ 521 5 e MARKEN 30 Hydro 2 Control Box Interior Layout GREEN ON RED OFF PRESS TO RESET GREEN ON RED OFF PR
11. 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 2 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 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 Indicator Always inspect oil level before use If necessary to 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 trippe
12. 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 12 Switch Wiring Table Valve Switch Wire 1 Wire 2 1 A 24 1 SW1A B 24 1 SW1B 9 A 24 2 SW2A B 24 2 SW2B 3 24 3 SW3A 24 3 SW3B 1 24 4 SW4A B 24 4 SW4B 5 A 24 5 SW5A B 24 5 SW5B 6 A 24 6 SW6A B 24 6 SW6B 7 A 24 7 SW7A SW1A 4124 1 SW1B B 24 7 SW7B 8 24 8 SW8A B 24 8 SW8B 9 A 24 9 SW9A B 24 9 SW9B Note Polarity is not an issue with 2 wire deck switches Connect ECB to Power Supply Follow these steps to connect power to ECB 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 OCB terminal 2 4 Connect power supply common lead to any GND terminal Hydro 2 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 SW2A SW2B G d Notice Valve wires supplied are 5M These can be extended with 3 SW3A SW3B TAT a 16 gauge wire if needed
13. 2 PA l Attached manifold on Hydro 2 HPU Remote manifold Distribution manifold Configuration The stock configuration of Hydro 2 is internally plumbed such that valves are pre assigned to a manifold and motor This is illustrated in the Function Assignment Table Hydro 2 unit uses valves 1 4 with manifold 1 and motor 1 Valves 6 9 are used with manifold 2 and motor 2 Valve Station 5 Double flow valve is located on the distribution manifold and is used with motors 1 and 2 Function Assignment The Hydro 2 unit is equipped with two manifolds either attached or remote per design specification Each manifold style has four 4 valve stations corresponding with four 4 ECB switches Assign each function to its own set of valve ports When assigning valves to functions be sure to separate functions that will run simultaneously to different manifolds Example 1 Run primary winches on different manifold than mainsheet Example 2 Run primary winches on different manifold than headsail furler Record the function name in the Function Assignment Table below 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 1 1 VS2 1 1 VS3 1
14. 2 8 6 1109 V 6 1109 8 8 1IOO V 8 1109 8 4 3ATVA 1109 V INTVA 102 8 9 1109 V 9 INTVA MOD HOLOVINOO HOLOIN 71109 8 S INTVA 1109 V S INTVA MOD YOLOVLNOD L HOLOIN 1109 8 SATWA 71109 V v INTVA 71109 8 INTVA 1109 V INTVA 1109 8 Z 3ATVA 71109 V Z INTVA 102 8 L SATWA 1109 V L INTVA Customer Supplied Switches L AN gt 96105 OOFSNL G6MS ca 1 OOFSN L A V6MS 6 V61OS V6dd 109 8 1lO9 V 63ATVA OOFSNL g8MS za LHM Y OOFSNL A L V8MS Mm gegd 8 vc 889 V ania lt e ca V8dd 109 8 1lO9 V 83ATVA 2 1 05 ania lt gt 007 1 8 lt 1 00 9 VZMS Mm Z Ve 299 V 5 L L e ca e OOFSNL Y O Vlad 103 8 1lO9 V ZINTVA gt 89105 00 9 VIMS 999 9 999 VV 22 9 418 lt V9 lOS 6 L
15. 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 uc p Use the built in double flow function to supply more oil to power intensive equipment Eu Fan cooled series wound nd motors are energy efficient at all speeds Drop in return line filters with status gauges provide a no mess Plumbing to manifolds is alternative to typical spin on styles under reservoir top so there 15 no exposed plumbing not visible Manifolds and pumps are p
16. ESS TO RESET 1 82 O O 8 JO O loo Of ca A I 22 bes pe Set E ELE m EI LH ET E I PFE LI ET E E 2 8 LE ET T EI i T E MA 2 1 1 mI T ee d EI hr cL IL ET 2 ILE EIL EII EID T LE del saam SESE ESE E FE 112 1 11 PT L i EET FL PT F TIT E FE ET HT ET TIT E h ET T L H h J FE HI ll u E TO TO wo JO O ls JO O sw JO O O llevo 2 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 relating to a specific warranty concern please refer to the following Harken Catalog Harken Website www Harken com Call or Email the ne
17. G cres s 15 16 Fill reservoir Hydraulic fluid Closed circuit Leak check One way function flush System validation Function pressure check Oil level and filter OPERATION cnica tic o as 17 Power up power down Oil level Motor thermal protection Single and multiple function operation Filter element replacement schedule Hydraulic oil change schedule ilc H 18 19 How to change oil Leakage inspection Cleanliness inspection Oil level inspection Additional maintenance points TROUBLESHOOTING TT 19 Miti d Ita O 20 31 Bill of Materials Exploded View Diagram 3D Rendering Electrical Schematic Motor Thermal Relay Schematic Suggested Wiring Practice for Motors Valve and Switch Wiring Schematic Control Box Mounting Dimensions Control Box Interior Diagram MARRANDI Rc Back Cover 2 Hydro 2 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 trim 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
