Tunnel mounting
Contents
1. XF Rev 4 2010 02 01 Page 19 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 9 Troubleshooting 9 1 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 9 2 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 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 Green light e 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 the2. Automatic intelligent monitoring will shut off the thruster if too low voltage 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 power light on the wireless control Electronic protection system prevents the thruster from continue to run in case of solenoid lock in Solenoid versions 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 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 from any damage this protection can be override by turning the main switch off and on Time delay when changing direction protects against mechanical and electric overload Shear pin between thruster motor and drive shaft protects mechanical parts if the prop
3. 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 Supporting washer Cable shoe Fuse Supporting washer 7 8 Recommended main switch Thruster model Partno 12 00087 12 00087 Main switch 12 00050 7 9 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 Main switch 12 00087 Rev 4 2010 02 01 Page 16 7 10 XForce Thruster Cable fuse and battery requirements Maximum cable length1 Minimum cable dimension Required min battery capacity XForce Thrust Spare Thruster m fuse P N XF 1 The distance attery one way 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 minimum 7 11 Wiring diagram Hovedstr msbryter Main Switch Sikring Fuse 10 AYSLIVE NYSLLVd Gul gronn yellow green Sort black Rosa pink 13 Gul grenn yellow green Bl blue 16 Gul yellow 14 9 Hvit white 1 ge Brun brown 2 o 5 Grenn green 3 P Gul yellow 4 7 Rosa
4. POWER indicator Red light VEREEEXODIUD e 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 Ifthe thruster is overloaded and requires time to cool down this will also be indicated by quick blink red e These error indications are shown when buttons on the N wireless remote are pushed UNIT C 0470 Similar light signals will be shown on the LED Picture left XF Rev 4 2010 02 01 Page 20 XF 9 3 The thruster works in only one direction Check connection on terminals 1 2 and 3 16 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 If the thruster still does not work study point 8 5 9 4 The thruster runs in contradicting direction If 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
5. 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 and saw cutter or a file to remove all needed area for installation Pre drill the four fastening holes with 2 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 supply from 1 A fuse connected after thruster main switch or directly to MCU from MCU serial no 200473 and later Connecting the RCU control cable 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 Joystick 1 White 1 White 2 Brown 2 Brown 3 Green 3 Green 4 Yellow For details see the wiring diagram 7 11 and 7 12 If more than one steering control position in use the wires must
6. enghoy X FORCE PNGBO THRUSTER SYSTEMS XForce stern thruster series Installation and user manual XF60SR XF90SR XF130SR ig Gie English version C 0470 According to NS EN ISO 9001 2000 FCC ID R78 RC 01 R78 ECU 01 Art no 117 00165 XF Rev 4 2010 02 01 Page 1 Contents le INTRODUCTION e 2 OPERATION et rrr 4 21 KrOLCe IntellideltprotectloTcOPI FOL E eg ea ba roD 4 22s HOW dO ODerate tne D prd DV vL Ve dotate Da ba Du ARE EVE KB RE TEE Be aa 4 2 2 1 Operating panel Versio x M In p oO UMP UL DE 4 2 2 2 ODeratmdInst cllolis ssa espe detained eism dM en E MEE 5 2 2 3 Pii ve fo ates a ib Kol NENNEN TP NEP 5 2 2 4 ACU TEE 6 2 2 5 Coding Of wireless remote eame peces eiu nsn er EM cid sec rua 6 2 2 6 Batten replacement heehee coll eaten eo 7 3 TECHNICAL SPECIFICATIONS WIRELESS REMOTE CONTROL 8 4 DIMENSIONS REMISE MMOL D ree 8 4 1 Dimensions XF60SH XF90SR and XF130SRHR essesseseseenee II I meme nennen meer 8 4 2 Dimensions RCU Remote Control Unit ce ccccccccceceseeceeeeeseeeeeeeeeeseeecesseeeceeseaee
7. 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 2 4 RCU Remote Control Unit 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 IMPORTANT Turn off the thruster main switch when not in use A The radio receiver current consumption will be approx 3 5 W as long as it is turned on 2 2 5 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 seconds When you hear a short sound signal and the green power light starts to flash the remote control is prepared for coding and will stay in coding mode for 5 minutes or until the coding
8. pink 13 Gul yellow 14 Gronn green 15 Bl blue 16 17 12 09 Rev 2 Rev 4 2010 02 01 Page 17 7 12 Wiring diagram single and double joystick ae DOUBLE JOYSTICK PANEL BOW THRUSTER WHITE i e BROWN _ COMMON E DIRECTION 2 V OUTPUT THRUSTER CONTROL UNIT REAR VIEW ttt DIRECTION 1 BROW COMMON LL HT GREEN DIRECTION 2 t BAM V OUTPUT THRUSTER ware CONTROL _ GREEN PARALLELL CONNECTIONS IF SEVERAL PANELS ARE CONNECTED XF e IMPORTANT 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 e BROWN i SUPPLY FUSED 1 am mamie CONNECTED AFTER BOW THRUSTER MAIN SWITCH PARALLELL CONNECTIONS IF SEVERAL PANELS ARE CONNECTED E SINGLE JOYSTICK PANEL REAR VIEW e he control unit and electric motor must be the same voltage version as the battery system it is connected to Rev 4 2010 02 01 Page 18 8 Maintenance WARNING Before maintenance the main switch must be turned off Seasonal maintenance 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 supp
