CT35 / CT45
Contents
1. t is possible to reduce the cable section to facilitate easy connection but only over a short distance In this case appropriated crimp fittings should be used at the connections Please consult the Electrical installation diagram p 11 for more information MAIN POVVER FUSE Fuse sizes for overcurrent protection are to be determined on the basis of the cable sections in the circuit and NOT the amperage dravvn by the appliance thruster motor in the circuit Thruster Maximum Amperage Max Power Fuse size CT35 250 A 125 A CT45 250 A 125A 9 BATTERIES Thrusters are high amperage consumers with instantaneous demands thus we recommend you use maintenance free starting type batteries with high CCA outputs For example Exide Maxxima 900 12V capacity 55Ah starting current 800CCA www max power com Manual CT35 amp CT45 April 2008 10 ELECTRONIC CONTROL BOX 11 Install a fused circuit breaker switch in the boat s main DC distribution panel marked BOVV THRUSTER This circuit breaker svvitch should ideally be supplied from a different battery bank to the one used for povvering the thruster The installer must protect the positive supply cable of the thruster s control box by means of a 8A fuse The size of the power cables red amp black depends on the length of the cable run the voltage drop in these cables should not exceed 5 of the nominal battery voltage For safety reasons and2. Spare Parts VVVVVV max povver com 13 Manual CT35 amp CT45 22 SPARE PARTS LIST O 001 b Z xm NODO QI RO N o Description Electric Motor CT35 CT45 Motor fixing screvvs Motor drive pin and spring Relay cover Plastic screvvs for relay cover Complete relay Electronic control box Motor support Drive leg fixing screvvs Drive leg tunnel fibre seal Composite drive leg CT35 includes n 9 10 12 14 Propeller drive pin Propeller Propeller nut Composite drive leg CT45 includes n 9 10 12 14 Fuse holder T1 Fuse 125 A Extraction handle www max power com Quantity IE JENSEN EN ENE 56 ND S A April 2008 Reference MP052020 MP024030 MP025097 MP052020 MPOP4022 MP023011 MPOP5701 MP028005 MP024025 MP025090 MP028000 MP025070 MP025000 RT204070 MP028002 OPT13119 OPT13114 OPT13118 Manual CT35 amp CT45 23 TROUBLESHOOTING GUIDE Before contacting your nearest troubleshooting guide Problem The control panel does not light up The relay is clicking but the motor is not running The motor is running but the thruster is not vvorking The thruster lacks povver April 2008 Max Power distributor please check the below Check Check the 6 wire connector behind the joystick Check the thruster s electronic control box 6 wire connector Check the circuit breaker switch in the boat s main DC distribution panel Chec
3. n some cases it vvill be easier to mark and drill these holes BEFORE laminating the tunnel After drilling use the gasket to verify the holes axes and adjust them with a round file where necessary These holes must be completely clean before inserting the screws Position the leg the gasket between the leg and the tunnel and the motor support and then tighten the the two screws alternatively Finally mount the propeller s to control the general alignment If the general set up is correct remove the propeller s the leg and the gasket www max power com 4 Manual CT35 amp CT45 April 2008 Apply a thin coating of silicon grease or sealing compound to both sides of the gasket this must be resistant to hydrocarbons and vvater Re assemble all parts as before positioning and then tightening the two 6mm screws alternatively using a 5mm Allen key maximum torque 12 Nm Check that the propellers rotate freely without resistance or friction It is imperative that the holes and the screws remain free of sealing compound otherwise there is a risk of an incorrect assembly of the parts Caution do not use graphite grease NOTE The composite drive leg e is pre filled with oil and sealed for life e does not require anodes e must not be disasembled even partially exclusion waranty 4 ELECTRIC MOTOR 12 volts After having greased the motor shaft and the drive pin place the motor on its support The motor should ce
4. capacity and condition of your batteries aswell as cable sections used VVVVVV max povver com 5 Manual CT35 amp CT45 April 2008 Ensure that all electrical connections are correctly tightened Under no circumstances should any flammable products be stored next to the electrical components of the thruster N It is essential to install a manual battery isolator and if possible an electric battery isolator at the base of the thruster motor povver line When using a manual battery isolator it must be visible clearly marked amp easily accessible Thruster motor power supply These values are given as an indication assuming that the batteries are charged at 10096 and in charge that is 13 8V The performance data of the CT35 CT45 is measured vvith an approx consumption of 250 Amps and approx 11V at the motor s connections Please refer to the characteristics given by the manufacturer of the batteries that vvill be used see section 9 Batteries Povver vviring Measure the shortest and most direct route possible betvveen the battery ies and the electric motor remembering to allovv for both positive and negative cables Recommended cable sections Cable lengths CT35 CT45 12V L lt 5m 2 5 x 2 50 mm 5 lt Ls 10m 5 x 2 70 mm 10 lt L lt 15 m 7 5 x 2 95 mm 15 lt L s 20 m 10 x 2 120 mm For all connections use appropriate terminals for the cable sections chosen
