Installation and user manual XForce stern-thruster series XF
Contents
1. The battery lifetime is more than 2 seasons based on normal leisure use IMPORTANT Always install at least one fixed XF Thruster panel 2 3 Operating instructions The remote control is battery operated To ensure longer life it will automatically go into sleep mode five minutes after the last button was pushed Deactivation is signalled with two short sound bursts and a blinking POWER indicator The remote control is activated by holding down any button for 1 5 seconds When the remote control has been activated the selected thruster can immediately be operated by pressing the arrow button in the desired direction The thruster will be running as long as the button is depressed Max 4x30 sec 2 3 1 Directions for use Push the left arrow button and the thruster moves the boat to port e Push the right arrow button and the thruster pushes the boat to starboard e Pushing the centre twin arrow buttons on the wireless remote activates both bow and stern thruster simultaneously in opposite directions The boat will start to rotate about the vertical axis Requires both bow and stern thrusters installed Green light NB Activation is indicated by a steady green light in the POWER indicator and a short sound All subsequent use of buttons is shown on the associated indicator above the button accompanied by a short sound Rev 3 2009 01 26 Page 5 Orange light Low voltage at the electronic unit is indi2. Use large washers with large cable lug Recommended torque 20Nm M8 A4 Plastic nuts to be mounted on top of plastic cover Supporting washer Cable shoe Fuse Supporting washer 7 8 Recommended main switch Thruster model Partno XF60Stern 12 00050 12 00087 12 00087 XF 90 Stern 12 00087 XF130Stern Main switch 12 00050 7 8 1 Main switch terminal The main switch terminal must be isolated as shown in the left hand picture i e by using rubber caps or plastic nuts a7 Main switch 12 00087 7 9 XForce Thruster Cable fuse and battery requirements Maximum cable length1 Minimum cable dimension Required min battery capacity XForce Motor Thrust KG amp fuse P N Length m ft Dim 2 Thruster V kW mm2 AWG SAE SEEN m 33 70 2 0 100 12 pu SEEN ER 24 4 1 10 1 33 70 2 0 100 Ah 24 V wear om m ene 12 00300 12 5 1 10 1 33 95 3 0 100 Ah 12 V 1700 400 12 00400 24 5 mM 1 10 1 33 95 3 0 150 Ah 24 V 1050 12 00350 24 7 1 10 1 33 120 4 0 175 Ah 24V 1150 12 00400 The distance from the thruster unit the battery each cable Use of even larger cable dimensions and battery capasity will give the thrusters better performance 2 Wiring insulation rating is 105 C 221 F minimum XF Rev 3 2009 01 26 Page 17 7 10 Wiring diagrams 7 10 1 XForce stern 60 90 130 Wireless Remot
3. e Turn off the main switch e Remove the rubber cover on the Control Unit e Change position on DIL switch 8 on S100 and exchange wires 1 and 3 on the 12 pin green connector e Turn on the main switch and verify in a safe and controlled manner correct operation from all operation panels and the remote transmitter Ifthe operating direction when using the fixed panel is wrong exchange wires 1 and 3 on the green 12 pin connector Rev 3 2009 01 26 Page 21 9 6 The thruster runs for short intervals or a clicking sound is to be heard from the thruster Check the voltage on battery and battery on the control unit when trying to run the thrusters The voltage must be minimum 10 5 V 12 V system and 21 V 24 V system 9 7 The thruster stops working after a long period of use Intelligent electronic protection WARNING 10 10 1 10 1 1 XF The system has intelligent monitoring to measure run and pause time The XForce Thruster is not permitted to start if the voltage on the thruster is below 10 0V on 12V system 20 0V on 24V system If the voltage at the thruster drops below 9 0 18 0V when thruster is running warning will occur by showing orange light power light on the wireless control Of security reasons the system permits continuous running of the thruster in 4 intervals of 30 sec After each interval the thruster will stop Switching off on the joystick or switch panel will make the thruster run again If repeate
4. and thicker cables will give less voltage drop and thus better performance NB Please notice how the cable lugs on copper bar number 4 is mounted turned towards each other to maximize space and ease of montage Cable lug for bar number 5 is turned the opposite direction compared with number 1 2 og 3 If ever needed to dismount the cables start from the right side and reverse the above procedure 7 6 Connecting to the bow thruster See the pictures and wiring diagram for correct connections XForce Stern 60 90 130 NB Correct cable bolt nut torque is Terminal bolt M8 brass 10 Nm 7 4 Ib ft Terminal bolt M10 brass 15 Nm 11 1 Ib ft WARNING After connecting the cables to the connection bolts with correct torque the bolts with cables will still be able to move relative to XF Rev 3 2009 01 26 Page 15 the terminal plate To make sure that no short circuits contact between the terminals can occur the cables should be secured in such a manner that no short between the terminals can be caused by movement or vibration The bolts must be protected by plastic cap nuts or protective rubber caps 7 6 1 Motor terminal connections The terminal bolts are active current leaders The pictures show correct connected cables on the motor terminals Please note that cable lug is mounted to the terminal with brass washers on both sides of the cable lug then another washer and nut on top of the cable lug Finally mount
