Nexus 21 Water Pump 3 User Manual

INTRODUCTION  
Nexus Pumpset PF-0,3 /S  
Installation Manual  
Thank you for choosing a Nexus Pumpset. Through this manual we will help you install  
your new Nexus product. Please read through this manual carefully before starting your  
installation.  
1 Introduction  
The Pumpset should be connected to the boat's hydraulic steering system according to  
figure 1. The Pumpset motor only operates when carrying out a rudder command. When  
the boat is on course, the Pumpset stops. A variable speed motor drive adjusts optimal  
rudder speed and provides for minimum power consumption and maximum rudder posi-  
tioning accuracy. Most existing multiple station steering systems have lock valves, which  
automatically isolate stations from each other and from the autopilot Pumpset. A lock  
valve should be installed so that the helm can be isolated.  
2 Installation  
Note! Because most installations differ, the following items are not supplied and need to  
be sourced or made locally: Support bracket for Pumpset, 4 mounting screws and wash-  
ers, hydraulic fittings and piping.  
2.1 Installing the Pumpset  
The Pumpset is splashproof and should be mounted in a cool dry location, which mini-  
mises hydraulic piping and wiring runs. The enclosed figure indicates the piping required  
for the different hydraulic steering systems. The Pumpset may be mounted horizontally  
(Pumpset feet down) or vertically with the pump positioned above the motor. Be certain to  
leave adequate space to access the bleed screw. Four screws and washers are required  
to hold the Pumpset resilient feet to the mounting surface. In any case be sure, to mount  
the pumpset itself or, if not possible, the pumpset-reservoir at the highest position of the  
hydraulic system.  
2.2 Installing hydraulic fittings and piping  
It is recommended that all fittings to be installed are aligned with the Pumpset before it is  
mounted. The type of hydraulic fittings required i.e., straight or 90° angle, will depend on  
the mounting position of the Pumpset and the location of piping.  
Recommended size for all connections are hydraulic hoses and fittings with an inner di-  
ameter of 8 mm (0.32”) minimum to reduce the drag.  
Use only hydraulic hoses, suitable for a working pressure of 1,000 PSI (70bar). The hy-  
draulic fittings selected must be suitable for the hydraulic hoses size used.  
Note! All ports on the Pumpset are 1/4" NPT.  
Pipe sealant or teflon tape is required on all male pipe thread fittings. Be certain to keep  
the sealant or tape at least two threads away from the starting threads to prevent threaded  
tape or sealant from contaminating the system.  
 
INSTALLATION  
2.3 Pumpset oil filling  
If the Pumpset is used together with the Nexus Linear Drive, fill the Linear Drive first and  
then connect the Linear Drive to the Pumpset before filling the Pumpset. See the Linear  
Drive oil filling procedure in separate manual.  
Use hydraulic oil viscosity grade ISO 20. About 110 ml is needed for the Pumpset only  
without piping. Fill the Pumpset via the reservoir.  
Once the boats main steering system has been filled, open the Pumpset bleed screw (on  
top of the Pumpset), two complete turns. Wait until clear oil void of any air exits from the  
bleed screw, then resecure the bleed screw. Then fill up the uppermost helm Pumpset or  
reservoir of the main steering system, if necessary.  
Pumpset PF-0,3S with solenoid and reservoir  
Pumpset PF-0,3  
2.4 Connec-  
tion  
Note! For correct  
wire dimensions  
see Nexus  
Autopilot manual  
”Wire Thick-  
ness”.  
Connect the Pumpset wires to the Nexus Servo Unit as follows:  
·
·
Orange wire to Servo Unit terminal marked "MOTOR 1".  
Black wire to Servo Unit terminal marked "MOTOR 2".  
For Pumpset PF-0,3S with solenoid, connect also the two red wires as follows:  
·
·
One solenoid red wire to terminal marked 16 ”+”.  
One solenoid red wire to terminal marked 17 "GND".  
It does not matter which wire red wire goes to which terminal.  
3 Dockside testing  
When the complete electrical installation is checked and the power is turned on, there are  
further procedures to be carried out in order to completely remove any air in the system.  
See 12 "Dockside Testing" of the Nexus Autopilot manual.  
 