18. HYDRO POWER UNIT 2 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 3 UNIT SELECTION AND PARTS EIS osorno a rta rana 4 eX M M 9 6 POWER UNITINSTALLATION UU Ul nS 1 8 Planning installation Location in boat Secure power unit Mount control box HYDRAULIC 4 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 ELECTRICAL INSTALLA HON constancias 12 14 Wire selection Connect deck switches to ECB Connect ECB to power supply Connect HPU motor and valves to ECB Connect HPU to battery COMMISSIONIN
19. L 9 mus Ta 3 4 gt gt qas CIN CHO OOFSN L A 85 8 9 V9dd 103 8 1lO9 V 93AT1VA AN gt gt as 1OS VS IOS CLAU C IHM 00FSN 4 O0vYSNI VSMS VSMS O0vSNI Ld L L N3349 TE a LIN L a 4 Ld 5 5 S3AT1VA gt 9710 OOFSNL grAAS Y ia VyMS abad v vc cgo avert 0090010 7 017 0006 ZOSIN VE 22 9 anis lt VV 1 Ld Vrdd MOD 8 1lO9 V VANIVA 2 ge TOS OOFSNL gEMS Y Mm vc vyao ania 5 gt Ve lOS vedd MOD 8 1lO9 V 3AT1VA Hc lOS O0vYSNI gScCMS Y VE MS 22 v vc edo GND sania lt Vc lOS e Ld OOPGNL g MS 2 S MOD 8 1lO9 V CANIVA 2 La A VLMS glad L y c qO GND LO drc 330 No TOYHL
20. NNECTION NO CONNECTION SW3B GND SW4A NO CONNECTION NO CONNECTION SWA4B PB1A VALVE 1 COIL A ps VALVE 1 COIL B AE 0 PB1B SW1A SW1B PB2A VALVE 2 COILA E 0 24 2 SW2A VALVE 2 COIL B 21 0 2 SW2B PB3A VALVE 3 COIL A 41 9 24 3 SW3A VALVE 3 COIL B 0 SW3B PB4A VALVE 4 COILA 41 VALVE 4 COIL B 21 SW4B 27 Valve and Switch Wiring Schematic 5 9 Customer Supplied Switches M12 FEMALE INTERFACE CABLE Y 12 PLUG VALVE CONNECTOR PB5A BLUE GND VALVE 5 GND a BLACK 1 NOT USED 1 24 VDC
21. NOI CH HOLOIN ania lt GND Vi 8d MOD 8 1lO9 V LIATVA C9 Vict 99 0090010 7 017 0006 o 330 TOYHLNOI L HOLOIN 089 VOL DAA vC 25 2 Valve and Switch Wiring Schematic 1 4 Customer Supplied Switches VALVE 1 A B 24 VDC 22 WATTS VALVE 2 A B 24 VDC 22 WATTS VALVE 3 A B 24 VDC 22 WATTS VALVE 4 A B 24 VDC 22 WATTS VALVE CONNECTOR 1 NOT USED 2 SOLA 3 COMMON 4 S0L B 5 1 NOT USED 2 SOLA 3 COMMON 4 S0L B 5 1 NOT USED 2 SOL A 3 COMMON 4 SOL B 5 1 USED 2 501 A 3 COMMON 4 S0L B 9 PE M12 FEMALE INTERFACE CABLE 1 424 VDC 7 2 SOL A Tl 3 COMMON 4 SOL B 5 PE 2 1 1 24 VDC 2 50 A 2 3 COMMON 4 SOL B 5 PE 2 1 1 24 VDC 2 SOL A 3 3 COMMON 4 SOL B 5 PE 2 1 1 424 VDC 2 SOL A 3 4 FA 3 C0MMON 4 SOL B 5 PE 2 1 Hydro 2 BLUE GND BLACK GREEN YELLOW GND BROWN 424 VDC WHITE BLUE GND BLACK GREEN YELLOW GND BROWN 424 VDC WHITE BLUE GND BLACK GREEN YELLOW GND BROWN 424 VDC WHITE BLUE GND BLACK GREEN YELLOW GND BROWN 424 VDC WHITE GND SW1A NO CONNECTION NO CONNECTION SW1B GND SW2A NO CONNECTION NO CONNECTION SW2B GND SW3A NO CO
22. are fully charged Check relief valve opening pressure Check oil level in reservoir Check system pressure under load 19 H 51337 Bill of Materials 331N3O ONILVOTd 00 3ATVA 1A SNI IIAA 4459 VZ 19 SS ON 1d 14 GAH dOLANV1 80547 ASSY SVO AlddflS Q IOJINYW ISOH 9 LSIG OL ISOH 9 OSGAH ANVIL 3SOH Z1 Od GAH SOHS 8 81 0071 81 9 1 S 1S3 YIHSVM SS 91 6 AONVS T3 A31 LHOIS UIS SOHS 91 X SC BW I33S VO ANVIL 104 OSCAH H 15 SS SC l X 01 GION3IOS OLLIIW 14 FIVW AJNO WANIWATV 31V W33 31VW34 1dN SNOIJYA SNOIVA 1141 a a ANV I8 ZZY LS H X 3dld 3IVW 31VW LdN Utr ASSY 431714 6 0 ASSY 1 4 1814151 ANVL WANIWN TV 04 8v ASSY JOLOW IWNdA OYCGAH 540 9 ERE TVIalalvw LA Vd ONIMVAG 100191 BIC VS 968191 Hydro 2 267806 20 Exploded View Diagram OF HOS 8 3dld 1 3NI1 Ngn138 434931 7114 HOS 6 3dld 8 NOLLINS SONLLLIH 321 ZL ISOH 31
23. arest 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 Online Catalog www harkenstore com Email harken harken com Harken Australia Pty Ltd 1B Green Street Brookvale 5 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 e 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 infoOharken it Harken New Zealand Ltd 30 36 Fanshawe Street P O 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 200 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 polskaQharken pl Harken Sweden AB Main Office and Harken Brandstore V stmannagatan 81B SE 113 26 Stockholm Sweden Telephone 46 0303 61875 Fax 46 0303 61876 Mailing address Harken Sweden AB Box 64 SE 440 30 Marstrand Web harken se Email harken harken se Harken UK Ltd Bearing Ho
24. ce contact Harken to find the repair site nearest you See www harken com 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 flames 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
25. ctly 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 nadequate cleanliness when filling i e dirty drums or containers e Filling to improper levels 18 Hydro 2 Leakage 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 15 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
