vetus BOW22024D Electric Bow Thruster 220kgf Instruction Manual

Installation and user manual
BOW22024D
220 kgf – ø 300 mm

BOW22024D Electric Bow Thruster 220kgf

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

Owner’s Name and Address . . . . . . . . . . . .
Thruster model, Serial Number . . . . . . . . . . . .

BOW22024D – 220 kgf – ø 300 mm – 24 Volt
020529.06
Installation and user manual bow thruster BOW22024D

Safety

Warning indications
Where applicable, the following warning indications are used in this manual in connection with safety:

DANGER
Indicates that great potential danger exists that can lead to serious injury or death.

WARNING
Indicates that a potential danger that can lead to injury exists.

  Caution
Indicates that the usage procedures, actions etc. concerned can result in serious damage to or destruction of the engine. Some CAUTION indications also advise that a potential danger exists that can lead to serious injury or death.

  Note
Emphasises important procedures, circumstances etc.

Symbols
 Indicates that the relevant procedure must be carried out.
 Indicates that a particular action is forbidden.

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.

Pass on the safety instructions to others using the bow thruster.

WARNING
This product should only be installed and maintained by qualified personnel who have read and understood the instructions and precautions in this manual. Failure to follow the instructions in this manual may result in serious injury or property damage. The manufacturer shall not be liable for any damages resulting from improper installation or maintenance by unqualified personnel.

General rules and laws with regard to safety and accident-prevention also need to be applied.

• Never touch the moving ends of the bow thruster whilst in operation.
• Never touch hot parts of the bow thruster and never place flammable 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.

Introduction

These installation instructions give guidelines for fitting the VETUS bow thruster ‘BOW22024D’.
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 installation 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
• The installation is carried out in compliance with the recommendations given in this installation manual, in particular with regard to:
  – Sufficiently large diameter of the battery cables so that voltage drop is reduced to a minimum.
  – The manner in which 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 recommend- ed battery capacities and battery cables.
If significantly larger batteries in combination with very short battery cables of significantly larger diameter than recommended are used then the thrust will increase. In such cases the maximum length of usage must be reduced in order to prevent damage to the motor.

Installation recommendations

3.1 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 planing boat the tunnel should, if possible, be so situated so that when the vessel is planing 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. Note
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.

3.2 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 abso-lutely essential.
• The electric motor must be positioned in such a way that it is al-ways well clear from the maximum bilge water level.

3.3 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 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 a 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 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.

Note
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.

3.4 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.
In order to limit the negative effect of this on the thrust and on hull resistance during normal operation as much as possible, the follow-
ing 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.

3.5 Installation of the thrust tunnel

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

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

  Steel| GRP| Aluminium
  320 (12 19/32”)| 320 (12 19/32”)| 320 (12 19/32”)

• Dependent on the vessel’s construction material, cut out the holes by means of 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 Isophtalic polyester resin (Norpol Pl 2857).
Pre-treatment: The outside of the tunnel must be roughened.
Remove all of the top surface down to the glass-fibre. Use a grinding disc for this.
Important: After the tunnel been sawn to length, treat the end of the tube with resin. This will prevent water seeping in.
Laminating: Apply a coat of resin as the first coat. Lay on a glassfibre mat and impregnate 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 which comes into contact with water with ‘epoxy paint’ or 2-component polyurethane paint.
• Then apply anti-fouling treatment if required.

3.6 Drilling the holes in the thrust-tunnel

• Mark the installation position of the bow thruster by means of 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.

3.7 Protection of the bow thruster against corrosion
To prevent corrosion problems, do not use copper based antifouling. 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 purpose.

Corrosion of a steel or aluminium thrust tunnel can be reduced by ensuring that the tail piece 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

In order to install the tunnel, consult chapter 4 ‘Installation recommendations’.
For overall dimensions see drawing, page 106.

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

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

4.2 Installation tailpiece and intermediate flange

• Ensure that the plastic shim plate (1) has been positioned on the tail piece.

