Copenhagen Subsea VS User manual

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Thruster Manual
Version 2.5
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Thruster Manual
The design and configuration of your Copenhagen Subsea thruster
might differ from the thruster pictured in this manual.

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Thruster Manual
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Approvals
Change History
Version no.
Changes
1.0
Initialization of document
1.1
Grammatical corrections
1.2
Connector interface and motor controller added
1.3
Maintenance section added
1.4
Graphical updates in Maintenance section
1.5
Grammatical corrections
1.6
Grammatical corrections
1.7
Record of conformity section added
1.8
Changes in Maintenance section and record of conformity section
1.9
Changes in: Assembly/disassembly, temperature conditions, sealing …
2.0
Changes in: Use loctite 577 on bolt and screws and insert bearing ring
2.1
Changes in: Mounting the Thruster - text added
2.2
Pt1000 noise removal using capacitor – explanation added
Warning added regarding the thruster – It has to be fully submerged
during operation
2.3
Changes in: Electrical connection
Operation header added - insert blue sealing plug when operating
2.4
Changes in: Warnings, Precautions against overheating and Storage
2.5
Section deleted: Zink anode
Section added: Electrical Isolation of the Thruster when Mounting
Changes in: Mounting the Thruster & CRE Marine
Replace Loctite 577 with AquaShield Grease
By Name
Date
Prepared
PNI
2016-04-14
Approved
ANB
2016-04-21
Released
ANB
2016-04-21

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Thruster Manual
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Contents
Thruster Manual ........................................................................................................................1
Mounting the Thruster ...............................................................................................................5
Electrical Isolation of the Thruster when Mounting.....................................................................6
Main Water Inlet........................................................................................................................7
Electrical Connection..................................................................................................................8
Subconn..................................................................................................................................... 8
SubConn10 pins ............................................................................................................. 8
SubConn16 Pins ............................................................................................................. 9
CRE Marine .............................................................................................................................. 10
C-Class 8 way ............................................................................................................... 10
J-Class 9 way................................................................................................................ 11
Motor controller interface........................................................................................................ 12
Precaution against overheating ................................................................................................ 12
Pt 1000 temperature sensor – noise removal ............................................................................ 12
Maintenance............................................................................................................................14
Operation ................................................................................................................................ 14
Storage Temperature ................................................................................................... 15
Flushing the thruster after use.................................................................................................. 16
Use AquaShield grease on bolts and screws .............................................................................. 17
Remove Propeller .................................................................................................................... 18
Insert Propeller ........................................................................................................................ 19
Remove bearing ring ................................................................................................................ 20
Insert bearing ring.................................................................................................................... 22
Remove Rotor.......................................................................................................................... 23
With propeller: ............................................................................................................ 23
Without propeller: ....................................................................................................... 24
From inlet side:............................................................................................................ 25
Insert rotor .............................................................................................................................. 25
Disposal of the thruster............................................................................................................28
Record of Conformity ...............................................................................................................28

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Warnings
The design and configuration of your Copenhagen Subsea thruster might differ from the thruster pictured
in this manual.
Disconnect the thruster from power when handling it.
Operate the thruster under water only. The warranty will not cover damages resulting from
running the thruster without water to lubricate its bearings.
Connect the aluminum housing of the thruster to a sacrificial zinc anode to prevent corrosion.
If the thruster is exposed to liquids other than seawater or freshwater with a PH value between 6
and 9, the warranty will not cover any direct damages or any following damages.
Make sure the motor temperature is always below 70 degrees Celsius.
Use only Copenhagen Subsea A/S specially designed transport boxes for transportation.
Under no circumstance disassemble the rotor from the stator without using the appropriate tools
as described in this manual as this may cause personal injury due to the strong magnetic forces
that hold the rotor in place.
Be aware of the thruster is delivered with no propeller safeguarding to prevent access to the
rotating propeller to protect against human injuries. Therefore, consider mounting a propeller
guard when installing the thruster into your application or take other safety precautions.
During operation the thruster needs to be fully submerged in water.