5. approx 14 4V DC and apparently a good no load voltage of approx 12 8 V DC No load voltage must be measured directly on the battery posts after a couple of hours without charging from motor or landbased supply Special high start current and similar kind of batteries are normally suited for only the smallest thruster models and windlasses as they normally have too little capasity Ah 10 2 1 Battery cables lugs 4 e Battery cables must be related accordingly to the equipment it is N connected to Please refer to the product specifications for 28 E recommended relation between size and length Generally SSS speaking a thicker cable dimension will give better performance S especially with longer cables Use only cable lugs of high quality XF These must only be mounted on the cables with correct tool and correct according to the procedure from the cale lug manufacturer Never use a vise wrench or similar to press on a cable lug Although it may look like a good connection over time it may become a source of ignition The difference between two types of cable lugs is clearly shown in the picture The left one illustrates a ring type cable lug and is acceptable for products with currents up to ca 200A The right cable lug is of press on type and shall be used on thrusters Battery connection The pictures show a correct connected batterycable Notice that the cable lug is mounted onto the batterypost
6. erngbo XX FORCE ENGBO THRUSTER SYSTEMS Installation and user manual XForce stern thruster series XF 60 Stern XF 90 Stern XF 130 Stern C 0470 NS EN ISO 9001 2000 FCC ID R78 RC 01 R78 ECU 01 Art nr 117 00145 XF Rev 3 2009 01 26 Page 1 Contents t INTRODUGTION uu u u AAA EA AAEREN RUE 3 2071 OPERA ION tr 4 2 1 XForcenteligen protecior u u u u L u Z uyu usan uu s Gaanhakauyiinastishukukayaastabkuenhikass 4 2 2 SHOW lO NO NUS IOI eai a E E XE 4 2 2 1 Operatitig panel versi ns Weddin N lave oral need Et NES 4 Operan INS TUCO e e a 5 2 9 1 Directions BOIS C3 u TM 5 2 4 Upgrade to wireless remote control cccccccccssesecccaesececcceeuseceeeceeueeecesauseceseseaaeeeessssaaeeeessssageeeessssegeeeseeaas 6 2 4 1 Antenradristallatlobis uu yuyu Pack ca uut eid nessa r uate hada ean usu a aaoo puer 6 2 4 2 E 7 3 TECHNICAL SPECIFICATIONS WIRELESS REMOTE CONTROL 7 1 DIMENSIONS STETIT 8 Ali E ttiJusterdimersi lls toon u m saa a au 8 42 Control ni itdiTieqSI6S u L u y MET US 8 5 INSPALELA ON uu l l u u IEEE 9 Ole JAVOld Walter dalTidde u u tec uu rus ones muspa ioa Dau aasawa a Qasa umaka ka Ed 9 5 1 1 Companmen
7. rubber cover on the Control Unit e Change position on DIL switch 8 on S100 and exchange wires 1 and 3 on the 12 pin green connector Rev 3 2009 01 26 Page 14 Turn on the main switch and verify in a safe and controlled manner correct operation from all operation panels and the remote transmitter If the operating direction when using the fixed panel is wrong exchange wires 1 and 3 on the green 12 pin connector 7 5 Control box connections Tips for mounting Pre cut correct cable lengths and mount cable lugs in advance so mounting the cables on the box can be done in a comfortable position before the unit is mounted in the boat One will need 2 pcs 13mm spanners to secure the M8 bolts Correct torque is 20 Nm for the Stainless Steel bolts A4 NB Always begin the mounting assembly from the left entering the bolt with a big washer through the cable lug into the hole from the right All cable lugs shall always be on the right side in direct contact with the copper bar NB On bar 4 two cables as shown on picture Use M8x20mm bolts for copper bars number 1 2 3 and 5 and M8x25mm for bar number 4 It shall also be mounted a plain washer between cable lug and lock nut Mount the three first cables with the cable lugs pointing in the same direction as shown in the pictures The mountingbolts are not active current leaders and their only purpose is to assure a tight connection between the cable lugs and bars Shorter
8. 0 Brass copper 15 Nm The picture shows isolating rubber caps mounted on both terminals For improved understanding the interrupter is not mounted on the bulkhead XF Rev 3 2009 01 26 Page 24 Declaration of Conformity ned X Manufacturer O The manufacturers authorized ENGBO AS Wirgenesvei 7 N 3157 Bark ker NORWAY 47 3300 3150 47 3300 3160 support engbo no We the undersia resentative established within EEA Address Telephone number Telefax number E mail and declare under our responsibility that the following products Remote control unit and or electronic control unit for electric side thrusters and electric windlasses and mooring motors Engbo AS Complete BP series thruster systems Complete CT series thruster systems with control units Mini Midi Maxi and 30 and 40 series windlasses and mooring systems RC 01 and ECU 01 units and modules Is tested to and conforms with the essential test suites included in the following standards which are in force within the EEA Standard Product Description Manufacturer Brand Name Model Type Reference to report file LITT CITI U 5 1 301 489 1 V 1 4 1 Test report 04 695 3 N Comlab variable speed drive off EN301489 17V 1 212 Testreport 04 695 3 N Comlab variable speed drive off EN 61800 32000 Test report 04 695 3 N Comlab var
