Survey
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
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