MAX power R300, R315, R321 User Manual
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BBUUIILLTT BBYY ________________________________
DDEELLIIVVEERREEDD
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A copy of this manual must remain
on board for consultation
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1 INSTALLATION MANUAL RETRACT R 300 Last update: December 2013
MAX POWER
I . INTRODUCTION
A AFTER SALES SERVICE
ADDRESS MAX POWER
Via Philips 5, 20900 Monza (MI), Italy
TEL + 39 039 200 1973-936
FAX + 39 039 2004299
RETRACT SERIAL N° S
IMPORTANT GENERAL INFORMATION
With a constant concern of improving our products, we reserve the right to make
changes to this manual without prior notification.
All statistics and explanations within this manual were believed to be correct at the
time of printing.
Each RETRACT installation requires a preliminary study of performance and
feasibility.
This study covers 4 distinct sub systems
1. The RETRACT thruster unit
2. Hydraulic equipment
3. Electrical control system
4. Electrical Power system if fitted with Electro pump
CHECK LIST FOR THE PROJECT MANAGER
It is very important to carefully read the entire manual before starting the installation.
At the end of the manual, you will find a MAJOR POINT CHECKLIST when you are
inspecting the work of your installers. All the points listed must be strictly respected
for the proper and safe operation of the RETRACT system.
The RETRACT should be installed by a professional specialising in this type of
installation.
Architects, construction shipyards and surveyors should be contacted before
installation.
All official bodies or classification experts should be contacted before the installation.
. R315 / R321
2 INSTALLATION MANUAL RETRACT R 300
MAX POWER
All mechanical installation must apply with the conditions as laid down in the country
of the boats registration.
All electrical installation must apply with the conditions as laid down in the country of
the boats registration origin.
All hydraulic installation must apply with the conditions as laid down in the country of
the boats registration origin.
POSITIONING OF THE RETRACT UNIT
IMPORTANT Correct positioning is essential for correct operation.
The difference between the centre of gravity of the submerged surfaces and the
centre of gravity of the surfaces exposed to side wind forces results in a rotational
torque.
One of the bow thruster’s primary functions is to neutralise this torque.
Therefore the distance between the thruster and the yachts extremities must be as
LONG as possible.
See installation drawing
The following considerations are essential when determining the position of the
RETRACT.
The top of the turbine must be 300 mm below the water line when fully extended.
In other words the turbine should be at least one full diameter below the water line.
The mounting-flange should be parallel with the bottom of the hull.
the structural compatibility of the mounting base,
the access needed for installation, and removal of unit,
IMPORTANT make sure that there is enough room to allow for complete removal of
the RETRACT unit, and room for the connection of the hydraulic piping, either by the
direct coupling of the flexible hoses or by the use of metallic elbow connections.
sufficient access for all maintenance procedures must be allowed for.
NOTE Always make sure that there is enough room for the manual override system.
See drawing
To install a RETRACT in the stern, make sure that the turbine flow is clear of all
obstacles, or select the best possible compromise.
3 INSTALLATION MANUAL RETRACT R 300
MAX POWER
INSTALLATION OF THE RETRACT UNIT
CONSTRUCTION OF THE MOUNTING BASE
MAX POWER can supply as an option, a G.R.P. laminated mounting base, or an
aluminium machined mounting-flange. These options allow you to save considerable
installation time, and assure precise installation.
The general method and materials used must be adapted to the particular hull
material (laminated wood, GRP, sandwich, aluminium, or steel). Naval Architects,
Classification Societies or engineering firms should be consulted.
The thruster’s mechanical stresses are spread over the hull by the mounting base.
Installation, which should be executed by welding or bonding to the hulls plating,
normally reinforces the hull, The mounting base may be attached to frames and
stringers as well.
After the mounting base has been made and fitted the RETRACT should be
temporarily secured on the flange to check its height its, centring, the accessibility of
fittings and the ease of operation for manual override system.
GRP HULLS
The mounting base may be moulded into the hull during construction or
prefabricated, and then laminated onto the hull later.
METAL HULLS
The mounting base may be constructed with the hull or prefabricated, and then
welded onto the hull later.
IMPORTANT In both cases, the top surface of the mounting base (or the flange)
must be given particular attention and machined perfectly flat in order to accept the
O ring seal of the RETRACT base flange and ensure perfect water tightness.
The bolts fixing the RETRACT onto the mounting flange must be inserted from top to
bottom. Provide sufficient access underneath the flange to allow for tightening the
nuts.
If the access is not possible, provide a special mounting flange with metric 10 mm
studs or tapped holes.
CONSTRUCTION OF HULL OPENING & CLOSING PLATE
The required hull opening dimensions are L = 350 mm x W = 260 mm.
