SIDE-POWER PPC840 Sleipner Power Control Unit User Manual

SIDE-POWER PPC840 Sleipner Power Control Unit

PRODUCT INFORMATION

Technical specifications

| PPC840
---|---
Supply voltage| 36-60V
Output voltage| 20-100% x Vbatt
Output current| Max. 550A
Regulation| PWM, S-link controlled
Protection| Thermal, under-voltage, overcurrent
Dimensions (WxHxD)| 190x304x143mm

Compatible products

PPC 840

SPP 285 TC 48V
Thrust kg/lbs| Thruster Voltage| Model| Max output current
---|---|---|---
 |  | PPC840| 550A
285/628| 48 V

Dimensions PPC 840

(Drawing not to scale)

Planning and important precautions
Before installation, it is important that the installer reads this guide to ensure necessary acquaintance with this product.

• The thruster must NOT be installed in compartments that require ignition-proof electric equipment. If necessary, make a separate compartment.
• The electromotor will generate some carbon dust so that any storage compartment must be separated from the thruster to prevent the stored items from becoming dusty/dirty.
• If you are installing the Side-Power in a small room /compartment, it should be ventilated to ensure the cooling of the electromotor.
• If the height in the room you are installing the Side-Power is limited, the Side-Power can be installed horizontally or at any angle in between.
  • If the electromotor is positioned more than 30° off vertical, it must be supported separately.
  • The electromotor must be handled carefully. Do not lift it by the internal connections/main terminals or put it down on the driveshaft.
  • Beware to keep installation within the advised measurements. No part of the propeller or gearhouse must be outside the tunnel.
• The electromotor, its components, contacts/plugs, or other joints in the control cables must be mounted so that they will keep dry at all times.
• We advise you to paint the gearhouse and propellers with antifouling. PS! Do not paint the zinc anodes, sealings, or propeller shafts.
• Do not finish the inside of the tunnel with a layer of gelcoat / topcoat or similar. There is only room for a thin layer of primer and two layers of anti-fouling between the tunnel and the props.
• With the boat on land, only run the thruster for a fraction of a second, as without resistance it will accelerate very fast to a damaging rpm. Also, while the thruster is in the air, make sure that the propellers have come to a complete stop before performing a direction change of the thruster, as it might cause damage to the thruster.
• The PPC Power control unit should be installed in a dry, ventilated place – cable connections facing down. Mount unit with battery positive cable branching out at the unit terminal, not at the thruster motor. Allow free space at min 200mm over, 150mm under, and min. 100mm in front and at the sides. Take into consideration that a 5 m multicable shall be plugged in between the thruster motor and the PPC unit.
• This manual is intended to support educated/experienced staff and is therefore not sufficient in all details for the correct installation.
• Don’t install the electromotor at close range to easily flammable objects as it will reach over 100°C before the temperature switch is activated.
• Do not store items close to the thruster motor as it gets hot as well and any loose items near the thruster motor can cause problems with electrical wiring coming loose and short-circuiting.
• When installed in boats approved or classified according to international or special national rules, the installer is responsible for following the demands of these regulations/classification rules. The instructions in this guide can not be guaranteed to comply with all different regulations/classification rules.
• These instructions are only general instructions. If you are not skilled to do this work, please contact professional installers for assistance.
  • NB! Faulty installation of the tunnel, thruster, PPC Power Control unit, or panel will render all warranties given by Sleipner Motor AS void.

Note! Refer to the manual for the specific thruster used for correct sizing of battery capacity and cable dimensions.

DO NOT connect any other control equipment to the S-link controlled products except Side-Power original S-link products or via a Side-Power supplied interface product made for interfacing with other controls. Any attempt to directly control or at all connect to the S-link control system without the designated and approved interface will render all warranties and responsibilities for the complete line of Side-Power products connected void and null. If you are interfacing by agreement with Sleipner and through a designated Side-Power supplied interface, you are still required to also install at least one original Side-Power control panel to enable efficient troubleshooting if necessary.

Electrical installation

• Cable size
  • The cable lengths to be used for calculation are the total of A+B+C+D+E in Fig. 1.
• You must use the correct cable size and batteries with a high cranking capacity to feed the thruster because it is the actual voltage at the motor while running the thruster that decides the output rpm of the motor and thereby the actual thrust.
• A main switch that can take the load without a noticeable voltage drop must be installed in the main positive lead so the power for the thruster can be turned off independently of the rest when not on board or in emergencies. This should be placed in an easily accessible place and the boat’s instructions should inform that this should be turned off like the boat’s other main switches.
• We also advise installing a fuse in the positive lead for protection against short-circuiting of the main cables. This fuse should be of adequate quality which normally means that it is physically large as these have less voltage drop than the simple/small ones. It should be of the slow type and sized to take the amperage draw for at least 5 minutes.
• It is highly recommended to install a Side-Power Automatic Main Switch 897724, (from serial# 0017664 or higher). The AMS will be activated when the panel is turned on and contains an automatic short circuit fuse and a manual emergency stop. The AMS will also provide feedback to the panel regarding evt. faults.
• The cable ends must be fitted with terminals and these must be well isolated against contact with anything but the proper connection point.
• Terminals must be properly tightened. Secure/hold the inner nut when tightening (Fig. 2). Tighten the ø10mm / 3/8″ bolt with 15 Nm/11lb/ft.
  • Do NOT use washers between lugs and terminals, this can cause overheating. Washers must be placed in the outer position before tightening the nut.

