Watt & Sea Racing Unit User`s Manual
Contents
1. Owner Date of purchase of the hydrogenerator Type of boat Type of fixing on the transom if custom made specify Serial N on the installation manual of the hydrogenerator of the converter Conditions of use frequency of using specific conditions having created the defect Defect noticed Signature Retailer Installer Date of purchase of the hydrogenerator Is the defect evident Is the installation in conformity with the Contact details of the installer instruction manual Defective parts to be replaced N of authorization for after sales return 552. for example LEGRIS 1025 PO6 01 In order to connect multiple hydrogenerators to the same pump you must use a T junction diameter 6mm for example LEGRIS 3104 06 00 The quick release couplings can be used without tools First depressurize the circuit then push the ring in and slide the tube out The tube must slide out easily Figure 16 Disconnecting the quick release couplings LEGRIS The pump housing contains a hydraulic micro pump a check valve a solenoid and a digital pressure gauge filling valve gt lt H HYDRO 1 check valve gt lt _F HYDRO 2 pressure sensor oil tank PUMP BOX Figure 17 Hydraulic circuit blueprint 46 watk amp sea 6 1 Connecting the hydraulic circuit Thread the hydraulic tubing from the transom to the pump Connect the pump to the circuit with the quick release couplings located on the lower section of the housing Note At this point do not connect the hydrogenerators 6 2 Filing the oil reservoir and bleeding the circuit Place a bucket to collect the oil that will be drained during the bleeding process Fill the oil reservoir with mineral oil low viscosity type FUCHS Renolin Extra 22 S To fill the reservoir remove the filler cap and use a large caliber syringe When the reservoir is full bleed the circuit using switch in manual and pump mode Cap Figure 18 Oil filler cap When you have finished bleeding the circuit you can connect
3. e Connect the batteries last 34 Wwatk amp sea 1 4 Operation Check the support structure blades and electric circuit on a regular basis Propeller blades are very sturdy though they might warp or break when running up against a hard immersed object WARNING NEVER TOUCH THE PROPELLER BLADES WHILE THEY ARE SPINNING WARNING NEVER USE THE HYDROGENERATOR AS A LADDER STEP BECAUSE THE SHAFT MAY WARP WARNING ELECTRIC CONVERTER REACHES HIGH TEMPERATURE WHILE OPERATING Wwatk amp sea 2 PACKAGE CONTENTS Check the package content against the list below 1 HYDROGENERATOR RACING 1 CRADLE 1 KIT FOR PROPELLER BLADES 1 CONVERTER 12V OR 24 V 2M of 10 mm battery cable 1 FIXATION KIT 2 Plates 2 SS bolts 1 COTTER PIN 1 INSTRUCTION GUIDE 3 TOOLS amp SUPPLIES REQUIRED tt RACING Watt amp sea Ga Figure 1 Package contents 3 phase cable 3x2 5mm minimum to connect the hydrogenerator to the converter RS485 3x0 5 mm2 cable for the databus between the converter and the pump Quick Disconnect Terminals 6 35mm blue Crimp pliers Terminals for battery connecting cables 10mm or 6mm depending on converter model Connectors for 3 phase cables Outlet box PVC Metric Allen wrench set Hubs amp screws for the pump converter Gasket 6mm Hydraulic tube polyamide 6x4mm for example LEGRIS 1025P0601 6mm T junction if multiple hydrogenerators
4. client date of purchase type of boat description of defect or malfunction of the part and description of the conditions of use of the system The returned systems or components are accepted only in the event of prior written agreement All returns items will have to be carried out in carriage paid If the replaced product proves to be due to a defect included in the guarantee then the expenses of return will be refunded In no case the returned systems or components will be refunded but only replaced Situation not covered by the guarantee This guarantee does not apply if the system Suffered from accidents underwent modifications or repairs without authorization Was not installed by a professional installer and according to the procedure specified by WATT amp SEA in the installation manual supplied with the products Was o Was inadequately installed and maintained or use in overload conditions o Abused or neglected The guarantee takes into account neither the failures resulting from the simple wear or the normal ageing of the structures and materials nor the stripes star cracks or cracks which would appear at the time of a shock In no case WATT amp SEA will be responsible for the special fortuitous or indirect damage If you encounter a problem with your WATT amp SEA product Get in touch with your dealer installer to help you to solve the problem 53 Wwatk amp sea 54 watk amp sea 12 FORM FOR WARRANTY RETURN