9. F Rev 3 2009 01 26 Page 10 XF 4 Buffthe propeller tunnel s interior and exterior and clean well with degreaser Paint the tunnel with primer and antifouling paint 5 Carefully apply suitable marine sealant on the bracket 8 and support plate 6 Guide the bracket from within through the transom 6 IMPORTANT Make sure the oil nipple is positioned upwards Specified sealants Sikaflex 291 W rth Sealant 0890100 or similar NB Do not use sealant of hard caulk type left 7 Apply sealant to support plate 6 and bolts 23 25 Place the plate on the transom and fit the attachment bolts from within the transom through the bracket and transom Fasten the bolts thoroughly 4 8 Carefully apply sealant to the gear housing 2 before fitting the gear housing to the bracket is NB Make sure to put sealant wherever leakage might occur to prevent any kind of leakage NB Make sure the sealant does not obstruct the oil hole See 9 Guide the gear housing from within the tunnel through the hole NB No propeller s should be fitted during this process 10 Guide the two attatchment bolts 23 from within the transom through the bracket and fasten gear housing and propeller tunnel to the transom 11 In some cases the tunnel flanges 1b must be modified to fit close to the transom 11 12 Fit the motor 12 2 to the bracket 12 3 and screw the units together The motor has to be properly supporte
10. and electric overload e Shear pin between thruster motor and drive shaft protects mechanical parts if the propeller is obstructed from rotation 2 2 How to operate the thruster e Move the joystick press the touch panel to right and the thruster Will be activated to starboard e Move the joystick press the touch panel to left and the thruster Will be activated to port 2 2 1 Operating panel versions There are 4 different XForce Thruster panels available Touch panel Part no 12 79001 e Easy to install e Designed similar to Engbo winch panel XF Rev 3 2009 01 26 Page 4 Single Joystick Part no 12 79002 e ON OFF switch e LEDs for indication of power and direction Double joystick Part no 12 79003 e Needed if both bow and stern thruster installed e ON OFF switch e LEDs for indication of power and direction Wireless remote control Part no 12 47014 e Floating splash proof hand held remote control unit e he wireless remote control can be used to operate maximum two thrusters and two windlasses bow and stern e Activates both bow and stern thruster simultaneously in opposite direction by pushing the centre buttons e Operation range of 30 m under normal conditions e High quality narrow band unit with two way communication with the electronic control unit Each electronic control unit has a unique code Equipped with anti slip strips on the back Hand neck cord is included as standard easily removed
11. cated by an orange light in the POWER indicator Red light The indicator will quickly blink red in case of system faults and slowly blink red together with short sounds if the remote is unable to communicate with the electronic unit If the thruster is overloaded and requires time to cool down this will also be indicated by quick red flashing These error messages are shown when buttons are pushed 2 4 Upgrade to wireless remote control XForce Thrusters can be delivered with 3 different versions electronic control units MCU 1 Relay box power contactor 2 Relay box power contactor with integrated radio receiver Transistor controlled power electronics with integrated radio receiver that replace the conventional power contactor Available from summer 2008 The new electronic unit contains no open contacts and is very flexible as regards voltage The control electronics are software based and feature an integrated radio receiver that communicates with the wireless remote control and built in system to protect the thruster motor and electronic components IMPORTANT Turn off the thruster main switch when not in use The radio receiver current consumption will be approx 3 5 W as long as it is turned on lt 2 4 1 Antenna installation If wireless remote control option is to be implemented after choosing version 2 or 3 e lf not already installed the MCU must be fitted with an antenna e The remote contr
12. d 4 times total 2 minutes running the thruster will need to cool down for 25 minutes before being ready to run again This to protect the motor and control unit against overheating NB In an emergency situation to save the ship at the possible expense of the thruster this protection can be override by turning the main switch off and on Check the thruster control unit fuse cables and electric connections for visible signs of overheating bad connection and short circuit Installation of equipment with high currents Special considerations Preface introduction Engbo has experienced that over 90 of our service problem enquieries is related to power supply This document has been made to try to address and help avoid the most common and known problems that can arise General There are special considerations that must be taken into account regarding installation use and maintenance of high current consumption equipment It is therefore especially important that only persons with the appropriate knowledge are doing this kind of work The most common products which this document applies to are electrical bow and or stern thrusters windlasses and electrical starters for main and or help engines Similar precautions must also be taken with generators and charging systems for batteries Such equipment has or can have for shorter periods many hundreds of ampere of current consumption In rush current in an electrical motor of t
13. d to support the weight of the motor and reduce tension on the transom and thrusters bracket See 5 1 1 NB Place support under the motor body do not place under the fan guard 13 Attach the oil hose to its base on the bracket 8 and mount the oil container 31 close to the stern thruster but above the water line The hose should be mounted in such a way that no air traps are formed which could hamper the oil flow to the gear housing Fill the oil container and open the oil drain plug in the gear housing until oil leaks out Put the oil plug back in place This is done to speed up the oil flow to the gear housing and also to purge any air that is left in the hose Refill the oil container 31 Paint gear housing with primer and antifouling paint NB Do not paint the zinc anode or its contact area Install the propeller s 4 according to the propeller installation instructions NB The propeller marked LH should be put on port side and the one marked RH on starboard side Rev 3 2009 01 26 Page 11 Apply bottom coating All wet parts in the tunnel must be covered with bottom coating Ensure that the installation has no leaks when the boat is set afloat 6 2 Propeller installation Symmetrical 4 blade kaplan propellers Glass fibre reinforced acetal POM XForce 60 Stern and XForce 90 Stern e Install the driver pin 1 into the hole in the propeller shaft 2 e Fit the propeller 3 with t