Wiring diagram

Wiring diagram example

Charging of thruster battery bank
Onboard charging systems are most commonly 12V or 24V. When charging the 48V thruster battery bank a converter is required. It is the boatbuilder/installer’s responsibility to arrange this correctly.

Technical wiring diagram, thruster motor

Control panel and control-leads

Control panel installation:

• You can install as many panels as you wish by using optional Side-Power S-link T-connectors If two or more panels are operated at the same time in opposite directions, the thruster will stop. When two or more panels are operated in the same direction, the thruster output will be determined by the panel giving the largest signal.
• When using original Side-Power equipment it is all “plug & go”.
• If the drive direction of the thruster is the opposite of what is expected, the blue and grey wire must be changed on the thruster solenoid or the drive direction can be altered in the control panel SETUP (refer to control panel manual).
• The mechanical installation of the panel is described in the manual following the panel.
• The thruster control should be placed in a position where it is easy to use, and it is very common to use the thruster at the same time as your gear/throttle lever so it is normally a user-friendly solution to be able to access these with one hand for each control.

Important user precautions

• Ensure that you know the location of the main battery switch that disconnects the thruster from all power sources (batteries) so that the thruster can be turned off in case of a malfunction.
• Always turn the main power switch off before touching any part of the thruster, as an incidental start while touching moving parts can cause serious injuries.
• Always turn the control device off when the thruster is not in use.
• The maximum continuous usage time of the electrical thruster is approximately 3 minutes. The electromotor has a bbuilt-inthermal cut-off switch that will shut off the electromotor if it is overheating and re-engage it when it has cooled down some. This should be considered when planning your maneuvering.
• This also means that the thruster will limit its total running time per period so that you can not count on the thruster to hold you in a current and side wind for extensive periods. Depending on the surrounding temperatures etc. the thruster will be able to run approximately 10 % of the time.
• Never use a thruster close to somebody in the water, as the thruster will draw objects close by into the tunnel and contact with the rotating propellers will cause serious injuries.
• With the boat on land, only run the thruster for a fraction of a second, as without resistance it will accelerate very fast to a damaging rpm. Also, while the thruster is in the air, make sure that the propellers have come to a complete stop before performing a direction change of the thruster, as it might cause damage to the thruster.
• If the thruster stops giving thrust while the electromotor is running, chances are that there is a problem in the drive system. You must then immediately stop trying to run it, and turn it off, as running the electromotor for more than a few seconds without resistance from the propeller, can cause serious damage to the electromotor.
• When leaving the boat always turn off the main power switch for the thruster.
• We advise always keeping the main engine(s) running while using a thruster. This will keep the batteries in good charge condition. This will also give better performance to the thruster, as a higher voltage at the thruster results in a higher torque (power) in the electromotor.
• Please note that the performance of a thruster strongly depends on the voltage available at the electromotor. This voltage will decrease over time because aging batteries have a reduction of capacity. By installing new batteries the effect of the thruster should be back at the original level.
• Make sure that only one control is used at the same time, if two panels are operated in opposite directions at the same time the thruster will not run at all. If they are operated in the same direction the thruster will run in this direction.
• If the thruster is not performing or functioning as usual, the cause for this must be found and corrected as soon as possible to avoid causing any other or further damage to the equipment. You must also turn off the main battery switch immediately in case the problem is of electric origin.
• Never store anything (e.g. equipment, sails, ropes, etc.) in the same compartment as the thruster. When the thruster runs for a longer period it will get hot and will cause damage.

**How to use Side-Power thrusters

**

How to use a bow thruster

1. Turn main power switch for the bow thruster on. (Always turn off the main power switch when not on board.) A Side-Power Automatic Main Switch will turn on/off when the panel is turned on/off.
2. Please take some time to exercise thruster usage in open water to avoid damage to your boat.
3. Turn the control panel on by pushing both “ON” buttons on the original Side-Power panel simultaneously.
4. Move the joystick in the direction you wish the bow to move. Other controls like foot switches or toggle switches on the throttle can be used. These are connected to the S-link control system by an S-link interface (Refer to schematics in the interface manual for installation)
5. Depending on the sideways speed of the bow, you must disengage the control device shortly before the bow is in the desired direction, as the boat will continue to move after stopping the bow thruster.

How to use a single stern thruster
Some boats might however have installed a single stern thruster because of space limitations in the bow. In this case, the stern thruster is used in the same way as a single bow thruster or moving the boat’s stern.

How to use a bow and stern thruster combined
The combination of a bow and stern thruster offers total maneuverability to the boat and the opportunity to move the bow and the stern separately from each other. This enables you to move the boat sideways in both directions and to turn the boat around its axis staying at the same place. Refer to the PCJ control panel manual for detailed instructions.

