Thruster 110 & 110HV

Thruster Service Manual

For: EM&I
Date: 25th April 2022
Revision: EM&I 01
 Revision EM&I 01

Contact Information
Please address any communication regarding this document to:

Ocean Modules Sweden AB

Örsätter Industrigallerian
S-597 91 Åtvidaberg
Sweden

Email: support@ocean-modules.com
Home page: www.ocean-modules.com
Telephone: +46 120 12800

Copyright notice
Copyright © 2021 Ocean Modules Sweden AB

All rights reserved. The copyright of this Thruster Service Manual including texts, graphs, photos,
drawings, and illustrations are the property of Ocean Modules Sweden AB. The Purchaser shall have
no right to use such design, specification, or illustration for the benefit of any third party without the
prior written consent of Ocean Modules Sweden AB. No part of this manual may be reproduced or
disclosed to any third party in any manner without the prior written consent of Ocean Modules
Sweden AB.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

Contents

1 THRUSTER MODELS ................................................................................................................. 5

1.1 Thruster assembly drawing .................................................................................................................. 6

2 INSPECTIONS AND MEASUREMENTS.................................................................................. 8

2.1 Thruster history ................................................................................................................................... 8

2.2 Inspections .......................................................................................................................................... 8

2.3 Short circuits...................................................................................................................................... 10

2.4 Typical procedures............................................................................................................................. 11

3 PREPARATION ........................................................................................................................ 12

3.1 Electrostatic Discharge (ESD) ............................................................................................................. 12

4 THRUSTER DISASSEMBLY ................................................................................................... 13

4.1 Removing the spring cup ................................................................................................................... 13

4.2 Removing the end gable and Motor control card............................................................................... 13

4.3 Removing the motor control card ...................................................................................................... 14

4.4 Removing the front gable .................................................................................................................. 14

4.5 Removing the inner gable .................................................................................................................. 15

4.6 Removing the propeller and propeller shaft ...................................................................................... 15

4.7 Removing the shaft from the rotor .................................................................................................... 16

4.8 Drying the stator................................................................................................................................ 17

5 THRUSTER ASSEMBLY ......................................................................................................... 18

5.1 Assembly of the shaft and the rotor .................................................................................................. 18

5.2 Assembly of the front gable ............................................................................................................... 19

5.3 Assembly of a new propeller ............................................................................................................. 20

5.4 Assembly of Front Gable and Rotor Shaft .......................................................................................... 21

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.5 Assembly of the inner gable .............................................................................................................. 22

5.6 Thruster front end assembly .............................................................................................................. 23

5.7 Re-attaching the motor control card.................................................................................................. 24

5.8 Thruster back end assembly .............................................................................................................. 26

5.9 Oil filling with a vacuum pump .......................................................................................................... 28

5.10 Topping up and closing with the spring cup ....................................................................................... 29

6 THRUSTER TESTING ............................................................................................................. 31

6.1 Bench test.......................................................................................................................................... 31

6.2 In-water test ...................................................................................................................................... 32

7 PARTS, TOOLS AND CONSUMABLES ................................................................................ 33

7.1 Special Tools ...................................................................................................................................... 33

7.2 Consumables ..................................................................................................................................... 35

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

1 THRUSTER MODELS
This manual covers the servicing of both Ocean Modules thruster models (Figure 1). Both thrusters
have most of the components in common (except for motor control card, connector and some
wiring). Both models have been updated several times and parts between the revisions may differ in
appearance but are in most cases compatible. Some of the main changes to the thrusters are to the
propeller shaft that has been upgraded to a higher-grade steel to reduce problems with cavitation
and wear, and the aft gable with spring cup, which was modified with the horseshoe locking ring to
remove the problem with leaks caused by overtightening. Please be aware that the new end gable
(with horseshoe), spring cup, rolling diaphragm and piston are not interchangeable with the old
version end gable, spring cup, rolling diaphragm and piston. Ocean Modules no longer stocks the old
end gable, spring cup and piston, so if one of these parts needs replacing, it will be necessary to
upgrade to the new version by replacing all four parts.

