vetus BOW1254DE Thruster Bow Instruction Manual

vetus BOW1254DE Thruster Bow

Product Information

The BOW1254DE is a bow thruster designed for marine vessels to improve maneuverability in tight spaces and adverse conditions. It comes with extended runtime capabilities for prolonged use.

Specifications

• Model: BOW1254DE
• Extended Runtime
• Part Number: 020580.03

Product Usage Instructions

Introduction
Read through the manual thoroughly to understand the installation and operation procedures for the bow thruster.

Safety
Ensure all safety precautions are followed during installation and use to prevent accidents or damage to the vessel.

Use
Operate the bow thruster according to the provided instructions to enhance the vessel’s maneuvering capabilities.

Installation Recommendations
Follow these steps for proper installation:

1. Position the thruster tunnel correctly.
2. Install the bow thruster in the thrust tunnel.
3. Connect the thrust tunnel to the ship’s hull securely.
4. Install grid bars in the tunnel openings for protection.
5. Drill holes in the thrust tunnel as needed.
6. Protect the bow thruster against corrosion.

Installation
Proceed with the installation process by:

1. Preparing for installation.
2. Mounting the tailpiece and intermediate flange.
3. Completing the final assembly.

Frequently Asked Questions (FAQ)

• Q: How do I choose the right battery for the bow thruster?
  A: Refer to section 6.1 in the manual for guidance on selecting the appropriate battery for optimal performance.

• Q: What should I do in case of technical issues?
  A: Section 7 of the manual provides information on common problems and troubleshooting steps to resolve them effectively.

Make sure that the user of the vessel is supplied with the owner’s manual.

Introduction

• These installation instructions give guidelines for fitting the Vetus bow thruster ‘BOW1254DE’.
• The quality of installation will determine how reliably the bow thruster performs. Almost all faults can be traced back to errors or imprecision during installation. It is therefore imperative that the steps given in the installation instructions are followed in full during the installa-tion process and checked afterwards.
• Alterations made to the bow thruster by the user will void any liability on the part of the manufacturer for any damages that may result.
• The thrust given by the bow thruster will vary from vessel to vessel depending on the effect of the wind, the water displacement and the shape of the underwater hull.

The nominal thrust quoted can only be achieved under the most favourable conditions:

• Make sure that the batteries are supplying the correct voltage during use
• During the installation process the ‘Installation recommendations for bow thrusters’, must be followed, specifically concerning:
  • Sufficiently large diameter of the battery cables so that voltage drop is reduced to a minimum.
  • How the tunnel has been connected to the hull.
  • Use of bars in the tunnel openings.
  • These bars should only be used where this is strictly necessary (if sailing regularly in severely polluted water.)
  • The bars must have been fitted correctly.

Following the above recommendations will result in longer life and better performance of your bow thruster.

• For maintenance, please consult the ‘Maintenance and Warranty Book’ supplied.
• Never allow the bow thruster to operate for a long period; the maximum length of usage is restricted because of heat release in the electric motor. After use the motor must be allowed to cool off.

Note
The maximum continuous length of usage and the thrust as specified in the technical details are based on the recommended battery capacities and battery cables. If significantly larger batteries in combination with very short battery cables of significantly larger diameter than recom-mended are used then the thrust will increase. In such cases, the maximum length of usage must be reduced to prevent damage to the motor.

Safety

Warning!
When using the bow thruster watch out for swimmers or light boats which could be in the near vicinity of the bow thruster tunnel openings.

Pass on the safety instructions to others using the bow thruster. General rules and laws concerning safety and accident prevention also need to be applied.

• Never touch the moving ends of the bow thruster whilst in opera-tion.
• Never touch hot parts of the bow thruster and never place flam-mable materials in the vicinity of the bow thruster.
• Always stop the bow thruster before checking components or adjusting the bow thruster.
• Always disconnect the battery terminals during maintenance work.
• Ensure maintenance work is safe by only using tools suitable for the purpose.
• Always deactivate the main switch when the bow thruster is not in use for long periods.

Use

• Switch on the main switch.
• Consult the handbook supplied with the control panels for in-structions on using the bow thruster.

Never switch in one movement from starboard to portside or reverse, but wait until the propeller stands still, before giving it a command to operate the electric motor in the opposite direction.

Care!
If 2 control panels are installed never operate the bow thruster from both panels simultaneously.