5. in order to obtain all the functions provided by the thruster controller an electric battery isolator needs to be installed in the thruster motor positive supply cable Max Power advises the use of an electric battery isolator ref OPTI3160 3 f an electric battery isolator is not used then simply seal off the two grey wires coming out of the control box It is important to isolate the thruster motor power circuit by means of a manual battery isolator after having used the thruster Please refer to the drawing Relay and control box connections p 12 for more detail on the wiring of the control box to the thruster CONTROL PANEL AND THRUSTER CONTROL BOX FUNCTIONS To switch the thruster ON or OFF follow the instructions given in the diagrams on the follovving page VVhen svvitched ON the control panel vvill beep once and the green LED in the red push button will light up When switched OFF the control panel will beep twice and the green LED in the red push button vvill go out The thruster controller provides a time delay betvveen left and right thrust in order to avoid rapid direction changes There is no delay vvhen thrusting to same side If the thruster motor overheats the control panel will start beeping and the green LED will flash until the thruster motor has cooled down As soon as the overheating alarm sounds there are 10 seconds of actual thruster use before the unit automatically shuts dovvn t vvill then not be pos
6. Address Email Postcode Country Name of skipper Tel Owner s signature Date To be completed by the installer Installation details Thruster model Installation date Electric Hydraulic Date of launching boat Model and hull number of boat Builder Build year Pleasure or commercial boat Hull construction material L O A Waterline length Width Poids total en charge Tunnel Diameter Thickness Material amp Length If Electric Battery Type Size amp Number Installation checklist Electric Before using thruster During use Voltage at batteries Voltage at thruster motor Ampere in motor power circuit Mechanical YES NO Check if the drive coupling between the motor and drive leg is correctly tightened Check cable connections are sufficiently tightened The thruster installation has been checked and the thruster functions correctly Important Please consult this manual for more details www max power com 18
7. Manual CT35 amp CT45 April 2008 P O W ER CT35 CT45 With electronic thruster control INSTALLATION OPERATION MAINTENANCE Serial NO ______________________ Installation date THIS MANUAL MUST BE KEPT ONBOARDAT ALL TIMES Max Power S A S 10 all e Frangois Coli 06210 MANDELIEU FRANCE T l 33 492 19 60 60 Fax 33 492 19 60 61 mail mp max power com www max power com www max power com Manual CT35 amp CT45 April 2008 Contents Section Title Page 1 General installation guidelines 2 2 Tunnel 3 3 Composite motor support and drive leg 4 4 Electric Motor 5 5 Propellers 5 6 Protection grills 5 7 Electrical installation 5 8 Main povver fuse 6 9 Batteries 6 10 Electronic control box 7 11 Control panel and thruster control box functions 7 12 Control panel installation 8 13 Tests 9 14 Electrical measurements 9 15 Operation 9 16 Alarms or thermal switch off 10 17 Safety 10 18 Maintenance 10 19 Electrical installation diagram 11 20 Relay and control box connections diagram 12 21 Spare parts diagram 13 22 Spare parts list 14 23 Troubleshooting guide 15 24 Worldwide distribution network 15 25 Warranty coverage 16 26 Warranty form 18 The use of qualified marine personnel with experience in bow thruster installation is strongly advised Where possible the boat manufacturer s design departments architects and or shipyards should be consulte