Figure 1. Left, thruster 110 (02-00016-09) and right, thruster 110HV (02-00191-07)

Thruster 110 Thruster 110HV

For ROV model ROV V8 Sii and ROV V4 ROV V8 M500
Product number 02-00016-xx 02-00191-xx
Revisions (in 2020) 9 7
Power input 150 V, 5A 300 V, 2A
Isolated driver input 15 VDC, 100 mA 15 VDC, 100 mA
Control signal +/- 5 VDC +/- 5 VDC
RS232 data output NO YES
Connector, Wet-mate 6-pin bulkhead Dry-mate 7-pin
Oil Shell Odina X420 Shell Odina X420
Table 1. Thruster comparison.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

1.1 THRUSTER ASSEMBLY DRAWING

Figure 2. Thruster 110HV 02-00191-07 (revision 07). All parts for Thruster 110 and 110HV are common except for the
bulkhead/penetrator and the Motor control card.

Item Nr Product Number Title Qty

5 40-00288-08 House 1
10 40-00701-09 Front gable 1
15 40-01314-03 Aft gable 1
20 40-00721-07 Shaft 1
30 40-00703-01 Nozzle 1
40 40-00704-02 Propeller bushing 1
45 40-01317-02 Piston 1
50 40-00294-03 Bearing sleeve 1
55 40-01499-01 Spring Cup extended 1
60 40-00296-05 Inner gable 1
65 70-04200-35 O-ring 42 2
70 50-00351-00 Motor Elements (Stator) 1
64-02020-40 Spring Pin 1
80 60-00055-01 Angular Contact Ball Bearing 2
60-00056-01 Propeller 1
100 60-00111-01 Rolling Diaphragm 1
110 60-00313-01 Spring 1
130 40-00844-01 Driver pin 1
135 40-00729-01 Nozzle spoke spacer 3
140 60-00078-01 Sealing (Spring removed) 1

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

141 60-00078-01 Sealing 1

70-01100-10 O-ring 11 1
145 61-04040-45 M4x40 A4 MF6S 3
150 61-04008-45 M4x8 A4 MF6S 3
155 61-04020-44 M4x20 A4 MC6S 3
160 61-06016-44 M6x16 A4 MC6S 1
175 70-01242-17 O-ring 12 1
51-00245-01 7-pin Connector Straight Mold (Thruster 110HV) 1
(1)
51-00023-06 6-Pin Connector (Thruster 110) 1
185 04-00120-03 Motor Control Card assy (Thruster 110HV) 1
185(2) 30-00113-02 Motor Control Card assy (Thruster 110) 1
190 93-01010-01 String Ø2mm 1
255 60-00266-01 Plugg 1
260 63-06411-43 Washer AZ 1
60-00059-01 Disc Spring 1
325 40-01316-01 Nut Plate 1
93-01001-02 Ondina oil 917 Shell
60-00082-01 Shims 10x16x0,1
60-00083-01 Shims 10x16x0,2
60-00084-01 Shims 10x16x0,5
Table 2. Thruster 110HV 02-00191-07 (revision 07). All parts for Thruster 110 and 110HV are common except for the
bulkhead/penetrator (1) and the Motor control card (2).

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

2 INSPECTIONS AND MEASUREMENTS

2.1 THRUSTER HISTORY

It is a good idea to be informed of why the thruster needs service, since this information will help
with fault-finding, which tools and spare parts that will be required, and choosing service procedures.

Relevant information:

- Runtime, how long has the thruster been in operation?

- Has an insulation fault been detected?
- Is there suspicion of a loose propeller shaft (loose from rotor).
- Is there suspicion of a short circuit in the high voltage circuit.
- Is there a suspicion that the thruster is leaking oil?
- Other.

2.2 INSPECTIONS
2.2.1 Inspect propeller, cowling, front gable, aft gable
Turn the propeller and sense the resistance. A high magnetic resistance indicates that the 300VDC
circuit has a short circuit. A short circuit can be confirmed by measuring the resistance in the high
voltage circuit with a multimeter. A short circuit is normally located in the motor control card, which
can be replaced. If the short circuit is in the stator, the stator will need replacing.

If, when turning the propeller, there is a section (of a full rotation) that has a high magnetic
resistance, there may be a problem with a Hall element switch. When the thruster has been
disassembled, inspect the cables for damage. If the cables are ok, the problem may be the Hall
element sensor itself. A damaged Hall element sensor will cause the thruster to suddenly stop but it
will normally restart after the propeller has been tuned by hand. A thruster with faulty Hall element
sensor will not cause any damage but may be a nuisance when is stops during operation. If the Hall
element sensor is damaged, the stator will need to be replaced.

