Download DC Proportional Thrusters

DC Proportional
Thrusters
6 to 23 HP
24 or 48 VDC
and Hydraulic
24 VDC @ 6 HP
or
48 VDC @ 13 HP
48 VDC @ 23 HP
Motor Installation Manual
WESMAR 24 & 48 VDC
Proportional Thruster
Installation Manual
June 2014
Western Marine Electronics
14120 NE 200th Street, Box 7201
Woodinville, WA 98072-4001 USA
T: (425) 481-2296 / F: (425) 486-0909
Email: [email protected]
Web: www.wesmar.com
DC Pro
Table of Contents
Introduction........................................................................................................................
Coupling Arrangement: Motor Couplings
........................................................................
DC Pro V2-8 M Thruster
........................................................................
Control Stations ........................................................................................................................
Joystick Control Stations
................................................................................................
Operation and Maintenance
................................................................................................
DC PRO Control Station Start Up
....................................................................................
DC Pro Driver Card Troubleshooting ....................................................................................
Specifications and Wiring Diagrams ....................................................................................
System Troubleshooting Notes ................................................................................................
Page 4
June 2014
5
7
8
9
10
12
13
16
20
37
WESMAR
Installation
DC PRO Thruster
Introduction
Powerful, Quiet Strength
Continuous Operation
Fully Proportional Thrust
Remote Station
No Solenoids
Extended use DC thruster
The first of its kind--offers continuous operation with a DC
electric thruster for those not wanting to install a more expensive hydraulic system.
Variable speed motor
The variable speed motor allows the operator to apply the
appropriate amount of thrust depending on wind or current.
Gives the operator full control over how much power they
want to use.
Remote control
A new full function optional remote control station operates
both bow and stern thruster and makes technical docking
maneuvers a snap.
Fully Proportional DC Control
•
•
•
•
•
•
•
•
WESMAR
Extended Duty Operation
No DC electric motor duty cycles
No thermal over-heat switch required
No directional solenoid switches
Standard built-in motor brake between direction
changes
Remote Control
•
•
•
•
Optional remote control - 50 ft of interconnect
Operates both bow and stern thrusters
Multiple station sights for easy remote plug in
Ergonomic remote control design
•
•
•
•
Operates with just one on/off magnetic switch
No directional miss fires
Eliminates a complete wiring circuit
No contacts or washers to arc out
Less Wiring
Easy installation
No solenoids and easy mounting arrangement for simple
installation. No hoses, fittings and pumps to install, because
it’s electric. The system is completely adaptable for upgrading
all existing thruster systems.
0-100% thrust port or starboard
User adjustable at any time
Operation LEDs
Power on/off switch
June 2014
Page 5
DC Pro
DC PRO Thruster
This manual has been created as an aid to understanding
WESMAR bow thrusters, and to provide some helpful tips. Use it only as a guide. Installations should be
performed by a professional boat yard or a competent
marine service yard.
One feature that distinguishes our bow thrusters
from the competition is that all WESMAR drive legs are
stainless steel, and a sacrificial zinc nut is installed on the
propeller shaft to reduce electrolytic corrosion (Fig. 1).
When you receive your WESMAR DC Pro bow thruster, you should find the following equipment:
• DC Pro electric motor assembly with driver card (Fig
2, 3)
• Pre-installed coupling and motor
• 1 interconnect PCB J-box assembly
• 50' motor to J-box cable assembly
• Owner's manual
Figure 1: V2-12 Thruster 12 inch counter rotating dual
props.
Optional equipment includes:
• Control stations with 50 ft of interconnect cable
• Remote control
Figure 2: 13 HP, 48V Motor
Figure 3: 23 HP 48 V
Page 6
June 2014
WESMAR
Installation
Coupling Arrangement:
Motor Coupling
Set screws (2 locations per
half )- use LocTite to prevent coupling movement on
shifts.
Thruster input
shaft coupling
Reuland RC3 0875-187
Input & Output
Hytrel insert
Set screw (2 locations per half )
Motor output
shaft coupling
Note: V6 & V8 series
custom manufactured at
WESMAR
Figure 4: Motor Coupling
WESMAR
June 2014
Page 7
DC Pro
DC Pro Thruster
V2-8 48 VDC 13HP
V2-8 24VDC 6HP
Pre-wired motor
4/0 cable
Motor adapter
Directional cables
Coupling
Reuland RC3-0875-187
with RC3 insert
Oil fill & Breather
ports 1/4NPT
S.S. 4 blade
Kaplan props
5/8 size B
zinc nut assembly
Shaft key & pin
Oil drain plug
Figure 6: Saddle and Gasket
Page 8
June 2014
WESMAR
Installation
Control Stations*
Joystick
Control
to port or
starboard
Throttle
Control
LED
Station on
LED
Mounting plate
Joystick
Control
to port or
starboard
Throttle
Control
LED
Mounting plate
On/Off
Station on
LED
On/Off
Joystick
Control
to port or
starboard
Throttle
Control
LED
Mounting plate
Joystick
Control
to port or
starboard
Mounting plate
Figure 7: Dual Control Station
Throttle
Control
LED
Figure 8: Single Control Station
Interconnect Control Station Panel
Allows connections of up to
5 Bow and 5 Stern thruster
stations (including the
master).
