Tunnel mounting
Contents
1. 9 DIMENSIONS zcn a aa a 9 XForce TNEUSITCIS acii aa u ma aa a a a a a a a asa 9 Control unis MCU and BG 2 ioci usa aa a waska saa asss EMA 10 INSTALLATION OF CONTROL UNITS u u aaa a 10 XF20222 2 u u d T tun EDI MM IE M MEME Q aasan sg 10 BGU XF40R XF60R XF75R 09g XF90R2uu uuu k vicus In oo ocu aus masu upaku ass 10 INSTAELATIQNu uu u Su u u a m uwa 11 HESSE cicli uuu u u i 11 DAINIK m uy S ua nuna anu a 11 the uuu uuu vasca 11 suu umaman c 11 m Imm 12 Adapting NG ec 12 Cleaning m obtusa iu abesset sedia etd cadi M bait 12 Prevent OU uu uuu bua o o UTE 13 PS Le iN Me u n a E basu a ataqa m 14 m TT UT a a 14 0 Cel Meteo Mr mc nce 15 1 Directions for high speed boat special installations nnns 15 MEA GIORNO UU MNT HE TR 15 THRUSTER I2. nnn anna anna 30 10 5 The thruster runs in contradicting direction J J J 30 10 6 The thruster runs for short intervals or a clicking sound is to be heard from the MCU 31 10 7 The thruster stops working after a long period of use 31 10 7 1 Intelligent electronic protection control cccceeecccseseecceescccceueeecseeeecsaececseseecsegeeecsseeesauseessaueeesaueeesssneeessaneeessags 31 11 INSTALLATION OF EQUIPMENT WITH HIGH CURRENTS T J J 31 14 1 Special considerans eee cio Pera uum akaw e eco Era e EE RE 31 11 1 1 PRCTACEIMMIFOCUCTIO Nancie EE 31 k2 Banery Dr 32 11 2 1 Battery able SIUS cR PT 32 112 25 Baten connectie T r 32 MEE LU xen eom T DITE 32 11 2 4 Main switch connection ANTT mU c 33 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 a
3. 20 detur secre me Q 21 erra Hc PE 21 Connecting the control cable to MCU XF20 J J 21 Connecting the control cable to XF40R 60R 75R and 90 R 22 u k u a 22 20 Connecting Motor Control Unit MCU J l J J Q J J 22 Connecting to the Dow IB SIer uya u Z yu aaa 23 Connecting the Cables t the Datlery uuu uuu aqa Sua aqu as 24 FUSOGORDBECUHo9NSS uuu upam saus E 24 FReconmendedimaiiswilehuu any UN 24 Rev 8 2010 01 05 Page 2 8 10 1 u 25 8 11 XForce thruster cable fuse and battery requirements J J 25 8 12 Wiring RTL TM 26 Slat SXE ZOTHSIAV VEION a e 26 o 22 I2 ClOCIOMIC E E EN EN assia asna as 26 68 123 6 OR SOR SANG
4. 27 GOUBIC JOVSUGCK 27 9 MAINIENANCE uuu a E oen Ln ue a ated 28 91 a Ae ce eae 28 9 1 1 Er 28 9 1 2 COMOSIOMSG OC ferae pu EP Ipse c IUE 28 9 1 3 28 9 1 4 High current cable connections 28 9 1 5 JOVSIICK Operator Panel ege u uu sansapa 29 9 1 6 CIV SVAN CHAP Sr uu TRECE E 29 9 1 7 HIS ING a RET 29 10 TROUBLESHOOTINQ u uu 2 uu uu uuu ture aa RM 29 10 1 The thruster does not WOEFK l au su vade 29 10 2 The thruster does not work or has an unexpectedly low performance 29 10 3 The thruster runs in wrong ull 30 10 4 The thruster just works in one direction
5. PARALLELL CONNECTIONS IF SEVERAL PANELS ARE CONNECTED XF Rev 8 2010 01 05 Hovedstramsbryter Main Switch Sikring Fuse Gul grann yellow green 17 12 09 Rev 2 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 VHE e BROWN 2 GREEN 3 SUPPLY FUSED 1A YELLOW _ I CONNECTED AFTER BOW THRUSTER MAIN SWITCH PARALLELL CONNECTIONS IF SEVERAL PANELS ARE CONNECTED SINGLE JOYSTICK PANEL REAR VIEW Page 27 IMPORTANT e The control unit and electric motor must be the same voltage version as the battery system it is connected to 9 MAINTENANCE AN WARNING Before maintenance the main switch must be turned off 9 1 Seasonal maintenance check Prior to use before each season or at least once a year the following checks must be carried out 9 1 1 9 1 2 9 1 3 Mechanical check Check for loose bolts supports covers and cable supports Check the propeller Corrosion check The XForce integrated gearhousing and thruster bracket are made of very corrosion resistant materials XF 20 Glass fibre reinforced composite material 40 XF 60 75 90 and XF130 Stainless steel AISI 316 An faulty configuration of the on board electric system c
6. XFORCE ENGBO TARUSTER SYSTEMS Installation and user manual 20 XF 40R XF 60R 5H XF 90H C 0470 According to NS EN ISO 9001 2000 FCC ID R78 RC 01 R78 ECU 01 Part no 117 00164 XF Rev 8 2010 01 05 Page 1 Contents 1 2 2 1 2 2 2 2 1 2 3 2 3 1 2 4 2 4 1 2 4 2 2 4 3 o oco N O O O O O O O O O O O O lll O I O O gt G N 7 7 1 9 7 1 1 7 1 1 7 1 1 8 8 1 8 2 8 2 1 8 3 INTRODUCTION 3 OPERATIONS Gneci IEEE ERI u Sus 4 Intelligent electronic protection control 4 Operation of Jovsuck touch DANG u uuu u uui oyun aa 5 SIONS secca MM LL D IM DM ED I iMi De A 5 Opera No SOO O tit 5 Directions Tor USE nenesa a a a a 5 Upgrade to wireless remote cene 6 Antenna installation err 7 Coding of WireleSsi remote CoNo una a a Dead 7 Battery replacements a TED 8 TECHNICAL SPECIFICATIONS WIRELESS REMOTE CONTRQOLL