The longitudinal centre line of the opening coincides with that of the mounting flange
But the transversal centre line of the opening is offset by 27 mm to the rear with
respect to the transversal centre line of the mounting flange.
The opening is closed by a plate which may be made from the cut-out hull section, or
specially fabricated.
4 INSTALLATION MANUAL RETRACT R 300
MAX POWER
This closing plate should bear against a flexible seal fixed to a 30-mm wide rebate.
While the hull opening closing plate is being made, the RETRACT must be
temporarily secured on the mounting base flange to facilitate correct closing plate
fabrication.
The hull plate must be fixed to the supplied aluminium adjustable mounting
has 4 elongated holes for initial adjustment).
the gasket in the hulls rebate can be made either out off soft cellular neoprene rubber
or moulded in soft
SIKAFLEX (or a similar product) to form a flexible seal .Precaution
must be taken to ensure that the flexible gasket does not glue the closing plate to the
hull while drying .The plate must rest evenly, on the gasket with a reasonable
pressure.
IMPORTANT To prevent marine growth inside the casing, it is essential that once the
unit is raised, no light is allowed to enter. Therefore the closing plate gasket is
essential and requires careful and permanent fixation.
FINAL FITTING OF THE RETRACT UNIT TO THE MOUNTING BASE
CAUTION To ensure absolute cleanliness, hydraulic lines and ports must remain
plugged until connection to hydraulic system .
Final installation on the mounting base must be made after thoroughly cleaning and
then liberally coating both joining surfaces (case and base) with a good quality
marine grease. This is so that the O ring seal is compressed flat, evenly, smoothly
and squarely when the bolts are tightened.
Under no circumstances should the RETRACT be glued or bedded down with a
marine type mastic/glue such as Sikaflex or other similar product.
The flange bolt should be tightened sequentially and in successive passes until the
two surfaces touch. If desired, a torque wrench can be used and the bolts can be
tightened to a torque of 4,0 kg/M. The flange bolts should be metric size 10 mm of
stainless steel, and should have a large stainless steel washer placed above a nylon
washer. The nylon washers avoid stainless steel contact with the aluminium case.
The nuts should be type NYLOCK.
The 2 lifting lugs provided by MAX POWER, should be put in a small plastic bag,
along with the hydraulic pipe plugs, for storage and future use by the ships crew or
owner.
FINAL ADJUSTING OF THE CLOSING PLATE (see drawing)
Once the thruster is permanently bolted onto the mounting base and has been
correctly tightened, reinstall the plate and check it’s adjustment.
( which
5 INSTALLATION MANUAL RETRACT R 300
MAX POWER
When testing the cover plate fit, either use the manual raising lever or the raise/lower
unit.
When the upper travel limit has been reached, the mechanical locking device, which
consists of the locking cam (b) and the locking lever (c) must engage automatically.
Although the RETRACT R300 is delivered completely tested and folded in the UP
position, the locking lever can not be definitively adjusted at the factory. The locking
lever adjustment eccentric ( e ) has been set at the factory in the medium position.
The adjustment procedure is as follows.
Adjust the hull closing plate by performing several up down manoeuvres using
the elongated holes in the aluminium mounting plate to make initial
adjustment.
Tighten the bolts holding the aluminium mounting using locktite .
Remove the retaining screw (f) on the plastic bush
Place the manual raising lever (a) on the end of the lifting arm and press down
to raise the arm (turbine) to maximum height. while holding the manual lifting
arm a second person can rotate the eccentric (e) right or left, to raise or lower
the locking lever to the position required
Replace the bush retaining screw in the nearest convenient hole (two holes
provided)
Should the turbine still have some movement when locked increase the
locking bolt height using the eccentric by one half hole.
Should at this point the thruster only just, not quite lock, then the locking
pressure can be very slightly increased using the pressure limitor on the up
down unit. The locking pressure should not exceed 50 bar .
This entire procedure is only possible when the soft flexible gasket is
correctly and permanently installed.
UP/DOWN UNIT INSTALLATION
The raise/lower unit should be near the RETRACT unit. It should be installed in an
readily accessible and dry place.
The hydraulic ports (LA and LB) on the raise/lower pump unit and the raise/lower ram
(VA and VB) must be connected A to A and B to B.
These flexible hoses must be 3/16″ or 1/4 ″ with an operating pressure rating of at
least 100 bar.
CAUTION to prevent the risk of electrical earth leakage’s, the hydraulic hoses
connected directly to the RETRACT should be non-conductive (non-metal braided
6 INSTALLATION MANUAL RETRACT R 300
MAX POWER
hose) high pressure thermoplastic hose. Absolute internal cleanliness is essential.
After pipes and hoses have been equipped with their fittings, they must be blown out
with compressed air, then plugged until connected.