5. minimize losses from cable length We provide 2 meter long connecting cables for batteries We recommend shortening any extra cable to reduce losses If the installation needs an overall distance of more than 2 meters 6 feet extend the cables with wider section ones or replace them entirely with wider section cables We recommend connecting the hydrogenerator directly to the battery bank on its proper terminal The converter of the hydrogenerator will charge the batteries when needed Connecting the hydrogenerator through a hub is possible if charging several battery compartments is needed Nevertheless those systems affect the output and a loss of about 5 will result An electric arc might occur when connecting this is normal due to the charging of the condensers into the converter WARNING respect the converter polarity positive from converter to battery positive and converter negative to battery negative Inverting the polarity will result into the fuse to blow and might ruin the device itself 5 3 Connecting the hydraulic pump to the batteries The hydraulic pump must be placed in an accessible position with good access to all the switches and the oil gauge The battery power supply is connected to 2 terminals Fast On 6 35mm labeled bat for the positive terminal and batt for the negative terminal Check the correct functioning of the device by putting it in manual mode and activate pum
6. onboard electricity consumption e What happens in case of impact The lifting system allows inserting a fuse that will release the device in case of impact However risk of direct impact on the device is minimal given its position on the transom aft of the keel centerboard and rudder e Can Iuse the device while run my boat main engine The system in not designed to replace the alternator of your engine It can nevertheless be used while operating your main engine though the output may be lower because of the engine propeller turbulences 10 2 At dock e What should do with the device in harbor You may either leave the device on the transom in lifted position or stow it away in your cockpit locker if you own a portable model 52 watk amp sea 11 WARRANTY Conditions and coverage Our products are designed for specific conditions of use that our customers must respect They are guaranteed against any defect of manufacturing during 2 years from the date of purchase of the dealer The guarantee is limited to the replacement of the defective components or if necessary of the whole device by simple exchange on reception of the litigious part In accordance with the common right the purchaser will have the burden to proof the anteriority of the latent defect which he calls upon The returned device or parts will have to be accompanied by the warranty return form see below dully documented with the name and address of
7. that features passive ventilation allowing long durability of the device in a humid environment However this converter must be affixed inside the boat preferably near the battery to be charged WARNING THE CONVERTER CAN REACH A HIGH TEMPERATURE WHILE OPERATING TAKE THIS INTO CONSIDERATION FOR ITS INSTALLATION NOTE To allow proper ventilation the converter must be mounted on a vertical bulkhead with ventilation grids in vertical position Once a proper place is designated follow this procedure e Drill 4 holes using the provided template Fig10 e Remove the cover 6 M6 screws e Secure the device in place with the appropriate screws e Put the cover back in place with its gasket NOTE Carefully put the gasket back in place 0060 Figure 8 Converter dimensions Figure 9 Drilling template 40 watk amp sea 4 6 Mounting the hydraulic pump The hydraulic pump is delivered in a waterproof casing that contains the electrical panel the pump and it s oil tank Two switches located on the side of the pump allow an easy manual control of the blade s position The casing must be placed vertically if possible near the c