• Again, if in doubt, try in open water first!

Troubleshooting

Before seeking assistance at the help desk of your Side-Power dealer/distributor please perform these tests and make notes of all measurements to ensure that they have as much information as possible to work on.

NB! All check points and solutions must be carried out after consulting the relevant information elsewhere in this manual to under-stand how the system is intended to work. If you are unable to understand what to check, you must consult a professional.

• The electromotor runs, but there is no thrust
  

  • Check
    If the flexible coupling between the motor and driveshaft is not fitted correctly inside the boat.

  • Solution
    Check the flexible coupling/shear pin and the motor installation to ensure the correct connection of the flexible coupling before re-fitting the electromotor.

  • Check
    Are the propellers in the tunnel fastened correctly on the prop shaft (key/drive pin present)

  • Solution
    Re-fasten or replace the propeller and/or key/drive pin.

  • Check
    With the motor removed, turn the driveshaft from inside the boat to feel if the gears are engaging and turning the prop shaft.
    Solution
    In case of a failure inside the gearhouse, we advise getting a replacement gearhouse instead of attempting to repair the internal gear and bearing system.

• The thruster does not start at all or works only in one direction
  

  • Check
    Refer to the PCJ Control Panel manual for detailed explanations of fault codes shown in the anel display.

  • Solution
    Check that a SCAN SYSTEM procedure has been completed according to the description in the panel manual.

• The thruster has an unexpectedly low performance.
  

  • Check
    Check the voltage at the thruster when running.

  • Solution
    If less than 42V the thruster will not perform at specified effect.

  • Check
    Check that all the brush springs sit correctly on the brushes in the electromotor.

  • Solution
    If one or more brushes are loose/have no tension from the brush-spring, the performance will be low.

  • Check
    Check that the propeller, gearhouse, and tunnel are free from growth/barnacles, etc.

  • Solution
    If there is growth in the tunnel, this will disturb/block the water flow, and especially barnacles on the propeller will greatly reduce performance.

Warranty Statement

1. The equipment manufactured by Sleipner Motor AS (The “Warrantor”) is warranted to be free from defects in workmanship and materials under normal use and service.
2. This Warranty is in effect for owo years (Leisure Use) or one year (Commercial use) from the date of purchase by the user. Proof of purchase must be included, to establish that it is inside the warranty period.
3. This Warranty is transferable and covers the product for the specified period.
4. In case any part of the equipment proves to be defective, other than those parts excluded in paragraph 5 below, the owner should do the following:
   • Prepare a detailed written statement of the nature and circumstances of the defect, to the best of the Owner’s knowledge, including the date of purchase, the place of purchase, the name and address of the installer, and the Purchaser’s name, address, and telephone number;
   • The Owner should return the defective part or unit along with the statement referenced in the preceding paragraph to the warrantor, Sleipner Motor AS,or an authorized Service Centre, postage/shipping prepaid and at the expense of the Purchaser;
   • If upon the Warrantor’s or Authorized Service Centre’s examination, the defect is determined to result from defective material or workmanship, the equipment will be repaired or replaced at the Warrantor’s option without charge, and returned to the Purchaser at the Warrantor’s expense;
   • no refund of the purchase price will be granted to the Purchaser unless the Warrantor is unable to remedy the defect after having a reasonable number of opportunities to do so. Before a refund of the purchase price, the Purchaser must submit a statement in writing from a professional boating equipment supplier that the installation instructions of the Installation and Operation Manual have been complied with and that the defect remains;
   • warranty service shall be performed only by the Warrantor, or an authorized Service Centre, and any attempt to remedy the defect by anyone else shall render this warranty void.
5. There shall be no warranty for defects or damages caused by faulty installation or hook-up, abuse or misuse of the equipment including exposure to excessive heat, salt or freshwater spray, or water immersion except for equipment specifically designed as waterproof.
6. No other express warranty is hereby given and there are no warranties which extend beyond those described in section 4 above. This Warranty is expressly instead of any other expressed or implied warranties, including any implied warranty of merchantability, fitness for the ordinary purposes for which such goods are used, or fitness for a particular purpose, and any other obligations on the part of the Warrantor or its employees and representatives.
7. There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and representatives for injury to any person or persons, or damage to property, loss of income or profit, or any other consequential or resulting damage or cost which may be claimed to have been incurred through the use or sale of the equipment, including any possible failure or malfunction of the equipment, or part thereof.
8. The Warrantor assumes no liability for incidental or consequential damages of any kind including damages arising from collision with other vessels or objects.
9. This warranty gives you specific legal rights, and you may also have other rights which vary from country to country.

SLEIPNER MOTOR AS P.O. Box 519 N-1612 Fredrikstad Norway www.side- power.com

DECLARATION OF CONFORMITY
We, Sleipner Motor AS P.O. Box 519 N-1612 Fredrikstad, Norway declare that this product with accompanying standard remote control systems complies with the essential health and safety requirements according to Directive 93/68/EEC.

PPC840 1.0.0 – 2017

References

• Sleipner - Ocean born. Tech bred.

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