7. Channel separation Address range Temperature range Relative humidity without condensation 105 g Model dependent 120 Dimensions HxWxD 129x53x23 mm Model dependent 150x200x40mm Environment protection Splashproof IP 41 IP41 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 4 DIMENSIONS 4 1 XForce thrusters 20 XF60R XF75R og 9 XF40R ma a e c XF2 ss XF40R 270 150 120 15 8 192 198 655 160 230 XF6GOR 310 150 130 1548 192 210 655 160 XF75R 310 190 130 50 8 200 20 75 185 J XF90R 310 190 amp 130 50 8 200 20 75 185 All measures in tables given in mm XF Rev 8 2010 01 05 Page 9 4 2 Control units MCU RCU he electronic and TEE versions EE SIR measures All measures in tables given in mm All measures in tables given in mm 5 INSTALLATION OF CONTROL UNITS 5 1 MCU XF20 e Use the two slots on both sides of the control unit for attachment e hecontrol unit should be installed vertical with the battery cables down 5 2 RCU 40R XF60R XF75R og XF90R e Unscrew the four screws and remove the top cover e Make use of the holes in the bottom cover to fast
8. Brass copper 10 Nm e M10 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 Rev 8 2010 01 05 Page 33
9. 1 16 Use a centre punch prior to drilling Drilling holes for the bracket bolts The 4 bracket holes must be drilled 9 mm 11 32 Drilling the insertion hole Use a saw drill designed for glass fibre cutting with the correct size according to the thruster model to be fitted Slow speed is recommended XF Rev 8 2010 01 05 Page 17 e Insert hole before final filing Remove excess material e Use a or cutter to even out the edges of the hole Use a vacuum cleaner to clean up e Remove the sticker before installation of the cutter 7 1 6 Test mounting 1 Test installation of the bracket provisionally without the bolts to ensure optimal adjustment Trim the hole with a file if necessary 7 1 7 Placement of bolts Apply suitable marine sealant in holes for bolts Fastening of bolts must be done from the outside of the tunnel inside boat Use the spacer nut the washer and the M8 nut as shown in the picture to press in the bolts NB Carefully grease the upper part of the threads Do not grease the contact area between the bolt head and the tunnel Tighten the nut carefully so that the bolts attach to the tunnel and then remove the spacer nut the washer and nut Use a 13 mm spanner to tighten up the 8 bolts Rev 8 2010 01 05 Page 18 7 1 8 Test mounting Il Test mount the bracket and propeller provisionally The propeller may need to be turned while being mounted because of the bolt
10. by qualified personel A Pull in tools Spacer nut washer and M8 nut B Bracket mounting bolt set Bolts washers and locknuts C Propeller mounting set Driving pin washer and locknut e These instructions assume a tunnel has been correctly mounted in the hull 7 1 Preparations Start work from the inside Remove all possible remains from the moulding process and hone down with a file 7 1 1 Determine the centre lines Define a tunnel centre line and the optimum propeller centre line The tunnel centre line is determined with reference to the tunnel and not to the boat NB See left hand picture for suggestion on how to find a centre line or line up the template sticker directly on the tube 7 1 2 Installation template e The darkest grey area shown on the installation template is the contact area for the bracket and must not be removed Before installing the bracket clean and dry the contact area to achieve optimal contact for the sticker Rev 8 2010 01 05 Page 16 7 1 4 Stick the installation template sticker exactly over the centre line and cross line The propeller may be mounted slightly offset The bow thruster may be mounted at any angle from 02 90 Installation from 45 to horizontal requires a support for the motor WARNING The motor has to be properly supported to offload weight and tension on tunnel transom Pre drill All marked holes must be pre drilled 2 0 mm