14. e Touch Panel Single Joystick Dobbel Joystick Joystick Touch Panel Thruster Control Antenna as Brown M ok M 1 NA I ad C 2 m g E Fuse Main Switch D lt TH D2 A2 Di 1 Thruster Electric Motor XF Rev 3 2009 01 26 Page 18 7 10 2 Wiring diagram single and double joystick BOW THRUSTER DIRECTION 1 COMMON tt 4 v OUTPUT THRUSTER CONTROL UNIT DOUBLE JOYSTICK PANEL T S REAR VIEW T mm rTTT DIRECTION 1 TU mon HH lee 3 DIRECTION 2 Ye 4 VOUTPUT THRUSTER CONTROL UNIT n d PARALLELL CONNECTIONS 12121 04 IF SEVERAL PANELS ARE CONNECTED my OM IMPORTANT XF de PARALLELL CONNECTIONS IF SEVERAL PANELS ARE CONNECTED SINGLE JOYSTICK PANEL REAR VIEW CONNECTION DIAGRAM ON SYSTEMS WITHOUT WIRELESS CONTROL OPTION OR SERIAL NO BEFORE 200473 SUPPLY FUSED 1A CONNECTED AFTER BOW THRUSTER MAIN SWITCH PARALLELL CONNECTIONS IF SEVERAL PANELS ARE CONNECTED SINGLE pal PANEL REAR VIEW The control unit and electric motor must be the same voltage version as the battery system it is connected to Rev 3 2009 01 26 Page 19 8 Maintenance A XF WARNING Before maintenance the main switch must be turned off Seasonal mai
15. e four fastening holes with 22 4mm 3 32 e Hemove the drill template and remove the red cover film from the gasket e Install the panel carefully and fix it in place with the four black stainless screws e Connect the wires to the panel as shown on the connection diagram s e wires are connected by pressing in the button placed under the hole while the wire is being pushed into the hole Release the button when the wire is in place e Check for good connection by pulling gently in the wires e Correct connection is 1 White Direction 1 2 Brown Common 3 Green Direction 2 4 Yellow supply from 1 A fuse connected ater thruster main switch or directly to MCU from MCU serial no 200473 and later 7 3 Connecting the control cable e wires are connected by pressing in the button placed over the hole while the wire is being pushed into the hole e Release the button when the wire is in place e Check for good connection by pulling gently in the wires NB The wiring must be connected as follows Touch panel 1 Green 2 Brown 3 White Joystick from MCU serial no 200473 1 Green 2 Brown 3 White 4 Yellow On boats with more than one steering control position the wires must be connected in parallel into 1 2 3 and 4 7 4 ontradicting direction If the operating direction when using the remote transmitter is wrong follow the procedure below e Turn off the main switch e Remove the
16. er Ensure that no objects are in the tunnel before testing Make sure that the battery is fully charged before testing The thruster must only be operated in water Do not remove belt cover when power is connected NB All cables between the motor control unit and the motor should be kept as short as possible for optimum performance 7 1 Installation touch panel Decide where to place the panel Drill a 15 mm hole Thread the panel cable trough the hole Clean the surface Remove the covering paper on the back of the panel and stick the panel onto the surface The holes in the panel corners may be used to fasten the panel with screws if needed Tighten with care NB For optimum appearance be particular about lining up the panel before sticking it on 7 2 Installation joystick The joystick panel single or double comes complete with e Joystick with gasket and connection plug s e Drill template e Self tapping screws e Manual Mounting e Turn off the main switch to the electrical thruster e Select the mounting position for the joystick panel The desired position must be even and in a location that will prevent water from rain or sea spray to be able to access the back of the panel Remove all grease dust or dirt before affixing the drill template XF Rev 3 2009 01 26 Page 13 e Mount the drill template sticker and use a hole saw and a file to remove all needed area for installation Pre drill th
17. he 2 screws 4 e Make sure that the screws 4 enter the groove in the propeller shaft 2 and that the driver pin is located properly into the groove 8 in the propeller e Lock the propeller into position with the screw 6 washer 5 and cotter pin 7 e Bolt torque M6 ab 8 Nm and M8 ab 20 Nm Xforce 130 stern e Install the driver pin 1 into the hole in the propeller shaft 2 e Fit the propeller 3 making sure the drive pin is located properly in the groove on the propeller 5 e Fasten the propeller 3 with the locking nut 4 Locking nut torque M6 ab 8 Nm and M8 ab 20 Nm XF Rev 3 2009 01 26 Page 12 7 Electrical connections IMPORTANT e Professional qualified craftsmen must carry out the electrical work and responsibility for the installation rests entirely in the hands of the installer e Failure to adhere to these requirements will result in the loss of guarantee coverage WARNING e The electric power must be turned off during installation e minimum requirements stated below with reference to battery capacity cable length and cable diameter must be adhered to in order to avoid reduced performance and operational malfunction e Battery capacity Refer to XForce Thruster requirements 7 9 Recommended main switch e XF 60 Stern Part 12 00050 e 90 Stern 130 Stern Part 12 00087 WARNING e Mind your fingers when testing the propell