8. the hydrogenerators and top up the oil level Verify in manual mode that the blades rotate and adjust correctly when following the preset commands 47 watk amp sea 7 CHARACTERISTICS 7 1 Technical characteristics e Hydrogenerator e Converter Nominal power 500W Nominal power 500W Voltage 3 phase 40V Regulated voltage ABS 14 3V or 28 6V Current 9A Floating voltage 13 8V or 27 6V Weight 8 5kg Current 40A or 20A Weight 3 5kg e Hydraulic Pump Dimensions 250 x 180 x 130 mm Voltage 12V or 24V 10 2 In x 7 1 In x 5 1 In Tank capacity 300mL Max Pressure 7 bars Weight 1 kg J LI ef oe 9 x o 3 O 3 Figure 19 Racing hydrogenerator dimensions 48 watk amp sea 7 2 How it works e The hydrogenerator It includes a permanent magnet alternator producing very low 3 phase current 0 40V This technology allows high efficiencies but also generates high voltage during over speed To prevent tension from surging over 40V an electronic protection cuts off the voltage above 40V This circuit is imbedded into the body of the hydrogenerator and thus protects the output e Protection against overvoltage some notes When the device works over speed it produces a specific and audible rumble This can occur for several reasons 1 A cable has been disconnected or the fuse blew and the converter is not anymore linked to the batteries The device runs freewheel and is n
9. Wwatk amp sea HYDROGENERATEUR RACING Instruction manual HYDROGENERATOR SERIAL NUMBER CONVERTER SERIAL NUMBER HYDRAULIC PUMP SERIAL NUMBER 29 30 Wwatk amp sea CONGRATULATIONS You own the most powerful hydrogenerator of its kind Designed for transoceanic racing and cruising this device will drastically change your energy management at sea and become your main source of power while sailing Conceived and built in France by WATT amp SEA llc Tamaris 3 Z A du Bout Blanc 15 rue de la Brigantine 17000 La Rochelle FRANCE www wattandsea com Wwatk amp sea TABLE OF CONTENTS SAFETY NOTICE Mechanical hazard Electrical hazard Installation Operation PACKAGE CONTENTS TOOLS amp SUPPLIES REQUIRED 4 MECHANICAL INSTALLATION 4 1 Installing the propeller blades 4 2 Placing the device on the transom 4 3 Installing the cradle on the transom 4 4 Running a line of the immersion lifting system 4 5 Mounting the electronic converter 4 6 Mounting the hydraulic pump 5 ELECTRICAL INSTALLATION 5 1 Three phases wiring of the hydrogenerator 5 2 Connecting the converter to the batteries 5 3 Connecting the hydraulic pump to the batteries 5 4 Connecting the RS485 Bus 5 5 Replacing the fuse of the converter and the hydraulic pump 6 HYDRAULIC INSTALLATION 6 1 Connecting the hydraulic circuit 6 2 Filing the oil reservoir and bleeding the circuit 7 CHARACTERISTICS 7 1 Technical c
10. ansforming the alternative voltage of the alternator in a continuous voltage compliant with batteries This voltage is reached only when batteries are full In normal functioning the in board voltage is lower than 14 3V or 28 6V 7 3 Performances As detailed in Chapter Placing the device on the transom the performance strongly depends upon the right location on the transom the quality of water flow and the speedometer calibration 500 400 300 w 200 100 0 5 6 7 8 9 10 11 12 13 14 15 16 17 Speed knots 50 watk amp sea 8 MAINTENANCE The hydrogenerator has been designed for offshore races and benefits from the latest technology for its reliability Metallic parts are made either in specially treated aluminium or in stainless steel A4 The best sealing is obtained with a hi tech ceramic carbon gasket used in industry These gaskets have a lifetime of several thousands of hours and will painlessly support a circumnavigation The body is filled with lubricating oil that is slightly pressured to prevent any water seepage In addition the alternator is factory immersed in a resin that encapsulates electrical conductors Should dampness occur the electric parts are resistant to damage Therefore this device does not need any particular maintenance other than cleaning external parts e Regularly clean the body of the device e Check regularly that the device mountings are tight e Check that all the
