Exalto 255BS User manual

Quality Marine Equipment
Type: 255BS
Exalto windshield wiper
Cat. nos. 211255.35/211255.65 (12V) - 212455.35/212455.65 (24V)

Safety
Exalto windshield wipers are easy to install, yet a fair amount of technical
knowledge (mechanical and electrical) is required of the installer. Please
consult the manual or contact your vendor in case of doubt during installation
or malfunctioning.
Safety symbols
An exclamation mark in front of the text warns you, that injury or damage can
occur if a procedure is badly performed.
Dangers
The installation and use of Exalto wipers will not inflict any personal dangers or
damage, provided that installation is done according to the procedures
specified in the manual.
• Never remove covers or other safety provisions, unless maintenance is being
performed and all safety requirements are obeyed.
• The installer must provide all necessary covers.
• Always disconnect the electrical circuit when performing maintenance.
Prevent the installation from being started (accidentally) by others.
Safety provisions
The safety provisions will protect the user against contact with moving,
electrical or hot parts. Some of them have to be provided by the installer.
There are several safety provisions:
• This wiper comes complete with a built-on cover. It prevents users from direct
contact with moving parts of the motor. Never remove this safety provision.
• Make sure the wiper has enough ventilation when placing it behind a panel
or cover.
• Place a fuse (see specifications) in the main cable.
Safety requirements
Before the Exalto wiper is installed, we strongly recommend the following:
• Read the entire manual before installation.
• Make sure your working environment as well as the wiper parts are clean.
• Check to be sure no parts are missing or damaged.
• Use only high quality tools and have them within reach when installing.
• Handle the parts with care.
2
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• Never install or maintain the wiper with the electrical voltage applied, unless
this is specifically mentioned in the manual.
• Clear your tools after installation.
Use of the manual
Read the entire manual before installation. In this manual you can find the
following expressions and symbols:
Hint!
Gives you advice on how to perform a task more easily.
Attention!
Alerts you to possible problems and safety warnings.
3
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Contents
1 Introduction ........................................................... 5
1.1 Introduction ...................................................... 5
1.2 Environmental factors ............................................. 5
1.3 Modified use and guarantee conditions ............................ 5
2 Technical data ......................................................... 6
2.1 General ........................................................... 6
2.2 Electrical data 12 and 24 Volt ...................................... 6
2.3 Mechanical data................................................... 6
3 Installation ............................................................ 7
3.1 Preparation ....................................................... 7
3.2 Installation of mechanical parts .................................... 7
3.3 Electrical installation .............................................. 8
3.4 Final installation................................................... 9
4 Operation and use....................................................11
4.1 Preparation for first use...........................................11
4.2 Use ..............................................................11
5 Maintenance..........................................................12
5.1 General maintenance.............................................12
5.2 Servicing.........................................................12
5.3 Changing the wipe arc and park position..........................12
5.4 Rough determination of wipe arc and wiper blade.................13
5.5 Disassembly and assembly .......................................14
6 Troubleshooting......................................................15
7 Declaration of conformity ............................................16
8 Parts list ..............................................................17
9 Drawings and schemes ...............................................18
9.1 Assembly overview...............................................18
9.2 Internal wiring diagram...........................................19
4

1 Introduction
With this user manual we want to guide
you thru the installation and use of the
Exalto windshield wiper. Please follow all
instructions and install all safety
provisions.
1.1 Introduction
The Exalto windshield wipers are
especially designed to keep working even
with the most extreme weather conditions
at sea.
All external parts are made of corrosion resistant materials. The housing of the
self-lubricating bearings is made of bronze. All arms and blades have a black,
weather-resistant coating, to prevent reflection of the sunlight.
Wiper type 255BS is designed to be mounted in the bulkhead or in the glass
window. The wiper arc is stepless adjustable from 40° to 90°. Standard the
255BS is supplied for a bulkhead thickness of 35mm and 65mm. The
pantograph arms have adjustable lengths; between 750mm and 1000mm. The
motor of the 255BS has insulated earth return.
1.2 Environmental factors
In the wiper, materials are used that are harmful for the environment
(e.g. copper). The parts of the wiper can be re-used or recycled. No harmful
substances are disseminated when using or disassembling the wiper.
1.3 Modified use and guarantee conditions
All modifications or defects in the product are subject to the Orgalime General
Conditions of Sale. Please contact your vendor in case of any questions or if you
want to use Exalto wipers in a non-maritime environment or other applications.
5

