user`s guide
Contents
1. Note Phoenix EDGE ESC s require 5V on the brown and red wires The orange wire is for the PWM signal 2015 CrustCrawler Inc 12 V 6 0 05 19 2015 Hi Flow Thruster Connection 3 wire Connections to the 400HFS L Thruster Can be connected in any order Clockwise Rotation Right Hand Thrusters Red Red Red PWM Black Blue Thruster Black White White Counter Clockwise Rotation Left Hand Thrusters Red Red Red PWM White Blue Thruster Black Black White Note Swapping any 2 of the 3 thruster wires connected to the ESC will reverse the rotation of the propeller e Note See page 12 for more information on propeller and correct rotation information 2015 CrustCrawler Inc 13 V 6 0 05 19 2015 Red Red Red Software PWM Black Blue control ESC Thruster 1 ac ite ite prog gt Black Whit Whit ram microcontroller a F Red Red Red PWM Black Blue ESC Thruster 2 Pololu Black White White Ch 1 Ch 2 Red Red Red Ch 3 i i PWM Black Blue ESC Thruster 3 Ch 4 Black White White Ch 5 Red Red Red PWM Black Blue ESC Thruster 4 Black White White Red Red Red PWM Black Blue ESC Thruster 5 Black White White e The diagram above depicts an example of thruster control using a Castle creations Phoenix EDGE ESC and the Pololu Servo Controller PSC This is just one example of many ways of which you can control the 400HFS L thruster 2015 CrustCrawler Inc 14 V 62. control full forward 2ms square wave full reverse Ims square wave neutral 1 5 ms square wave Customization of throttle and brake curves along with forward and reverse characteristics can be programmed using the Castle Creations Castle Link USB programming kit Each thruster will require 1 ESC Do not attempt to connect and control 2 thrusters with 1 ESC e Any brushless speed controller with a rating of at least 20 amps with reverse capability can be used with the 400HFS L Thruster 2015 CrustCrawler Inc 9 V 6 0 05 19 2015 Best Practices Ensure that you provide a solid soldered connection when connecting the ESC to the thruster Also when using the enclosed shrink tubing ensure that the tubing is sealed on the inside and the outside to ensure a waterproof seal Liquid Tape or other liquid sealants that dry to a hard waterproof encasement will work e Always use wires that are equal to or greater in thickness than the wires on the thruster and ESC e The Phoenix ESC s are not meant to propagate a signal through long lengths of wire As a best practice the Phoenix EDGE ESC s should be within 1 to 10 feet of the thrusters depending on wire size used Longer lengths of wires can be used between the thrusters and the ESC s but performance will have to be monitored 2015 CrustCrawler Inc 10 V 6 0 05 19 2015 e A Pololu Servo Controller can be used to attach each Phoenix ESC to
3. e Always practice safe electrical handling and safety practices when working around water Break In Period The Hi Flow thruster can be run at any speed right out of the box fully submersed However do not run the Hi Flow thruster out of the water at high speeds for longer than 30 to 60 seconds or overheating and possible damage can occur Thruster Control Any brushless motor control software hardware can be used to operate the Hi Flow thrusters CrustCrawler offers a specifically engineered Phoenix ESC controller from Castel Creations which has special firmware developed especially for the Crustcrawler series of ROV thrusters We have also have a suggested control diagram in this manual for thruster control as an option However thruster control is up to you our customer 2015 CrustCrawler Inc V 6 0 05 19 2015 Connecting the Castle Creation Electronic Speed Controller ESC to the Hi Flow Thruster CrustCrawler has engineered a special UV resistant potted and completely waterproof housing for the Castle Creations Phoenix ESC brushless electronic speed controller This design allows you to bolt the ESC directly to your UROV All of the Hi Flow thrusters have been internally wired the same way so the diagrams shown on the subsequent pages will apply to any series of Hi Flow thruster Figure 1 Phoenix EDG ESC Controller non potted version shown e The Phoenix ESC uses Pulse Width Modulation PWM for brushless motor
4. 2015 CrustCrawler Inc V 6 0 05 19 2015 A Note about Throttle Settings and Maximum Power of the Thruster Whatever throttle you choose to use computer joystick etc with the 400HFS L Hi flow Thruster it is important to note the following 1 Once you complete the calibration routine of the throttle device you are using with the Phoenix ESC ESC s it is important to note that your full throttle settings DO NOT DIRECTLY relate to the maximum power rating of the thruster Always calibrate your throttle position to ensure they are within the operating parameters of the thruster e Failure to do so will result in thermal damage to the 400HFS L thruster motor e The 400HFS L thrusters are equipped with a thermally conductive heat sink compound around the thruster motor to keep the thruster motor running cool within its operating thrust range The 400HFS L is designed to run with a burst thrust of 7 10 pounds of thrust maximum for short periods of time max 20 seconds recommended As a general rule always ensure that you do not overheat the thruster when running the units for long periods of time 2015 CrustCrawler Inc 6 V 6 0 05 19 2015 1 66 Dimensions 42 19mm gt 3 4 86 87mm 6 25 15 87cm e Kort Nozzle Inlet 2 80 71mm e Kort Nozzle Outlet 2 44 62mm 2015 CrustCrawler Inc V 6 0 05 19 2015 Safety e Always unplug the Hi Flow thruster before handling the propeller in any way