Each remote control comes
with 50' of Interconnect
Cable.
Figure 9: Interconnect Control Station Panel
* Controls are splash proof. Caution should be taken to prevent water intrusion.
WESMAR
June 2014
Page 9
DC Pro
Joystick Control Stations
3.125
2.375
1.98
1.55
WESMAR
TM
THRUSTER
1.325
2.375
OFF
3.125
ON
1.28
2.36
Figure 10: Single Control Joystick
Page 10
June 2014
WESMAR
Installation
3.125
2.375
WESMAR
TM
THRUSTER
1.98
BOW
4.375
1.55
5.125
STERN
1.18
2.36
OFF
ON
1.325
Figure 11: Dual Control Joystick
WESMAR
June 2014
Page 11
Electric Thruster
Operation and
Maintenance
WESMAR bow thrusters are hard working, powerful
units. DC Pro units are continuous duty operation
systems. They do not require an over-heat switch, or
a directional overheat switch. Also, the motor comes
equipped standard with a built-in motor brake to prevent motor damage between direction changes. Also,
the motor is fully proportional, deliverying 0-100%
thrust port and starboard giving complete control of
these bow thrusters.
Maintenance
The WESMAR bow thrusters are low-maintenance
systems that require only occasional routine servicing.
When looking over your thruster, check the following:
• Examine the oil level in the bottom gear pod. If low,
fill with SAE 90W gear oil.
• Check the zinc bolt and nut on the end of the propeller shaft for electrolytic corrosion.
• Examine breakers and/or fusing system.
Motor Output
Input Shaft
Insert
Figure 12: Motor Couplings
• Keep battery supply fully charged.
• Oil reservoir: fill 3/4 full with 90 wt gear oil.
Couplings
DC Pro units use custom couplers with Lovejoy L-75
inserts or Reuland RC-3 couplers. Before ordering
couplings, recheck shaft diameters and measure key
ways. Make sure that the set screws are tight onto the
shafts - use LocTite to help secure the set screw into the
couplings for input and output shafts.
Page 12
WESMAR
Installation
DC PRO Control Station Start Up
(Please Read prior to wiring control Station)
WARNING: Complete all connections before connecting to battery. Disconnect
before adding additional stations.
Start Up: (All Stations connected to interconnect box, interconnect cable
wired to interconnect box and connected to motor controller and electrical
connections made. Battery switch Off.)
1) Recheck that all wiring is secure and in the proper location.
2) Check that all joysticks are clear of debris and in the free center position. The primary joystick rocker switch should be off.
3) Have the cover of the interconnect box off at this time.
4) Turn on the main battery switch
5) Turn on the rocker switch on the primary joystick. Red LED should be on. If green LEDs are flashing at this time it is okay.
6) If the green LED is flashing on the motor controller, check the flash code fault description and re-check all connections. If it is a steady green LED, proceed to the next step.
7) Using a multi-meter, check for the electrical centering to 2.5v of each joystick, using test points as shown in the Figure on Page xx. If red LEDs in the bos are cascading, check for centering values again.
8) When centering is complete, go to each joystick and check for proper operation. Green LEDs should only come on when there is a thruster command.
At Master Helm Control
6) Red 'power light' should now be on at master control station.
Note: If blinking green LED light on the motor controller (Driver Card) is noticed at this time, and unit is
not running as described, go back to start and redo all steps. Make sure Battery connections are removed
first and all steps are followed.
WESMAR
June 2014
Page 13
DC Pro
Page 14
June 2014
WESMAR
Installation
& DUAL SEC
64.1662.5
WESMAR
June 2014
Page 15
DC Pro
DC PRO Thruster
Driver Card
Troubleshooting
Page 16
June 2014
WESMAR
Installation
6HP 24V and 13HP 48V DC Pro Models
Fault Finding
The MillipaK controller includes a number of features designed to help the user track down operational faults,
wiring faults or internal controller faults. The Diagnostic LED mounted next to the calibrator connectors on the
front of the controller serves as a simple diagnostic tool with the codes shown in table 1. In addition to the LED
indication a more detailed description of any faults detected may be found by using the calibrator with the codes
shown in table 2.
ON
Off
1 flash
2 flashes
3 flashes
4 flashes
5 flashes
6 flashes
7 flashes
8 flashes
10 flashes
No fault, normal condition
Internal controller fault
Programming error
Illegal start condition - controls must be in “off” position
SEVCON short circuit
Contactor fault or motor open circuit
Not used
Control station not connected
Low or high battery voltage or BDI cutout operating
Over temperature or timed cutback
Power up autozero has not yet been completed
Table 1: Flash Fault Descriptions
ID
0
1
Fault
System OK
Thermal Cutback
2
Timed Current Limit
Cutback
3
Control Wire Off
4
Control on at Power Up
Description
On
Maximum power available to the
motor has been reduced due to excessive Heatsink temperature
Maximum power available to the
motor has been reduced by the
timed current limit cutback function
Input wire from control has been
disconnected
Control potentiometer not at zero at
power up
Flash
8
8
6
6
Table 2: Flash Fault Descriptions
WESMAR
June 2014
Page 17
DC Pro
V2-12 23HP DC Pro Model
The MillipaK controller includes a number of features designed to help the user track down operational faults,
wiring faults or internal controller faults. The Diagnostic LED mounted next to the calibrator connectors on the
front of the controller serves as a simple diagnostic tool with the codes shown in table 1. In addition to the LED
indication a more detailed description of any faults detected may be found by using the calibrator with the codes
shown in table 2.