18. his kind will typically be around 2 3 times nominal current and can easily exceed 1000 A for short periods Currents of these sizes will generate heat in all components including cables It is therefore very important that all components including the connections of these components are done correctly to keep the connection resistance and the total resistance in the electrical circuit as low as possible All connections between cable lug and components shall always be directly copper against copper or copper against brass There shall never be any washers of any kind or anything else between the connections Wrong or improper use or wrong connection of such high currents components will generate a lot of heat which in worst case can cause fire Rev 3 2009 01 26 Page 22 10 2 Battery The battery capacity must be related to the connected equipment and the use of this For recommened size and capacity please refer to the product specifications Generally will a battery with higher capasity give better performance Start type batteries can generally give higher currents for a short period than leisure standard type and is therefore better suited for the kind of equipment mentioned above It is important to understand the difference between battery voltage and battery capasity An old or damaged big battery can have rest capasity equivalent of a small motorcycle battery while it is still possible to measure a correct charging voltage of
19. iable speed drive on HELM lI e G Oe Ef Se 71 ERO WASH cM E ee BS RW qe GU wS C SMS P RENE And therefore complies with the essential requirements of the following directives Directive Name Directive number Further identification R amp TTE directive 1999 5 EC Eu Dy An s td d na EMC directive 89 336 EEC WROTE CUM y PE t dr LVD Directive 73 23 EEC Low Voltage Directive The following Notified Bodies have been consulted in the Conformity Assessment procedure whenever applicable Notified Body number Name and address Nemko AS Gaustadalleen 30 P O Box 73 Blindern N 0314 OSLO NORWAY N Nemko The technical documentation as required by the conformity assessment procedure is kept at the following address for a period ending at least 10 years after the last product has been manufactured at the disposal of the relevant national authorities of any Member State for inspection Engbo AS Wirgenesvei 7 N 3157 Barkaker NORWAY 47 3300 3150 47 3300 3160 support engbo no Product is CE marked in NORWAY Drawn up in N S NORWAY Date 2 3 2206 5 TLJ C Address Telephone number Telefax number EFi ENGBO AS et selskap i Engbo gruppen pb 2288 PT 3103 T nsberg ALL hh C 33003150 Fax 33 00 31 60 Signature and Company Stamp ystein Enger General Manager
20. isolating rubber caps or plastic cap nuts Not shown on these pictures 7 6 2 Connecting the cables to the battery DANGER Make sure that no cables are short circuited before connecting the battery WARNING e The electric power must be turned off during installation e tis recommended to use a dedicated battery bank for high ampere consumption equipment such as thrusters or in accordance with the engine manufacturer s recommendations e Check all high current connections tighten where necessary e Connect the plus and minus cables to the correct poles on the battery and the corresponding contacts on the control unit The plus cable must be connected via the fuse and main switch e Always turn off the thruster main switch when not in use e All cables between the control unit and the electric motor must be kept as short as possible Maximum cable length is 1 5 m 5 ft Minimum cable insulation rating is 105 C 221 F WARNING e To avoid overheating all connections between the power cable and components must be copper to copper or copper to brass No washers of any kind shall be mounted between the power cable lug and the copper bar component Rev 3 2009 01 26 Page 16 7 Fuse connections The picture shows the correct power cable connection to the fuse terminal Note that the fuse is mounted directly under the power cable lug without any washer in between There are supporting washers on each side
21. ligent protection control Intelligent electronic protection control e Automatic intelligent monitoring will shut off the thruster if too low voltage e The system has intelligent monitoring to measure run and pause time The XForce Thruster is not permitted to start if the voltage on the thruster is below 10 0V on 12V system 20 0V on 24V system If the voltage at the thruster drops below 9 0 18 0V when thruster is running warning will occur by showing orange light power light on the wireless control e Electronic protection system prevents the thruster from continue to run in case of solenoid lock in Solenoid versions Max continuous running time 4 intervals of 30 sec S2 2 min e Automatic intelligent monitoring measures run and pause time to protect the motor and control unit against overheating e Of security reasons the system permits continuous running of the thruster in 4 intervals of 30 sec After each interval the thruster will stop Switching off on the joystick or switch panel will make the thruster run again If repeated 4 times total 2 minutes running the thruster will need to cool down for 25 minutes before being ready to run again This to protect the motor and control unit against overheating NB In an emergency situation to save the ship at the possible expense of the thruster this protection can be override by turning the main switch off and on e Time delay when changing direction protects against mechanical
