Hydraulic Thruster Installation Guide - Golden · PDF fileRecommendations made by American Bow...

Hydraulic Thruster Installation Guide - Version 7.0

Hydraulic Thruster Installation Guide

Version 7.0

Hydraulic Thruster Installation Guide - Version 7.0

ABT-TRAC517-A Martin Avenue

Rohnert Park, CA 94928Tel: 707-586-3155 Fax: 707-586-3159

http://www.thrusters.com

Change LogDate Change

03/11/2014 Initial converted release

Version 7.0 Hydraulic Thruster Installation Guide– 1 –

! 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 mak-ing all stations active, may result in unwanted thruster operation and harm to the vessel or its occupants.

Hydraulic Thruster Installation Guide Version 7.0– 2 –

Important Notices The thruster tunnel is an integral part of the hull. Installation should be done only by profession-

als 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 WarningsBefore installation, read and understand the information in this manual.

The Hydraulic Thruster Installation Guide is intended for experienced marine engineering personnel. Proper gen-eral engineering standards and practices must be followed at all times.

System Hydraulic FluidUse only ISO 32 and ISO 46 hydraulic fluids in ABT-TRAC hydraulic systems. Using any other fluid voids the Arcturus Marine Systems warranty.

Corrosion ControlAll seagoing vessels must be protected from corrosion from galvanic and electrolytic potential. ABT-TRAC encour-ages 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 CoatingsOn Hydraulic SystemsReservoirs, 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 re-quests are made that other components in the system be painted.

On Thrusters, Propellers, and TunnelsUse bottom paint on thrusters and tunnels; use any available advanced propeller coating on propellers.

Standard WarrantyThis 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, includ-ing air freight, for the shipment of repaired or replacement parts back to customer (local laws may apply).


This warranty does NOT cover failure of parts due to mis-installation, damage, accidents, improper storage, or mis-use. 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.


Installing the TunnelTunnel Position

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 be-yond the tunnel opening.

Marking the Tunnel Cutout1. 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.

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.

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.

Figure 1. Proper Tunnel Position

At least one diameterbelow waterline

and one diameterabove the keel

Waterline

As far forward as possible

Figure 2. Scribing the Tunnel Opening

Tunnel outsidediameter radius


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.

Reducing DragThere 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 3. Ideal Tunnel Radius

1/10 the tunneldiameter roundoveror 45o chamfer

Figure 4. “Eyebrow” Hull Modification

“Eyebrow”

Figure 5. “Scallop” Hull Modification

Scallop


Tunnel GratesTunnel 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

X3.5” – 5.0”


Installing the ThrusterRefer 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 sup-plied 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).


8” TRAC InstallationHydraulic motor

Motor mounting bolts (2 or 4)Use medium strength locking compoundTighten to 40 ft/lbs (54.23 nm)

Leave 0.050” (1.27 mm) gap in coupling assembly

Key

Key

Key

Bell housing mounting bolts (7)Use high strength locking compoundTighten to 24 ft/lbs (32.54 nm) evenly

Make sure O-ring is in placebefore installing bell housing(p/n 26083 Standard AS568A#011 or #904)

Magnaloy coupling

Propeller

Cotter pin

NutCoat shaft threads withhigh strength locking compoundTighten to 50 ft/lbs (67.8 nm)

Coupling insert

Bell housing

Header tank �ttingInstall header tankbefore starting system

Thruster mounting bolts

Tunnel

Mounting gasketCoat both sides with highquality marine sealant such as3M 4200, 5200, or 4000

Remove set-screwbefore installingbell housing

Hydraulic motor shaft

Pinion shaft

Bell Housing Top View

Header tank breather�tting port

Safety Wire Guide

! IMPORTANTBell housing heights vary; be surethat 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-�tting the motor without the spline coupling)

There are a total of six thruster-mounting boltsUse anti-seizing compound on each boltUse safety wire to secure bolts (see below)Tighten to 24 ft/lbs (32.54 nm)


10” and 12” TRAC InstallationHyhdraulic motor

Motor mounting bolts (2)Use medium strengthlocking compoundTigten to 50 ft/lbs (67.8 nm)


Propeller

Cotter pin

NutCoat shaft threads withhigh strength locking compoundTighten to 80 ft/lbs (108.46 mm)

FastenersCoat with medium strength locking compoundTighten to 7 ft/lbs (9.49 nm)

There are a total of six thruster-mountingbolts in two diametersUse anti-seizing compound on each boltUse 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)

Spline couplingApply heavy grease

Nose cone

Bell housing


Tunnel


Key

Hyhdraulic motor shaft

Pinion shaft


Header tank �ttingInstall header tankbefore startingsystem

Safety Wire GuideBell Housing Top View




16” TRAC Installation

Safety Wire Guide

Hydraulic motorMotor mounting bolts (2 or 4)Use medium strength locking compoundTighten to 50 ft/lbs (67.8 nm)

Bell housing stabilizer boltsUse high strength locking compoundTighten to 5 ft/lbs (6.78 nm)

Key


SAE spline adapter(If applicable)

Propeller

Cotter pinNutCoat shaft threads withhigh strength locking compoundTighten to 100 ft/lbs (135.58 nm)

Spline coupling

Bell housing


Tunnel



Nose cone

There are a total of six thruster-mounting bolts in two diametersUse anti-seizing compound on each boltUse 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)