8. ce www max power com 16 Manual CT35 amp CT45 April 2008 4 VVarranty Terms f the material is used for anything other than for pleasure craft the guarantee is limited to a six month period Year 1 All factory testing diagnosis repairs and replacements are performed at no charge to the End User All parts and up to two hours of labour are covered for repairs and replacements conducted in the field Year 2 All factory testing diagnosis repairs and replacements are performed at no charge to the End User This excludes any damage or faults occurring from normal vvear and tear on the follovving items engine oil seals relay contacts If warranty is registered within the 3 month period following installation 5 VVarranty Exclusions Damage due to modifications or installation contrary to published specifications Cost of hauling the boat Damage due to repairs performed by an unauthorized service centre Damage due to lack of normal maintenance services Damage due to water Parts replaced due to normal wear and tear Repairs performed without knowledge of manufacturer please contact dealer to receive Repair Authorization Number Tampering of equipment by the End User Cost of travel to and from the job site Cost of economic loss including injury to any person damage to property loss of income or profit communication lodging inconvenience Consequential damage due to failure including those arising from collision wit
9. d prior to installation taking place For any boat requiring official classification bodies of approval should also be consulted at the earliest opportunity In any case all other bodies governmental or otherwise should be contacted to ensure conformity with legal regulations relating to the boat in question IT IS ESSENTIAL TO READ THE FOLLOWING MANUAL CAREFULLY BEFORE INSTALLING THE THRUSTER NB The thruster is delivered without accessories fuse fuse holder control panel VVVVVV max povver com 1 Manual CT35 amp CT45 April 2008 1 GENERAL INSTALLATION GUIDELINES n order to install the thruster in the most efficient position follovv the instructions belovv VVaterline e The minimum acceptable tunnel position is 94 mm belovv the vvaterline The tunnel is ideally positioned when the distance between the waterline and the top of the installed tunnel is 125 mm e The tunnel must be installed as far forward as possible NB A thruster turbine installed above its ideal position towards its minimum depth will lead to a progressive loss of performance VVhether vertical inclined or horizontal it is recommended to support the electric motor The electric motor generates heat when in operation The zone in which the thruster is installed must therefore be dry and ventilated The batteries used by the thruster must be charged by both the main engine s alternator and an appropriate battery charger If the thruster is insta
10. e thruster is not in use Install the control panel s in easily accessible positions without obstructing the main engine and or steering controls When fixing the panel with the stainless steel screws make sure to install the pre cut rubber seal as supplied with the panel ensuring that it is in the correct place A Only when totally finished and satisfied with the vviring and positioning of the unit clip on the face panel cover Please note that panels are only fully waterproof from the front if installed correctly Hovvever the area behind the dashboard should be kept dry to avoid the risk of oxidization of the cable connecter contacts For full control panel installation instructions please refer to the Installation Guidelines as supplied with each control panel www max power com 8 Manual CT35 amp CT45 April 2008 13 14 15 TESTS Vin 454 LA Activiating the thruster when the boat is out of the water is not advised under any circumstances Tests must be carried out with the boat in the water the battery ies charged at 100 and in charge and the engines running The maximum continuous operating runtime corresponds to S2 3mn norm However this can be affected by the ambient temperature ELECTRICAL MEASUREMENTS n normal usage mode i e thrusters running boat in the water with fully charged batteries under ongoing charge alternator electrical measurements should be made at the fol
11. er requires a minimum of ongoing maintenance Check the condition and charge of the batteries regularly as voltage drop is the most frequent cause of rapid deterioration of the relay Carry out a regular check of all electric components batteries connections power cables Remove the motor and clean out dust from the motor brushes with compressed air The electric motor must be kept dry and well ventilated NOTE All maintenance should be carried out by qualified and authorised personnel Composite drive leg and propellers The composite drive leg is pre filled with oil and sealed for life t does not require the oil changing The composite drive leg does not require an anode The composite drive leg must not be disassembled even partially this would void the warranty When the boat is out of the water check that there are no fishing lines plastic bags etc caught in the propellers s Paint the drive leg and propellers with antifouling make sure that they were well prepared and primer has been used Always keep the propellers and tunnel clean To prevent the build up of calcium on the drive shafts which would damage the oil seals cover the drive shaft and the oil seals stainless steel covers with silicon grease before fitting the propeller s This should be done on an annual basis after the cleaning of the outside of the leg Do not use aggressive solvents as they may damage drive leg seals If drive leg oil seals are f