11. ble going through the transom 42 watk amp sea After this transom point connect a tri phase cable of a larger section minimum 3X2 5mm2 between the hydrogenerator and the converter NOTE a cable of a smaller section than 3X2 5mm2 will affect the output of the device as well as its performance We recommend connecting the cables in a designated outlet box inside the boat to allow a better prevention against corrosion You may use this kind of connector that absorbs well vibrations and features a quick release connexion WAGO 222 412 The converter is connected with Quick Disconnect Terminals Fast on of 6 35mm First open the converter box pass the tri phase cable through the gasket hole then crimp the Quick Disconnect Terminals and connect them to their terminals ae 1 1 1 Ad Ad 2 hydrogenerator 3 48V dc input SOA FUSE DATA racing models only Figure 12 Phase converter wiring plan Arrows indicates phases in NOTE The converter is equipped with connections for 2 hydrogenerators and an auxiliary 48V Input so far 8 terminals NOTE phase order for each hydrogenerator is free The user has not to take into account the colours of the cable The connection of the three phases of each hydrogenerator has to be done as defined in Figure 12 43 Wwatk amp sea 5 2 Connecting the converter to the batteries The converter must be placed as close as possible to the batteries to
12. e largest mechanical risk They are made from Stainless steel and their outer edge can rotate at up to 62 MPH 100km h At this speed the blades are nearly invisible and can cause serious injury Under no circumstances should you install the turbine where a person could come in contact with the moving rotor blades Similarly due to the ideal hydrodynamic profile of the blades the trailing edge is very thin and may be sharp WARNING THE TRAILING EDGES OF THE ROTOR BLADES ARE SHARP AND MAY CAUSE INJURY WHEN ROTATING AT SPEED WARNING WHEN PLACING THE HYDROGENERATOR MAKE SURE THAT THE PROPELLER IS NOT WITHIN EASY REACH DO NOT ATTEMPT TO STOP THE PROPELLER WITH YOUR HAND WHILE THE DEVICE IS WORKING 1 2 Electrical hazard Heat in wiring systems is often a result of too much current flowing through an undersized wire or through a bad connection Batteries conduct very high intensity A short circuit in the Battery cables may cause a fire A fuse placed into the converter prevents this issue In the event of a failure of the fuse you must first identify the cause of the failure before replacing the fuse with it s equivalent For the fuse change procedure refer to chapter 5 5 WARNING FUSES MUST BE REPLACED WITH AN EQUIVALENT TO THE ORIGINAL MODEL WARNING ALWAYS RAISE THE HYDROGENERATOR UP BEFORE WORKING ON IT 1 3 Installation Please follow our safety guidelines during installation e Keep safety in mind Get helps
13. electrical connections are tight and clean not corroded e Do not operate the hydrogenerator with damaged or unbalanced propeller blades This might cause a premature wear or a break down Replace the propeller as soon as possible 9 SPARE PARTS WS H C 001 Cruising hydrogenerator WS CV C 12 12 Volts converter WS CV R 24 24 Volts converter WS K C 001 Aluminium cradle WS H P 001 3 blades propeller WS HPU 1 2 100 12V Hydraulic Pump WS HPU 24 100 24V Hydraulic Pump 51 Wwatk amp sea 10 FREQUENTLY ASKED QUESTIONS 10 1 Operation e What power can expect The power generated increases at the cube of the speed V3 At 7 knots the output power is about 120W or about 10Amp on a 12V battery At 11 knots the system produces 4 times more power i e 480W about 40A on a 12V battery These figures are instantaneous measurements and averages might be different according to the condition at sea e What speed loss is to be expected We currently don t have any reliable data on the effective drag of the device or about the speed loss it generates Our immersion and lifting trials at constant speed have not shown any substantial difference on the speedometer e What happens when the batteries are charged The electronic regulator automatically charges the batteries When the batteries are fully charged the propeller pitch decreases which diminishes the drag From that point on the system maintains the charge and covers
14. for example LEGRIS 3104 06 OO High performance Mineral Oil type FUCHS Renolin Extra 22 S minimum volume 350 mL 35 36 Wwatk amp sea 4 MECHANICAL INSTALLATION Your hydrogenerator is shipped partly as a kit Refer to the assembly drawing below and follow the instructions Please read carefully the instruction manual before proceeding to the installation 4 1 Installing the propeller blades e Remove the propeller cone 11 then the propeller blades support 10 pay attention to the spacer spring inside the shaft e Grease the hub slots and the blades e Clip the blades into their respective slots in the hub The mounting lug must be positioned behind the piston triangle 12 e Remount the propeller blades support with a moderate torque on the 3 screws CHC M5 Then remount the cone with similar moderate torque on the CHC M5 screw The blades must rotate freely inside their slots 12 ZEN Sy us S X TAS Sy N K ER Cs X mat ANS N A 23 a 1 Ko a Figure 2 Exploded view of the prop shaft Description Propeller blades support Propeller cone Piston 15 Propeller blades 15 23 EA watk amp sea 4 2 Placing the device on the transom Choosing the right place for the device is crucial to optimize its performance Be careful to respect the following conditions e Immersion depth The recommended depth from surface to propeller axis is 30c