2 Technical data
2.1 General
• Product ....................... Exalto windshield wiper
• Type .......................... 255BS
• Catalogue numbers ........... 211255.35 211255.65 (12V)
............................. 212455.35 212455.65 (24V)
2.2 Electrical data 12 Volt
• Torque (max.).................. 55 Nm
• Voltage ....................... 12 Volt
• Current ....................... 7A
• Power consumption (max.) .... 84 W
• Number of revolutions ........ Low 38 rpm, high 60 rpm
• Recommended cable .......... 5 wires, 1½ (16 g) or 2½ mm² (14 g)
............................. up to 10 m long
• Recommended fuse ........... 8 A slow blow
• Grounding .................... Insulated earth return
Electrical data 24 Volt
• Torque (max.).................. 55 Nm
• Voltage ....................... 24 Volt
• Current ....................... 4 A
• Power consumption (max.) .... 96 W
• Number of revolutions ........ Low 38 rpm, high 60 rpm
• Recommended cable .......... 5 wires, 1½ (16 g) or 2½ mm² (14 g)
............................. up to 10 m long
• Recommended fuse ........... 6 A slow blow
• Grounding .................... Insulated earth return
2.3 Mechanical data
• Dimensions ................... L x w x h = 250 x 126,7 x 126 mm
• Bearing diameters ............. Drive shaft Ø 20 / support shaft Ø 20 mm
• Mounting ..................... Through glass or bulkhead
• Bearing ....................... Bronze housing, self-lubricating
• Wiperarms .................... Model P10 up to 1000 mm
• Wiperblades .................. Up to 1200 mm
• Wipe arc ...................... Wipe arc slot 40°-90°,stepless adjustable
• Number of revolutions ........ Low 38 rpm, high 60 rpm
• Weight ........................ Approx. 4,80 kg
6

3 Installation
Read the chapter on safety. Check before installation if the parts are all present
and undamaged. In case of errors, contact your vendor.
3.1 Preparation
The complete wiper, with packaging, can be handled and transported by hand.
Leave the wiper in the packing, until you are ready to install it; this to reduce
the risk of damage. Make sure all parts, tools and other means are ready.
3.2 Installation of mechanical parts
1. The wipe arc of your wiper is not set. Please follow steps described in
paragraphs 5.3 and 5.4 to set the wiping arc prior to installation.
Determine the place where the wiper is to be installed. The dimensions are
shown below. The wiper can be installed in any position.
7

Attention!
When installing the wiper, reserve space for a housing or cover.
2. Place the windshield wiper in the pre-drilled holes of the bulkhead (see
figure). A rubber sealing plate must be placed at both sides of the
bulkhead.
Attention!
Do not fit the wiper arm before finishing the electrical connections.
3.3Electrical installation
3. Install a wiper switch in the dashboard.
Wiring diagram 255BS 12/24 Volt
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tape
4. Connect the wiper to the ship’s electrical installation; see the drawing above
(and the colour codes at page 19). Use a cable with 5 wires with a diameter
of at least 1½ mm2(16 g) up to a maximum length of 10 m. Use larger
diameters when using longer cables.
5. Fit a slow blow fuse of 8A (12Volt) or 6A (24 Volt) in the main cable.
6. Connect the switch to the wiper (refer to the switch manual for installation).
3.4 Final installation
7. Switch on the power and test the motor briefly. Wait until the motor stops
after turning off the switch. The motor will be in park position. The
standard park position is shown in the figure
under point 8.
Hint!
If you have doubts regarding the park position,
make a vane with tape to simulate the position of
the arms.
Attention!
The 255BS is suitable for wiper arms model P10 up
to 1000 mm and wiper-blades up to 1200 mm.
8. Place the wiper arm with the blade on the shafts. Fasten the nuts loosely
onto the shafts.
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Attention
To ensure the arm has the right spring pressure, install the wiper arm in such a way
that the shaft makes a 90° angle with the window (figure left) ánd that the shaft
makes a 90° angle with the wiper arm (figure right). If this is not the case, please
install spacer(s) to make the 90° angles.
9. Switch on the power and test the motor briefly again to check the wiped
area.
10. If the wipe arc is correct, adjust the position and the length of the arm if
necessary. Tighten the nuts properly now.
10
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4 Operation and use
4.1 Preparation for first use
If the wiper has been installed and been adjusted, the system can be prepared
for first use. We recommend a thorough inspection of the system to ensure
proper operation.
Check:
• if there are no leaks where the shafts go through the bulkhead;
• if the wiping arc cleans the entire window;
• if the park position is correct.
If the wiping arc or the park position is wrong, adjust them again. Follow the
procedure in paragraph 5.3.
4.2 Use
All Exalto windshield wipers are provided with the following functions:
• low speed;
• high speed;
• self parking.
Do not use the wiper on a dry window; excessive wear of the blades and the
motor can occur in this case. Clean the wiper arm frequently with fresh water
(see also paragraph 5.1).
Because of the big variety of wiper switches, we refer to the user manual of the
installed switch to learn about the functions of that specific switch.
11

