Engbo XForce XF 60 Stern Manuale utente

XF Rev: 2, 2008-02-21 Page 1

Installation and user manual

XForce stern-thruster series

XF 60 Stern

XF 90 Stern

XF 130 Stern

NS-EN ISO 9001:2000 FCC ID: R78-RC-01

R78-ECU-01

Art. nr. 117-00145

XF Rev: 2, 2008-02-21 Page 2

Contents

1. INTRODUCTION ..............................................................................................................3

2. OPERATION.....................................................................................................................4

2.1. XForce intelligent protection control................................................................................................................4

2.2. How to operate the thruster.............................................................................................................................4

2.2.1. Operating panel versions..........................................................................................................................................4

2.3. Operating instructions. ....................................................................................................................................5

2.3.1. Directions for use......................................................................................................................................................5

2.4. Upgrade to wireless remote control. ...............................................................................................................6

2.4.1. Antenna installation..................................................................................................................................................6

2.4.2. Battery replacement .................................................................................................................................................7

3. TECHNICAL SPECIFICATIONS WIRELESS REMOTE CONTROL................................7

4. DIMENSIONS ...................................................................................................................8

4.1. XF Stern thruster dimensions..........................................................................................................................8

4.2. Control Unit dimensions..................................................................................................................................8

5. INSTALLATION................................................................................................................9

5.1. Avoid water damage........................................................................................................................................9

5.1.1. Compartment area....................................................................................................................................................9

5.1.2. Determine the location for the stern thruster...........................................................................................................10

6. MECHANICAL INSTALLATION.....................................................................................10

6.1. Exploded view XForce 90 Stern....................................................................................................................10

6.2. Propeller installation......................................................................................................................................12

7. ELECTRICAL CONNECTIONS......................................................................................13

7.1. Installation- touch panel ................................................................................................................................13

7.2. Installation- joystick.......................................................................................................................................13

7.3. Connecting the control cable.........................................................................................................................14

7.4. ontradicting direction.....................................................................................................................................14

7.5. Control box connections................................................................................................................................15

7.6. Connecting to the bow thruster.....................................................................................................................15

7.6.1. Motor terminal connections.....................................................................................................................................16

7.6.2. Connecting the cables to the battery......................................................................................................................16

7.7. Fuse connections..........................................................................................................................................17

7.8. Recommended main switch..........................................................................................................................17

7.8.1. Main switch terminal...............................................................................................................................................17

7.9. XForce Thruster Cable, fuse and battery requirements................................................................................17

7.10. Wiring diagrams.........................................................................................................................................18

7.10.1. XForce stern 60/90/130..........................................................................................................................................18

7.10.2. Wiring diagram single and double joystick..............................................................................................................19

8. MAINTENANCE .............................................................................................................20

8.1. Mechanical check..........................................................................................................................................20

8.2. Corrosion check ............................................................................................................................................20

8.3. Battery/charger check ...................................................................................................................................20

8.4. High current cable/connections check ..........................................................................................................20

8.5. Joystick/operator panel check.......................................................................................................................20

9. TROUBLESHOOTING....................................................................................................21

9.1. The thruster does not work............................................................................................................................21

9.2. The thruster does not work or has an unexpectedly low performance.........................................................21

9.3. The thruster runs in the wrong direction........................................................................................................21

9.4. The thruster just works in one direction ........................................................................................................21

9.5. The thruster runs in contradicting direction...................................................................................................21

9.6. The thruster runs for short intervals or a clicking sound is to be heard from the thruster.............................22

9.7. The thruster stops working after a long period of use...................................................................................22

10. INSTALLATION OF EQUIPMENT WITH HIGH CURRENTS.........................................22

10.1. Special considerations...............................................................................................................................22

XF Rev: 2, 2008-02-21 Page 3

10.1.1. Preface/introduction................................................................................................................................................22

10.2. Battery .......................................................................................................................................................23

10.2.1. Battery-cables/lugs.................................................................................................................................................23

10.2.2. Battery connection..................................................................................................................................................23

10.2.3. Fuse connection.....................................................................................................................................................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 control units on 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 Tønsberg

Norway

E-mail: [email protected]

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. Compliance with regulations must be ensured by

the installer.