12. h other vessels or objects 6 Procedural Guidelines PLEASE VIEW THE TROUBLE SHOOTING LIST TO ASCERTAIN OR SOLVE ORIGIN OF PROBLEM PRIOR TO CONTACTING THE DEALER INSTALLER 1 Contact your dealer installer to report the problem a If you do not know who this is contact the nearest Max Power distributor b If you are in foreign waters please contact the nearest Max Power distributor 2 Ensure you have your serial number and model number to hand top right hand corner of vvarranty 3 Dealer Installer will come to site to decipher the cause of the fault 4 f the cause of fault is due to a manufacturing problem the dealer vvill contact Max Povver to receive Repair Authorization Number 5 If the problem is due to an installation error please contact your installer F POSSIBLE PLEASE TAKE PHOTOGRAPHS OF THE THRUSTER TO SHOVV PROBLEM The warranty as outlined above is only applicable to MaxPovver manufactured thrusters and optional equipment as used in marine pleasure industry The supplier holds the exclusive right to test the product and determine vvhether it is defective VVVVVV max povver com 17 Manual CT35 amp CT45 POWER 26 WARANTY FORM April 2008 VERY IMPORTANT Please complete this form and fax a COPY to Max Power with a copy of the installation invoice or the invoice of the yacht boat in order for the warranty to come into effect To be completed by the owner Name of owner Tel
13. k the control box s power fuse 8 A Check the motor s power fuse Check the main battery isolator Check the internal relay contacts Check battery conditions and connections Check the propellers are fitted Check the motor drive leg assembly Check that the tunnel is not obstructed or the propellors blocked Check the propellers are fitted Check the size of the batteries Check the batteries are sufficiently charged Check the connections are tightened correctly Check the power cables sections See p 6 Recommended cable sections 24 VVORLDVVIDE DISTRIBUTION NETVVORK To locate the nearest Max Povver distributor please consult the section Worldwide Distribution on our website www max power com www max power com 15 Manual CT35 amp CT45 April 2008 25 WARRANTY COVERAGE Introduction The purpose of this document is to set out the terms of warranty cover offered in relation to products purchased by the End User from Max Power or its approved network of resellers This document will adhere to the following format Section 1 Definitions Section 2 Period of Coverage Section 3 Warranty Registration Section 4 Warranty Terms Section 5 Warranty Exclusions Section 6 Procedural Guidelines Section 7 Service Centres 1 Definitions Authorized Repair Number The number given by Max Power on reporting a fault with your thruster Dealer An authorized Max Power sales centre End User The boat supplied with sup
14. lled using a dedicated battery bank this must be as close as possible to the thruster in order to reduce voltage loss in the electric cables CAUTION In no case should flammable products be stored near to the electric components of the motor For the CT35 mono the propeller must be centred in the tunnel n the case of the CT45 duo the drive leg must be centered in the tunnel n no case should the propellers of either models protrude out of the tunnel CT35 CT45 VVVVVV max povver com 2 Manual CT35 amp CT45 April 2008 2 TUNNEL Once the final tunnel position has been determined and all dimensions have been checked mark the centre point of the tunnel on both sides of the hull and drill holes of 8 10 mm on either side Using a metal rod construct a compass with a 68mm radius Insert through the holes and trace the ellipses as shovvn belovv After cutting the holes out follovving the elliptical guidelines use an abrasive disc to prepare the inside and outside surfaces of the hull for laminating approx 10 to 15cm around the holes Position the tunnel in the hull mark the positions of the different components as well as the areas that require laminating then remove the tunnel t is advisable to drill the tunnel before laminating it into position See section 3 Composite Motor Support and Drive leg for more details Replace the tunnel To secure its position apply reinforced fibreglass filler to all a