22. n it If measured voltage of less than 10 5 V 12 V system and 21 V 24 V system the performance will drop and in the end the thruster will stop working e f wireless remote is correctly coded and available check the POWER indicator on the remote Orange light e Low voltage at the electronic unit is indicated by an orange light in the POWER indicator Red light indicator will quickly blink red in case of system faults and slowly blink red together with short sounds if the remote is unable to communicate with the electronic unit e lf the thruster is overloaded and requires time to cool down this will also be indicated by a quick red flashing e These error indications are shown when buttons on the wireless remote are pushed 9 3 The thruster runs in the wrong direction e Check the panel cable connections on the control unit terminal e Swap wire 1 and 3 if necessary 9 4 The thruster just works in one direction e Check connection on terminals 1 2 and 12 pin connector on the control unit Remove the rubber cover closest to the connector and test both directions by pushing the small yellow switches e Ifthe thruster now works normal check the cable connections between the control unit and the joystick If the thruster still does not work study point 8 5 9 5 The thruster runs in contradicting direction If the operating direction when using the remote transmitter is wrong follow the procedure below
23. nents will render any warranty given by Engbo AS void IMPORTANT When installed in boats approved or classified according to international or special national rules the installer is responsible for following the demands in accordance with these regulations classification rules The instructions in this manual cannot be guaranteed to comply with all different regulations classification rules The remote control is approved for use in EU EFTA countries CE or US Canada FCC For other countries please contact your local authorities XF Rev 3 2009 01 26 Page 3 2 Operation IMPORTANT XForce thruster s must only be operated by persons with knowledge of the system Keep main engine s running when operating thruster s to ensure enough electrical power Only operate the thruster s with the propellers fully submerged Test running WARNING e Do not operate the thruster s without the belt cover installed e Make sure no one is within reach of the rotating propeller s e The propeller s must come to a stop before running in opposite direction otherwise the contactors will burn fuse NB When the boat is launched check that it moves in the correct directions when operating the control panel If not shift the cables connected to no 1 and no 3 on the control unit or when it concerns MCU with integrated radio receiver change position on DIL switch 8 on 5100 see 7 4 2 1 XForce intel
24. ntenance check Prior to use before each season or at least once a year the following checks must be carried out 8 1 Mechanical check e Check for loose bolts supports covers and cable supports Check the propeller 8 2 Corrosion check e Aninadequate configuration of the on board electric system can result in galvanic corrosion electrolysis Use of shore power combined with earth failure will some times accelerate the process This will lead to corrosion of the metal components L e Periodic inspection of gearhousing and metal parts is necessary to detect and initiate action to avoid corrosion damage such as replacing the zinc anode Unscrew the bolt switch zinc anode and screw the bolt back in place 8 3 Battery charger check e Check the battery for clean and tight terminals and correct electrolyte level e Check the charging voltage measured on the battery Correct charging voltage at 20 C 68 F is e 14 4 V on 12 V systems 28 8 V on 24 V systems 8 4 High current cable connections check e Check all high current components and connections including battery fuse main switch possible bulkhead feed through motor and control unit connections Minimum voltage measured on the motor during operation should be min 10 5 V on 12 V systems 21 0 V on 24 V systems e Allthruster performance specifications measured by 10 5 21 V If the voltage is below 10 5 V 21 V the contactor will have low contact press
25. ol and electronic unit must also be coded taught electronically to communicate with each other e Remove the left rubber cover Then push the antenna through the cover on one side e While holding down the antenna connector handle push the antenna all the way down into the bottom of the clamp Release the handle and the antenna is fixed in place XF Rev 3 2009 01 26 Page 6 Replace the rubber cover e Start by pushing the rubber cover in by the antenna and continue around the edge until the cover is fixed in place e Make sure not to twist the cover with the antenna The remote control will function over short distances even without the antenna Control Unit Mot 2 4 2 Battery replacement The remote control uses three regular AAA LROS alkaline batteries The battery life is more than two seasons under normal leisure use When replacing batteries open the unit by unscrewing all five screws NB e The screws are of different lengths and have O rings under the screw heads e Replace the batteries and make sure all point the same way with the up and the downwards towards the edge as illustrated e Reassemble the back cover and carefully screw the parts together until the housing gasket is slightly compressed The remote will remain waterproof as long as the O rings and gasket are intact with correct compression NB To ensure a long lifetime this remote control has acid proof machine screws and screw insert