INSTALLATION  
4 Maintenance and inspection schedule  
If the boat does not accumulate the hours indicated below within 3 months, the frequency  
is every 3:rd month.  
Warning !  
Failure to rectify any faulty conditions discovered as a result of the inspection could cause  
sudden loss of Autopilot control, with consequential danger. It is recommended that all  
items referenced in the following table be inspected before commencing any cruise.  
Type  
Equipment:  
Check for:  
Remedy:  
Inspection  
Frequency:  
200 hrs  
Hydraulic  
Oil reservoir level  
Oil condition  
Correct  
Fill  
Discoloration  
Contamination  
Damage  
Leaks & Corrosion  
Damage  
Flush system and  
replace the oil  
Replace  
1000 hrs  
1000 hrs  
1000 hrs  
Hydraulic hoses  
Hydraulic fittings  
Replace  
500 hrs  
Leaks & Loosening Tighten  
Piston rod seals  
on pumpset  
Linear drive  
Tiller arm  
Leaking  
Replace  
1000 hrs  
Mechanical  
Corrosion  
Corrosion  
Corrosion  
Loosening  
Corrosion  
Loosening  
Corrosion  
Loosening  
Replace or Repair  
Replace  
Replace  
Tighten  
Replace  
Tighten  
Replace  
Tighten  
2000 hrs  
2000 hrs  
2000 hrs  
500 hrs  
2000 hrs  
500 hrs  
Tiller bolts  
Rod end bolt  
on linear drive  
Trunnion bolts  
on linear drive  
2000 hrs  
500 hrs  
5 Specifications  
Type of Pumpset:  
Dimensions:  
Weight PF-0,3 (without oil):  
Weight PF-0,3S (without oil):  
Enclosure:  
Reversible axial piston pump, 5-cylinder  
Length 230 x width 105 x height 100 mm (91 x 41 x 40”)  
3 kg (6.60 lb)  
3,3 kg (7.27 lb)  
Splash proof  
Temperature range:  
Power supply:  
Peak pressure:  
-5° to +50° C (+40° to 122° F)  
Both Pumpsets available in 12 or 24 V DC  
70 bar (1000PSI)  
Ram capacity min - max:  
Peak flow rate:  
100 - 400 cc (6 - 24 in3) (no load)  
1150 cc/min (70 in3/min) (no load)  
Average power consumption: 2 - 4 A ca 36 Watts (at 12V)  
Piping pressure:  
Piping size:  
Port dimensions:  
Hydraulic oil viscosity:  
Warranty period:  
1000 PSI (70bar)  
Min. 8 mm (0.32”) inner diameter  
¼" NPT  
ISO 20  
2 years, see separate conditions  
CE approval: The product conforms to the EMC requirements for immunity and emission  
according to EN 5008-1 and EN 55022  
 
WARRANTY  
6 Warranty  
GENERAL  
All our products are designed and built to comply to the highest class industry standards. If the products are correctly  
installed, maintained and operated, as described in the installation and operation manual, they will provide long and  
reliable service. Our international Network of distributors can provide you with the information and assistance you may  
require virtually anywhere in the world.  
Please read through and fill in this warranty card and send it to your national distributor for product registration.  
LIMITED WARRANTY  
The warranty covers repair of defective parts due to faulty Manufacturing and includes labour when repaired in the  
country of purchase. The warranty period is stated in the product manual, and commences from the date of purchase.  
The above warranty is the Manufacturer’s only warranty and no other terms, expressed or implied, will apply. The  
Manufacturer specifically excludes the implied warranty of merchantability and fitness for a particular purpose.  
CONDITIONS  
·
The supplied warranty card and receipt with proof of purchase date, must be shown to validate any warranty  
claim. Claims are to be made in accordance with the claims procedure outlined below.  
The warranty is non-transferrable and extends only to the original purchaser.  
The warranty does not apply to Products from which serial numbers have been removed, faulty installation or in-  
correct fusing, to conditions resulting from improper use, external causes, including service or modifications not  
performed by the Manufacturer or by its national distributors, or operation outside the environmental parameters  
specified for the Product.  
·
·
·
·
The Manufacturer will not compensate for consequential damage caused directly or indirectly by the malfunction  
of its equipment. The Manufacturer is not liable for any personal damage caused as a consequence of using its  
equipment.  
The Manufacturer, its national distributors or dealers are not liable for charges arising from sea trials, installation  
surveys or visits to the boat to attend to the equipment, whether under warranty or not. The right is reserved to  
charge for such services at an appropriate rate.  
·
·
The Manufacturer reserves the right to replace any products returned for repair, within the warranty period, with  
the nearest equivalent, if repair within a reasonable time period should not be possible.  
The terms and conditions of the warranty as described do not affect your statutory rights.  
CLAIMS PROCEDURE  
Equipment should be returned to the national distributor, or one of its appointed dealers, in the country where it was  
originally purchased. Valid claims will then be serviced and returned to the sender free of charge.  
Alternatively, if the equipment is being used away from the country of purchase, it may be returned to the national dis-  
tributor, or one of its appointed dealers, in the country where it is being used. In this case valid claims will cover parts  
only. Labour and return postage will be invoiced to the sender at an appropriate rate.  
DISCLAIMER  
Common sense must be used at all times when navigating and the Manufacturer’s navigation equipment should only  
be considered as aids to navigation.  
The Manufacturers policy of continuous improvement may result in changes to product specification without prior no-  
tice.  
Copyright ©:  
Silva Sweden AB  
Kuskvägen 4, 191 62 Sollentuna, Sweden  
Tel: +46 -(0) 8 - 623 43 00. Fax: +46 -(0) 8 - 92 76 01  
This manual is written for Nexus Pumpset (Art. No.):  
12V PF-0,3 (21134), 24V PF-0,3 (21134-24)  
12V PF-0,3S (21341), 24V PF-0,3S (21341-24)  
Edition: August 1998  
 

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