15. lowing points At the batteries At the battery cut off switch At the fuse At the electric motor s connections At the power supply arriving at the thruster control box These measurements will enable you to detect voltage drop NOTE the voltage reading between the motors negative and positive connections should be approximately 10 5V during operation ZA The cumulative effect of voltage drops at these points can severely impair the thruster s performance Should the voltage measured be too low the following points need checking Are the batteries of sufficient capacity Are the batteries good quality Are the batteries sufficiently charged Are appropriate cable sections being used Are the connections sufficiently tightened OPERATION With the control system circuit breaker switch and manual battery isolator switched on Switch on the control panel as previously described in the manual Push the red button or incline the joystick to the left and the boat moves to the left Push the green button or incline joystick to the right and the boat moves to the right If during tests the boat moves in the wrong direction change around the blue and the brown wires on your power relay When manoeuvring remember that the boat s momentum continues after you release the joystick button therefore remember to release the control prior to reaching your desired position Care must be taken not to use the thruster in areas where the
16. ntre itself and align easily when correctly mounted on its support If not the drive leg motor support and tunnel are incorrectly assembled Most likely due to an uneven surface on the outside radius of the GRP tunnel If this is the case dissasemble the motor support drive leg assembly sand the tunnel so as to achieve a smooth exterior radius and repeat the previous steps Position the four 6 mm 2 motor support screws then tighten them alternatively maximum torque 20 Nm 5 PROPELLER S Insert the drive pin and propeller to be carried out twice for the CT45 duo Check that the propeller s turn s without resistance a little resistance due to the motor is normal Gradually tighten the 13 mm nut while holding the propeller tightly with your hand maximum torque 10 Nm Protect your hands during this operation to avoid risks of injuries caused by the edges of the propeller IMPORTANT to prevent against calcium deposits that damage the seals we recommend that you coat the shaft and stainless steel cover with silicon grease 6 PROTECTION GRILLS It is possible to install protection grills however installation of such grills will affect thruster performance 7 ELECTRICAL INSTALLATION CAUTION an incorrect electrical installation will cause rapid deterioration or even failure of the thruster Excessive voltage drop will cause premature wearing of the relays and brushes Special attention should be given to the quality
17. ound to be worn replace the drive leg with a standard exchange unit THE MAX POWER TEAM WISHES YOU SUCCESSFUL MANOEUVRING AND ENJOYABLE CRUISING www max power com 10 April 2008 Manual CT35 amp CT45 XI 19 ELECTRICAL INSTALLATION DIAGRAM A ddns yn9119 10 yueg Aieyeq juapuadapul soyejos Jeyeq 211199 3 yueg Aepeq JeJSNIY L ajqeo uo Buipuadap zwu z x Z D 10798uu09 lqeo 04U09 9 pajoadsal aq snul syno jua Juno uBiu u JUSWdiNba jeuonippe suonejnbal sajni j290 Auy Ajuo apinf e se SI We1Beip SIYL gN we Ge Q uole je su 2914 99 2 Sy 19 SELO www max power com April 2008 Manual CT35 amp CT45 20 RELAY AND CONTROL BOX CONNECTIONS sniu eu 10 p sn jeu o JUSpuadapu 291n0 S e WO peddns aq Ajjeap pinoys yoyms JO SIU L J8 SNIU Mog peyiew ued UONNUISIP 1291198919 uew s jeoq eu UO xoq OJjJUO9 J2 SNIU eu qo Ajddns ay u Yoyms 19Y291q 9119819 ue 2154 p yeorpul se asnj e JO sueaw Aq 8 4 s lqe Ajddns eanisod eu yoo od snu 18 y L 2 Gi 2 10 99uu09 MOII2A yeg j ued 04UO9 OL mee pou eyuM Joyejos Aoyeq 91139819 OL A ddns 5 Jinosio ci lonuoo KA suono uuoo xog 04JUOO pue el d Gy LO 9210 12 www max power com Manual CT35 amp CT45 April 2008 21 SPARE PARTS DIAGRAM CT35 CT45
18. plied equipment and the owner thereof Installer The authorized centre responsible for the installation of your thruster Manufacturer supplier of the equipment under warranty Pleasure Craft Vessels used for owner s personal use that have no commercial use i e Charter boats or work boats Resellers Max Power approved distributors and dealers Serial Number Number in upper right hand corner of Warranty document Supplier The manufacturer Max Power Warranty The terms and conditions that are covered by the manufacturer 2 Period of Coverage The equipment manufactured by the Supplier is guaranteed to be free from defective workmanship components and materials under normal usage conditions for a period of two years from the date of purchase by the End User This warranty is transferable to subsequent owners of this equipment during the period of coverage 3 Warranty Registration Register your purchase now to receive free extended warranty coverage This can be done using one of the following methods NB proof of purchase must be included to establish that equipment is still under warranty a The quickest and easiest method to register your warranty is to fax the attached installation check list and warranty registration to the Manufacturer Fax 33 4 92 19 60 61 b Mail in your warranty registration document please ensure that you make a copy before sending it 10 All e F Coli 06210 Cannes Mandelieu Fran
