Engbo XF 30 VR User manual

Rev: 4, 2010-02-01

Page 1

XForce thruster –VR series

Installation and user manual

XF 30 VR

XF 60 VR

XF 90 VR

XF 130 VR

English version

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

R78-ECU-01

Art. no. 117-00166

Rev: 4, 2010-02-01

Page 2

Contents

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

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

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

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

2.2.1. Operating panel versions...................................................................................................................................... 5

2.2.2. Operating instructions........................................................................................................................................... 5

2.2.3. Directions for use.................................................................................................................................................. 5

2.2.4. RCU –Remote Control Unit ................................................................................................................................. 6

2.2.5. Coding of wireless remote control ........................................................................................................................ 7

2.2.6. Battery replacement ............................................................................................................................................. 8

3. SPESIFICATIONS............................................................................................................8

3.1. Technical specifications wireless remote control.........................................................................................8

3.2. Dimensions XF30VR, XF60VR, XF90VR and XF130VR.............................................................................9

3.3. Dimensions RCU –Remote Control Unit.....................................................................................................9

3.4. Installation of RCU –Remote Control Unit.................................................................................................10

4. INSTALLATION OF THE THRUSTER...........................................................................10

4.1.1. Drilling tool kit..................................................................................................................................................... 10

4.1.2. Choosing and marking the location .................................................................................................................... 10

4.1.3. Cutting holes....................................................................................................................................................... 11

4.1.4. Tunnel centre hole.............................................................................................................................................. 11

4.1.5. Adapting the tunnel............................................................................................................................................. 11

4.1.6. Cleaning before fastening................................................................................................................................... 12

4.1.7. Prevent filling from running out........................................................................................................................... 12

4.1.8. Fastening the tunnel........................................................................................................................................... 13

4.1.9. Filler.................................................................................................................................................................... 13

4.1.10. Grinding.............................................................................................................................................................. 14

4.1.11. Directions for installations in high speed boats................................................................................................... 14

4.1.12. Coating............................................................................................................................................................... 14

5. THRUSTER INSTALLATION .........................................................................................15

5.1. The thrusters unit .......................................................................................................................................15

5.2. Preparations...............................................................................................................................................15

5.3. Not vertical installation ...............................................................................................................................15

5.4. Off centre installation..................................................................................................................................16

5.5. Drilling thruster installation holes ...............................................................................................................16

5.6. Apply sealant..............................................................................................................................................16

5.6.1. Specified sealants: ............................................................................................................................................. 16

5.7. Installation of the gearhousing ...................................................................................................................16

5.7.1. Propeller installation........................................................................................................................................... 17

6. ELECTRICAL CONNECTIONS......................................................................................18

6.1. Touch panel installation..............................................................................................................................18

6.2. Joystick (single/double) installation............................................................................................................18

6.3. Connecting the joystick ..............................................................................................................................19

6.4. Connecting the control cable to the RCU...................................................................................................19

6.5. Contradicting direction................................................................................................................................20

6.6. Connecting cables to the bow thruster.......................................................................................................20

6.7. Connecting cables to the battery................................................................................................................21

6.8. Fuse connections .......................................................................................................................................21

6.9. Recommended main switch.......................................................................................................................21

6.10. Main switch terminal...............................................................................................................................21

6.11. XForce Thruster Cable, fuse and battery requirements .........................................................................22

6.12. Wiring diagram........................................................................................................................................22

6.13. Wiring diagram single and double joystick .............................................................................................23

7. MAINTENANCE .............................................................................................................23

7.1. Mechanical check.......................................................................................................................................23

7.2. Corrosion check .........................................................................................................................................23

7.3. Battery/charger check ................................................................................................................................24

Rev: 4, 2010-02-01

Page 3

7.4. High current cable/connections check .......................................................................................................24

7.5. Joystick/operator panel check....................................................................................................................24

8. TROUBLESHOOTING....................................................................................................24

8.1. The thruster does not work.........................................................................................................................24

8.2. The thruster does not work or has an unexpectedly low performance ......................................................24

8.3. The thruster works in only one direction ....................................................................................................25

8.4. The thruster runs in contradicting direction................................................................................................25

8.5. The thruster runs for short intervals or clicking sound is to be heard from the thruster............................25

8.6. The thruster stops working after a long period of use................................................................................26

9. INSTALLATION OF EQUIPMENT WITH HIGH CURRENTS.........................................26

9.1. Special considerations. ..............................................................................................................................26

9.1.1. Preface/introduction............................................................................................................................................ 26

9.2. Battery........................................................................................................................................................27

9.2.1. Battery-cables/lugs............................................................................................................................................. 27

9.2.2. Battery connection.............................................................................................................................................. 27

9.2.3. Fuse connection................................................................................................................................................. 28

9.2.4. Main switch connection ...................................................................................................................................... 28

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 for 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: support@engbo.no

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. Suitable protective equipment must be used

during installation. 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. Beware there may be differences regarding choice of models in some of the

illustrations.

Rev: 4, 2010-02-01

Page 4

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.

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 10.4).

2.1. XForce 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 power light on the wireless control.

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

in. (Solenoid versions.)

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

unit against overheating.

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

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 from any damage, 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.

