Seastar Solutions DC1000 Montageanleitung

Before you do it your way,

please try it our way

OPERATING INSTRUCTIONS

AND OWNER'S MANUAL

www.seastarsolutions.com

T H I R T Y

ISO 9001

DC Power Steering Unit

Part # DC1000 & DC2000

Throughout this publication Warnings and Cautions (accompanied

by the International Hazard Symbol ) are used to alert the

manufacturer or installer to special instructions concerning a

particular service or operation that may be hazardous if performed

incorrectly or carelessly.

Observe Them Carefully!

These “safety alerts” alone cannot eliminate the hazards that they

signal. Strict compliance to these special instructions when performing

the installation and maintenance plus “common sense” operation

are major accident prevention measures.

Not ce to Boat Manufacturer

or Installer

Hazards or unsafe

practices which

COULD result in

minor injury or

product or property

damage.

CAUTION

Hazards or unsafe

practices which

COULD result in

severe personal

injury or death.

WARNING

Immediate hazards

which WILL result in

severe personal

injury or death.

DANGER

Information which is

important to proper

installation or

maintenance, but is

not hazard-related.

NOTICE

Cleaning fluids containing ammonia, acids or any other corrosive

ingredients MUST NOT be used for cleaning any part of this

Hydraulic Steering System. Failure to comply will cause serious

damage to the steering system, resulting in possible loss of

steering, causing property damage, personal injury and/or death.

WARNING

Help protect your boating environment by ensuring that all used oil

is disposed of properly.

NOTICE

Don't compromise performance... use genuine

SeaStar parts only!

• SeaStar helms • SeaStar Cylinders

• SeaStar hoses • SeaStar Oil

Substituting non SeaStar parts in any part of the SeaStar hydraulic

steering system may seriously compromise system performance.

INTRODUCTION

Index

Introduction.............................................................................. 1

How the System Works............................................................. 2

SeaStar DC Power Unit Compatibility Chart ................................ 3

Tools ........................................................................................ 4

Specifications ........................................................................... 4

System Overview....................................................................... 5

System Installation................................................................... 7

Step 1 Mounting & Plumbing ..................................................... 7

1.1 DC Power Unit Mounting ........................................... 7

1.2 Relief Module Installation ......................................... 8

1.3 Plumbing the DC Power Unit .................................... 9

Step 2 Electrical Connections ................................................. 12

2.1 DC Power Unit Battery Connections......................... 12

2.2 Ignition Connection ................................................ 13

2.3 Autopilot Connections............................................. 13

Step 3 Filling and Purging ....................................................... 14

3.1 Purging Using Fast Purge Kit (HA2266).................... 14

3.2 Purging Using Supplied Bleed Tubing....................... 15

Step 4 Autopilot Tuning .......................................................... 17

Step 5 System Verification and Operation Check ...................... 18

Maintenance ......................................................................... 18

Troubleshooting Guide ........................................................... 19

Statement of Limited Warranty .............................................. 21

Return Goods Procedure ......................................................... 21

Before proceeding with the installation please read these instructions

thoroughly to familiarize yourself with the workings of this SeaStar DC

Power Steering System. SeaStar Solutions cannot accept responsibility

for installations where instructions have not been followed where

substitute parts have been used or where modifications have been

made to our products. Warranty may be void if products other than

SeaStar Solutions products are used with this system.

DC Power Steering System

The SeaStar DC Power Unit is a self contained steering system

designed to provide an alternative to existing power steering

systems. Unlike conventional power steering systems which require

engine/pulley driven pumps oil coolers oil reservoir filter and

relief control valves the DC Power Unit is an integrated power

steering solution requiring only the DC Power Unit a steering

cylinder and one or multiple helm pumps. The end result will be

less power consumption and very little heat generation. Installation

of the SeaStar DC Power Unit requires fewer parts less installation

time and easy troubleshooting making it an all around user friendly

system. With the built in semi-automated purge system the

SeaStar DC Power Unit will help the installer bleed ALL of the air

out of the steering system in minimal time.

The DC Power unit incorporates an autopilot pump as well for a

cleaner more reliable installation than using external pumps.

HOW THE SYSTEM WORKS

Fi ure 1.