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Mounting the Thruster
•Use the four holes pattern on the mounting flange when mounting the thruster.
•Make sure the mounting bracket on your application is robust and stable.
•See drawing below for mounting holes pattern
•Use a bit of AquaShield grease on the thread of the M8 mounting bolts when mounting the
thruster.
•The material of the bolts has to be A4 and with the help of a torque wrench (18 Nm) screw in the
bolts in a criss-cross tightening sequence.
•The bolt must be mounted so that it has at least 12mm of its thread inside the mounting flange.
•It is essential to occasional retighten the mounting bolts with help of a torque wrench (18 Nm)
Mounting holes pattern for:
VS, VM, VL and VXL thrusters

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Electrical Isolation of the Thruster when Mounting
It is important to electrocally isolate the thruster when mounting the thruster onto the application. The
reason for this is to avoid corrosion and cathodic debonding. When ordering a propulsion solution from
Copenhagen Subsea, the necessary equipment to electrically isolate the thruster is included. For each
thruster unit following set of washers follows:
•2x plastic shoulder washers
•1x flat plastic washer
Depending on the thickness of the mounting bracket, different set of washers shall be used.
•If the mounting bracket is thick enough to use a shoulder washer on both sides of the mounting
bracket – the following set of washers are needed: (2x plastic shoulder washers)
Insert the plastic shoulder washer on both side of the mounting bracket and add a steel washer
between the mounting bolt and the plastic shoulder washer.
•If the mounting bracket is too thin to insert a shoulder washer in both sides on the mounting
bracket – the following set of washers are needed: (1x plastic shoulder washer & 1x flat plastic
washer)
Insert the shoulder washer between the thruster and mounting bracket. Hereafter, add the flat
plastic washer and a steel washer between the mounting bolt and the mounting bracket.
Plastic Shoulder
Washers
Steel Washer
M8 Bolt

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Main Water Inlet
To detect the main water inlet side of the thruster, look for the screws on the inside of the propeller. The
main water inlet is on the opposite side of the propeller blades from these screws.
Plastic Shoulder
Washer
Flat Plastic
Washer
Steel Washer
M8 Bolt

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Electrical Connection
When order thruster(s) from Copenhagen Subsea the thruster can be supplied with different connectors.
Copenhagen Subsea determine suitable connectors together with the customer for each indiviaual case.
When receiving the thruster the connector supplied for the thruster is either:
•CRE underwater connectivity - http://www.cre-marine.com/index.html
•Macartney - Subconn - https://www.macartney.com/what-we-offer/systems-and-
products/connectors/subconn/
Subconn
If the thruster is provided with a SubConn connector, please find the correct connector and read the
information below.
SubConn10 pins
In order to supply the motor with sufficient power from the motor controller, each of the 3 phases of the
thruster has been divided over two seperate pins on the connector:
Connector type: SubConn Circular 10 pins (OM10M)
Pin Connection
Phase 1
1 and 2
Phase 2
3 and 4
Phase 3
5 and 6
PE (Protected Earth)
7 and 8
Temperature Sensor
9 and 10
For handling instructions, please see SubConn book on the following link:
https://www.macartney.com/what-we-offer/systems-and-products/connectors/subconn/subconn-book/
For connector details, please click on the following link https://www.macartney.com/what-we-
offer/systems-and-products/connectors/subconn/subconn-circular-series/subconn-circular-6-8-and-10-
contacts/

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SubConn16 Pins
In order to supply the motor with sufficient power from the motor controller, each of the 3 phases of the
thruster has been divided over four seperate pins on the connector:
Connector type: SUBCONN circular 16 pins (OM16M)
Pin Connection
Phase 1
1, 2, 3 and 4
Phase 2
5, 6, 7 and 8
Phase 3
9, 10, 11, and 12
PE (Protected Earth)
13 and 14
Temperature Sensor
15 and 16
For handling instructions, please see SubConn book on the following link:
https://www.macartney.com/what-we-offer/systems-and-products/connectors/subconn/subconn-book/
For connector details, please click on the following link: http://www.macartney.com/what-we-
offer/systems-and-products/connectivity/subconn/subconn-circular-series/subconn-circular-12-16-and-25-
contacts/