• Switch off the main switch when leaving the ship.
• Keep in mind that the carbon brushes in the motor release fine (black) dust. Do not store fragile equipment near the bow thruster motor.

Installation recommendations

Positioning of the thruster tunnel
Several installation examples.

To achieve the optimum performance, position the thruster tunnel as far forward as possible.

If, in addition to controlling the movement of the bow, the stern of the vessel is required to move sideways, then a second thruster may be installed at the stern.

• For a planning boat, the tunnel should, if possible, be so situated that when the vessel is planning it is above the water level thus causing no resistance.
• Installation of two bow thrusters in tandem (for larger boats). In this case, depending on weather conditions, one or both bow thrusters may be used.

Tip:
We do not advise fitting 2 bow thrusters into one tunnel; this does not result in doubling the thrust!

When choosing the location for the thrust tunnel, take the following into account for optimum performance:

• The distance A shown in the drawing must be at least 0.5 x D (where D is the tunnel diameter).
• The length of the tunnel (distance B) should be between 2 x D and 4 x D.

Positioning of the bow thruster in the thrust-tunnel
When determining the exact position of the bow thruster in the thrust tunnel, the tailpiece MUST NOT protrude from the tunnel end.

The propeller should preferably be situated on the centreline of the vessel, but it must always be accessible from the outside.

• The electric motor can be installed in various positions.
• If the motor is set up horizontally or at an angle, support is essential.
• The electric motor must be positioned in such a way that it is always well clear from the maximum bilge water level.

Connection of thrust tunnel to ship’s hull
Direct connection of the tunnel to the hull, without a fairing, produces reasonable results.

• A. The connection to the hull can be abrupt.
• B. It is better to make the connection rounded with a radius ‘R’ of about 0.1 x D.
• C. It is even better to use sloping sides ‘C’ with dimensions 0.1 to 0.15 x D.

Connection of the thrust tunnel to the ship’s hull with fairing results in lower hull resistance during normal sailing.

• A. The connection with a fairing can be abrupt.
• B. It is better to make the connection with a fairing rounded with a radius ‘R’ of about 0.1 x D.
• C. The best connection is with a fairing using sloping side ‘C’ with dimensions 0.1 to 0.15 x D.

Tip:
The manner, in which the thrust tunnel is connected to the hull, has a great influence on the actual performance of the bow thruster and to the drag the hull experiences when underway.

• Length ‘L’ of the fairing should be between 1 x D and 3 x D.
• This fairing should be embodied in the ship’s hull in such a way that the centreline of the fairing will correspond with the anticipated shape of the bow wave.
• If the connection of the thrust tunnel and the boat’s hull is to be made with a sloped side, it should be executed in accordance with the drawing.
• Make the sloped side (C) with a length of 0.1 to 0.15 x D and make sure that the angle between the tunnel and the sloped side will be identical to the angle between the sloped side and the ship’s hull.

Grid bars in the tunnel openings
Although the thrust force will be adversely affected, grid bars may be placed into the tunnel openings, for protection of the thruster.

To limit the negative effect of this on the thrust and hull resistance during normal operation as much as possible, the following must be taken into account:

• Do not fit more bars per opening than is indicated in the drawing.
• The bars must have a rectangular cross-section.
• Do not fit round bars.
• The bars must overlap a certain amount.
• The bars must be installed so they are perpendicular to the expected waveform.

Installation of the thrust tunnel

• Drill 2 holes in the hull, where the centreline of the thrust tunnel will be, by the diameter of the marking tool.

• Pass the marking tool (homemade) through both pre-drilled holes and mark the outside diameter of the thrust tunnel on the hull.
  D [mm] (inches)

  Steel| GRP| Aluminium
  267| 265| 264
  (10 33/64”)| (10 7/16”)| (10 25/64”)

• Depending on the vessel’s construction material, cut out the holes utilizing a jigsaw or an oxy-acety-lene cutter.
• Install the thrust tunnel.

Polyester thrust tunnel:

• Resin: The resin used for the polyester thrust tunnel is Isophthalic polyester resin (Norpol Pl 2857).
• Pre-treatment: The outside of the tunnel must be roughened. Remove all of the top surfaces down to the glass fibre. Use a grinding disc for this.
• Important: After the tunnel has been sawn to length, treat the end of the tube with resin. This will prevent water from seeping in.
• Laminating: Apply a coat of resin as the first coat. Lay on a glass-fibre mat and impregnate it with resin. Repeat this procedure until you have built up a sufficient number of layers.