11. plastic nuts av 8 11 XForce thruster cable fuse and battery requirements 1 The distance from the thruster unit to the battery one way each cable Use of even larger cable dimensions and battery capacity will give the thrusters better performance 2 Wiring insulation rating is 105 C 221 minimum XF Rev 8 2010 01 05 Page 25 8 12 Wiring diagrams 8 12 1 XF 20 Relay version l is Joystick Touch panel S gt Antenne Motor kontroll enhet MCU AN NB Rel versjon Sikring Hovedstremsbryter Batteri Batteri Thruster Elektrisk motor 8 12 2 XF 20 electronic version Joystick Touch Panel Thruster Control c g Thruster Electric Motor Page 26 XF Rev 8 2010 01 05 8 12 3 XF 40R 60R 75R and 90R Gr8 grey 7 Sort black Rosa pink 13 Gul grenn yellow green Bla blue 16 Gul yellow 14 Hvit white 1 Brun brown 2 3 Gul yellow 4 Joystick 2 5 2 Gr grey 7 Rosa pink 13 Gul yellow 14 Gronn green 15 Bl blue 16 8 12 4 Single and double joystick BOW THRUSTER DIRECTION 1 COMMON DIRECTION 2 V OUTPUT THRUSTER CONTROL UNIT DOUBLE JOYSTICK PANEL REAR VIEW DIRECTION 1 COMMON DIRECTION 2 V OUTPUT THRUSTER CONTROL UNIT
12. 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 9 1 6 drive maintenance The belt drive usually requires no maintenance To inspect the belt the belt cover must be removed NB XF 60 Remove the lock plug on both sides of the cover before removing the belt cover Replace the opposite way NB XF 20 XF 40 XF 75 XF 90 and XF 130 Snap off on the belt cover 9 1 7 Inspect the belt Make sure that no teeth are damaged or worn Correct tension is when the belt can be twisted about 45 degrees If adjustment is required loosen the 2 4 flange bolts and increase or decrease the tension by adjusting the bolt under the motor Tighten the flange bolts and recheck the belt tension 10 TROUBLESHOOTING 10 1 The thruster does not work Turn on the thruster main switch Check fuse Check battery Check all el connections on the control unit and battery cables 10 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 run it If mea
13. Ensure that the installation has no leaks when the boat is set afloat 8 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 Battery capacity Refer to XForce Thruster requirements 8 11 Recommended main switch e 20 and 40 Part no 12 00050 e 60 75 90 and 130 Part no 12 00087 WARNING e Mind your fingers when testing the thruster 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 8 1 Touch panel installation Decide where to place the panel 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 pa
14. NSTALLATION u u au Uns C Q u was qua 16 e ME 16 Determine The centre NSS uuu uuu u uy amin buka E ELE 16 HVS LeU AAU ON LCI ALC y uu u Em 16 pie qilla s nus s usapu tie saa 17 Drilling holes for the bracket bolts a a rr 17 Bilino TS MSE THOM hole y uu u r OE US 17 SS TO UNE CL EE E SES ER 18 Placemeniiofpo j uu t L 18 mouet eec ccce 19 enna 19 D eati esos n rina Labia r 19 1 Iistall fhe abusuta sap n tna ten ique M ci La e ta cue 19 2 PropelerinstallalloD oae Qs ftit m ici i te cae P ALL akun as ata D Sat u De ce dnte Led 19 ELECTRICAL 5 20 To cMpanel u l uA
15. Nm 7 4 lb ft e Terminal bolt M10 brass 15 Nm 11 1 Ib ft NB View the pictures and enclosed wiring diagrams for correct connections The copper bars are active current leaders The pictures show correct connected cables Please note that cable lug is mounted to the terminal with washers on both sides of the cable lug then another washer and nut on top of the cable lug NB Direct contact between terminal copper bar and cable lug is important Do not put washer or nut in between Finally mount isolating rubber caps or plastic cap nuts Not shown on these pictures Rev 8 2010 01 05 Page 23 WARNING After connecting the cables to the connection bolts with correct torque the bolts with cables will still be able to move relative to 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 8 8 Connecting the cables to the battery e DANGER e Make sure that no cables are short circuited before connecting the battery e WARNING e The electric power must be turned off during installation e 15 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
16. an 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 Periodic inspection of gearhousing and metal parts is necessary to detect and initiate action to avoid corrosion damages Battery charger check Check the battery for clean and tight terminals and correct electrolyte level Check the charging voltage measured on the battery Correct charging voltage at 20 C 68 F is 9 1 4 14 4 V on 12 V systems 28 8 V on 24 V systems Check all high current components and connections including battery fuse main switch possible bulkhead feed through motor and control unit connections High current cable connections check Minimum voltage measured on the motor during operation should be 10 5 Von 12 V systems 21 0 V on 24 V systems All thruster performance specifications measured by 10 5 21 V If the voltage is below 10 5 V 21 V the contactor will have low contact pressure 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 XF Rev 8 2010 01 05 Page 28 9 1 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 the control unit and