9. the green 16 pin connector Rev 4 2010 02 01 Page 21 The thruster runs for short intervals or a clicking sound is to be heard from the thruster e 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 12V system and 21 V 24V system 9 5 The thruster stops working after a long period of use Intelligent electronic protection WARNING e he 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 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 e In an emergency situation to save the ship from any damage this protection can be override by turning the main switch off and on e Check the thruster control unit fuse cables and electric connections for visible signs of overheating bad
10. uses three regular AAA LROS3 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 The screws are of different lengths and have O rings under the screw heads Replace the batteries and make sure all 3 batteries have the and the correct 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 Rev 4 2010 02 01 Page 7 3 Technical specifications wireless remote control remote Power supply 3x1 5VDC From thruster From thruster normal leisure use Communication Operating frequency Channels Channel separation Address range Temperature range Relative humidity without condensation 105g Model dependent Dimensions HxWxD 129x53x23 mm Model dependent Environment protection Splashproof 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 4 Dimensions 4 1 Dimensions XF60SR XF90SR and XF130SR Thruster model n XF60SR_ 300 185 250 max45 1305
11. 8 400 250 2310 max82 320 172 225 375 XF Rev 4 2010 02 01 Page 8 4 2 Dimensions RCU Remote Control Unit mc jla m c o eE r XF60SR XF90SR XF130SR All measures in table given in mm 8885525535355 EEE COOCOO leo o9 4 3 Installation of RCU Remote Control Unit e Unscrew the four screws and remove the top cover e Make use of the holes in the bottom cover to fasten 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 5 Installation of the thruster 5 1 Avoid water damage IMPORTANT Please read these instructions carefully and in their entirety before starting the installation To avoid water damage to components please consider the following e all drain holes in the thruster installation compartment e Drain the surrounding compartments and hatches to the bilge aea in front of the thruster s installation compartment e Ifthe 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 e Ensure that the thruster s installation compartment will not be dripped on if a cockpit deck or hatch drain fails
12. T Always install at least one fixed XF Thruster panel 2 2 2 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 pressed down Max 4x30 sec 2 2 3 Directions for use Push the left arrow button and the thruster moves the boat to port Push the right arrow button and the thruster pushes the boat to starboard 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 Green light indicates everything normal and ready Rev 4 2010 02 01 Page 5 engt t amori were cegatd m Image B XF Orange light Orange light
13. be connected in parallel into 1 2 3 and 4 XF Rev 4 2010 02 01 Page 14 7 4 Contradicting direction On boats with more than one steering control position the wires must be connected in parallel into 1 2 3 and 4 If the operating direction when using the remote transmitter is wrong follow the procedure below e Turn off the main switch e Remove the rubber cover on the RCU e Change position on DIL switch 8 on S100 e urn on the thruster main switch and verify in a safe and controlled manner correct operation from all operation panels and the remote transmitter e If the operating direction when using the fixed panels is wrong exchange wires 1 and 3 on the green 16 pin connector 7 5 Connecting cables to the bow thruster Directions for mounting e Pre cut correct cable lengths and mount cable lugs advance so that mounting the cables on the thruster can be done in a comfortable position before the unit is mounted in the boat NB Correct cable bolt nut torque is e Terminal bolt M8 brass 10 Nm 7 4 Ib ft e Terminal bolt M10 brass 15 Nm 11 1 Ib ft WARNING After connecting the cable on the motor treminal to the connection bolt with correct torque the bolt with cable will still be able to move relative to the terminal plate NB View the pictures and enclosed wiring diagrams for correct connections The copper bars are active current leaders The pictures show correct connected cables Pleas
14. connection and short circuit 10 Installation of equipment with high currents XF 10 1 Special considerations 10 1 1 Preface introduction e Engbo has experienced that over 90 96 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 occur e In general there are special considerations that must be taken into account regarding installation use and maintenance of high current consumption equipment It is therefore extremely important that only persons with the appropriate knowledge are doing this kind of work e he 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 e Similar precautions must also be taken with generators and charging systems for batteries e ouch equipment has or can have for shorter periods many hundreds of ampere of current consumption e 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 e 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 a
15. 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 P O Box 2288 Postterminalen N 3103 T nsberg 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 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
