Hydraulic Thruster Installation Guide Hydraulic Thruster Installation Guide -
Change Log Date Change 03/11/2014 Initial converted release ABT-TRAC 517-A Martin Avenue Rohnert Park, CA 94928 Tel: 707-586-3155 Fax: 707-586-3159 http://www.thrusters.com Hydraulic Thruster Installation Guide -
! IMPORTANT Confirm that all jog levers are in the center (OFF) position before pressing the green start button and activating any jog lever station. Failure to make this check prior to pressing Start or making all stations active, may result in unwanted thruster operation and harm to the vessel or its occupants. 1 Hydraulic Thruster Installation Guide
Important Notices The thruster tunnel is an integral part of the hull. Installation should be done only by professionals with certified competency in the fabrication and repair of the hull material in question. Your naval architect must confirm and certify proper mechanical bonding of the tunnel to the hull as well as proper support of the tunnel. Recommendations made by American Bow Thruster (ABT-TRAC) are to be used as guidelines only. ABT-TRAC is not a naval architecture firm and is not qualified to advise on structural matters. ABT-TRAC strongly recommends that you seek the advice of a naval architect familiar with your vessel. Precautions and Warnings Before installation, read and understand the information in this manual. The Hydraulic Thruster Installation Guide is intended for experienced marine engineering personnel. Proper general engineering standards and practices must be followed at all times. System Hydraulic Fluid Use only ISO 32 and ISO 46 hydraulic fluids in ABT-TRAC hydraulic systems. Using any other fluid voids the Arcturus Marine Systems warranty. Corrosion Control All seagoing vessels must be protected from corrosion from galvanic and electrolytic potential. ABT-TRAC encourages all boat owners to enlist the services of a corrosion control expert to evaluate their vessel s corrosion control system and how their thrusters should be made a part of that system. ABT-TRAC thrusters are particularly resistant to all types of corrosion, especially bronze models. Serious corrosion problems, however, can take their toll on all types of equipment, especially on aluminum boats. Whatever system you use, you must take the thruster system into consideration and include it in your corrosion control system. Paint and Coatings On Hydraulic Systems Reservoirs, heat-exchangers, and bell housings are painted with Dupont 25P epoxy primer and IMRON 333 white polyurethane. These are the only components painted on a regular basis. The same coatings are used when requests are made that other components in the system be painted. On Thrusters, Propellers, and Tunnels Use bottom paint on thrusters and tunnels; use any available advanced propeller coating on propellers. Standard Warranty This warranty is offered by Arcturus Marine Systems, dba American Bow Thruster or ABT-TRAC. ABT-TRAC warrants all new products and systems to be free from defects in material and workmanship for a period of ONE YEAR from the date of system commissioning. Defective parts will be repaired or replaced at ABT-TRAC s option. Customer is responsible for freight costs associated with returning parts to ABT-TRAC. ABT-TRAC will pay freight costs, including air freight, for the shipment of repaired or replacement parts back to customer (local laws may apply). Hydraulic Thruster Installation Guide 2
This warranty does NOT cover failure of parts due to mis-installation, damage, accidents, improper storage, or misuse. Labor for parts removal and reinstallation is NOT covered. Arcturus Marine Systems (ABT-TRAC) shall NOT be liable for special, incidental, or consequential damages of any kind including but not limited to vessel haulout costs or lost revenue. The warranties described above shall be the sole and exclusive warranties granted by ABT-TRAC and shall be the sole and exclusive remedy available to the purchaser. 3 Hydraulic Thruster Installation Guide