26. ommended ssi u chews cnini estaba beet sin espe cachet aieo Atene 17 7 8 1 MAIN SWITCH uu uuu uu geese eens mua ma seeds oes eee 17 7 9 XForce Thruster Cable fuse and battery requirements 17 TAGs Winnog diagrams u iee a inaw dna eaa dean Paca ipa CD sees usa V abe alone Waska Nene 18 218 0 3 PE 18 7 10 2 Wiring diagram single and double arar ar n nnns nns 19 WEE Cg le ePre 20 cM es ecesie u Eo ou oem 20 Oe CNE CK aa e 20 93 Bater cenarger Chekas a a 20 84 High current cable GONMeCONS CHECK ss c u u uuu uuu aa ea a get asa eE 20 9 b 5 2 2 Does edendo Hf Cen pap dent qd uide ouo o dest en edad suees 20 TROUBLESHOOTING Ou uii ista io a ere 21 Oils does uu xu nion a obse e aeree eati tii uen cs a denas 21 9 2 The thruster does not work or has an unexpectedly low 21 9 9 he thruster runs in the wrong dire clionu u oe Sos abla l radix s edic dura LE E 21 9 4 The thruster just works Imon edirecti 5ilu r uuu uuu u u u y nennen nnne nnne nnn
27. oring and mooring systems the thrusters constitute a complete system for manoeuvring and mooring your vessel The control units on both thrusters and winches are based on the same modules which makes it possible to manoeuvre and anchor using one single wireless remote control To achieve maximum benefit from your XForce thruster please study this manual thoroughly before installing and making use of the thruster panels Keep this manual onboard Do not hesitate to contact us if you have any questions Best regards Engbo AS P O Box 2288 Postterminalen N 3103 Tensberg Norway E mail support engbo no Web www engbo no IMPORTANT Please read the entire instruction carefully before starting on the installation work The installation instructions are only produced for professional use of qualified personnel and are not intended for non professional use Engbo will not assume any liability whatsoever for damage incurred either damage to materials or personal injury which may result if the installation instructions are not followed or if the work is carried out by non professional personnel The manufacturer does not assume any liability for the installation of the thruster panels Qualified installers should be familiar with these installation instructions The responsibility for the installation rests entirely on the installer Compliance with regulations must be ensured by the installer Faulty installation or connection of any compo
28. reducit te tu cius uuum Rd qM aM a a e a mM RIEN Red M DD qM D I ILS as 9 5 1 2 Determine the location for the stern thruster nnn nnns nnne nnns nens 10 o MECHANICAL INSTAELATIQODN scit l RE NECI E cu ERE cux E u evo Du 10 Belz Exploded VIGW XROIGO 90 SII s au Q u utasa eia eee eco wee oie eto o I este stesse ober bayi 10 62 Probeler misballalObgsssastesisnoddakictestsaxb ode m odit ts latro suc aa ban fano ayasa kasuku 12 f ELECTRICAL CONNECTIONS 2 MERETRPE FERE 13 7 1 Installation touch panel a a r 13 2 lnstallalor JOVSIICK i uia acis uu Sa S xoa Dna tai d SS e tea kutu Sia q Gu kaskas aus ul ea 13 7 3 Connecting the control cable sirsie UI R u uuu Gawa aaa qaqaia akka qa 14 7 4 ontradicting direction NE mms 14 e Cedo Mee COMMS CH OAS ap TTE TU 15 zb GOMMECUMNG to Me DOW MUSTE s e ecc un unga uan un ated tale cuu Seated amu dead dus 15 7 6 1 Motor TERIA CONNEC eor uuu u ux po Seit dea esa uquspa soe 16 7 6 2 Gonneciing the cables 10 The Daten uu a Rte ila quer M px meer ue ITA I apu erecta pus Done 16 Tiles FUSC CONNECCION NN OOo OS 17 7 65 Rec
29. rom centre of tunnel to water line XF 130 Stern 6 Mechanical installation 6 1 Exploded view XForce 90 Stern Details differ from XForce 60 and XForce 130 12 6 12 5 Determine the location for the stern thrusters see installation drawing and dimensional drawing Before you make any cut outs in the transom please consider the following Make sure that the water flow from the thruster is not obstructed by stern drive trim tabs or other moving parts as this will reduce the thrust significantly The propeller tunnel may be positioned off centre on the transom if required by space restrictions Make sure the propeller tunnel does not interfere with the engine s exhaust outlet pipe or allow exhaust to be sucked into the tunnel The efficiency is reduced considerably if exhaust comes into the tunnel Make sure that it is possible to install a motor support 5 1 1 Such a device is necessary to reduce stress on the thruster components and tunnel transom 1 Once the position is determined hold the propeller tunnel horizontally on the outside of the transom and mark the cut out for the bracket and the holes for the attachment bolts Use the support plate 6 as a template 2 Cut the hole for the bracket 8 in the transom and drill the holes for the 10 mm bolts 3 Seal the cut out section and the bolt holes with two component primer or equivalent sealer to prevent water from entering into the transom X
30. s in the housing The screws may penetrate the housing if screwed carelessly or too much force is used Not covered by the warranty 3 Technical specifications wireless remote control RC 01 ECU 01 3x1 5 VDC From thruster integrated 3 x AAA LROS batteries 2 3 years normal leisure use Not applicable Model dependent 127x53x22 mm Model dependent 68 IP 41 May apply to other countries For information please contact local authorities for the country concerned Conditional upon correct installation and intact rubber gasket and O rings XF Rev 3 2009 01 26 Page 7 4 Dimensions 4 1 XF Stern thruster dimensions XForce C Thruster mm XF60 Stern 300 185 250 max45 XF90 Stern 300 185 250 max45 XF 130 Stern 400 250 2310 max82 J XForce thruster NE mm 102 4 02 in I SEP XF 60 Stern Relay box 66 XF 60 Stern Transistor controlled power electronics with integrated 215 T31 radio receiver XF 90 Stern Relay box 66 XF 90 Stern Transistor controlled She power electronics with integrated 215 131 radio receiver 4 2 Control Unit dimensions 235 9 23 in 243 9 57 in XF 130 Stern Relay box 195 111 XF130 Stern Transistor controlled power electronics with integrated 215 131 radio receiver XF Rev 3 2009 01 26 Page 8 5 Installation 5 1 Avoid water damage IMPORTANT Please read these instructions caref