A parachute valve is installed in the B port in the up/down unit and this is very easily
blocked by contamination!
Should during closing plate adjustment or thruster operation the up down unit motor
ceases to function check the up down unit fuse (16 A).
The up down unit pressure limiter is normally pre set , should you need to re adjust
it slightly do not forget that the up down unit functions constantly on maximum
pressure while the thruster is thrusting. This to hold the turbine in the down position.
TRANSMISSION LUBE OIL TANK INSTALLATION
Retract thrusters are no longer equipped with Transmission lub oil tanks.
HYDRAULIC POWER SYSTEM INSTALLATION
All the hydraulic power equipment, such as the piping, reservoir, pump, directional
valve, etc. should be installed in compliance with the usual rules of accessibility to
enable periodic checks and maintenance.
PRESSURE PIPING
All hydraulic high pressure power circuit piping must comply with high pressure
standards, and have a diameter at least equal to that recommended (see diagram )
in order to reduce pressure loss especially when the installation’s layout requires
long hose lines.
All power circuit piping must have a continuous service pressure rating of at least 280
bar. Fittings must be of good quality, and crimped as per manufacturer instructions.
All power circuit piping connected directly to the thruster unit must be of non
conductive thermo-plastic type.
The following rules must be taken into account when positioning the hydraulic power
components.
Flexible hydraulic hoses must not have a bend radius less than the manufacturers
stated minimum. Also the larger the bend the higher the efficiency of the system.
Small radius metallic elbow fittings must be avoided on the pressure piping.
The pump intake hose line (from the reservoir) must be of a quality that is not subject
to pinching crimping or collapse.
This hose should preferably be shorter than 2 meters and have no more than two 90degree elbows bends.
7 INSTALLATION MANUAL RETRACT R 300
MAX POWER
OIL RESERVOIR
The reservoir should be mounted as close to the pump as possible and must always
be higher than any other component in the system. The reservoir must be mounted
at a height that allows the breather to be situated 500 mm, (18 ″) or higher, above the
waterline. If this is not possible, then the breather can be removed and installed on
the end of an extension pipe or hose.
Mounting the reservoir too low could result in oil draining back, or overflowing the
tank. Be sure to allow enough space above the reservoir to service the filter.
If MAX POWER does not supply the reservoir, then provide a return filter of 60
microns and a suction strainer.
CAUTION the oil tank must be installed above the pump so as to gravity feed to the
pump.
The thrusters’ motor case drain must return directly to the top of the tank. With
no filters check valves or other drain lines connected to it. Backpressure on the RD
(drain line) will cause damage to the hydraulic motor.
The reservoir must be flushed after installation.
DIRECTIONAL CONTROL VALVE BLOCK
The directional control valve (DCV) must be placed between the pump and the
RETRACT unit. it is recommended to locate the DCV as near to the RETRACT as
possible (in an accessible and dry place) it is preferable for maintenance reasons
that the unit is mounted horizontally. The valve block is fitted with a pressure relief
valve that has been factory tested and set to your thruster’s maximum pressure.
ELECTRO HYDRAULIC PUMP (EHP) INSTALLATION
The Electro hydraulic pump should be as close as possible to the batteries to
reduce voltage drop in the electrical lines.
Other important considerations in EHP installation are
- Sufficient cooling air available to the motor
- Proper maintenance access
- A dry well ventilated position
- Secure fixation support and straps to prevent movement in any sea
condition
Hydraulic pumps must never be allowed to run dry, not even for a few seconds,
prime circuit before start up.
8 INSTALLATION MANUAL RETRACT R 300
MAX POWER
MECHANICAL DRIVEN HYDRAULIC PUMP (MDP) INSTALATION
The pump/clutch assembly (PCA) may or may not be supplied by MAX POWER.
However the following general rules apply to all types of pump/clutch installations.
If MAX POWER supplies the assembly, additional documentation will be supplied.
In order to prevent pump damage, always pay particular attention to the pump’s
designed rotation direction.
Some pumps have drain lines, these must be connected directly to the bottom of the
reservoir.
NOTE when installing a hydraulic pump driven directly by generator set, provide a
device for shedding the vessel’s electrical mains network. Control box terminals
N° 21 negative and N° 22 positive give a signal that can be used for this purpose.
FILLING THE HYDRAULIC CUIRCIT
MAX POWER recommends the use of ISO GRADE 15 to 32 hydraulic oils for the
power circuit. This mineral oil has already been used by Max Power during the run in
tests and consequently the RETRACT motor and piping are already filled with this
kind off oil.
CAUTION Biodegradable and mineral (commonly used) oils are non-compatible and
should not be mixed or used together. Mixing them will deteriorate certain hydraulic
elements. If you intend to use a biodegradable oil, thoroughly flush the existing
mineral oil from the RETRACT unit first with the appropriate oil.