Tunnel Position Figure 1. Proper Tunnel Position Installing the Tunnel Waterline At least one diameter below waterline and one diameter above the keel Position the tunnel as far forward as possible while maintaining adequate tunnel length. Ideally, the tunnel should be three diameters long, and at minimum, it must be long enough so that no part of the thruster protrudes beyond the tunnel opening. Marking the Tunnel Cutout 1. Carefully measure and mark the center point of the tunnel on both sides of the hull interior; make sure the location is square in all directions. 2. Drill a 3/16 (4.7625 mm) diameter hole at each center point. As far forward as possible 3. Bend a 1/8 (3.175 mm) steel rod into a scribing tool with a diameter equal to the tunnel s outside diameter radius. Figure 2. Scribing the Tunnel Opening Tunnel outside diameter radius 4. Pass the scribing tool through the holes in the hull and scribe the tunnel openings on both sides of the hull. 5. Carefully cut the tunnel openings at the scribe marks, keeping the cutting tool parallel to the ground. Hydraulic Thruster Installation Guide 4
6. Round-over the edge of the tunnel where it meets the hull to 1/10 the tunnel diameter. This minimizes inlet turbulence. One-tenth the tunnel diameter is the ideal radius, but may not always be practical. On metal tunnels where performance is critical, use a 45 chamfer. Figure 3. Ideal Tunnel Radius 1/10 the tunnel diameter roundover or 45o chamfer Reducing Drag There are two hull modifications that may help to reduce drag near the tunnel opening: creating an eyebrow or scalloping the hull as shown in Figure 4 and Figure 5. Figure 4. Eyebrow Hull Modification Eyebrow Figure 5. Scallop Hull Modification Scallop 5 Hydraulic Thruster Installation Guide
Tunnel Grates Tunnel grates keep people, animals, and debris out of the thruster tunnel, as well as possibly reduce tunnel drag and propeller freewheeling. Install grates vertically with the bars approximately 3.5 (89 mm) to 5 (127 mm) apart. Figure 6. Proper Tunnel Grate Orientation 3.5 5.0 X Hydraulic Thruster Installation Guide 6
Installing the Thruster Refer to the following installation diagrams for your thruster size. In general, the thruster is mounted in the tunnel with screws and a gasket. Be sure to check for sufficient propeller clearance before final installation; using the supplied gasket is not required and is dependent on the amount of propeller clearance.! IMPORTANT After installing the thruster, be sure to install the header tank before starting the system (refer to Mounting the Header Tank on page 13). 7 Hydraulic Thruster Installation Guide
Hydraulic motor shaft Magnaloy coupling Coupling insert Bell housing Hydraulic motor 8 TRAC Installation Motor mounting bolts (2 or 4) Use medium strength locking compound Tighten to 40 ft/lbs (54.23 nm) Key Leave 0.050 (1.27 mm) gap in coupling assembly Bell housing mounting bolts (7) Use high strength locking compound Tighten to 24 ft/lbs (32.54 nm) evenly! IMPORTANT Bell housing heights vary; be sure that there is 0.100 0.350 (2.54 mm 8.89 mm) clearance between the ends of the hydraulic motor and the pinion shaft (check this clearance by dry-fitting the motor without the spline coupling) Header tank fitting Install header tank before starting system Tunnel Mounting gasket Coat both sides with high quality marine sealant such as 3M 4200, 5200, or 4000 Remove set-screw before installing bell housing Make sure O-ring is in place before installing bell housing (p/n 26083 Standard AS568A #011 or #904) Thruster mounting bolts Key Pinion shaft There are a total of six thruster-mounting bolts Use anti-seizing compound on each bolt Use safety wire to secure bolts (see below) Tighten to 24 ft/lbs (32.54 nm) Propeller Cotter pin Nut Coat shaft threads with high strength locking compound Tighten to 50 ft/lbs (67.8 nm) Key Bell Housing Top View Safety Wire Guide Header tank breather fitting port Hydraulic Thruster Installation Guide 8