19. re may be people swimming or floating debris Maximum running time 2 3 min depending on ambient temperature VVVVVV max povver com 9 Manual CT35 amp CT45 April 2008 16 17 18 ALARMS OR THERMAL SWITCH OFF The thruster s electric motor is fitted with a thermal switch as standard If the thruster motor overheats the buzzer in the control panel vvill start beeping and the green LED in the red push button vvill flash until the thruster motor has cooled dovvn again As soon as the overheating alarm sounds there are 10 seconds of actual thruster use before the unit automatically shuts down The unit will then not be able to be svvitched on again until the motor has cooled dovvn SAFETY Switch off means to cut the power at both the DC equipment panel control power supply amp the thruster battery isolator thruster power supply after having used the thruster Under no circumstances should any flammable products be stored next to the electric components of the thruster Care must be taken not to use the thruster in areas where there may be people svvimming or in the vvater close to the thruster CAUTION Never tamper with the thruster thruster turbine if not 100 sure that both the control and povver circuits have been isolated except if taking electrical measurements on the thruster motor or relay MAINTENANCE Control panels should be protected from the natural elements vvhile the thruster is not in use The thrust
20. reas both inside and out taking care to entirely fill the space between the hull and the tunnel Laminate using a minimum of 8 layers of ISOPHTALIC RESIN alternated with mat and roving In difficult to access areas i e under the tunnel it is possible to only apply reinforced filler Once the filler has set on the outside finish vvith a vvaterproof under coat follovved by sanding and application of a vvaterproof finish coat n order to optimise the flovv of vvater vvhilst sailing and to avoid turbulence due to the tunnel leave 1 to 4 cm of Finish these vvith several coats of reinforced filler in order to obtain the required hydrodynamic lines Once all laminating work is complete apply a vvatertight barrier www max power com 3 Manual CT35 amp CT45 April 2008 DO NOT LAMINATE THE AREA OF THE TUNNEL TO VVHICH THE ELECTRICAL MOTOR SUPPORT WILL BE FIXED Do not laminate this area CT35 RELIEF Do not laminate this area II DEFLECTOR CT45 3 COMPOSITE MOTOR SUPPORT AND DR VE LEG For the CT35 Mono The propeller must be at the center of the tunnel The motor support and the drive leg vvill therefore not be centered in the tunnel For the CT45 Duo The motor support and the drive leg vvill be centered in the tunnel For both models Locate and mark the intended position of the holes for the fixing screvvs and the leg hub You can use the motor support and the leg s gasket to mark these holes
21. sible to svvitch the thruster on until the motor has cooled down If the thruster has not been used for a period of thirty minutes it will automatically svvitch itself off Before switching off automatically the control panel will beep once followed by a second beep a few seconds later after which the thruster svvitches itself off n order to isolate the thruster motor povver circuit as described in the previous tvvo paragraphs it is necessary to install an electric battery isolator as advised by Max Power Please consult the Electrical installation diagram p 11 for more information www max power com 7 Manual CT35 amp CT45 April 2008 Control Panel Instructions Touch panel Red button with LED Green To switch the thruster on or off push and hold down both the red and green buttons for several seconds THRUSTER Simple Joystick Joystick To switch the thruster on or off push and hold down the Red button red button whilst pushing the joystick to the right for with LED several seconds THRUSTER Joystick Double Joystick Red button To switch the thruster on or off push and hold down the with LED red button whilst pushing the joystick to the right for several seconds This is the same for both the Bow Joystick thruster and the Stern thruster Red button with LED STERN THRUSTER 12 CONTROL PANEL INSTALLATION Control panels should be protected from the natural elements while th
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