26. d an indicator light on ECB will illuminate After this occurrence the motor requires a variable cooling period based ambient conditions warranty may be voided gt gt Single and Multiple Function Operation Electronic Control Box ECB Oil Level Internal Thermal Switch Override Indicator CAUTION 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 override is engaged HPU CAUTION Motor operation beyond temperature limits will cause damage to motor and possibly other components The Hydro 2 is designed to operate either two single flow functions on different manifolds or one double flow function at a time All functions are powered by either one or both motors If additional functions are operated simultaneously oil flow will be divided among all functions and performance across all operating functions will decrease Hydro 2 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
27. ernal 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 operation 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 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 8 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
28. ersonal 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 10 AWG 5 26 mm Battery to HPU Motor 00 AWG 67 4 mm 0000 AWG 108 mm 12 Hydro 2 Electrical Installation Connect Deck Switches to the EGB 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 Note Deck switches must be N O normally open Follow these steps to connect deck switches to ECB 1 Select moisture barrier gland insert 2 Pass
29. flush hoses thoroughly before use Failure to do so may void warranty Measure Hose Run 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 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 2 Hydraulic Installation Hose and Fitting Selection Recommendation Functions must be connected to the HPU manifold using proper hydraulic hose size and type Required hose type is SAE 100 R2 or SAE 100 R8 Hose size is determined by flow and run length between HPU and function When ordering specify that all hoses are flushed filled with clean oil and capped at point of purchase In most conditions Harken recommends 150 46 grade oil See Oil Equivalent Table pg 15 If hoses are shipped they may not contain oil Harken can supply flushed clean empty hoses if ordered when purchased exception noted in Hydraulic Oil section pg 15 Recommended Hose ID for Hose Lengths Under 40 12 m mm Single Flow Case Drain
30. n location Location in Boat Filter status indicator e Dry and well ventilated typically near the engine room e HPU and ECB to be mounted within close mutual proximity recommended maximum 5 m wire run See Electrical Installation pg 12 e Provide necessary clearance for HPU e HPU in close proximity to battery and power supply to reduce voltage drop See Electrical Installation pg 12 e Provide access for maintenance and servicing Make access available to filler tube filter filter status indicator and site gauge e Central to the system as illustrated in Typical System diagram Case Drain Port e Provide routing for hydraulic hoses from HPU to functions Hoses attach to manifold horizontally e 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 Hydro 2 Installation Securing Hydraulic Power Unit of the tank lid or the HPU components Introduction of contaminants can cause operational problems and possibly I 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 Lido pad a
31. nction 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 Hydro 2 unit is sized to fully power two functions or one double flow function 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 when 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 50 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 2 unit They should be purchased as required by the original equipment manufacturer Hydro 2 11 Electrical I
32. nd tie downs follow 1 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 22 to the mounting pad be lashed over the HPU tank as 50 mm L illustrated Approximate clearance required for installation e 200 mm Mount Control Box 100 mm 100 mm Choose a suitable location for the electronic control Box ECB as described in the planning section The ECB is L 14 97 380 mm W 11 03 280 mm x H 5 12 132 mm and is mounted from outside using four 4 M6 47 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 cables and deck switches connect to ECB See Electrical Installation pg 13 CAUTION Cleanliness is crucial for any hydraulic system Contamination is the primary cause of seal failure Most A hydraulic hoses contain manufacturing debris when purchased Attaching a dirty hose will contaminate the system Always