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CRE Marine
If the thruster is provided with a CRE Marine connector, please find the correct connector and read the
information below.
C-Class 8 way
In order to supply the motor with sufficient power from the motor controller, each of the 3 phases of the
thruster has their individual pin on the connector:
Connector type: CRE C-Class 8 ways (PLCO8M)
For handling instructions, please see on the following link: http://www.cre-marine.com/support.html
For connector details, please click on the following link: http://www.cre-
marine.com/electrical_connectors.html
Pin Connection
Phase 1
3
Phase 2
5
Phase 3
7
PE (Protected Earth)
1
Temperature Sensor
8 and 2
N/A
6
N/A
4

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J-Class 9 way
In order to supply the motor with sufficient power from the motor controller, each of the 3 phases of the
thruster has their individual pin on the connector:
Connector type: CRE C-Class 8 ways (PLJ09M)
For handling instructions, please see on the following link: http://www.cre-marine.com/support.html
For connector details, please click on the following link: http://www.cre-
marine.com/electrical_connectors.html
Pin Connection
Phase 1
2
Phase 2
3
Phase 3
4
PE (Protected Earth)
1
Temperature Sensor
8 and 5
N/A
6
N/A
7
N/A
9
1
2
3
4
8
5
9
7
6

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Motor controller interface
For electrical connection and communication to the motor controller, please see the user documentation
of the motor controller supplied with the thruster.
Precaution against overheating
Make sure the motor temperature is always under 70 degrees Celsius. Set this limit as the maximal
motor temperature in the motor controller.
Pt 1000 temperature sensor – noise removal
M
otor temperature is monitored via a Pt1000 resistor placed as close as possible to the motor windings.
Linear relationship between resistance/temperature together with an analog converter gives a very
accurate temperature measurement. However, being the sensor close to the winding makes it behave
like an antenna, meaning that pulses will be induced at the switching frequency.
This can be seen in the next Figure, where pulses at 16 kHz (switching frequency supplied to the motor)
appear to have a peak to peak value of 8.7 V.
Most analog converters have a low pass filter good enough to make the signal from the Pt1000 sensor
stable and usable to read temperature. If this is not the case and the noise is too high, it is then
recommended to consider the use of a small capacitor in parallel with the analog converter input. See
Figure below.

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In the following Figure, the results of using 1 capacitor (rated 1 µF / 63 V) can be seen. Peak to peak value is
reduced from 8.7 V to 2.05 V and RMS is reduced from 402.2 mV to 77.1 mV.

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Maintenance
The thrusters from Copenhagen Subsea A/S, are due to their construction, extremely robust and durable -
but is nevertheless important to take good care of your thruster. Proper care will ensure a long life time of
the thruster, and provide reliable operation for many years to come.
Besides flushing the thruster with fresh water after use, visual maintenance inspection of the inside of the
thruster is required to ensure that the inside space is clean. Dirt must be cleaned-off with a piece of water
soaked cloth – do not use any chemicals.
The first visual maintenance inspection has to be done after 50 hours of operation. Hereafter the visual
maintenance is only be required after each 200 hours of operations for the rest of the thruster’s lifetime.
To perform the visual maintenance inspection on the rotor and stator, it is necessary to partly disassemble
the motor. This is done by removing the bearing ring and pulling out the rotor as described in the
procedure below. Maintenance video can also be seen in
https://www.copenhagensubsea.com/maintenance
The rotor may be pulled out from both sides, depending on which side is most accessible. However, the
preferred side is the outlet side.
Operation
Before launching the thruster into the water, insert the blue sealing plug in the flushing holes on the flange
ring. The sealing plugs are included in the order, when ordering a propulsion solution from Copenhagen
Subsea A/S.
•If the thruster is the compact configuration, insert the blue sealing plug on both sides of the
thruster.
•If the thruster is the symmetric configuration, insert the blue sealing plug on both sides of the
thruster.
•If the thruster is the asymmetric configuration, insert only the blue sealing plug in the side of the
outlet.