SEASTAR Hydraulics

DC Power Steering System 3

SeaStar DC Power Unit Compatibility

DO NOT use extruded nylon tubing for plumbing this system. ONLY use

SeaStar Outboard type steering lines for all helm pump connection

and ONLY use Dash - , 2000psi hose for PRS/TNK connections.

3/ " Copper tubing is also acceptable as a substitution for SeaStar

lines, provided 4' SeaStar hose sections are used to connect the

copper to any fittings.

Failure to follow the above may lead to loss of steering control

causing property damage and/or personal injury or death.

WARNING

Never use Brake Fluid. Any non-approved fluid may cause irreparable

damage, loss of steering, and cancellation of warranty.

In cases of extreme emergency any non-toxic non-flammable fluid

may provide temporary steering.

CAUTION

The DC Power Unit is compatible with the following SeaStar

steering equipment:

All 1.4 and 1.7 SeaStar Non-Feedback helms. DC Power Unit is NOT

compatible with Hynautic Capilano or other manufacturers’ helms.

Helms

Recommended hydraulic fluids are:

Hydraulic Fluid

Cylinders 9" STROKE, 2" DIA. 11" STROKE, 2" DIA. 9" STROKE 2.5" DIA.

SINGLE YES YES YES

(HC5801 2) (HC5803 2) (HC5805)

TWIN YES (HC5801 2 YES (HC5804 NOT

& HC5802) & HC5803 2) Recommended

DC POWER STEERING UNIT

DC Power Unit is designed specifically for use with SeaStar NFB helms.

DO NOT use Hynautic, Capilano, or other manufacturers Helms.

NOTICE

• SeaStar Steering Fluid

• Fluids meeting MIL H5606

Specifications

• Automatic transmission fluid

Dextron II may be used in an

emergency

4SEASTAR Hydraulics

16-1/8" (410 mm)10-5/8" (270 mm)

15-3/4" (400 mm)

Fi ure 2.

DC POWER STEERING UNIT

You will need the following tools to complete your installation.

Tools

Specifications

• 5/32" and 1/4" Allen keys

• Phillips head screw driver

• Slotted/Flat head screw driver

• PST Liquid Teflon based pipe

sealant

• 3/4" and 7/8" open ended

wrenches

• Electrical cut and crimp pliers

• ALL other tools noted in your

helm pump and steering

cylinder owner’s manual

• Funnel

• Crescent wrench

DO NOT Use Teflon Tape.

WARNING

DC 1000

• Power unit = 24Volts

• Autopilot pump = 12Volts

0-60 in3/min

(fully adjustable)

• Peak current draw

@ 1250psi = 72A

• Idle current draw = 0.2 amps

• Average current draw = 10-15

amps

(depending on application)

• Weight = 55 lb (25kg) Dry

• Tank Capacity = 1.85 gal (7L)

DC 2000

• Power unit = 24Volts

• Autopilot pump = 24 Volts

0-60in3/min

(fully adjustable)

• Peak current draw @

1250psi = 72A

• Idle current draw = 0.2 amps

• Average current draw = 10-15

amps

(depending on application)

• Weight = 55 lb (25kg) Dr y

• Tank Capacity = 1.85 gal (7L)

DC Power Steering System 5

System Installation

• Install SeaStar helm pump(s) using installation instructions

provided with your helm.

• Install steering cylinder using the installation instructions

provided with your cylinder.

Install non-vent plug part # HA5432 into ALL helm pump stations

on board vessel. Failure to properly install non-vent plugs can

result in loss of steering causing property damage, personal injury

and/or death.

Included with your kit

Additional items required

for installation

WARNING

STEP 1

System Overview

DC POWER STEERING UNIT

• Power steering cylinder (See cylinder selection guide and

page 3 for DCPU compatibility).

• Hoses (See hose information on page 9).

• Liquid Teflon Sealant (DO NOT USE TEFLON TAPE).

• Helm (1.4 or 1.7 NFB models ONLY).

• Non-vent caps for helms.

• Wiring (see "Wiring Connections" section for details).

• 90A peak power supply on vessel.

• Autopilot controller (Optional).

• Fast Purge Kit (Optional).

• SeaStar Steering Fluid.

1.85 gal (7L) for Power Unit tank

0.13 gal (1/2L) for each steering cylinder

0.26 gal (1L) for each helm station

Additional 1–2 gal (4–8L) depending on hose length and type

• Misc. mounting hardware.