• Place one packing (2) between the tail piece and the tunnel.

• Apply a sealant (e.g. polyurethane or silicone) between the tail piece and packing, and between the packing and the tunnel wall.

• Place the tail piece in the hole in the tunnel.
  Any extra packings used should be ones capable of justifying the tail piece.
  *) e.g. Sikaflex®-292.
  

• Grease the hole of the intermediate flange and position this flange.

• Check dimension ‘H’; it must be between 49 and 54 mm (between 1 15/16” and 2 1/8”).

• If the dimension ‘H’ is less than 49 mm (1 15/16”), fit an additional gasket between the thrust tunnel and the intermediate flange.

• Check again dimension ‘H’.

• Now fit the intermediate flange permanently to the tail piece 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.
*) A suitable grease is VETUS ‘Shipping Grease’, Art. code: VSG.

4.3 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 by means of the bolt (6)

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

• Grease the input shaft with an installation compound, like ‘Molykote® G-n plus’
• Fit the flexible coupling to the input shaft of the tail piece and secure the coupling with the locking screw.
• Grease the shaft of the electric motor with an installation compound, like ‘Molykote® G-n plus’.
• Grease the threads of the fastenings 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.

*) A suitable grease is VETUS ‘Shipping Grease’, Art. code: VSG.

Electrical installation

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

5.1 Choice of battery
The total battery capacity must be sufficient for the size of the bow thruster. See page 107 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 own 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 for 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 motor shaft and the tail piece input shaft.
• The connection between the tail piece output shaft and the propeller.

5.2 Main switch
The main switch must be fitted to the ‘positive 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, (see page 111) 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 onboard network.

5.3 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 suppy a fuse holder, VETUS part no.: ZEHC100. See page 107 for the size of the fuse to be used.

5.4 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 on page 107.

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 diameter than recommended are used then the thrust will increase. In such cases the maximum operating time must be reduced in order to prevent damage to the motor.

5.5 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 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).

5.6 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 on page 110.

• Fit the control cable between the bow thruster and the control panel through the vessel and connect the jack connections together.
If it is necessary to cut the intermediate cable and reconnect it take care to ensure the correct colours are connected together.
N.B: The colours of the wire cores in the intermediate cable may differ from the wire core colours as used on the bow thruster motor and on the control panel!
If there are two steering positions, the second control panel can be connected to the first one.
5.7 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

Test run

WARNING!
Never operate the bow or stern thruster without load!
Switch off the bow or stern thruster immediately if it no longer provides thrust during operation!
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.

Use

WARNING!
This product should only be operated by persons who have read and understood the instructions and precautions in this manual. Failure to follow the instructions in this manual may result in serious injury or property damage. The manufacturer shall not be liable for any damages resulting from improper operation.

WARNING!
Never operate the bow or stern thruster without load!
Switch off the bow or stern thruster immediately if it no longer provides thrust during operation!

• 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.

Trouble shooting

Electric motor does not operate

• 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.

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 line has become caught in the propeller.

Control panel fuse is burnt out [1]

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

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

outboard gear oil SAE8OW or EP 90
Housing| bronze
Propeller|
Diameter| 295 mm (11 5/8″)
No. of blades| 7
Profile| asymmetrical
Material| polyacetal (Delrin ®)
Rated thrust| 2200 N (220 kgf, 495 lbf)
Control circuit|
Fuse| Blade type fuse ‘ATO’ 5 A
Current solenoid switch| 1.4 A
Thrust-tunnel|
Steel model|
dimensions| O.D. 320 mm, wall thickness 7,5 mm
treatment| blasted, coated with: SikaCor Steel
Protect. Suitable for all kinds of protection systems.
Plastic model|
dimensions| I.D. 300 mm, wall thickness 10 mm
material| glass fibre reinforced polyester
Aluminium model|
dimensions| I.D. 300 mm, wall thickness 10 mm
material| aluminium, 6061 or 6062 (AIMg1SiCu)
Weight|
Excl. thrust-tunnel| 68 kg (150 Ibs)

1. The control current fuse is in the bow thruster motor. A spare fuse can be found in the relay cap, see p. 114.

2. See table on page 107
   Length of usage:

3. 2.5 min. continuously or max. 2.5 min. per hour at 760 A (24 Volt).