CONTROL SYSTEM INSTALATION
Although MAX POWER has used the best materials available, the installer should
endeavour to install all electrical equipment with the view that it should be in a
ventilated and dry environment at all times. Control panels mounted at helm stations
must be provided with watertight protection if the station is exposed to the weather.
All wiring must be insulated from ground and its installation executed in compliance
with safety and classification standards.
CONTROLL SYSTEM
The Retract R300 control system is all centralised in the electronic control box
All numbers indicated on our diagrams must be connected 1to 1 and 2 to 2 ,wire
sections must be respected to the letter .
All Retract equipment is connected to this box
All wires should be carefully labelled to reduce the chance of error and simplify
checking and troubleshooting.
9 INSTALLATION MANUAL RETRACT R 300
MAX POWER
All wire ends for terminals should be tinned before inserting into terminal blocks.
The control system of the RETRACT requires 30 amps of stabilised 24 v dc power.
If you are installing an EHP system you must use a different battery supply than
that used for the EHP power.
The 24 volt input power is automatically transformed to produce 12 volts for the
control panel use control panel only
The major power consuming components of the RETRACTS electrical system (the
raise/lower unit, the directional valve solenoids, and the electromagnetic clutch, or
power relays if EHP) are supplied with 24 volts from the control box.
Switching the thruster system on is achieved by a two-pole 32-amp circuit breaker
(not supplied by Max Power) which should normally be located on the main electrical
panel.
.
Power system wiring
(EHP only)
The same criteria’s as mentioned above applies. The electrical power cables must be
off a sufficient size (see diagram) and should be connected directly from the batteries
to the fuse ,main breaker, the power relays and finally the EHP.
There should be no other equipment or connections in the circuit. ( Use conductive
grease on the cable connections)
Cables that are specified larger than is possible to fit into the terminal blocks should
be thinned back and tinned to fit. They should not be forced into the terminal blocks.
Note : the Electro-pump does not have a specific polarity.
The supply cable diameter (area section) should be sufficient so that the voltage drop
between battery and motor is no greater than 2 volts for a 24 volts supply.
Always make your cable runs as short as possible
The most commonly found errors on EHP installations are voltage drop related
Excessive voltage drop will cause, low performance, over heating ,and
unreliability of power relays .
Optional equipment
An extra relay can be added on the negative battery wire and is controlled by
terminals 31 & 32 (same as the positive relay). This option is highly recommended in
aluminium , steel ,carbon fibber hulled vessels.
10 INSTALLATION MANUAL RETRACT R 300
MAX POWER
CHECKS, TESTS & ADJUSTEMENTS
BEFORE LAUCHING
IMPORTANT Before the launch, verify that the RETRACT unit inspection top plate
has been replaced (if it was removed during installation) and that all the lower flange
bolts have been tightened. Torque for all these bolts is 4 kg/m.
Before carrying out the below test we recommend to disconnect the wire at terminal
N° 32 in the control box.
→ Check all fittings for tightness and leaks.
→ The transmission is already filled with oil at the time of delivery.
→ Max Power uses HYPIOD HD 80W/90 oil in the transmission, therefore, fill the
transmission lube oil header tank with a similar grade oil. The function of this
lubricant tank is to ensure a constant pressure, as well as a visual control of
the oil-level. The tank should be filled to the ¾ level. Purge air in tube before
fitting the pipe to the RETRACT.
Perform UP / DOWN tests (standard joystick control panel).
→ Check UP / DOWN operation.
→ The up down unit has a second function; it blocks the turbine in the down
position when thrust is applied.
Move joystick to port or starboard and check that the up/down hydraulic pump
is puling the turbine down.
AFTER LAUNCHING
Check for water leaks.
Switch on the system power at the breaker and repeat the UP / DOWN tests.
Execute a few short left and right manoeuvres to fill the circuits and thereby purge
the system of all air. After each manoeuvre, check and fill if necessary, the hydraulic
tank. Repeat until the level remains stable. Do not allow the Electro-pump to run dry.
Warning All hydraulic systems develop very high pressures. Failure of piping,
connections etc that have been improperly installed, will most likely happen on start
up. Stay clear of these components. Wear eye protection, and be aware that highpressure oil can cause major skin damage.
Check the thrust direction :
With the Joystick to the left (port), the vessel should move to port and conversely. If
the direction is not correct, inverse to connectors on the hydraulic distributor.
Note he left and right thrust tests must be made under normal conditions of
use. In other words that means that the batteries are fully charged that the
main engine alternator is running and the batteries are being correctly
recharged. (if Electro-pump)
11 INSTALLATION MANUAL RETRACT R 300
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