17. as a unique code Equipped with anti slip strips on the back Holder and hand neck cord is included as standard 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 31 Directions for use e 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 Rev 8 2010 01 05 Page 5 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 ab
18. change wires 1 and 3 on the green 12 pin connector Image 3 8 6 XF20 Connecting Motor Control Unit MCU 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 in direct contact with the copper bar Use M8x20mm bolts for all copper bars Mount the three first cables with the cable lugs pointing in the same direction as shown in the pictures Rev 8 2010 01 05 Page 22 e The mountingbolts not active current leaders and their only purpose is to assure a tight connection between the cable lugs and bars Shorter and thicker cables will give less voltage drop and thus better performance e f ever needed to dismount the cables start from the right side and reverse the above procedure NB See wiring diagram correct connections 8 7 Connecting to the bow thuster XF 20 NB Correct cable bolt nut torque is e Terminal bolt M6 brass 7 Nm 5 18 e Terminal bolt M8 brass 10 Nm 7 4 lott XF 40R 60R 75R and 90R NB Correct cable bolt nut torque is e Terminal bolt M8 brass 10
19. ction can be override by turning the main switch off and on e ime delay when changing direction protects against mechanical and electric overload e Shear pin between thruster motor and drive shaft protects mechanical parts if the propeller is obstructed from rotation Rev 8 2010 01 05 Page 4 2 22 Operation of joystick touch panel e Move the joystick press touch panel to right and the thruster will be activated to starboard e Move the joystick press touch panel to left and the thruster will be activated to port 2 2 1 Panel versions There are 4 different XForce Thruster operation panels available Touch panel Part no 12 79001 e Easy to install e Designed similar to Engbo winch panel 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 Splash proof hand held remote control unit 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 h
20. d as low in the hull as possible prevent air being drawn into the tunnel the upper part of the tunnel should be at least its diameter below the surface Use appropriate drawing instrument refer to your dealer regarding availability of drawing cutting tools to mark the point at which the hole for the bow thruster tunnel is to be inserted e Mark out the hole in its entirety on the inside of the hull so as to ascertain the optimum position for the tunnel NB Make sure that the tunnel is mounted as transverse in the boat as possible After having located the centre spots check both sides according to selected reference spots in the hull 6 1 3 Cutting holes The installation process can begin once the location of the tunnel has been marked NB Do not cut complete circles at first Small ears should be left at the top and bottom of the circle in order to support the tool during the operation A file can then be used to remove the ears once both holes are complete Rev 8 2010 01 05 Page 11 6 1 4 Tunnel centre holes e Drill the centre holes diam 25mm for the tool centre tube on both sides of the hull e Enter the tool centre tube through the hull from the outside and cut out the large holes from both sides e is important to cut with care by turning the tool several times making it possible for the cutting machine to work itself through the hull 6 1 5 Adapting the tunnel e Enter the tunnel an