15. haracteristics 7 2 How it works 7 3 Performances 8 MAINTENANCE 9 SPARE PARTS 10 Frequently asked questions 10 1 Operation 10 2 At dock 11 WARRANTY 12 FORM FOR WARRANTY RETURN AUN 1 1 1 1 1 2 3 31 32 watk amp sea TABLE OF FIGURES Figure 1 Package contents Figure 2 Exploded view of the prop shaft Figure 3 Double installation on a Pogo40 Figure 4 Installation on a catamaran Figure 5 Cradle dimensions Figure 6 Immersing lifting lines path Figure 7 Device lifted in upper position Figure 8 Converter dimensions Figure 9 Drilling template Figure 10 Dimensions of hydraulic pump Figure 11 Wiring schematic Figure 12 Phase converter wiring plan Arrows indicates phases in Figure 13 Mini Fuse 10A Figure 14 Pump switches Figure 15 Type of fuses use Figure 16 Disconnecting the quick release couplings Figure 17 Hydraulic circuit blueprint Figure 18 Oil filler cap Figure 19 Racing hydrogenerator dimensions 35 36 37 37 38 39 39 40 40 41 42 43 44 45 46 46 47 48 Wwatk amp sea 1 SAFETY NOTICE Safety first was our goal in building the hydrogenerator However precautions must be taken as when using any mechanical or electrical device Keep in mind safety rules when installing and operating the hydrogenerator Be aware at all times of hazards in operating the propeller 1 1 Mechanical hazard While rotating the propeller blades present th
16. in cradle s fixations is around 300 kg 661 pounds Your mounting system should be designec accordingly The cradle must be fastened to 8mm chain plates that will be securely mounted on the transom Chain plates must be placed vertically Use the drawing below to adapt the mountings to your boat NOTE when immersed in working position the shaft must be vertical SECTION A A Figure 5 Cradle dimensions watk amp sea 4 4 Running a line of the immersion lifting system Your hydrogenerator comes with a lifting system designed after lifting rudders systems It allows easy access to the propeller when the device is in upper position which allows weed cleaning without leaning over board We recommend inserting a self release clam that will release the device when running against an immersed hard object Immersion and lifting are performed with 2 lines attached into specific eyelet Figure 6 Immersing lifting lines path Lifting weight is around 40 kg 88 pounds We recommend to placing a 4 1 pulley hoist for easier lifting of the device and a 6 1 for the lowering line on the cruising model NOTE When the hydrogenerator is immersed the leg must be blocked in the throat done for this purpose If not some mechanical deterioration could appear Figure 7 Device lifted in upper position 39 watk amp sea 4 5 Mounting the electronic converter The electronic converter is fitted into a waterproof box
17. m 12 inches The machine comes with a profiled 0 61 meter aluminium fin that can be cut to fit any configuration The deeper the device is located and the farther the propeller is from the hull wake the better it iS However the deeper the boom is the more stress on mounting will result In addition the device will be harder to lift We consider that a length of 0 61 meter is a satisfactory compromise that suits most installations on multihulls because they don t lean or on very wide mono hulls when a device is installed on each side e Flow quality A good water flow is crucial to a good output NOTE do not place the device in close proximity to the wake of a rudder or to a saildrive Whenever possible offset the device several inches off to the side of the centerline or off to the side of the rudder e Examples of installation Figure 4 Installation on a catamaran CN STRUCTURES OUTREMER YACHTING The hydrogenerators were placed parallel to The hydrogenerator is placed parallel to the the rudders but with a 30cm offset to avoid rudder but off its wake the wake 37 Wwatk amp sea 4 3 Installing the cradle on the transom Depending on your transom structure and to ease stress on the cradle plate you might need to reinforce the structure of the transom WARNING Because the lever arm is important the maximum effort