16. e note that cable lug is mounted to the terminal with washer the nut and 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 XF Rev 4 2010 02 01 Page 15 7 6 Connecting cables to the battery DANGER Make sure that no cables are short circuited before connecting the battery WARNING The electric power must be turned off during installation It is recommended to use a dedicated battery bank for high ampere consumption equipment such as thrusters or in accordance with the engine manufacturer s recommendations Check all high current connections tighten where necessary Connect the plus and minus cables to the correct poleson the battery and the corresponding contacts on the control unit The plus cable must be connected via the fuse and main switch Always turn off the thruster main switch when not in use 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 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 7 7 Fuse connections
17. ele Brute eut bt Dat eerta 21 9 4 The thruster runs in contradicting nennen nnns 21 The thruster runs for short intervals or a clicking sound is to be heard from the thruster 22 9 5 thruster stops working after a long period of 22 10 INSTALLATION OF EQUIPMENT WITH HIGH CURRENT S 22 10d peclalColnsiderdllOEiS ii voe LOU 22 PO ME ice c 22 10 2 suco TED 23 XF Rev 4 2010 02 01 Page 2 102 1 Baten cables IUS eee ee 23 10 22 Baie 23 1023 FUSS COM SCT OIA 24 10 2 4 Main switch CONNECTION 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 anchoring and mooring systems the thrusters constitute a complete system for manoeuvring and mooring your vessel The
18. eller 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 operation panels available Touch panel Part no 12 79001 e Easy to install e Designed similar to Engbo winch panel Rev 4 2010 02 01 Page 4 XF Single Joystick Part no 12 79002 XFORCE POWER eo ON OFF switch LEDs for indication of power and direction Double joystick Part no 12 79003 Needed if both bow and stern thruster installed ON OFF switch LEDs for indication of power and direction Wireless remote control Part no 12 47014 Splash proof remote control unit The wireless remote control can be used to operate maximum two thrusters and two windlasses bow and stern Activates both bow and stern thruster simultaneously in opposite direction by pushing the centre buttons Operation range of 30 m under normal conditions 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 backside Holder and hand neck cord is included as standard easily removed The battery lifetime is more than 2 seasons based on normal leisure use IMPORTAN
19. eseaeeesseaecesseeeessaees 9 4 3 Installation of Remote Control Unit cccccccseseceeeeeeeeeeeeeceeseesecesseeecesseaceeseaeeeesseaeeeeseeeeeseaes 9 5 INSTALLATION OF THE 9 Dilly HAVOIG Water damag Emme 9 52 10 5 3 Determine the location for the stern thruster lessen nnne nnnm 10 5 MECHANICAL INSTALLATIONsscstsst p eaes US ae ES HRS aS Usa avs Eae S ago 11 dexploded view XP OO SR rie en iE doas se tee eee 11 O2 Propeller e ll 12 f EEECTRICAL GCONNEG TIONS EC MERE 13 Tole IAStallavtionvOr Ne TOUCH PANG EE mE 13 J2 MOYSUCK MSTA AVON oves cO N 14 7 3 Connecting the control 14 7 4 Contradicting 15 7 5 Connecting cables to the bow thruster lsssesesssssssssssssseseeee nennen nnne nnne nnn nnne nnn nnn nnns nnns 15 7 6 Connecti
20. has been finished Image A 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 Rev 4 2010 02 01 Page 6 XF Alt 2 Joystick installed Turn the thruster main switch off Disconnect the cables to the joystick connected to 1 2 and 3 on the green plug on the remote control unit RCU Prepare two short wires 5b 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 Turn the power on The receiver will now understand that coding is requested and automatically connect to your wireless control and will immediately be ready for use This will be confirmed by a short sound signal and the green power light will turn from flashing to permanent Turn the thruster main switch off Disconnect the short wires and connect the joystick cables Turn the power on and check that the wireless control is functioning 2 2 6 Battery replacement The remote control
21. he boat is set afloat 6 2 Propeller installation e Symmetrical 4 blade kaplan propellers Glass fibre reinforced acetal POM e XF60SR and XF90SR e Install the driver pin 1 into the hole in the propeller shaft 2 e Fit the propeller 3 with the 2 screws 4 e 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 8 ab 20 Nm Rev 4 2010 02 01 Page 12 XF130SR 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 20Nm 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 The 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 malf
22. lts thoroughly 8 Carefully apply sealant to the gear housing 2 before fitting the gear housing to the bracket 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 left XF Rev 4 2010 02 01 Page 11 14 15 Be aware the gear housing is prefilled with oil Guide the gear housing from within the tunnel through the hole NB No propeller s should be fitted during this process Guide the two attatchment bolts 23 from within the transom through the bracket and fasten gear housing and propeller tunnel to the transom In some cases the tunnel flanges 1b must be modified to fit close to the transom 11 Fit the motor 12 2 to the bracket 12 3 and screw the units together The motor has to be properly supported to support the weight of the motor and reduce tension on the transom and thrusters bracket See 5 3 NB Place support under the motor body do not place under the fan guard 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 Apply bottom coating All wet parts in the tunnel must be covered with bottom coating Ensure that the installation has no leaks when t
