MaxPower CT165 Manual del propietario

www.max-power.com

CT165 / CT225

With electronic thruster control

INSTALLATION OPERATION MAINTENANCE

Serial No.: ------------------------------------------------------

Installation date: -------------------------------------------------

THIS MANUAL MUST BE KEPT ONBOARD AT ALL TIMES

Manual CT165 & CT225

Last update: December 2013

Via Philips 5, 20900 Monza (MI), Italy

Tel. +39 039 200 1973-936 - Fax +39 039 2004299

www.max-power.com E-mail:[email protected]

www.max-power.com 1

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 power 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 consulted, 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).

Manual CT165 & CT225

Last update: December 2013

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1. GENERAL INSTALLATION GUIDELINES

In order to install the thruster in the most efficient position, follow the instructions below:

• The minimum acceptable tunnel position is 188mm below the waterline

• The tunnel is ideally positioned when the distance between the waterline

and the top of the installed tunnel is 250mm

• 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.

Whether 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 installed 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.

The drive leg must be centered in the tunnel and under no circumstances should the

propellers protrude out of the tunnel.

Manual CT165 & CT225

Last update: December 2013

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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 –10mm ∅on either side.

Using a metal rod, construct a compass with a 132mm radius. Insert through the holes

and trace the ellipses, as shown below.

After cutting the holes out following 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. It 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 areas,

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 with a waterproof under coat, followed by

sanding and application of a waterproof finish coat.

In order to optimise the flow of water whilst sailing, and to avoid turbulence due to the

tunnel, leave 1 to 4 cm of Finish these with several coats of reinforced filler in order to

obtain the required hydrodynamic lines.

Once all laminating work is complete, apply a watertight barrier.

Manual CT165 & CT225

Last update: December 2013

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DO NOT LAMINATE THE AREA OF THE TUNNEL TO WHICH THE ELECTRICAL MOTOR

SUPPORT WILL BE FIXED.

3. COMPOSITE MOTOR SUPPORT AND DRIVE LEG

The motor support and the drive leg must be centered in the tunnel.

Locate and mark the intended position of the holes for the fixing screws and the leg hub.

You can use the motor support and the leg’s gasket to mark these holes.

In some cases it will 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.

Apply a thin coating of silicon grease or sealing compound to both sides of the gasket

(this must be resistant to hydrocarbons and water). Re-assemble all parts as before,

positioning and then tightening the two 10mm ∅screws alternatively, using a 6mm Allen

key, (maximum torque: 35 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:

• is pre-filled with oil and sealed for life

• does not require anodes

• must not be disasembled, even partially (exclusion waranty)

Manual CT165 & CT225

Last update: December 2013

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4. ELECTRIC MOTOR (12 / 24 volts)

The upper coupling (motor side) is adjusted in the factory. Position the lower coupling on

the drive leg shaft and push it down as far as it will go (lightly grease the shaft

beforehand).

Place the flexible red coupler on the drive leg side coupling, (part n° 8 on the CT165 /

CT225 – Spare Parts diagram, page 13)

Now fit the electric motor onto the motor support and tighten the four 10mm Ø motor

support screws alternatively (maximum torque: 40Nm).

Push the lower coupling up into place using a screwdriver et tighten the two 4 x 10mm

Allen screws (maximum torque: 10Nm).

The upper and lower couplings must be adjusted to leave 2mm of play (+/- 1mm)

between both of them.

Check that the propellers turn without resistance (a little resistance due to the motor is

normal).

Ensure that air can flow freely to allow the motor to cool whilst in operation.

Please note that the motor side coupling is already in position and does not need

adjusting.

5. PROPELLERS

Insert the drive pin and propellers.

Check that the propellers turn without resistance (a little resistance due to the motor is

normal).

Position the propeller blades so as they are not in horizontal alignment and not

directly opposite each other.

Tighten the 22mm nut (maximum torque: 25Nm).

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 GRIDS

It is possible to install protection grids, however, their installation may 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, capacity and condition of your

batteries, aswell as cable sections used.

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.

Last update: December 2013

Manual CT165 & CT225

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It is essential to install a manual battery isolator and if possible an electric

battery isolator at the base of the thruster motor power line.

When using a manual battery isolator it must be visible, clearly marked & easily

accessible.

Thruster motor power supply (24V):

These values are given as an indication, assuming that the batteries are charged at

100% and in charge, that is 25.4V.

The performance data is measured with an approx. consumption of 560A and 22V for the

CT165, and 690A and 22V for the CT225, at the motor’s connections.

Please refer to the characteristics given by the manufacturer of the batteries that will be

used (see section 9 “Batteries”).

Power wiring:

Measure the shortest and most direct route possible between the battery(ies) and the

electric motor; remembering to allow for both “positive and negative” cables.

Recommended cable sections:

Cable lengths CT165 CT225

L ≤5 m (2,5 x 2) 70mm² 70mm²

5< L ≤10 m (5 x 2) 70mm² 95mm²

10 < L ≤15 m (7,5 x 2) 120mm² 150mm²

15< L ≤20 m (10 x 2) 150mm² 200mm²

For all connections, use appropriate terminals for the cable sections chosen.

It 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

8. MAIN POWER FUSE

Fuse sizes for overcurrent protection are to be determined on the basis of the cable

sections in the circuit and NOT the amperage drawn by the appliance (thruster motor) in

the circuit.

Thruster Maximum Amperage Max Power Fuse size

CT165 / 12V 560A 250A

CT225 / 24V 690A 200A

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.

Manual CT165 & CT225

Last update: December 2013

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10. ELECTRONIC CONTROL BOX

Install a fused circuit breaker / switch in the boat's main DC distribution panel marked

BOW THRUSTER.

This circuit breaker / switch should ideally be supplied from a different battery bank to the

one used for powering 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 & 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, and 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. .

If 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.

11. CONTROL PANEL AND THRUSTER CONTROL BOX FUNCTIONS

To switch the thruster ON or OFF follow the instructions given in the diagrams on the

following page.

When switched ON the control panel will 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 will go out.

The thruster controller provides a time delay between left and right thrust in order to avoid

rapid direction changes. There is no delay when 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 down. It will then not be possible to switch 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

switch 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 switches itself off.

In order to isolate the thruster motor power circuit, as described in the previous two

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

Manual CT165 & CT225

Last update: December 2013

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12. CONTROL PANEL INSTALLATION

Control panels should be protected from the natural elements while the 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.

Only when totally finished and satisfied with the wiring 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.

However 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.

Manual CT165 & CT225

Last update: December 2013

www.max-power.com 9

13. TESTS

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.

14. ELECTRICAL MEASUREMENTS

In 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 following 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 motor’s negative and positive connections

should be approx. 22V for a 24V system.

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?

15. 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 there may be people

swimming or floating debris.

Maximum running time: 2-3 min (depending on ambient temperature).

Manual CT165 & CT225

Last update: December 2013

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