33. nstallation Harken Hydro Units include 24 volt DC motors standard 12 VDC motors are available by special order If a 12VDC motor was specified with system refer to 12VDC motor electrical installation supplement for additional information 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 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 p
34. off the tank as the hoses are filled A CAUTION Never run the HPU pump without oil This will void warranty 01 Equivalent Table Manufacturer Amoco Ashland Valvoline Atlantic Richfield BP Chevron USA Citgo Petroleum Corp Citgo Petroleum Corp Conoco Continental 550 Brand Name Rykon 46 Evergol 46 Duro AW S 215 Energol HLP AW Hydraulic Oil 46 A W Pacemaker XD 46 A W 46 Super Hydraulic Oil 21 Nuto H46 Nuto H46 Manufacturer Gulf Mobil Mobil Pennzol Phillips Petroleum Corp Shell Shell Texaco Union Filler tube Brand Name 46AW DTE 20 Series 25 DTE 10 Series 19 Magnus A 315 Tellus 46 Tellus T46 SUNTAC WR 150 WR Rando HD 46 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 Hydro 2 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 int
35. replumbed saving space installation time and additional hardware Hydro 2 HPU Coated aluminum tanks have hardcoat anodized 6061 T6 aluminum top plates Manifolds are made with clear anodized aluminum Sealable penetrations into control box provided for deck switch wiring lt External shut off switches Electronic Control Box ECB Prewired and waterproofed control boxes are molded from extremely tough polycarbonate Deutsch receptacle and plug connects motor power cables to ECB Hydro 2 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 pressure 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 Weigh
36. t Power Number of simultaneous 24v DC current draw Capacity continuous output Without manifolds With attached manifolds unit functions functions Motor amps gal psi gpm barelm Ib kg Ib kg Fasteners Hydro 1 4 1 1 4000 Watt 210 7 9 30 200004 140015 89 40 5 102 46 1 M10 Hydro 2 9 2 x 4000 Watt 2 210 185 70 200008 140030 182 82 6 194 88 2 10 3 15 3 3 x 4000 Watt 3x210 185 70 2000 12 1400 45 233 105 9 246 111 4 M10 One function delivers double flow output 8 using 2 motors This number is reduced by one when a double flow function is in use Wiring to Connect Valves to ECB 1 Cable per Valve a Hydraulic Power Unit HPU You must Supply Suitable Hydraulic Hoses See pg 9 owitches Battery Cable with Suitable Fuses HPU Mounting Bolts Four 4 M10 Depth of Threaded Holes in Tank Bottom 15 mm ECB Mounting Bolts Four 4 or 1 4 Mounting Pad to Secure Power Unit to Boat See pg 11 Hydraulic Oil See See pg 15 Flow Control Valves If Required See pg 11 Electronic Control Box ECB Included with Unit 1 Hydraulic Power Unit HPU 2 Electronic Control Box ECB 3 Electric Wiring Cables with Terminals 2 Cables per motor to connect power unit motor to ECB Pressure Reducing Valves If Required See pg 11 1 Cable per valve to connect power unit to ECB Pressure Relief Valves If Required See pg 11 4 Hydro 2 Safety Important Safety Informa
37. t and additive level In operating conditions with high levels of airborne particles and or elevated thermal loads reduce intervals between oil changes 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 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 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 Take 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 dire
38. tion 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 product warranty IMPORTANT Identifies condition or task requiring special attention Hydro 2 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 servi
39. to hands or face from pressure build up or heated fluids e 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 Never remove a hose line from a pressurized motor or cylinder 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 e 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 e Do not lift hydraulic equipment by the hoses or swivel couplers Use the carrying handle or other means of safe transport 6 Hydro 2 Installation While unpacking the hydraulic power unit HPU and electronic control box ECB inspect for irregularities During transport the power 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 installatio
40. use Ampress Lane Lymington Hampshire 5041 8LW England Telephone 44 01590 689122 Fax 44 01590 610274 Web harken co uk Email enquiries harken co uk Please visit http www harken com locator aspx to locate Harken dealers and distributors H 50335 H 51337 H 52730 Printed in USA 08 13 V 2
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