A polyester thrust tunnel should be finished as follows:

• Roughen the hardened resin/glass fibre. Apply a top coat of resin.
• Treat the side of the tunnel that comes into contact with water with ‘epoxy paint’ or 2-component polyurethane paint.
• Then apply anti-fouling treatment if required.

Drilling the holes in the thrust-tunnel

• Mark the installation position of the bow thruster using the intermediate flange.
• Use the drill pattern supplied, to determine the correct position of the holes to be drilled.

Important:
The pattern of the holes must be positioned precisely on the centreline of the tunnel.

Consult the template for the dimensions of the holes to be drilled. Drill the holes through the thrust tunnel and take care that the holes are free of burrs.

Protection of the bow thruster against corrosion

• To prevent corrosion problems, do not use copper-based anti-fouling. Cathodic protection is a ‘must’ for the protection of all metal parts under water and the bow thruster is supplied with a zinc anode for this pur-pose.
• Corrosion of a steel or aluminium thrust tunnel can be reduced by ensuring that the tailpiece is completely insulated from the thrust tunnel.
• NOTE: The gaskets supplied are already electrically insulated. However, the bolts and the shaft need to be fitted with insulation material, for example, nylon bushes.

Installation

• To install the tunnel, consult Chapter 4 ‘Installation recommendations’.
• For overall dimensions see drawing.

Note
The areas in which the electric motor of the bow thruster and the battery are positioned must be dry and well-ventilated.

Preparation
The bow thruster will be delivered fully assembled. Perform the following steps:

• Remove the propeller.
• Remove the motor from the intermediate flange.
• Remove the intermediate flange from the tailpiece.

The 2 bushes are only required for transport and are now no longer needed.

Installation of the tailpiece and intermediate flange

• Ensure that the plastic shim plate (1) has been positioned on the tailpiece.
• Place one packing (2) between the tailpiece and the tunnel.
• Apply a sealant (e.g. polyurethane or silicone) between the tailpiece and packing, and between the packing and the tunnel wall.
• Place the tailpiece in the hole in the tunnel. Any extra packings used should be ones capable of justifying the tailpiece. *) e.g. Sikaflex®-292.
• Grease the hole of the intermediate flange and position this flange.
• Check dimension ‘H’; it must be between 77 and 80 mm (between 3 1/32” and 3 5/32”).
• If the dimension ‘H’ is less than 77 mm (3 1/32”), fit an additional gasket between the thrust tunnel and the intermediate flange.
• Check again dimension ‘H’.
• Now fit the intermediate flange permanently to the tailpiece and grease the threads of the bolts with ‘outboard gear grease’*) before inserting and tightening them.

Note
Check for possible leaks immediately the ship returns to water.

Final assembly

• Check again dimension ‘H’.
• Make sure that the key (1) is properly positioned in the keyway of the shaft.
• Grease the shaft with ‘outboard gear grease’*) and install the propeller (2) with the lock washer (3) and the hexagonal nut (4).
• Secure the nut by bending the tag of the washer.
• Fit the zinc anode (5) to the propeller shaft using the bolt (6)

The propeller should run a minimum of 1.5 mm (1/16”) free of the thrust tube wall, all around.

• Grease the input shaft with an installation compound, like ‘Molykote® G-n plus’
• Fit the flexible coupling to the input shaft of the tailpiece and secure the coupling with the locking screw.
• Grease the shaft of the electric motor with an installation com-pound, like ‘Molykote® G-n plus’.
• Grease the threads of the fastening bolts with ‘outboard gear grease’*) and install the electric motor to the intermediate flange. Use one of these bolts to fasten the relay support as well.
• For a first check, turn the propeller by hand, it should turn easily, whilst being connected to the output spindle of the electric motor.

Electrical installation

Check that the voltage, recorded on the motor-type plate, is in agreement with the vessel’s circuit voltage.

Choice of battery
The total battery capacity must be sufficient for the size of the bow thruster for the applicable battery capacity.

• We recommend Vetus maintenance-free marine batteries; these can be supplied in the following sizes: 55 Ah, 70 Ah, 90 Ah, 108 Ah, 120 Ah, 143 Ah, 165 Ah, 200 Ah and 225 Ah.
• We also recommend that each bow thruster is powered by its separate battery or batteries. This allows the battery bank to be placed as close as possible to the bow thruster; the main power cables can then be short thus preventing voltage losses caused by long cables.