Faulty installation or connection of any components will render any warranty given by Engbo

AS void.

IMPORTANT:

When installed in boats approved or classified according to international or special national

rules, the installer is responsible for following the demands in accordance with these

regulations / classification rules. The instructions in this manual cannot be guaranteed to

comply with all different regulations / classification rules. The remote control is approved for

use in EU/EFTA countries (CE) or US/Canada (FCC). For other countries, please contact your

local authorities.

XF Rev: 2, 2008-02-21 Page 4

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:

•Do not operate the thruster(s) without the belt cover installed.

•Make sure no one is within reach of the rotating propeller(s)

•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 7.4).

2.1.XForce intelligent protection control

Intelligent electronic protection control

•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 light power light on the wireless control.

•Electronic protection system prevents the thruster from continue to run in case of solenoid lock-

in. (Solenoid versions.)

Max continuous running time: 4 intervals of 30 sec – S2 = 2 min.

•Automatic intelligent monitoring measures run and pause time to protect the motor and control

unit against overheating.

•Of security reasons, the system permits continuous running of the thruster in 4 intervals of 30

sec. After each interval, the thruster will stop. Switching off / on the joystick or switch panel will

make the thruster run again. If repeated 4 times, (total 2 minutes running), the thruster will need

to cool down for 25 minutes before being ready to run again. This to protect the motor and

control unit against overheating.

NB: In an emergency situation, to save the ship at the possible expense of the thruster, this

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 propeller is

obstructed from rotation.

2.2.How to operate the thruster

•Move the joystick / press the touch panel to right and the thruster

will be activated to starboard.

•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 panels available.

Touch panel (Part no.12-79001)

•Easy to install.

•Designed similar to Engbo winch panel.

XF Rev: 2, 2008-02-21 Page 5

Single Joystick (Part no.12-79002)

•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)

•Floating, splash-proof, hand-held 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 back.

•Hand/neck cord is included as standard (easily removed).

•The battery lifetime is more than 2 seasons based on normal leisure

use.

IMPORTANT! Always install at least one fixed XF Thruster panel.

2.3.Operating instructions.

The remote control is battery-operated. To ensure longer life, it will automatically

go into sleep mode five minutes after the last button was pushed. Deactivation is

signalled with two short sound bursts and a blinking “POWER” indicator. The

remote control is activated by holding down any button for 1.5 seconds. When

the remote control has been activated, the selected thruster can immediately be

operated by pressing the “arrow” button in the desired direction. The thruster will

be running as long as the button is depressed. (Max 4x30 sec.)

2.3.1.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.

XF Rev: 2, 2008-02-21 Page 6

Orange light

Low voltage at the electronic unit is indicated by an orange light in the “POWER”

indicator.

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 messages are shown when buttons are pushed.

2.4.Upgrade to wireless remote control.

XForce Thrusters can be delivered with 3 different versions electronic control units (MCU).

1. Relay box (power contactor)

2. Relay box (power contactor) with integrated radio receiver.

3. Transistor-controlled power electronics with integrated radio receiver that replace the conventional

power contactor. (Available from summer 2008.)

The new electronic unit contains no open contacts and is very flexible as regards voltage. The control

electronics are software based and feature an integrated radio receiver that communicates with the wireless

remote control and built in system to protect the thruster motor and electronic components.

IMPORTANT! Turn off the thruster main switch when not in use. The radio

receiver current consumption will be approx 3.5 W as long as it is turned on.

2.4.1. Antenna installation

If wireless remote control option is to be implemented after choosing

version 2 or 3:

•If not already installed, the MCU must be fitted with an antenna.

•The remote control and electronic unit must also be coded/taught

electronically to communicate with each other.

•Remove the left rubber cover. Then push the antenna through the cover

(on one side).

•While holding down the antenna connector handle, push the antenna all

the way down into the bottom of the clamp. Release the handle and the

antenna is fixed in place.