5 Maintenance
5.1 General maintenance
To keep the Exalto wiper in good condition, you are advised to:
• clean wiper, arms and blades with fresh water after every journey in salt water
(to prevent salt from clogging moving parts);
• never use the wiper on a dry window.
5.2 Servicing
As long as the wiper system functions normally and is kept in good shape (see
paragraph 5.1), servicing the motor is not necessary. Check yearly (monthly
when used intensively) if the wiper blades are worn. Replace blades when worn
or when the blades leave many stripes across the glass. In case of failure or
adjustments, have servicing done solely by qualified mechanics. In chapter 6,
Troubleshooting, a list is given of possible problems and their solutions.
5.3 Changing the wiping arc and park position
If the wiped area is not optimal, the wipe arc and park position can be changed.
Always isolate the electrical circuit before opening the housing.
Adjusting the wipe arc
• Isolate the electrical circuit;
• Move the screw in the slot from the shaft lever away from the shaft for a
smaller and towards the shaft for a larger wipe arc
• Fasten the nut again (max 33Nm/24,34 ft.lbs)
• Run the motor briefly to park it
• Place the motor lever in the desired park position(see text below)
12

L
D
E
GH
GW
W
H
D= distance top side
glass to center
of spindles
E= eye level
GH = glass height
GW= glass width
H= vertical displacement
L= length of arm
W= width of wiped area
EXAMPLE
1000
900
800
700
600
500
400
300
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
40°
45°
50°
55°
60°
65°
70°
75°
80°
85°
90°
Wipe arc
Armlength (L)
Wiped area width (W)
Determination of wipe arc
Units in mm
Adjusting the park position
• Place the motor lever loose on the shaft, parking right or left(see drawing in
paragraph 3.4 and below for reference)
• Place the motor lever in such a way that it forms an almost straight line with
the connection lever(see drawing)
• Tighten the motor lever well now
• Place the wiper in the bulkhead
• Adjust the wiper arm to the correct length, if necessary.
Mount the wiper motor assembly and test run the wiper for a few minutes to
check if everything works well.
5.4 Rough determination of wiping arc and wiper blade
With this method the wiping arc and the
wiper blade length can roughly be
determined. Please contact your vendor
to calculate your configuration more
accurately.
•Determine length of pantograph arm
(L): L = E + D
•Get the maximum wiped area width
(W): W = ±0.9 * GW
•Find the intersection of L en W in the diagram below;
•The wipe arc-line closest to the intersection, shows the wipe arc;
•Find in the table below the vertical displacement of the blade (H);
•Now the wiper blade length can be calculated:
13

90°
86
103
117
132
146
161
176
190
205
220
234
249
264
278
293
263
250
105
85°
92
79
119
132
145
158
197
184
171
210
223
236
94
80°
82
70
105
117
129
140
175
164
152
187
199
211
222
234
83
75°
73
62
93
104
114
124
155
145
135
165
176
186
196
207
73
70°
63
55
81
90
100
109
136
127
118
145
154
163
172
181
63
65°
55
47
71
79
86
94
117
110
102
125
133
141
149
157
54
60°
47
40
60
67
74
80
100
94
87
107
114
121
127
134
45
55°
40
34
51
57
62
66
85
79
74
90
96
102
107
113
36
50°
33
26
43
47
52
56
70
66
61
75
80
84
89
94
30
45°
27
23
35
38
42
46
57
53
50
61
65
68
72
76
25
40°
21
19
26
30
34
37
45
43
40
48
51
54
57
60
400
Armlength (L)
350
300
450
500
550
600
750
700
650
800
850
900
950
1000
Determining the vertical displacement of the wiper blade
Wipe arc
Vertical displacement of the blade (H)
Units in mm
Length of wiper blade = 0.9 * 2 * (E - H)
5.5Disassembly and assembly
Prevent injuries when disassembling: disconnect the wiper from the power
supply. Keep all necessary tools within reach and remember the chapter on
safety. Provide well protected packaging, if you’re going to stock or transport
the wiper assembly.
5.5.1 Removing the wiper assembly from the bulkhead
1. Disconnect all the electric connections of the wiper.
2. Remove the wiper arms.
3. Remove the nuts (19, 12, 21) and plates (16, 17) on the outside.
4. Remove the wiper from the holes in the bulkhead.
5. If you want to replace the wiper, follow chapter 3.
5.5.2 Disassembling the drive crank lever
1. Disconnect all the electric connections of the wiper.
2. Remove the wiper from the bulkhead; (see 5.5.1).
3. Unscrew the nut and bolt on the drive crank-lever and remove the lever.
4. For adjusting the wiping arc and replacing, follow section 5.3.
5.5.3 Removing the motor from the wiper assembly
1. Disconnect all the electric connections of the wiper.
2. Remove the wiper arm.
2. Disassemble the drive crank lever (9) (see 5.5.2).
3. Unscrew the motor and remove it.
4. When replacing, screw the motor on the housing. Follow section 5.3 to
install the drive crank lever in the correct park position.
14