Note

• Be sure to only use ‘sealed’ batteries if the batteries are located in the same compartment as the bow thruster.
• The Vetus ‘SMF’ and ‘AGM’ maintenance-free batteries are ideally suited to this application.
• Batteries that are not ‘sealed’ may produce small amounts of explosive gas during the charging cycle.
• Sparks generated by the carbon brushes of the bow thruster motor may ignite this explosive gas.

Always use batteries whose type and capacity are compatible with their use.

Caution
In extreme cases, for example, when a battery with a capacity of five times or more than suggested is used, there is the danger of causing permanent damage to one or more of the following shaft connections:

• The connection between the motor shaft and the tailpiece input shaft.
• The connection between the tailpiece output shaft and the propeller.

Main switch

• The main switch must be fitted to the ‘posi-tive cable’.
• The Vetus battery switch type BATSW600 is a suitable switch.

Main switch with remote control

• Instead of a storage battery main switch, a remotely controlled main switch annex emergency stop can be installed.
• This remotely controlled main switch is available for 12 or 24-volt DC. Vetus art. code: BPMAIN12 respectively BPMAIN24.

NOTE:
When using a series-parallel switch the main switch must be suitable for the board system voltage.

Use a 12 Volt main switch if a 24 Volt bow thruster has been connected in combination with a series-parallel switch to a 12 Volt on-board network.

Main power cables (battery cables)
The minimum diameter must be sufficient for the bow thruster’s current draw in use and the voltage drop must not be more than 10% of the voltage supplied, consult the table.

Note

• The maximum duration of engagement and the thrust, as specified by the technical details in your bow thruster installation and operating manual, are based on the recommended storage battery capacities and storage battery connection cables.
• If appreciably larger batteries in combination with very short connection cables with appreciably larger diameters than recommended are used then the thrust will increase. In such cases, the maximum operating time must be reduced to prevent damage to the motor.

Connecting the main power cables
Make sure that no other electrical parts come loose when connecting the electric cables.

Check all electrical connections after 14 days. Electrical parts (such as bolts and nuts) may come loose as a result of fluctuations in temperature.

• Connect the main power supply cables.

Note

• Be careful not to rotate the bolt and nut 1 while connecting the cables.
• To prevent this from happening, keep an open-ended span-ner on nut 1 while screwing on bolt 2, without rotating this spanner.
• The torque for nut 2 is 9 – 11 Nm (6.5 – 8 ft. lbf).

Fuses

• A fuse must be included in the ‘positive cable’ for the main switch, as close to the battery as possible.
• This fuse protects the on-board power cabling from short circuits. For all fuses, we can supply a fuse holder, Vetus part no.: ZEHC100. See the size of the fuse to be used.

Bow thruster control panels

• Fit the control panel next to the steering position. There must be at least 50 mm (2”) space behind the panel.
• If 2 bow thrusters have to be operated simultaneously, for example on a catamaran, consult the diagram.
• Fit the control cable between the bow thruster and the control panel through the vessel and connect the jack connections.
• If it is necessary to cut the intermediate cable and reconnect it take care to ensure the correct colours are connected.
• N.B: The colours of the wire cores in the intermediate cable may differ from the wire core colours used on the bow thruster motor and the control panel!

If there are two steering positions, the second control panel can be connected to the first one.

If it is found during test running that the thrust direction does not correspond with the direction switch on the control panel then the blue (no.

1. and the white (no. 4) wires on the relay must be interchanged.

Warning!

• Do NOT test the bow thruster while the ship is out of the water unless you are certain that everyone is at a safe distance from the thrust tube.
• Never allow the bow thruster to run for longer than 5 seconds with the ship out of water.

Delay when reversing the thrust direction
If a delay is desired where one of the following operating devices is installed, a delay switch can be installed.

Operating device:

• BPJSTA, separate turn switch (Joystick),
• BPSM, operating panel for side mounting,
• FSxx, foot switch button

Delay: Vetus art. Code: BPTD

Troubleshooting

• Check that the battery main switch is ‘ON’.
• Check whether the control panel fuse has burnt out. [1]
• Check if the main fuse has burnt out. [2] In all the above cases, the ‘POWER’ indicator LED is not lit.
• The electric motor has overheated and its thermal Protection has broken the circuit of the control current.
• The panel gives a warning signal three times ( . – . . – ) and the LED will glow red.
• As soon as the motor has cooled down enough, the LED will resume glowing green and the bow thruster can be put back in service.