21. d mark out where to cut where the tube is protruding NB Please read point no 6 1 11 Directions for high speed boat special installations e Cut off and adapt the tunnel on both sides 6 1 6 Cleaning before fastening e Rub down the surface of the tunnel both on the outside and inside to remove all wax Wipe off with acetone Rev 8 2010 01 05 Page 12 Typical cut tunnel ready for installation Observe the rubbed ends Rub down the surface of the hull both on the outside and inside to remove all wax Wipe off with acetone Remove all topcoat from a surface area of at least 100 mm around the holes on the inside of the hull e g using a circular sanding disc to get adhesion for the polyester Vacuum clean and wipe off with acetone NB If the boat has a sandwich hull the core around the tunnel must be ground away sufficiently to allow the application of the glass fibre mat Prevent filling from running out Should it be impossible to fit the tunnel with glass fibre all the way around the entire space beneath the tunnel must be filled Fig left The filling must be uniform and might be made from talcum powder and polyester or equivalent To prevent the filling from running aft a waxed plate made after the bilge and tunnel shapes must be put in place whilst filling and curing e Sometimes also the joint between hull and tunnel must be taped to prevent the filling from
22. ds When you hear a short sound signal and the green power light starts to flash the remote control is now prepared for coding and will stay in coding mode for 5 minutes or until the coding has been finished Image A Image XF Rev 8 2010 01 05 Page 7 Image D XF 2 How to put the receiver unit in code mode Alt 1 Touch panel installed e Press and keep both switches on the touch panel down while simultaneously switching on the power to the receiver unit Image B and C e The receiver will now understand that coding is requested and automatically connect to your wireless control and the wireless remote control will immediately be ready for use e This will be confirmed by a short sound signal and the green power light will turn from flashing to permanent e Check that the wireless control is functioning Alt 2 Joystick installed e Turn the thruster main switch off e Disconnect the cables to the joystick connected to 1 2 and 3 on the green plug on the remote control unit RCU e Prepare two short wires 5 cm Remove the insulation in both ends and connect these between 1 and 2 as well as between 2 and 3 on the green plug Image D e Turn power receiver will now understand that coding is requested and automatically connect to your wireless control and will immediately be ready for use e This will be confirmed by a short sound signal and the green power light will turn from
23. ection the operating direction when using the remote transmitter is wrong follow the procedure below Turn off the main switch Remove the rubber cover on the Control Unit Change position on DIL switch 8 on S100 Turn on the main switch and verify in a safe and controlled manner correct operation from all operation panels and the wireless remote If the operating direction when using the fixed panels is wrong exchange wires 1 and 3 on the green 12 pin connector XF Rev 8 2010 01 05 Page 30 10 6 The thruster runs for short intervals or clicking sound is to be heard from the MCU 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 10 7 The thruster stops working a long period of use 10 7 1 WARNING 11 Intelligent electronic protection control 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
24. en the unit e Alteratively attach the unit by using Sikaflex or similar adhesive NB By installing the unit with the gren plug turned down moisture in the contact can be avoided XF Rev 8 2010 01 05 Page 10 6 INSTALLATION 6 1 Tunnel installation IMPORTANT Please read the entire instructions carefully before starting the installation DANGER e installation of the thruster s must not be carried out in a confined space where combustible or explosive gases could be present e The manufacturer assumes no liability whatsoever for the installation of the propeller tunnel and its attaining parts Qualified craftsmen must carry out the work and responsibility for the installation rests entirely in the hands of the installer IMPORTANT Use only an original XF tunnel made of fabric glass fibre reinforced polyester Smooth in outside surface 6 1 1 Drilling tool kit Makes the tunnel installation very efficient and shortens the installation time considerably Consists of Compass for easily locating the tunnel centre spot Electric straight grinder including centre rods for cutting the holes in the hull Adapters for all thruster dimensions For more information ask your dealer or contact Engbo AS directly 6 1 2 Choosing and marking the location e Select a suitable position for the bow thruster For the best result make sure that the bow thruster is located as far forward an
25. f current consumption In rush current in an electrical motor of this 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 8 2010 01 05 Page 31 11 2 Battery XF 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 bat