• Misc. crimp or solder connectors for making electrical

connections.

• One HF5529 fitting kit per additional helm station

SeaStar

DC Power

Unit x 1

Relief Valve

Module x 1

Bleeder Tube with Clamps x 1

Screws for Relief Valve x 3

Quad Ring

Seals x 2 90° Elbow

Fittings x 2

6SEASTAR Hydraulics

Making Electrical Connections

• Refer to page 12 of this manual for electrical connections.

Prior to making electrical connections of any type, be sure to vent

installation area of any fumes. Failure to do so may result in a

fire causing property damage and/or personal injury or death.

Filling and Purging Procedure

• Refer to page 14 of this manual for filling and purging of the

steering system.

Autopilot Tuning

• Refer to page 17 of this manual to adjust autopilot speed.

System Verification & Operation Check

• Refer to page 17 of this manual to verify system operation.

WARNING

STEP 2

STEP 3

STEP 4

STEP 5

TO AUTOPILOT

(RED/BLACK)

+IGNITION

+BATTERY

–BATTERY

Fi ure 3.

• Mount DC Power Unit. Refer to page 7 for mounting details.

• Install relief module on power steering cylinder. Refer to page 8

for installation details.

DO NOT mount the DC Power Unit in an area where pump noise

may disturb passengers.

• Install steering hoses using the figures and table shown on

page 9 and page 10.

The DC Power unit may be HOT to the touch. DO NOT mount the

DC Power Unit in an area where fabrics and/or any other

flammable material may come in contact with the unit.

WARNING

NOTICE

DC POWER STEERING UNIT

DC Power Steering System 7

MOUNTING

HOLES (4)

3/8" DIA.

15-1/8" (384 mm)

6-3/4" (172 mm)

Fi ure 4.

NOTICE For installations with minimal clearance behind unit, it is advised

that electrical connections are made prior to mounting the Unit.

NOTICE For installations in areas where pump noise may disturb passengers,

the use of rubber isolation mounts is recommended. SeaStar Solutions

part # HA2222.

1.3

1.1

1.2

Install Helm Pump(s)

• Install SeaStar Helm pump(s) using the instructions provided

with your helm(s).

Install Steering Cylinder(s)

• Install SeaStar steering cylinder(s) using the instructions

provided with your cylinder(s).

DC Power Unit Mounting

• Using the four mounting holes on the base of the unit mount

the DC Power Unit in the desired location. Confirm that there

will be sufficient room for filling/purging hose connections and

future access to the unit.

Mount the unit in a cool

location, away from any

sources of excessive heat,

such as engine manifolds, and

also free of any water splash.

CAUTION

Step 1 Mounting and Plumbing

SYSTEM INSTALLATION

8SEASTAR Hydraulics

TAPPED

HOLES (3)

ENSURE QUAD RING SEALS

SEAT PROPERLY IN COUNTER

BORES ON RELIEF MODULE

Fi ure 5.

DC POWER STEERING UNIT

1.4 Relief Module Installation

• Remove steering cylinder from its packaging and inspect servo

valve block. The cylinder MUST have three tapped holes on the

face of the servo valve block as shown in figure 5 below. If the

servo valve block does NOT have these tapped holes contact

SeaStar Solutions Technical Support.

• Remove fittings from the PRS and TNK ports on the steering

cylinder servo block if required.

• Inspect valve block face. It MUST be free of ALL contaminants

including thread sealant debris burrs gouges or large

scratches. Clean as required.

• Install both quad rings (items #2) into relief valve module as

shown in Figure 5.

• Insert three (3) socket head cap screws (items #1) into relief

valve module (item #3) and fasten to front face of cylinder servo

valve as shown in Figure 5. Torque mounting bolts to 40 in.lb.

• Clean threads and apply a Teflon based liquid pipe sealant to the

threads of the fittings that were removed in the second point

above. Install fittings into the ports on the relief module. DO NOT

USE TEFLON TAPE. Torque fittings to 200 in. lb.

WARNING

Ensure that the quad rings

remain seated in the relief

valve module and are not

pinched and/or rolled between

the module block and the

servo cylinder valve. Failure do

so will result in fluid leaks

causing property damage,

personal injury and/or death.

NOTICE

All cylinders manufactured

during or after January 2008

will have mounting provisions

for the relief module.

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