6 Troubleshooting
In this chapter, several malfunctions are mentioned combined with possible
causes and solutions. Please leave servicing to qualified mechanics.
6.1 Wiper does not work after switching on
• Possible causes:
1. Wiper switch is not working properly.
2. Burned or incorrectly sized fuse.
3. Electrical connections are wired incorrectly or might be damaged.
4. The wiper motor has failed.
• Solutions:
1. Test and replace it. Check if the current is (and keeps being) too high.
2. (See solution 1).
3. Measure the voltage across the motor and check all connections if there is
none.
4. Replace the motor and check for drag or a high current.
6.2 Wiped area or park position is not correct
• Possible causes:
1. The wiper arms were placed without parking the motor first.
2. The wipe arc is set wrong or changed due to high loads (e.g. spring
pressure of arms too high, drag).
3. The wires are connected incorrectly.
• Solutions:
1. Remove the wiper arms. Run the motor shortly to park it and re-install the
arms according to chapter 3.
2. Determine the wiping arc if needed (see paragraph 5.4) and set the wiping
arc again (see paragraph 5.3).
3. Check and reconnect the wiring (see the scheme in paragraph 3.3).
6.3 Motor runs, but arms do not move
• Possible causes:
1. Mechanical joints are loose.
2. Parts are broken.
3. Grooves of shafts are worn.
• Solutions:
1. Check if the arms are well fastened. If not, open the housing (follow
chapter 5) and check all joints and parts to see if they are loose, broken
or worn.
15

7 Declaration of conformity
MANUFACTURER’S DECLARATION
according to Appendix II sub B of Directive 89/392/EEG (Machines)
Exalto B.V.
Nijverheidsstraat 12
3371 XE Hardinxveld-Giessendam
The Netherlands
Phone: [phone]
Fax: [phone]
hereby declares that
Exalto windshield wiper type 255BS
... is intended to be built into another machine or as a component, or is to be
integrated with other machines to a machine where Directive 89/392/EEG
applies to;
...does not fully comply to the requirements of mentioned Directive;
... complies to the following harmonised standards:
Pleasure yachts
• NEN-EN-ISO 10133 Extra-low voltage D.C. installations (1997)
(regarding color codes)
...and declares that the sub-assembly in question shall not be set into
operation until the complete machine, into which the sub-assembly is fitted,
shall be complete and conforms to all aspects of Directive 89/392/EEG.
Hardinxveld-Giessendam
18-04-2014 (m-d-y)
16

8 Parts list
Qua Part Dimensions Cat. no.
1Motor 24 Volt 2100.2455RHD-R01
1Motor 12 Volt 2100.1255RHD-R01
1 Wiper housing 255 BS 2197.035
2 Shaft bulkhead 35 mm 2197.157
2 Shaft bulkhead 65 mm 2197.187
1 Idler spindle with lever bh 35mm 2197.106
1 Idler spindle with lever bh 65mm 2197.107
1 Driven Spindle with lever bh 35mm 2197.103
1 Driven Spindle with lever bh 65mm 2197.104
2 Nyloc Nut M8 M8 2100.071
1 Nut M6 A4 M6 2100.080
1 Hex Bolt M6x25 M6x25 2100.077
1 Motorlever 255 BS 2197.081
Spacer M8 2197.098
3 Hex Bolt M6x16 2100.075
3 Serrated lockwasher ss M6 M6 2100.413
8 Nut M20x1 2100.350
2 Weathercap Ø26 x 20 2100.361
4 Spacer 18x12x1 mm 2100.400
2 Locking Ring Ø12 x 4 2100.410
2 Spacer M8 2197.098
2 Locking ring 6mm 2197.097
1 S.S. Plate 2100.482
2 Rubber locking plate 2100.492
1 Connection lever 2100.939
1 Connection lever 2100.940
1 Nut M10 din934 A4 M10 2197.090
1 Hex Bolt M10x35 M10x35 2197.091
4 Spacer M10 M10 2197.092
1 Hex. flange nut wih teeth, M10 M10 2100.069
17

9 Drawings and schemes
9.1 Assembly overview
18

black
white
yellow
red
blue
+
-
0 1 2
L
P
B
H
9.2 Internal wiring diagram
The following diagram explains the way the wiper motor works.
Wiring diagram
Function Polarity Switch code Cable 12/24V
high speed + H white
low speed + L yellow
earth - black
common leg P blue
self parking + B red
19

Exalto B.V.
•
P. O. Box 40
3370 AA Hardinxveld-
Giessendam
T
he Netherlands
•
T [phone]
•
F+31 (0)184 618 200
•
[e-mail]
• I www.exaltowipers.com
© Exalto B.V. 04-2014