26. flashing to permanent e Turn thruster main switch off e Disconnect the short wires and connect the joystick cables e Turn the power on and check that the wireless control is functioning 2 4 3 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 3 batteries have the and the correct e Reassemble the back cover and carefully screw the parts together until the housing gasket is slightly compressed The remote will remain splashproof 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 inserts in the housing Following text must be removed The screws may penetrate the housing if screwed carelessly or too much force is used Not covered by the warranty Rev 8 2010 01 05 Page 8 3 TECHNICAL SPECIFICATIONS WIRELESS REMOTE CONTROL Motor Control Unit Remote Control Unit remote 01 RCU Power supply 3x 1 5 V DC From thruster From thruster 3 x AAA LR03 batteries integrated integrated Battery life Not applicable Not applicable normal leisure use Communication Operating frequency Channels
27. greed that distributing through two channels and brand names would make our thrusters even more available Together with Engbo anchoring and mooring systems the thrusters constitute a complete system for manoeuvring and mooring your vessel The control units for 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 POB 2288 Postterminalen 3103 Norway E mail support engbo no Web www engbo no XF Rev 8 2010 01 05 Page 3 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 res
28. 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 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 8 9 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 Use large washers with large cable lug Recommended torque 20Nm M8 A4 Plastic nuts to be mounted on top of plastic cover e Supporting washer e Cable shoe e Fuse e Supporting washer 8 10 Recommended main switch Main switch 12 00050 Thruster model 12 00050 12 00050 12 00087 12 00087 Rev 8 2010 01 05 Page 24 Main switch 12 00087 8 10 1 Main switch terminal The main switch terminal must be isolated as shown in the left hand picture e g by using rubber caps or
29. is mounted onto the batterypost 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 If 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 Follow the instructions for applying the correct torque on the bolts After the cables have been mounted protective and isolating rubber cap shall be mounted 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 Correct torque for a Stainless Steel bolt A4 is 20 Nm Rev 8 2010 01 05 Page 32 11 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
30. is to be implemented after choosing version 2 or 3 e If not already installed the MCU must be fitted with an antenna The remote control 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 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 Motor Control Unit WWV XF40R XF60R XF75R and XF90R are supplied with the power contactor fixed to the thruster motor and separate electronic Remote Control Unit RCU with integrated receiver for the wireless remote enclosed The antenna is preinstalled inside the electronic thruster control 2 4 2 Coding of wireless remote control Procedure for serial no above 8600 Important If your wireless control has serial no lower than 8600 use the procedure enclosed your remote 1 How to put the wireless control unit in code mode e Select the pair of switches on the remote control to be coded e Press down both switches simultaneously for approximately 12 secon
31. nel 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 XF Rev 8 2010 01 05 Page 20 8 2 Joystick installation The joystick panel single or double comes complete with Joystick with gasket and connection plug s Drill template Self tapping screws Manual Mounting Turn off the main switch to the electrical thruster 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 Mount the drill template sticker and use a hole saw and cutter or file to remove all needed area for installation Pre drill the four fastening holes with 02 4mm 3 32 Remove the drill template and remove the red cover film from the gasket Install the panel carefully and fix it in place with the four black stainless Screws Connect the wires to the panel as shown on the connection diagram s The 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 Check for good connection by pulling gently in the wires Correct connection is 1 White Direction 1 2 Brown Common 3 Green Direction 2 4 Yellow