Principal dimensions

Battery capacity, battery cables

Bow thruster| Battery capacity required| Total length of plus- and minus cable| Cable cross-section| Main power fuse, see 5.3
---|---|---|---|---
Minimum| Maximum| ‘slow blow’| VETUS art. code
BOW22024D
220 kgf – 24 V| CCA 1267| CCA 2533| 0 – 4,5 m|  0 – 14.8 ft| 50 mm²| AWG 00| 500 A| ZE500
---|---|---|---|---|---|---|---|---
4,5  – 6,3 m| 14.8 – 20.7 ft| 70 mm²| AWG 000
6,3  – 8,6 m|  20.7 – 28.2 ft| 95 mm²| AWG 0
8,6 – 10,9 m|  28.2 – 35.8 ft| 120 mm²| AWG 0000
10,9 – 12,6 m| 35.8 – 41.3 ft| 2 x 70 mm²| 2 x AWG 00
12,6 – 13,5 m| 41.3 – 44.3 ft| 150 mm²| AWG 300 MCM
13,5 – 17,1 m|  44.3 – 56.1 ft| 2 x 95 mm²| 2 x AWG 000
17,1 – 21,6 m| 56.1 – 70.9 ft| 2 x 120 mm²| 2 x AWG 0000
21,6 – 27,1 m| 70.9 – 88.9 ft| 2 x 150 mm²| 2 x AWG 300 MCM

Wiring diagram

Simultaneous operation of two bow thrusters with one panel

12.2 Series-parallel switch
Bow and stern thrusters that are only available for 24 Volts*) can be connected to a 12 Volt onboard network with the help of a seriesparallel switch.

By installing a series-parallel switch:

• the 2 (12 Volt) storage batteries will be engaged in series during use, so that the 24 Volt bow thruster receives the necessary 24 Volts of power.
• the 2 (12 Volt) storage batteries will be engaged in parallel during recharging, and can be  coupled to the 12 Volt charging system.

VETUS can provide a series-parallel switch that is ready to be connected to the VETUS 24 Volt bow thruster. VETUS art. code: BPSPE.
If the battery that has been installed for the bow thruster will also be powering other (12 Volt) systems, the following must be taken into account:
Both batteries will be providing power to 12 Volt systems via the charging current cables and charging current contacts of the seriesparallel switch.

WARNING
A continuous stream of at most 100A may be carried through the charging current contacts of the series-parallel switch, and at most an intermittent current of 150A at 20% duration of engagement. Never use these storage batteries as starting batteries and never
connect an anchor capstan to them.

Tip
If an isolating switch is included in the charging current cable, the storage battery sets can be isolated, should they not be charged for a long period of time, in order to prevent excessive discharging.
The way in which the bow thruster is to be operated will remain unchanged after a series-parallel switch has been installed!

1
2| 1| VP000074| Motor with solenoid for BOW220| Motor with solenoid for BOW220
1| SET0176| Set relais 24 V| Set of solenoid switches 24 V
3| 1| SET0131| 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| BP1074| Koppeling| Coupling
7| 1| BP1076B| Tussenflens| Intermediate flange
8| 1| SET0164| Staartstuk compl.| Tailpiece compl.
9| 1| SET0221| Zinkanode compl. met schroef| Zincanode c/w screw
10| 1| SET0171| Kunststof schroef compl. met montageset| Plastic propeller c/w mounting set
11| 1| BP1069| Pakking 2 mm| Gasket 2 mm
12| 1| BP1070| Pakking 1 mm| Gasket 1 mm
13| 1| BP1055| V-ring| V-ring
14| 1| TS110| 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 Printed in the Netherlands
020529.06 2023-10
Copyright © 2023 VETUS B.V. Schiedam Holland
020529.06

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