Check if it is possible to turn the propeller. A piece of wood or similar could have been caught between the propeller and the tunnel.

The electric motor turns slowly

• The battery is flat.
• Bad electrical connection(s) due to e.g. corrosion.
• The carbon brushes are not making proper contact.
• The battery capacity is reduced because of very low temperatures.
• Weed or fishing lines have become caught in the propeller.

The control panel fuse is burnt out [1]

• Short circuit in the operating circuit; check the wiring.

The electric motor turns (too) fast but there is no thrust

• The blades of the propeller have been damaged by a foreign object having entered the propeller or tunnel.

After pressing the on/off switch on the panel, the panel is not switched on.

• The on/off switch must be pressed a second time within 6 seconds.
• The LED will then remain green and the buzzer will confirm that the panel is ready for use by giving the signal (- . -).

Technical Data

Type: BOW1254DE

Electric motor

• Type: reversible DC motor
• Voltage: 24 V DC
• Current: 470 A [3]
• Rated output: 5.7 kW
• No. of revolutions: 3650 rpm
• Rating: S2 – 10 min. [3]
• Protection: IP20

Motors conform to CE (2004/108/EC, EMC – EN55011, EN61000)

Transmission

• Gears: Bevel gear helical teeth
• Gear ratio: 2.33: 1
• Lubrication: oil bath, approx. 0.1 litre (3.4 fl.oz.) outboard gear oil SAE80W or EP 90
• Housing: bronze

Propeller

• Diameter: 246 mm (9 11/16”)
• No. of blades: 6
• Profile: asymmetrical
• Material: polyacetal (Delrin ®)
• Rated thrust: 1400 N (140 kgf, 315 lbf )

Control circuit

• Fuse: Blade type fuse ‘ATO’ 5 A
• Current solenoid switch: 1.4 A
• Control circuit wires: 1.5 mm2 (14 AWG)
• Extension cable: 6, 10, 16, 18 or 20 m (20’, 33′, 52′, 59′, or 65′)

Thrust-tunnel

Steel model

• dimensions: O.D. 267 mm, wall thickness 7,1 mm
• treatment: blasted, coated with SikaCor Steel Protect. Suitable for all kinds of protection systems.

Plastic model

• dimensions: O.D. 265 mm, wall thickness 7 mm
• material: glass fibre-reinforced polyester

Aluminium model

• dimensions: O.D. 264 mm, wall thickness 7 mm
• material: aluminium, 6061 or 6062 (AlMg1SiCu)

Weight

• Excl. thrust-tunnel: 36 kg (82 lbs)

Parts List

BOW1254DE

|  |  | Service onderdelen|

Service parts

---|---|---|---|---
pos.| qty| part| benaming| description
1| 1| BP3017E| Elektromotor 5,7 kW – 24 V| Electromotor 5.7 kW – 24 V
2| 1| BP37424| Set relais 24 V| Set of solenoid switches 24 V
3| 1| SET0130| Set van 8 stuks koolborstels| Set of 8 pcs of carbon brushes
4| 1| BPC00200| Relaiskap| Relais cover
5| 1| SET0006| Set van 2 stuks kartelmoeren| Set of 2 pcs knurled nuts
6| 1| BP117| Koppeling| Coupling
7| 1| BP194B| Tussenflens| Intermediate flange
8| 1| SET0163| Staartstuk compl.| Tailpiece compl.
9| 1| SET0151| Zinkanode compl. met schroef| Zincanode c/w screw
10| 1| SET0090| Schroef compl. met montageset| Propeller c/w mounting set
11| 2| BP118| Pakking 2 mm| Gasket 2 mm
12| 1| BP119| Pakking 1 mm| Gasket 1 mm
13| 1| BP170| V-ring| V-ring
14| 1| TS95| Thermische beveiliging| Thermal Protection
15| 1| BP256| Reserve zekering 5 A| Spare fuse 5 A

Fokkerstraat 571 – 3125 BD Schiedam – Holland
Tel.: +31 (0)88 4884700 – sales@vetus.com – www.vetus.com

References

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