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Storage Temperature
Operating temperature (water temperature surrounding the thruster) is between -5 ºC to 40 ºC. Storage
temperature for thruster is from -45 ºC to 60 ºC.
Always make sure that the thruster temperature during operation (sensed temperature inside the thruster)
does not exceed 70 ºC. All thrusters are equipped with a Pt1000 sensor that allows easy and stable
temperature readings.
If the thruster is to be operated or stored in air temperatures below 0 ºC, below procedures must be
followed to prevent the rotor from being locked by ice:
After recovery: When recovering the thruster from water to air temperatures below 0 ºC:
•Power-off the thruster.
•Blow out any remaining water from the thruster by applying a light air pressure through the
flushing hole.
•Flush the thruster with an antifreeze fluid with a mixture ratio of 4/5 (antifreeze/water)
•Turn the rotor by hand to distribute the anitifreeze fluid.
Before launch into water: When a thruster with a material temperature below 0 ºC is submerged, the
water can crystalized on its surface, and if the thruster is started instantly the ice can prevent the thruster
from rotating freely, with subsequent overheating. To avoid this, it is important to heat up the thruster
before launching into water.

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Flushing the thruster after use
To extend lifetime of the thruster, it should be flushed with fresh water after use.
When flushing the thruster, the power must be disconnected.
•The thruster has the blue sealing plug placed in the flushing hole - remove this blue sealing plug
and insert the blue coupling nozzle instead.
•A Ø6x1 hose fits the coupling nozzle.
•Mount a hose to the coupling nozzle and flush with a lot of fresh water through the hose.
Max 3-4 bar
•Turn the propeller round by hand during flushing.
Important note: The coupling nozzle has to be sealed during operation so that no small particles (sand,
sediments, etc) can flow through and cause possible erosion on the inner surfaces of the thruster.
Coupling nozzle

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Use AquaShield grease on bolts and screws
All bolts and screws have been fixed with AquaShield grease from the manufacturer. Contact the
manufacturer to find the nearst dealer of AquaShield grease.
https://www.houghtonintl.com/en/products/aquashield%E2%84%A2#:~:text=AQUASHIELD%E2%84%A2
%20%E2%80%93%20Houghton%20International
If a thruster bolt or a screw has to be changed, swapped or re-fixed, always add a bit of AquaShield
grease on the thread. Use a torque wrench to make sure the screws are properly tighten according to the
following values:
•For inlet and outlet rings: 2 Nm
•For bearings : 4.6 Nm
•For propeller: 3.6 Nm

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Remove Propeller
The power must be disconnected from the thruster when replacing the propeller.
•The outlet ring closest to the propeller screws must be removed.
•Remove the outlet ring by loosening and removing the M5 Socket head cap screws from the
thruster.
•Be careful not to damage the coupling nozzle when removing the outlet ring.
•Loosen and remove all six M5x8 Socket countersunk head screws from the inside of the propeller.
•
Gently drag the propeller out of the thruster.

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Insert Propeller
•Gently press the propeller into the thruster.
•Be aware of aligning the M5 threads and the holes for screws when inserting the propeller.
•Add a bit of AquaShield grease on the thread of all six M5x8 socket countersunk head screws.
•Mount the M5x8 socket countersunk head screws on the inside of the propeller and tighten
them.
•Be careful not to damage the coupling nozzle when adding the outlet ring to the thruster.
•Add a bit of AquaShield grease on the thread of all the M5 socket head cap screws.
•Mount all the M5 socket head cap screws into the outlet ring and thruster and tighten them.

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Remove bearing ring
•Remove the thruster outlet ring in the same order as described in the “remove propeller” section.
•Remove the 6 screws from the bearing ring
•Make sure the holes are clean: remove previously applied AquaShield grease
•Place the bearing puller parallel with the bearing ring and align the 3 pins with 3 of the 6 holes
going through the bearing ring. Make sure the 3 pins stand firmly on the bottom of the screw holes
•Be careful not to damage the coupling nozzle when placing the bearing puller.
•Make sure that the main handle is fully retracted, that the puller plates are close together, and that
the 3 pins stand firmly on the bottom of the screw holes.