32. 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 S100 see 10 5 2 1 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 e Automatic intelligent monitoring measures run and pause time to protect the motor and control unit against overheating Max continuous running time 4 intervals of 30 sec S2 2 min 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 prote
33. ove the button accompanied by a short sound Green light indicates everything normal and ready Orange light Orange light indicates warning conditions e g low voltage at the electronic unit 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 indications are shown when buttons are pushed 2 4 Upgrade to wireless remote control XF20 can be delivered with 3 different versions electronic Motor Control Units MCU 1 Relay box power contactor 2 Relay box power contactor with integrated radio receiver 3 Transistor controlled power electronics with integrated radio receiver that replaces the conventional power contactor The new electronic unit 3 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 Rev 8 2010 01 05 Page 6 2 4 1 Antenna installation If wireless remote control option
34. ponsibility for the installation rests entirely on the installer Suitable protective equipment must be used during installation Compliance with regulations must be ensured by the installer Faulty installation or connection of any components 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 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
35. running out Rev 8 2010 01 05 Page 13 e When the filling is cured remove the waxed plate Grind smooth clean with acetone e Coat the glass fibre mats with plastic and fill the gap between tunnel and hull with glass fibre putty all the way down to the mats and alongside the hull Fig left Fastening the tunnel Remove all topcoat from a surface area of at least 100 mm around the holes on the inside of the hull e g using a circular sanding disc to get adhesion for the polyester Vacuum clean and wipe down with acetone Bond the tunnel to both sides of the hull On the inside the bonding must cover 100 mm It is recommended that you use 7 layers of 450 g glass fibre mat for this purpose The process is easier if the area between the tube and the hull is first smoothened out with glass fibre filler NB Make sure that any gap between the tunnel and the hull is completely filled with polyester glass fibre In areas difficult to get at a polyester glass fibre compound filler must be filled in NB To avoid any kind of misfitting of the thruster bracket there should be no glass fibre polyester where the bracket is to be mounted Can easily be avoided by covering the contact area for the bracket with plastic or similar there should be insufficient room for bonding around the tunnel this 5 should instead be completely filled with polyester based filler Filler Smooth ou
36. s protruding in the tunnel Make sure that the propeller rotates freely in the tunnel Do not install the driving pin washer and locking nut yet 7 1 9 Specified sealants Sikaflex 291 Wurth Sealant 0890100 or similar Important Do not use sealant of hard caulk type 7 1 10 Apply sealant Apply suitable sealant to the bracket and the bolts Make sure leakage Is impossible 7 1 11 Install the XForce thruster Install the bracket and turn the propeller into place Do not install the driving pin washer and locking nut yet Mount the washers and lock nuts and fasten with even turns in succession making sure that the propeller can rotate freely all the time Locking nut torque M8 ab 20 Nm Make surfaces even Smooth out the sealant in order to make surfaces even 7 1 12 Propeller installation Symmetrical 4 blade kaplan propellers Glass fibre reinforced acetal POM Install the driver pin 4 into the hole in the propeller shaft 5 Fit the propeller 3 making sure that the driver pin is located properly into the groove in the propeller Fit the washer 2 and fasten the propeller 3 with the locking nut 1 Locking nut torque M6 ab 8 Nm and M8 ab 20 Nm Rev 8 2010 01 05 Page 19 Fastening the propeller Use a piece of wood e g broomstick to prevent the propeller rotating while fastening the lock nut Apply bottom coating All wet parts in the tunnel must be covered with bottom coating NB