10 and 12 TRAC Installation Motor mounting bolts (2) Use medium strength locking compound Tigten to 50 ft/lbs (67.8 nm) Spline coupling Apply heavy grease Bell housing Header tank fitting Install header tank before starting system Tunnel Hyhdraulic motor Hyhdraulic motor shaft Bell housing mounting bolts (7) Use high strength locking compound Tighten to 24 ft/lbs (32.54 nm) evenly Make sure O-ring is in place before installing bell housing (p/n 26083 Standard AS568A #011 or #904) Thruster mounting bolts! IMPORTANT Bell housing heights vary; be sure that there is 0.100 0.350 (2.54 mm 8.89 mm) clearance between the ends of the hydraulic motor and the pinion shaft (check this clearance by dry-fitting the motor without the spline coupling) There are a total of six thruster-mounting bolts in two diameters Use anti-seizing compound on each bolt Use safety wire to secure bolts (see below) Tighten 3/8 bolts to 24 ft/lbs (32.54 nm) Tighten 1/2 bolts to 50 ft/lbs (67.8 nm) Mounting gasket Coat both sides with high quality marine sealant such as 3M 4200, 5200, or 4000 Pinion shaft Remove set-screw before installing bell housing Propeller Cotter pin Nut Coat shaft threads with high strength locking compound Tighten to 80 ft/lbs (108.46 mm) Nose cone Key Fasteners Coat with medium strength locking compound Tighten to 7 ft/lbs (9.49 nm) Bell Housing Top View Safety Wire Guide 9 Hydraulic Thruster Installation Guide
16 TRAC Installation SAE spline adapter (If applicable) Spline coupling Header tank fitting Install header tank before starting system Hydraulic motor Motor mounting bolts (2 or 4) Use medium strength locking compound Tighten to 50 ft/lbs (67.8 nm) Hydraulic motor shaft Bell housing mounting bolts (7) Use high strength locking compound Tighten to 24 ft/lbs (32.54 nm) evenly Bell housing Bell housing stabilizer bolts Use high strength locking compound Tighten to 5 ft/lbs (6.78 nm)! IMPORTANT Bell housing heights vary; be sure that there is 0.100 0.350 (2.54 mm 8.89 mm) clearance between the ends of the hydraulic motor and the pinion shaft (check this clearance by dry-fitting the motor without the spline coupling) Tunnel Thruster mounting bolts There are a total of six thruster-mounting bolts in two diameters Use anti-seizing compound on each bolt Use safety wire to secure bolts (see below) Tighten 3/4 bolts to 100 ft/lbs (135.58 nm) Tighten 3/8 bolts to 24 ft/lbs (32.54 nm) Mounting gasket Coat both sides with high quality marine sealant such as 3M 4200, 5200, or 4000 Remove set-screw before installing bell housing Make sure O-ring is in place before installing bell housing (p/n 26083 Standard AS568A #011 or #904) Pinion shaft Propeller Cotter pin Nut Coat shaft threads with high strength locking compound Tighten to 100 ft/lbs (135.58 nm) Key Nose cone Fasteners Coat with medium strength locking compound Tighten to 7 ft/lbs (9.49 nm) Bell Housing Bottom View Safety Wire Guide Header tank breather fitting Make sure O-ring is in groove before installing bell housing Hydraulic Thruster Installation Guide 10