ON
OFF
1 flash
2 flashes
3 flashes
4 flashes
5 flashes
6 flashes
7 flashes
8 flashes
No fault, normal condition
Internal, controller fault
Programming error
Illegal start condition - control must be in “off” position
SEVCON short circuit
Contactor fault or motor open circuit
Not used
Control station not connected
Low or high battery voltage
Over temperature or timed butback
Table 3: Flash Fault Descriptions
ID Fault
0
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
System Okay
Thermal Cutback
Maximum power available to the motor has been reduced due to excessive heatsink temperature
Time Current Limit Cutback
Maximum power available to the motor has been reduced by the Timed Current Limit Cutback Function
Control Wire Off
Input wire from control has been disconnected
Control On at Power Up
Thruster control not at neutral at power up
Two Direction Fault
Two directions selected together
Sequence Fault
Direction or FS1 switch closed at power up
Low Battery Fault
Battery voltage is too low
High Battery Fault
Battery voltage is too high
High Battery Faults with Line Con- Battery voltage is too high before the line contactor is
tactor Open
closed
Configuration Range Fault
A personality is out of range
Configuration CRC Fault
The personality CRC is incorrect
Line Contactor Welded Fault
Line contactor is welded
Line Contactor did not Close Fault Line contactor is open circuit
Page 18
June 2014
Flash Fault
On
8
8
6
6
2
2
7
7
7
1
1
4
4
WESMAR
Installation
V2-12 23HP 48VDC DC Pro Thruster only
ID
Fault
Description
14
Bypass contactor is welded at end of bypass
15
16
17
Bypass Contactor Welded Fault
MOSFET Short Circuit
VA Detect Fail
MOSFET Off
18
MOSFET On
19
20
MOSFET Short Circuit
during power Up
Drive 2 Off
21
Drive 2 On
22
Drive 1 Off
23
Drive 1 On
Short circuit Armature MOSFETs detected
12V Supply Failure
MOSFETs did not pulse during power on
failsafe checks (failsafe circuit enabled)
MOSFETs pulsed during power in failsafe
checks (failsafe circuit disabled)
Short circuit armature MOSFETs detected
during failsafe checks
Contactor 2 did not pulse during power on
failsafe checks (failsafe circuit enabled)
Contactor 1 did not pulse during power on
failsafe checks (failsafe circuit disabled)
Contactor 1 did not pulse during power on
failsafe checks (failsafe circuit enabled)
Contactor 1 pulsed during power on failsafe
checks (failsafe circuit disabled)
Flash
Fault
4
3
0
0
0
3
0
0
0
0
Table 4: Fault Numbers and Descriptions
Fault clearance: Any fault indication will be cleared by re-initiating the start sequence aft erht cause of the fault
has been removed.
WESMAR
June 2014
Page 19
DC Pro
DC PRO Thruster
Specifications and Wiring Diagrams
(Including DC Pro Hydraulics)
Page 20
June 2014
WESMAR
Installation
WESMAR
June 2014
Page 21
DC Pro
Page 22
June 2014
WESMAR
Installation
WESMAR
June 2014
Page 23
DC Pro
78.11862.0
Figure 13: Proportional DC Motor Wiring Harness
Page 24
June 2014
WESMAR
78.10920.0
Installation
Figure 14: Main Panel Connection Cable
WESMAR
June 2014
Page 25
DC Pro
ELECTRIC AND HYDRAULIC
CONNECTION CABLE SINGLE & DUAL SEC STATION
Figure 15: Thruster Drive Cable
WESMAR
June 2014
Page 26
Installation
WESMAR
June 2014
Page 27
DC Pro
64.10661.5
Figure 16: Main Panel Single Joystick
Page 28
June 2014
WESMAR
64.10663.5
Installation
Figure 17: Main Panel Dual Joystick
WESMAR
June 2014
Page 29
DC Pro
Figure 19: Electric Interconnect Station
Page 30
June 2014
WESMAR
Installation
Figure 20: Electric Interconnect Joystick Connection
WESMAR
June 2014
Page 31
DC Pro
Figure 21: DC Pro Interconnect Joystick Station
Page 32
June 2014
WESMAR
Installation
WESMAR
June 2014
Page 33
DC Pro
Page 34
June 2014
WESMAR
Installation
WESMAR
June 2014
Page 35
DC Pro
Page 36
June 2014
WESMAR
Installation
System Troubleshooting Notes
WESMAR
June 2014
Page 37
DC Pro
System Troubleshooting Notes
Page 38
June 2014
WESMAR