5. 0 05 19 2015 Throttle Calibration of the Castle Creations Phoenix ESC When the Castle creations Phoenix ESC is first connected to the Hi Flow 400HFS L thruster the Phoenix must be calibrated to your throttle The throttle used can take many forms but is not limited to e Software Throttles e Joysticks e Sliders Once the Phoenix ESC is calibrated to each thruster there is no need to calibrate the Phoenix ESC again unless you have changed to a different type of throttle Calibration Steps The Phoenix manual has basic steps on how to calibrate the Phoenix to your throttle We have summarized those steps below Before proceeding with the steps below ensure that your Phoenix ESC is solidly connected soldered and insulated to your 400HFS L thruster and you have the proper power connections Step 1 With power off to your Phoenix ESC move your throttle to full forward throttle Step 2 Turn on the power to your Phoenix ESC You will hear a series of short beeps followed by a steady series of beeps Step 3 Once there is a steady series of beeps move your throttle to full reverse throttle You will hear a series of short beeps followed by a steady series of beeps Step 4 Once there is a steady series of beeps move your throttle to neutral or center There will be a series of short beeps followed by silence Your Phoenix ESC ESC is now calibrated to your throttle Caution Always remember to ensure y
6. 400HFS L Hi Flow Thruster Product Guide and Warranty oboti Crust rawler D Development esign amp Hi Flow Thruster Warranty CrustCrawler has a strong commitment to the high quality production of it s HI FLOW THRUSTERS and to provide industry leading after sales support for our customers Every HI FLOW THRUSTER GOODS is fully covered by a comprehensive warranty to the original owner OWNER against defects in materials or workmanship for a period of 1 month from the date of shipment whether or not use starts from that date All claims under this limited warranty shall be deemed waived unless received by CrustCrawler within 10 days of delivery if visibly damaged or defective and otherwise within 30 days after the defect to which each claim relates is discovered This is not an unconditional guarantee against all hazards or failures and the Limitations and Exclusions listed below apply THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS This warranty is extended to the original OWNER of the GOODS and is not transferable This warranty is limited solely to the repair or replacement at our factory of the defective GOODS CrustCrawler shall not be liable for any damage or harm nor for any exemplary special punitive consequential or incidental damages including but not limited to any loss of revenue profit or use resulting thereby If a
7. OV requirements No other thruster on the market has the programmable flexibility to set specific operating parameters for different environmental conditions than the CrustCrawler High Flow series Motor Specifications e Motor Type High efficiency brushless e Weight 185g 6 50z e Gear Ratio 4 28 1 e Shaft Diameter 5 0mm 1969 e Maximum Case Temperature 100C 212F e Operating Voltage 12 to 50 volts e Operates in forward and reverse thrust Connector Specifications e Depth Rating 300 ft e 3 wire Thruster Housing End Caps e T 6 Aluminum Thruster Seal e Motor Flexible polyurethane encapsulating compound e Shaft Seal Custom Lip Seal followed by encapsulating grease gallery Thruster Weight e Weight in air 1 pound 453kg e Weight in Water 9 ounces 255 grams Thruster Length e 6 25 15 87cm Finish e Black Red Type II Hard Anodized Finish Propeller e Size 2 36 60mm 4 blade e Material Solid Brass e Propeller Adapter Machined aluminum Anodized Type IT Black 2015 CrustCrawler Inc V 6 0 05 19 2015 Kort Nozzle Adaptor e Material 090 Aluminum e Offset 120 degrees Thrust Rating 1 6 pounds 45 to 2 72kg normal operating range approximately 140W to 180W max e 7 10 pounds 3 17 to 4 53kg max burst thrust e Note 1 Burst thrust is defined as the thruster range for short periods of time of less than 20 seconds