Pinion shaft

Make sure O-ringis in groovebefore installingbell housing

Bell Housing Bottom View

Header tankbreather �tting

! IMPORTANTBell housing heights vary; be surethat there is 0.100” – 0.350” (2.54 mm – 8.89 mm) clearance betweenthe ends of the hydraulic motor and the pinion shaft(check this clearance by dry-�tting the motor without the spline coupling)





20” TRAC Installation

Key


Safety Wire Guide

Hydraulic motor

Motor mounting bolts (2 or 4)Use medium strength locking compoundTighten 5/8” bolts to 80 ft/lbs (108.46 nm)Tighten 1/2” bolts to 50 ft/lbs (67.8 nm)


Bell housing mounting bolts (7)Use high strength locking compoundTighten to 50 ft/lbs evenly (67.8 nm)


Propeller

Cotter pin

Washer (if provided)

Spline coupling

Bell housing


Tunnel


Nose cone

There are a total of six thruster-mounting boltsUse anti-seizing compound on each boltUse safety wire to secure bolts (see below)Tighten to 100 ft/lbs (135.58 nm)


Pinion shaft

Header tankbreather �tting







24” and 28” TRAC Installation




Safety Wire Guide

Hydraulic motor

Motor mounting bolts (2 or 4)Use medium strength locking compoundTighten to 80 ft/lbs (108.46 nm)

Key


Propeller

Cotter pin

Washer (if provided)

Spline coupling

Bell housing


Tunnel

FastenersCoat with medium strength locking compoundTighten to 7 ft/lbs (9.49 mm)

Nose cone

There are a total of six thruster-mountingbolts in two diametersUse anti-seizing compound on each boltUse 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)


Pinion shaftRemove set-screwbefore installingbell housing

Header tankbreather �ttingInstall header tankbefore startingsystem



Mounting gasketCoat both sides with highquality marine sealant suchas 3M 4200, 5200, or 4000




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

30” (762 mm)Minimum

Waterline

Header TankFill 1/2 full

Remove cap

Secure hose to hullor bulkhead with nylon straps or clamps


Installing the Thruster HydraulicsFigure 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 con-nection 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)

P

A

A

B

BFrom Main System

To Case Drain


Installing Electrical ComponentsInstalling Thruster Control StationsInstall 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.

Central Control PLC/Switch BoxMount the central control PLC/switch box in the engine room in a dry, central location, where the ambient tem-perature 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 9. Thruster Control Stations

Figure 10. Central Control PLC/Switch Box

Wiring Terminal Strip

PLC Micro Controller

Control Relays

Glass Fuses


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 DiagramFigure 11 on page 17 illustrates generic TCS wiring.


Figure 11. Generic Wiring Diagram for the TCS

#10 RB2 ALARMBLUT2 V(–)BLK#11

PUMP CONTROLHIGH PRESSURE SOLENOID

FWD ISOLATION VALVE

NEG

DXDFDXDF

PA

W

WXFIV

A1A1A1B1B1B1T1T1T1A2A2A2B2B2B2T2T2T2

1 2 BP

STERNTHRUSTER

DCV

V(+)START

#12

#12

NEG

B2

T2

A2

J3RJ3+

SPARE

ORNRED

G

G

2G

1 1

A

2

T

STATION 3

(+) (–)24 VDC

J1RJ2RJ3R

STST

ALAL

J1+J2+J3+

WNSH

B1 #7 GRN

#2 J2R

B1

STALNEGA1

T1A2 #9

#7

#5#4#3

#6

#8

SPARE

B2A2T1

J2+

T2

#9

#11

#1

#8

#10

STARTORN

A1B1

STOP

WHT

T1

T2B2A2GRN

GRN/WHTBRN/WHTWHT/BLK

BRN

YEL

ALARM

STATION 2

V(–)

A2B2T2WHT

BLU

V(+)RED

BLK

BRN

R

G

J1+

A1NEGALSTJ1R

#5

#3

#1

#4

#2

#6

STATION 1

B1

RED

BRN/WHTT1

GRN/WHT

V(+)

A1

WHT/BLK

STARTSTOPYEL

ORNG

P

A

NEG

BOWTHRUSTER

DCV2

G1

T1

B1

A1

1

T

B

1G

22G

G

1 2

1. Start button (JR) creates a ground input to PLC requestingpower to selected station on J+. Pressing Start twice powersall stations including remote, if installed. Power is availablefor deck function on W, if applicable. Forward Isolation Valve(FIV) powers, if applicable.

2. Directional input from the jog lever sends +VDC to adirectinoal input (A1, B1, etc.) and brings the system to highpressure through a _VDC output on PA and power directionon thruster DCV.

3. Throttle is provided from the TCS to T with a variable +VDC output to the DCV.

4. Low oil level or high temperature create an open circuit onW for a warning tone every 3 seconds. Open on SH disablesall stations and returns the system to standby pressureand creates a tone every second.

Do not turn off power to switch box to silence alarm. Systemcan continue to overheat with breaker off.

Hydraulic Thruster Installation Guide - Golden · PDF fileRecommendations made by American Bow...

Documents

Transcript of Hydraulic Thruster Installation Guide - Golden · PDF fileRecommendations made by American Bow...