23. ng cables to the 16 Ll WEUSESSCOMMECUONS T UU UT m 16 7 8 Recommended main 16 Fas Eo mr 16 7 10 XForce Thruster Cable fuse and battery requirements ccccceeeeccecceeeeeeeeceeeeeeeeeeeeeseeeessaaeeeeeesaaees 17 a eat sei htc ace apache on naive an ea 17 7 12 Wiring diagram single and double joystick cccccceeecceceeeeeeeeeeeeeeeeeeeeeseeeseeeessaaeeceeessaeeeeeeessaaeeeesssaaess 18 MAINTENANGE domine ici ctc Aic nion E E 19 on PEMEI i ear iaie ike nio eee 19 02 14 um Tc TR 19 8 95 Bater enarger CNECK REO Emm 19 8 4 High current Cable CONNECIIONS CHECK uo Ote S Cae aa Comi 19 8 5 sJoySucK ODerator Daniel CDeckosssscsodium edem tabe toin dae Lust tees 20 9 TROUBLESHOOTING 5i moa iri Co i Verde ede eerie ona 20 9 1 The thruster does not WOK nennen enhn sages 20 9 2 thruster does not work or has an unexpectedly low performance 20 9 3 The thruster works in only one direction occ ana kan aedis
24. orts Check the propeller 8 2 Corrosion check e An inadequate configuration of the on board electric system can result in galvanic corrosion electrolysis Use of shore power combined with ground fault will some times accelerate the process This will lead to corrosion of the metal components 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 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 144 Von 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 e 10 5 Von 12 V systems e 21 0 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 will stop
25. s low as possible e All connections between cable lug and components shall always be directly copper against copper copper against brass There shall never be any washers of any kind or anything else between the connections e 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 4 2010 02 01 Page 22 XF 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 a battery with higher capasity will 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 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 lit
26. 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 4 2010 02 01 Page 23 XF 10 2 3 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 Correct torque for a Stainless Steel bolt A4 is 20 Nm 10 2 4 Main switch connection The bolt itself is an active current conductor The pictures show a correct main switch connection 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 M8 Brass copper 10 Nm 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 4 2010 02 01 Page 24
27. tle capasity Ah 10 2 1 Battery cables lugs a gt e Battery cables must be related accordingly to the equipment it is a 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 e 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 e 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 10 2 2 Battery connection e The pictures show a correct connected batterycable Notice that the cable lug 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 e texcists 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
28. to operate properly e All possible precautions should be taken to ensure that water leaks into the hull will be routed away from the stern thruster compartment e 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 e The electrical connections for the thrusters must be installed so that all junctions and connectors are kept dry at all times XF Rev 4 2010 02 01 Page 9 5 2 Compartment area e Thruster compartment area must be kept dry all time e Fabric glass fibre reinforced polyester tunnel e Motor support 5 3 Determine the location for the stern thruster Determine the location for the stern thruster see installation drawing and dimensional drawing Before you make any cut outs in the transom please consider the following e 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 Recommended minimum distance from centre of The propeller tunnel may be positioned off tunnel to water line centre on the transom if required by space restrictions e 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
29. tunnel e sure that it is possible to install a motor support Such a device is necessary to reduce stress on the thruster components and tunnel transom XF Rev 4 2010 02 01 Page 10 6 Mechanical installation 6 1 Exploded view XF90SR Details differ from XF60SR and XF130SR 12 5 12 6 12 2 26 19 18 29 26 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 Cutthe 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 4 Buff the 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 IMPORTANT Make sure the oil nipple is positioned upwards Specified sealants Sikaflex 291 Wurth Sealant 0890100 or similar NB Do not use sealant of hard caulk type 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 bo
30. unction e Battery capacity Refer to XForce Thruster requirements 7 10 Recommended main switch e 60SR Part no 12 00050 e 90SR XF130SR 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 battery and the thruster motor should be kept as short as possible for optimum performance 7 1 Installation of the touch panel e Decide where to place the panel e 15 mm hole e Thread the panel cable trough the hole Clean the surface e 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 Rev 4 2010 02 01 Page 13 7 3 7 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
31. 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 4 2010 02 01 Page 3 XF 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 S100 see 10 4 2 1 XForce intelligent protection control Intelligent electronic protection control
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