8. a specified channel to control each thruster independently with either software joystick control or both A single PSC can control up to 18 thrusters Figure 2 Polulo Servo Controller e The Pololu servo controller generates the PWM signals needed by the Phoenix brushless motor controllers for throttle control The Pololu servo controllers software can be used as a throttle control for the thrusters using its powerful control software as shown below Ei Pololu Maestro Control Center File Device Edit Help Connected to Firmware version 1 00 Emors Channel Settings Serial Settings Sequence Script Name Mode Enabled Target Speed Acceleration Position Servo g 149 0 ae si 149600185 1084 756 54 Oo 162 50 2203 06 oki o 2203 00 e 1496 00 7621 g 1496 0 y 1652 50 ES 13217512 4 2203 00 2 yes 11412512 1206 13 4 maza 1500 00 jes oz 0 00 44 1500 00 ii oz 0 00 44 255 75 yes OS 25575184 52 50 0S oH 5250 2000 0 S Servo aaa g o 1 2 3 4 5 6 7 8 9 o Apply Settings 2015 CrustCrawler Inc 11 V 6 0 05 19 2015 e For more detailed information on the operating parameters and wiring characteristics of the Castle Creations Phoenix ESC be sure to read the enclosed documentation that came with your ESC Power Signal Connection Signal cable from controller PWM only
9. blem can be resolved over the telephone or if return for repair is required Upon determining that the product may be defective under the terms of the limited warranty and that return to the repair facility is required CrustCrawler will issue an RMA number which you must complete and return to CrustCrawler Upon receipt of the RMA number the GOODS can then be shipped to CrustCrawler for evaluation 2015 CrustCrawler Inc 2 V 6 0 05 19 2015 Do not return the GOODS to CrustCrawler prior to the receipt of the RMA number The GOODS must be shipped in their original shipping containers and packing material or otherwise adequately packed for shipment and the RMA number must appear clearly on the outside of the package If the product is damaged during shipment or received in inadequate packaging this warranty may not apply For warranty shipping the OWNER is responsible for shipment of all GOODS to CrustCrawler and CrustCrawler will cover the costs of return shipment of GOODS to the OWNER up to 90 00 USD maximum In all cases the OWNER is liable for damage to the GOODS that may occur during shipment and should consider insuring the shipment both to and from CrustCrawler 2015 CrustCrawler Inc V 6 0 05 19 2015 CrustCrawler High Flow 400HFS L Series AUV UROV Thruster Technical Specifications CrustCrawler s High Flow AUV UROV 400HFS L thrusters where designed to be a reliable and customizable thruster for light duty UROV R
10. component is found to be defective during the period of this warranty CrustCrawler reserves the right to repair or replace the defective component or to refund the original purchase price at its own discretion In no event shall CrustCrawler be liable for more than the original purchase price of the defective GOODS Limitations and Exclusions This limited warranty does not cover e Damage caused by improper use improper maintenance incorrect reassembly or accidental damage e Items subject to normal wear including but not limited to surface finish seals motors gear box and cables unless found to be defective in workmanship or materials e Modification made to the HI FLOW THRUSTER without prior authorization from CrustCrawler Inc e Damage due to incorrect power connection as described in the User s Manual Damage or failure that is caused by acts of God acts of war or other such similar or dissimilar occurrences beyond CrustCrawler s control Shipping and Return Material Authorization RMA Forms Immediately upon identifying a problem which you believe to be subject to this limited warranty you must request warranty service by contacting CrustCrawler All requests for warranty service must be authorized by CrustCrawler prior to return of the GOODS You must first attempt to work with our technical support staff to help diagnose the problem This may include performing routine diagnostic procedures The technician can determine if the pro
11. our throttle setting is in the neutral position when powering on your Phoenix ESC ESC s Failure to do so could result in the thruster running at the current throttle setting or the Phoenix ESC going back into calibration mode 2015 CrustCrawler Inc 15 V 6 0 05 19 2015 A Note about Throttle Settings and Maximum Power of the Thruster Whatever throttle you choose to use computer joystick etc with the 400HFS L Hi flow Thruster it is important to note the following e Once you complete the calibration routine of the throttle device you are using with the Phoenix ESC ESC s it is important to note that your full throttle settings DO NOT DIRECTLY relate to the maximum power rating of the thruster Always calibrate your throttle position to ensure they are within the operating parameters of the thruster e Failure to do so will result in thermal damage to the 400HFS L thruster motor 2015 CrustCrawler Inc 16 V 6 0 05 19 2015 Right Hand Left Hand Propeller Configurations The Hi Flow thrusters come with either a right hand or left hand propeller configuration Right and left hand propellers are needed whenever 2 Hi flow thrusters are mounted in a parallel side by side configuration from each another With each propeller rotating in an opposite direction from each other the opposite rotation will cancel out each thrusters torque resulting in the UROV body traveling in a straight line e For all other single mount Hi Flow thrus