XF Rev: 2, 2008-02-21 Page 7

Replace the rubber cover.

•Start by pushing the rubber cover in by the antenna and continue around

the edge until the cover is fixed in place.

•Make sure not to twist the cover with the antenna.

(The remote control will function over short distances even without the antenna.)

2.4.2.Battery replacement

The remote control uses three regular AAA/LR03 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 point the same way with the +

up and the – downwards towards the edge as illustrated.

•Reassemble the back cover and carefully screw the parts together until

the housing gasket is slightly compressed. The remote will remain

waterproof 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. The screws may penetrate the housing

if screwed carelessly or too much force is used.

(Not covered by the warranty.)

3. Technical specifications wireless remote control

Wireless remote:

Motor Control Unit:

Model: RC-01 ECU-01

Power supply: 3 x 1.5 V DC

(3 x AAA/LR03 batteries) From thruster (integrated)

Battery life: 2–3 years (normal leisure use) Not applicable

Communication: Two-way, narrowband, GFSK modulation

Operating frequency: 868.075 – 869.125 MHz, CE (EU/EFTA)*

902.175 – 903.025 MHz, FCC (US/Canada)*

Channels: 16 for communication

Channel separation: 50 kHz

Address range: 65.535 (16 bit), spread among the 16 channels

Temperature range: -20 to +60 degrees Celsius/-4 to +131 degrees Fahrenheit

Relative humidity

(without condensation): 20% – 90%

Weight: 105 g Model dependent

Dimensions (HxWxD): 127x53x22 mm Model dependent

Environment protection:

(Floating)** IP 68** 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

XF Rev: 2, 2008-02-21 Page 8

4. Dimensions

4.1.XF Stern thruster dimensions

XForce

Thruster

XF 60 Stern 310 235 185 Max. 45 270 125 175

XF 90 Stern 310 235 185 Max. 45 330 172 222

XF 130 Stern 400 297 250 Max. 82 305 172 222

4.2.Control Unit dimensions

XForce thruster

XF 60 Stern / Relay box

150

XF 60 Stern / Transistor-controlled

power electronics with integrated

radio receiver

215

131

XF 90 Stern/ Relay box

150

XF 90 Stern / Transistor-controlled

power electronics with integrated

radio receiver

215

131

XF 130 Stern / Relay box

195

111

XF130 Stern/ Transistor-controlled

power electronics with integrated

radio receiver

215

131

XF Rev: 2, 2008-02-21 Page 9

5. Installation

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:

•Seal all drain holes in the thruster installation compartment.

•Drain the surrounding compartments and hatches to the bilge aea in front of the thruster’s installation

compartment.

•If the 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.

•Ensure that the thruster’s installation compartment will not be dripped on if a cockpit, deck or hatch drain

fails to operate properly.

•All possible precautions should be taken to ensure that water leaks into the hull will be routed away from

the stern thruster compartment.

•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.

•The electrical connections for the thrusters must be installed so that all junctions and connectors are

kept dry at all times.

5.1.1.Compartment area

•Thruster compartment

area must be kept dry all

time.

•Fabric glass fibre

reinforced polyester

tunnel.

•Motor support

XF Rev: 2, 2008-02-21 Page 10

5.1.2.Determine the location for the stern thruster

Recommended minimum distance from centre

of tunnel to water line:

Model A

XF 60 Stern 240

XF 90 Stern 240

XF 130 Stern 300

Determine the location for the stern thrusters; see installation

drawing and dimensional drawing.

Before you make any cut-outs in the transom, please consider

the following.

•Make 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.

•The propeller tunnel may be positioned off centre on

the transom if required by space restrictions.

•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 tunnel.

•Make sure that it is possible to install a motor support

(5.1.1.). Such a device is necessary to reduce stress

on the thruster components and tunnel/ transom.

6. Mechanical installation

6.1.Exploded view XForce 90 Stern

(Details differ from XForce 60 and XForce 130)

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. Cut the 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.

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