18. onverter and in an accessible location Note The casing of the pump must be placed vertically Once the location is chosen follow the procedure below e Pre drill 4 holes using the template provided 212x122mm e Open the lid by removing the 4 screws e Screw the waterproof casing into place then re place lid Figure 10 Dimensions of hydraulic pump 41 watk amp sea 5 ELECTRICAL INSTALLATION Recommendations regarding electric connections Please follow all local national safety rules before installation All electric cables must be carefully insulated For the highest safety run cables through plastic conduits WARNING CONNECTIONS MUST BE CHECKED ON A REGULAR BASIS TO DETECT ANY EVIDENCE OF CORROSION AND CLEANED WHEN NECESSARY waa Positive wire ame Negative wire 3 phases 3x2 5mm2 RS485 3x0 5mm2 battery hydraulic tube 6mm hydraulic tube Figure 11 Wiring schematic Unit conversion 2 5mm AWG 13 0 5mm AWG 20 6mm 1 8 5 1 Three phases wiring of the hydrogenerator WARNING LIFT THE GENERATOR UP BEFORE ANY OPERATION The hydrogenerator comes with a small diameter electric cable located at the bottom long enough to get through the transom This cable features a 3 phase wiring identified in black brown and grey colours A green amp yellow wire can be found for ground m We recommend the installation of a gasket diameter 6mm on the ca
19. ot slowed down anymore by the electromagnetic force 2 Batteries are charged or the battery capacity is too weak The converter has completed charging the batteries or the batteries can t absorb enough energy to slow down the propeller 3 The boat sails over the propeller speed range and the converter is stuck to its maximum capacity If the additional drag and the resulting sounds that come with it don t bother you you can keep on going e Signification of converter s LEDs The converter is equipped with 4 LEDs providing information below Twinkling BATT Presence or the Ubatt gt 11 7 9 lt Ubatt lt UBATT lt 9V battery a A er converter FLOAT FLOAT mode ABS CE Alarms system 4 Warning or low tension portly of the battery e Regulation of the wedging On the racing model pales modify their incidence according to the speed of the boat and the load of batteries In this way the protection anti surge brings in in service only in case of transients or safety and the drag is optimal whatever is the speed The regulation of pales is made by impulse when the speed of the turbine goes out of a predefined range This regulation is made in automatic mode when the switch manu auto is positioned on auto It is however possible to force this regulation by positioning the switch on the manual mode and by settling the slope of pales with the switch release pump 49 watk amp sea e The converter The converter is tr
20. p The pump must turn under the manual impulse WARNING DO NOT RUN THE PUMP DRY FOR MORE THAN 30 SECONDS Figure 13 Mini Fuse 10A Figure 14 Pump switches 44 watk amp sea 5 4 Connecting the RS485 Bus The converter and the hydraulic pump communicate through an RS485 Bus The RS485 regulates the inclination of the propeller blades when the automatic mode Is switched on The Bus contains 3 wires designated A B and GND They must be connected to terminals inside the converter housing and pump housing the terminals are also labeled A B and GND Once the Bus is correctly connected a green LED inside the pump housing will blink at 3x per second 5 5 Replacing the fuse of the converter and the hydraulic pump A maxi auto fuse grade 50Amp protects the 12V converter A mini auto fuse grade 25Amp protects the 24V converter A mini auto fuse grade 10Amp protects the hydraulic pump 12V and 24V maxi fuse E gt al Figure 15 Type of fuses use When a fuse blows you should first figure out the source of the problem and solve it before replacing it How to replace a fuse Disconnect the converter from the batteries Open the cover Replace the fuse Reconnect the batteries 45 watk amp sea 6 HYDRAULIC INSTALLATION The hydraulic pump controls the pitch of the hydrogenerator blades The pump is designed to be matched to a polyamide tubing exterior diameter of 6mm 1 4
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