12. r every use Failure to do so can leave water in the grease gallery which can lead to damaged thruster components e Before applying grease to the grease gallery after use tilt the thruster to 30 45 degrees and run for 40 60 seconds to ensure most of the water is purged from the grease gallery e NEVER run the Hi Flow thruster out of the water at full throttle Always run the thruster out of the water for testing etc at 50 max of full throttle for no longer than 40 60 seconds at a time The 400HFS L is designed to run in the water not out of the water e If your thrusters where used in salt water always rinse the entire thruster especially the front of the motor and prop assembly with fresh water after each use and re grease the grease gallery e Ensure that you provide a solid soldered connection when connecting the ESC to the thruster Always use shrink tubing and a good sealant compound to ensure that each connection is sealed and waterproof Liquid Tape is an excellent fast drying sealant that can be purchased at most hardware stores 2015 CrustCrawler Inc 18 V 6 0 05 19 2015 e Always ensure that water has been purged from the grease gallery of the thruster after each use and re greased 2015 CrustCrawler Inc V 6 0 05 19 2015 19 Applying Grease to the Grease Gallery pa Remove the grease screw as shown in figure 1 2 Apply the white lithium grease using the supplied grease s
13. ters that are mounted in your UROV either left or right hand propellers configurations may be used Clockwise Rotation Counterclockwise Hi Flow Thruster Rotation Right Hand Propeller Hi Flow Thruster Left Hand Propeller To determine the correct rotation of the propeller e Ifthe curve of the propeller is on the right sides of the blades above left Clockwise rotation forward thrust e Ifthe curve of the propeller in on the left sides of the blades above right Counterclockwise rotation forward thrust 2015 CrustCrawler Inc 17 V 6 0 05 19 2015 Important Please Read Important Information about the proper operation and care of the Hi Flow 400HFS L Thruster CrustCrawler s Hi Flow series of thrusters are designed to be a rugged affordable choice for all types of AUV ROV applications To ensure many hours of reliable use the best practices listed below will ensure a long service free life of the thruster motor and gearbox Operating Best Practices e The gearbox in the 400HFS L thruster is built extremely strong but as a best practice abrupt and full speed thruster changes of rotation should be avoided e NEVER attempt to remove the propeller assembly from the motor shaft Attempting to remove the prop assembly from the motor shaft can permanently damage other components of the thruster e NEVER leave the thruster soaking in water when not in use e Always re grease the grease gallery afte
14. to the body of the thruster e Use a thread locker type of sealant like Loctite or equivalent for each of the 4 screws when mounting the bracket to the thruster 2015 CrustCrawler Inc 24 V 6 0 05 19 2015 Support Support should you need it is available in 2 ways Forums http forum crustcrawler com phpBB3 index php Phone 480 577 5557 We strongly suggest questions dealing with control software wiring and other related configuration information be posted on our forums We use the forums to post code samples wiring diagrams and pictures to help resolve customer questions quickly and efficiently Remember we can t see your code or wiring over the phone but we can see it using our forums Please visit our web site frequently as we will be releasing more software and accessories in the coming months for our line of UROV and ROV products 2015 CrustCrawler Inc 25 V 6 0 05 19 2015
15. yringe until excess grease begins to emerge from between the prop adapter and grease gallery fitting Rotate the propeller 5 complete turns Repeat steps 1 2 5 Re install the grease screw m Grease Screw Figure 1 Remove Grease Screw 2015 CrustCrawler Inc 20 V 6 0 05 19 2015 Grease Syringe Figure 2 Apply grease using grease syringe Excess Grease tion Figure 3 Apply grease until excess grease emerges 2015 CrustCrawler Inc 21 V 6 0 05 19 2015 Note White Lithium grease is supplied to thruster orders of 3 units or more If you are using your own grease be sure to clean out the existing grease before applying a different type of marine grease or equivalent to the grease gallery as some grease can react to other grease types 2015 CrustCrawler Inc 22 V 6 0 05 19 2015 400HFS L Thruster Mounting Bracket Optional e Material Machined 6061 T6 Aluminum e Finish Hard Anodized Black e Mounting Screws Quantity 6 4 40 4 1 2 54cm e Thruster Mounting Screws Quantity 4 Stainless Steel 4 40 4 3 8 mounting screws e Bracket Kort Nozzle Clearance 31 7 8mm Mounting Hole Dimensions 625 1 70 Rk 1 0 2015 CrustCrawler Inc V 6 0 05 19 2015 1 37 23 Figure 3 400HFS L Thruster with Mounting Bracket e Use the supplied stainless steel 4 3 8 mounting screws to attach the thruster mounting bracket
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