31. ully and in their entirety before starting the installation To avoid water damage to components please consider the following Seal all drain holes in the thruster installation compartment Drain the surrounding compartments and hatches to the bilge aea in front of the thruster s installation compartment If the propeller shaft logs or rudder components with a high probability for leakage come through the bottom of the boat in the same compartment as the thruster you must make a separate compartment for the thruster to isolate it from these potential water leaks Ensure that the thruster s installation compartment will not be dripped on if a cockpit deck or hatch drain fails to operate properly All possible precautions should be taken to ensure that water leaks into the hull will be routed away from the stern thruster compartment You should consider installing an automatic bilge pump in the stern thruster compartment If you are not confident that you have been able to seal this compartment well this pump is absolutely necessary The electrical connections for the thrusters must be installed so that all junctions and connectors are kept dry at all times 5 1 1 Compartment area XF e Thruster compartment area must be kept dry all time e Fabric glass fibre reinforced polyester tunnel e Motor support Rev 3 2009 01 26 Page 9 5 1 2 Determine the location for the stern thruster Recommended minimum distance f
32. unu 21 9 5 The thruster runs in contradicting direction l u u y Se Reem 21 9 6 thruster runs for short intervals or a clicking sound is to be heard from the thruster 22 9 7 thruster stops working after a long period of use 22 10 INSTALLATION OF EQUIPMENT WITH HIGH CURRENTS 22 10 1 Specialkceonsideralioie uuu manu m beta oL n suat ma Qa Su aQ a unas Leads 22 XF Rev 3 2009 01 26 Page 2 10 1 1 Preface iNtrOdUCtiOn cccccceccecececcccececececucuccucecscueucucecueueausesscseuausecscueausucecseauausesscseuauceeaeaunecscauauaenecseauaunensesnass 22 10 2 ISSN um 23 1021 Baler Cables lUgS uuu uu uuu uuu ukun CC 23 0 2 2 i i elenco mm 23 Fuse 6 9 uuu u k uma Ssbaas an atusQkpskosqaakanaqsshasasqhasatasqhassestukusuesisab ssasoseqduspaspsq aabsosqsspasns ae rere 24 10 24 MAINES WING CONC CHOIR ENTE TT 24 1 Introduction First of all we would like to thank you for choosing the XForce Thruster Engbo AS has for several years supplied Volvo Penta with thrusters distributed as QL thrusters through Volvo Penta dealers and distributors In late 2006 Engbo and Volvo Penta agreed that distributing through two channels and brand names would make our thrusters even more available Together with Engbo anch
33. ure The contacts can then easily burn or fuse together and the thruster contactor must then be replaced NB The electronic security system will if necessary cut the power and the thruster stop 8 5 Joystick operator panel check The motor can be tested in both directions without the joystick operator panel connected as described below e Short between terminal 1 and 2 on the control unit and the motor will run in one direction e Short between 2 and 3 and the motor will run in the opposite direction e Measure zero resistance with wires disconnected from the control unit between the green and brown wire and between the brown and white wire from the joystick operator panel when operating the lever switch e This test will show whether the joystick operator panel with cable is working and whether the control unit is working Rev 3 2009 01 26 Page 20 9 Troubleshooting fan _ MA m o E n fi E tf AT E 5 i V an M V yi bae 4 L linm ry ma ru 4 2 3 u t s a x cee XF Control Unrt Al Battery Bripcra 9 1 The thruster does not work e Turn on the thruster main switch e Check fuse e Check battery e Check all el connections on the control unit and battery cables 9 2 The thruster does not work or has an unexpectedly low performance e Check the voltage at the control unit terminal battery and battery while trying to ru
34. with washer and nut only on the overside of the cable lug Nothing must be placed between the battery terminal clamp and cable lug It excists different kinds of battery connections Use only a type with bolts and not any kind of spring or clip on solutions e f more than one cable cable lug has to be mounted on the same battery post the one with the greatest current shall always be the lowest or closest to the battery e Follow the instructions for applying the correct torque on the bolts e After the cables have been mounted protective and isolating rubber cap shall be mounted Rev 3 2009 01 26 Page 23 Fuse connection The bolt itself is not an active current conductor and its only function is to assure a tight fit between the fuse and the cable lug The picture shows a correct connected cable to the fuseholder Please note that fuse and cable lug is in direct contact with a big washer over the fuse and under the cable lug There must be nothing between the fuse and the cable lug e Correcttorque for a Stainless Steel bolt A4 is 20 Nm 10 2 4 Main switch connection The bolt itself is an active current conductor e The pictures show a correct main switch connection e Please note that the cable lug is mounted directly onto the terminal post washer and nut is on top of the cable lug Different kinds of main switches with different kinds of terminals excist Correct torque is e M8 Brass copper 10 Nm e M1
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