SAE spline adapter (If applicable) Spline coupling Header tank fitting Install header tank before starting system Bell housing Hydraulic motor 20 TRAC Installation Motor mounting bolts (2 or 4) Use medium strength locking compound Tighten 5/8 bolts to 80 ft/lbs (108.46 nm) Tighten 1/2 bolts to 50 ft/lbs (67.8 nm) Hydraulic motor shaft Bell housing mounting bolts (7) Use high strength locking compound Tighten to 50 ft/lbs evenly (67.8 nm) Bell housing stabilizer bolts Use high strength locking compound Tighten to 5 ft/lbs (6.78 nm)! IMPORTANT Bell housing heights vary; be sure that there is 0.100 0.350 (2.54 mm 8.89 mm) clearance between the ends of the hydraulic motor and the pinion shaft (check this clearance by dry-fitting the motor without the spline coupling) Tunnel Thruster mounting bolts There are a total of six thruster-mounting bolts Use anti-seizing compound on each bolt Use safety wire to secure bolts (see below) Tighten to 100 ft/lbs (135.58 nm) Mounting gasket Coat both sides with high quality marine sealant such as 3M 4200, 5200, or 4000 Make sure O-ring is in place before installing bell housing (p/n 26083 Standard AS568A #011 or #904) Pinion shaft Propeller Cotter pin Nut Coat shaft threads with high strength locking compound Tighten to 125 ft/lbs (169.48 nm) Nose cone Key Fasteners Coat with medium strength locking compound Tighten to 7 ft/lbs (9.49 nm) Washer (if provided) Bell Housing Top View Safety Wire Guide Header tank breather fitting 11 Hydraulic Thruster Installation Guide
Hydraulic motor shaft SAE spline adapter (If applicable) Spline coupling Header tank fitting Install header tank before starting system Bell housing 24 and 28 TRAC Installation Hydraulic motor Motor mounting bolts (2 or 4) Use medium strength locking compound Tighten to 80 ft/lbs (108.46 nm) Bell housing mounting bolts (7) Use high strength locking compound Tighten to 50 ft/lbs (67.8 nm) evenly Bell housing stabilizer bolts Use high strength locking compound Tighten to 5 ft/lbs (6.78 nm)! IMPORTANT Bell housing heights vary; be sure that there is 0.100 0.350 (2.54 mm 8.89 mm) clearance between the ends of the hydraulic motor and the pinion shaft (check this clearance by dry-fitting the motor without the spline coupling) Tunnel Thruster mounting bolts There are a total of six thruster-mounting bolts in two diameters Use anti-seizing compound on each bolt Use safety wire to secure bolts (see below) Tighten 3/4 bolts to 135 ft/lbs (183.04 nm) Tighten 7/8 bolts to 225 ft/lbs (3 05.06 nm) Mounting gasket Coat both sides with high quality marine sealant such as 3M 4200, 5200, or 4000 Remove set-screw before installing bell housing Make sure O-ring is in place before installing bell housing (p/n 26083 Standard AS568A #011 or #904) Pinion shaft Propeller Washer (if provided) Cotter pin Nut Coat shaft threads with high strength locking compound Tighten to 150 ft/lbs (203.37 nm) Nose cone Key Fasteners Coat with medium strength locking compound Tighten to 7 ft/lbs (9.49 mm) Bell Housing Top View Safety Wire Guide Header tank breather fitting Install header tank before starting system Hydraulic Thruster Installation Guide 12
Mounting the Header Tank! IMPORTANT On some systems, the header tank fitting and plumbing must be connected before the drive line or motor are installed, otherwise they cannot be accessed. The fluid level in the header tank must be monitored regularly and the tank must be kept one-half full. Use only Chevron Delo Gear Lubricant SAE 80-90 to fill the header tank; the thruster is shipped pre-filled. Figure 7 shows the proper header tank location. Figure 7. Header Tank Location Remove cap Fill 1/2 full Header Tank Waterline Secure hose to hull or bulkhead with nylon straps or clamps 30 (762 mm) Minimum 13 Hydraulic Thruster Installation Guide
Installing the Thruster Hydraulics Figure 8 shows how to attach the thruster to the hydraulic system.! IMPORTANT Figure 8 illustrates only a small portion of the entire hydraulic system. Refer to the Hydraulic Installation Guide and your vessel s particular hydraulic system diagram for more detail. The directional control valve in the diagram is the most popular model; other models are available, but the connection criteria are the same. The system pressure line attaches to the port labeled P The tank return line attaches to the port labeled T (on the back in the diagram) The lines between the directional control valve and the thruster motor are attached to the ports labeled A and B Figure 8. Attaching Thruster to the Hydraulic System To Tank Return (on back) A P B From Main System A B To Case Drain Hydraulic Thruster Installation Guide 14