Rev: 4, 2010-02-01

Page 5

2.2.1. Operating panel versions

There are 4 different XForce Thruster operation panels available.

Touch panel (Part no.12-79001)

Easy to install.

Designed similar to Engbo winch panel.

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)

Splash-proof, 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 backside.

Holder and 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.

2.2.2. 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 pressed down. (Max 4x30 sec.)

2.2.3. 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.)

Rev: 4, 2010-02-01

Page 6

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.

Green light indicates everything normal and ready.

Orange light

Orange light indicates warning conditions, e.g low voltage at the electronic unit.

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 indications are shown when buttons are pushed.

2.2.4. RCU –Remote Control Unit

XF30VR, XF60VR, XF90VR and XF130VR are supplied with the power

contactor fixed to the thruster motor and separate electronic Remote Control

Unit (RCU) with integrated receiver for the wireless remote enclosed.

The antenna is preinstalled inside the electronic thruster control.

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.

Rev: 4, 2010-02-01

Page 7

Image A

2.2.5. Coding of wireless remote control

Procedure for serial no. above 8600

Important! If your wireless control has serial no. lower than 8600, use the

procedure enclosed your remote.

1. How to put the wireless control unit in code mode:

Select the pair of switches on the remote control to be coded.

Press down both switches simultaneously for approximately 12 seconds.

When you hear a short sound signal and the green power light starts to

flash, the remote control is prepared for coding and will stay in coding

mode for 5 minutes or until the coding has been finished.

(Image A)

Image B

Image C

Image D

2. How to put the receiver unit in code mode:

Alt. 1. Touch panel installed.

Press and keep both switches on the touch panel down while

simultaneously switching on the power to the receiver unit.

(Image B and C)

The receiver will now understand that coding is requested and

automatically connect to your wireless control and the wireless remote

control will immediately be ready for use.

This will be confirmed by a short sound signal and the green power light

will turn from flashing to permanent.

Check that the wireless control is functioning.

Alt. 2. Joystick installed.

Turn the thruster main switch off.

Disconnect the cables to the joystick connected to 1, 2 and 3 on the

green plug on the remote control unit (RCU).

Prepare two short wires (5 cm). Remove the insulation in both ends and

connect these between 1 and 2 as well as between 2 and 3 on the green

plug. (Image D).

Turn the power on.

The receiver will now understand that coding is requested and

automatically connect to your wireless control and will immediately be

ready for use.

This will be confirmed by a short sound signal and the green power light

will turn from flashing to permanent.

Turn the thruster main switch off.

Disconnect the short wires and connect the joystick cables.

Turn the power on and check that the wireless control is functioning.

Rev: 4, 2010-02-01

Page 8

2.2.6. 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 3 batteries have the (+) and the

(–)correct.

Reassemble the back cover and carefully screw the parts together until

the housing gasket is slightly compressed. The remote will remain

splashproof 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.

3. Spesifications

3.1. Technical specifications wireless remote control

Wireless remote:

Motor Control Unit:

Remote Control Unit:

Model:

RC-01

ECU-01

RCU

Power supply:

3 x 1.5 V DC

(3 x AAA/LR03

batteries)

From thruster

(integrated)

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

120

Dimensions (HxWxD):

129x53x23 mm

Model dependent

150x200x40mm

Environment protection:

Splashproof

IP 41

IP41

* 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

Rev: 4, 2010-02-01

Page 9

3.2. Dimensions XF30VR, XF60VR, XF90VR and XF130VR

Thruster model

Bmin

XF 30VR

252

132

118

210

140

XF 60VR

295

185

145

210

150

XF 90VR

370

185

230*

270

190

XF 130VR

385

250

320*

100

270

190

3.3. Dimensions RCU –Remote Control Unit

RCU

XF30VR, XF60VR, XF90VR

and XF130VR

172

150

119

200

188

Rev: 4, 2010-02-01

Page 10

3.4. Installation of RCU –Remote Control Unit

Unscrew the four screws and remove the top cover.

Make use of the holes in the bottom cover to fasten the unit.

Alteratively, attach the unit by using Sikaflex or similar adhesive

NB: By installing the unit with the gren plug turned down, moisture in the

contact can be avoided.

4. Installation of the thruster

IMPORTANT

Please read these instructions carefully and in their entirety before

starting the installation.

4.1.1. Drilling tool kit

Makes the tunnel installation very efficient and shortens the installation

time considerably.

Consists of:

Compass for easily locating the tunnel centre spot.

Electric straight grinder including centre rods for cutting the holes in the

hull.

Adapters for all thruster dimensions.

For more information ask your dealer or contact Engbo AS directly.

4.1.2. Choosing and marking the location

Select a suitable position for the bow thruster.

For best result, make sure that the bow thruster is located as far forward

and as low in the hull as possible. To prevent air being drawn into the

tunnel, the upper part of the tunnel should be at least its diameter below

the surface.

Use an appropriate drawing instrument (refer to your dealer regarding

availability of drawing/cutting tools) to mark the point at which the hole for

the bow thruster tunnel is to be inserted.

Mark out the hole in its entirety on the inside of the hull so as to ascertain

the optimum position for the tunnel.

NB: Make sure that the tunnel is mounted as transverse in the boat as

possible. After having located the centre spots, check both sides

according to selected reference spots in the hull.

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