37. supply from 1 A fuse connected after thruster main switch or directly to MCU from MCU serial no 200473 and later Connecting the control cable to MCU XF20 The wires are connected by pressing in the button placed over the hole while the wire is being pushed into the hole Release the button when the wire is in place Check for good connection by pulling gently in the wires NB The wiring must be connected as follows Touch panel and joy stick if Joystick if MCU serial above no MCU serial no below 200473 200473 White 1 White 2 Brown 2 Brown 3 Green 3 Green 4 Yellow XF Rev 8 2010 01 05 Page 21 8 4 8 5 Connecting the control cable to RCU XF40R 60R 75R and 90 R 1 White 2 Brown 3 Green 4 Yellow Contradicting direction On boats with more than one steering control position the wires must be connected in parallel into 1 2 3 and 4 the operating direction when using the remote transmitter is wrong follow the procedure below Turn off the main switch Remove the rubber cover on the MCU or RCU Change position on DIL switch 8 S100 Remove folloving text or exchange wires 1 and 3 on the 12 pin green connector XF20 Image 1 XF40R XF60R XF75R og XF90R Image 2 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 panels is wrong ex
38. sured 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 Green light Green light indicates that voltage and sytem is ok Orange light e Low voltage at the electronic unit is indicated by an orange light in the POWER indicator XF Rev 8 2010 01 05 Page 29 UNIT C 0470 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 blink red These error indications are shown when buttons on the wireless remote are pushed Similar light signals will be shown the LED Picture left 10 3 The thruster runs in wrong direction Check the panel cable connections on the control unit terminal Swap wire 1 and 3 if necessary 10 4 The thruster just works in one direction Check connection on terminals 1 2 and 3 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 If the thruster now works normal check the cable connections between the control unit and the joystick 10 5 The thruster runs in contradicting dir
39. t all the contact points edges on the hull exterior with glass fibre filler Use glass fibre filler to adjust and round the area between the tunnel and the hull lt is important to round off the edge between the hull and the tunnel to achieve optimal water passage and minimal cavitation noise Rev 8 2010 01 05 Page 14 6 1 10 Grinding e Working from outside the hull the outermost edges of each hole should be ground at an angle of 45 degrees to the innermost edge of the hole A Grind the complete circle at 45 degrees achieve maximum thrust and minimum noise round off the openings with a radius Rmin d 10 10 of the tunnel diameter 6 1 11 Directions for high speed boat special installations e On fast boats it may be necessary to make structural alterations to divert the flow of water in front of the tunnel This is to prevent water slamming into the propeller A Level with the hull B The tunnel should protrude 25 mm from the hull 6 1 12 Coating e Prime the hull exterior with two coats of two component primer Apply bottom coat to both the hull and the tunnel Apply topcoat e Grind all areas that have been moulded or ground and apply topcoat to avoid water access to the hull tunnel Rev 8 2010 01 05 Page 15 7 THRUSTER INSTALLATION WARNING e Do not install the thrusters in areas where inflammable or explosive gases may be present e Thruster installation must only be carried on
40. tery while it is still possible to measure a correct charging voltage of 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 11 2 1 Battery cables lugs f Battery cables must be related accordingly to the equipment it is 3 connected to Please refer to the product specifications for recommended relation between size and length Generally speaking a thicker cable dimension will give better performance especially with longer cables Use only cable lugs of high quality 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
41. 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 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 11 1 Special considerations 11 1 1 XF Preface introduction Engbo has experienced that over 90 of our service problem enquieries is related to power supply This section 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 auxiliary engines Similar precautions must also be taken with generators and charging systems for batteries ouch equipment has or can have for shorter periods many hundreds of ampere o
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