Installing Electrical Components Installing Thruster Control Stations Install Thruster Control Stations (TCSs) at steering stations near the main engine throttle and shift controls. A console cutout template and gasket are provided with each TCS. Make the console cutout as shown and drill the four mounting holes. The TCS mounts with four pre-installed stainless 10-32 studs. Extra long coupling nuts are provided for tightening. On variable speed TCSs there are three electronic adjustments (pots) that must be adjusted at startup. Keep this in mind when locating the TCS and before securing in place. The portion of the TCS that extends below the console is not weather resistant. In situations where the area below the mounting surface is open to the environment, fabricate and install a protective cover for the bottom of the TCS. Figure 9. Thruster Control Stations Central Control PLC/Switch Box Mount the central control PLC/switch box in the engine room in a dry, central location, where the ambient temperature will not exceed 120 F (48.89 C). Access to the relay box is key in troubleshooting. Nearly all control wiring leads to the central control PLC/switch box. Run all wires in the sizes indicated on the accompanying wiring diagram. Figure 10. Central Control PLC/Switch Box Wiring Terminal Strip Glass Fuses PLC Micro Controller Control Relays 15 Hydraulic Thruster Installation Guide
Wiring The system must be wired according to the wiring diagram that accompanies this document. Wire sizes in the diagram are minimum sizes. Using wire of insufficient size can cause system malfunction and equipment damage. It may also result in a fire, which can cause significant material damages and serious personal injury. TCS Generic Wiring Diagram Figure 11 on page 17 illustrates generic TCS wiring. Hydraulic Thruster Installation Guide 16
Figure 11. Generic Wiring Diagram for the TCS WN SH (+) ( ) 24 VDC G 1 2 J1R J2R J3R ST ST J1+ #1 J1R #2 ST #3 AL #4 NEG #5 A1 #6 STATION 1 RED V(+) G ORN START YEL STOP GRN/WHT A1 BRN/WHT B1 WHT/BLK T1 AL AL J1+ J2+ J3+ B1 #7 GRN A2 T1 #8 BRN B2 A2 #9 WHT T2 B2 #10 BLU ALARM T2 #11 BLK V( ) R SPARE #12 STATION 2 J2+ #1 RED V(+) J2R #2 ORN START G ST #3 YEL STOP AL #4 GRN/WHTA1 NEG#5 BRN/WHTB1 A1 #6 WHT/BLK T1 B1 #7 T1 #8 A2 #9 B2 #10 T2 #11 SPARE #12 GRN A2 BRN B2 WHT T2 BLU ALARM BLK V( ) R A1 A1 A1 B1 B1 B1 T1 T1 T1 A2 A2 A2 B2 B2 B2 T2 T2 T2 FIV WX W PA DF DX DF DX FWD ISOLATION VALVE PUMP CONTROL HIGH PRESSURE SOLENOID J3+ J3R A2 B2 T2 NEG RED ORN STERN THRUSTER DCV STATION 3 V(+) START G 1 2 G 1 2 1 P A B G 2 T A1 B1 T1 NEG BOW THRUSTER DCV 1 G 2 1 P G A 2 1 B G 2 T 1. Start button (JR) creates a ground input to PLC requesting power to selected station on J+. Pressing Start twice powers all stations including remote, if installed. Power is available for deck function on W, if applicable. Forward Isolation Valve (FIV) powers, if applicable. 2. Directional input from the jog lever sends +VDC to a directinoal input (A1, B1, etc.) and brings the system to high pressure through a _VDC output on PA and power direction on thruster DCV. 3. Throttle is provided from the TCS to T with a variable +VDC output to the DCV. NEG 4. Low oil level or high temperature create an open circuit on W for a warning tone every 3 seconds. Open on SH disables all stations and returns the system to standby pressure and creates a tone every second. Do not turn off power to switch box to silence alarm. System can continue to overheat with breaker off. 17 Hydraulic Thruster Installation Guide