2.2.2 Propeller shaft and rotor

Inspect the shaft where the shaft seal was located. If there is corrosion, cavities, or a notch in the
shaft, it is recommended that the shaft be replaced.

Inspect the rotor for damage. The magnets are easily damaged and broken bits attached to the rotor
should be removed.

If a thruster is reported to be inefficient (no thrust) but seams to function normally, the cause may be
a rotor that is no longer fixed to the propeller shaft. When the rotor and propeller shaft have been
removed from the thruster tube, verify that that the rotor is properly glued to the shaft.

2.2.3 Bearings
The bearings are investigated by feel. The bearings should run smoothly and with little play. Compare
with a new bearing to get a sense of the normal amount of play. The inner gable bearing can be
investigated in place and need not be removed if found to be in good condition.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

2.2.4 O-ring sealing surfaces

Since the sealing of the thruster is crucial for its integrity, it is recommended that the O-rings not be
reused; that O-rings are replaced (with the right type and size), and that they are not damaged
during assembly. Inspect the O-ring seat for scratches and irregularities. Make sure that the O-ring is
greased. Use the O-ring protection tools (V, VI)during assembly.

2.2.5 Thruster oil

When emptying the thruster of oil, pour the contents into a transparent container so that it can be
examined. The oil should be clear and without contaminants. If there is water present it will
accumulate at the bottom of the container as small droplets. If you suspect water ingress, search for
the probable cause like; a worn shaft seal and shaft, O-rings that do not seal, a damaged rolling
diaphragm, a loose spring cup, etc. If the oil is greyish the bearings may be worn. If the oil is black, it
is probably caused by a burned component on the motor control card. There may also be other
contaminants (particles), which come from damage to the rotor or may have been introduced during
assembly. Make sure to thoroughly clean the thruster from contaminants since they may cause
isolation faults and short circuits.

2.2.6 Isolation faults

The most common fault on a thruster is the isolation fault. It can range from very slight to serious,
and if it is not corrected, may ultimately cause a thruster failure. Isolation faults may be caused by a
number of different defects such as: water ingress, conductive contaminants, damaged cables, bad
insulation, etc.

Before dismantling the thruster measure the resistance between the high voltage circuit and the
thruster tube. The tube is anodized and not conductive, but normally one of the three screws holding
the front gable will have sufficient contact with the tube for the measurement. Use a multimeter set
to 200MΩ and measure the resistance between the high voltage positive (150/300 VDC), on the
connector, and the tube/screw. Turn the propeller with your fingers and alternate the direction,
during the measurement. The measurement should remain on the maximum reading 200MΩ. If the
resistance is lower than 200MΩ there is an isolation fault that need to be located and remedied.

When the motor control card has been extracted from the thruster tube, do a new isolation fault
measurement. This time measuring between the high voltage positive (150/300 VDC), on the
connector, and the aluminum cooling flange on the underneath the motor control card (the motor
control card and cooling flange shall not be in physical contact with the thruster tube but the cables
to the stator can remain connected). If the resistance is lower than 200MΩ there is an isolation fault,
most probably due to bad insulation between a MOSFET (the 6 components screwed tight against
the cooling flange, see Figure 19) and the cooling flange.

Isolation faults in the stator windings can be detected by measuring the resistance between two of
the windings and the tube (conductive area normally found in one of the three holes). The resistance
shall be more than 200MΩ. An insulation fault in the windings may have been caused by damage to
the insulating lacquer on the windings. Inspect the windings visually. Damaged insulation can
sometimes be repaired by adding lacquer to the damaged area.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

Figure 3. Simplified illustration of the windings in the stator.

2.3 SHORT CIRCUITS

If a thruster has ceased to work, has blown a fuse, etc., it is probable that the high voltage circuit has
shorted. This can be tested before the thruster is disassembled. With a multimeter set to continuity
testing, measure the high voltage circuit (see Table 3). If the multimeter signals continuity, the motor
control card will have a short circuit and will need to be replaced.

If a thruster is running unevenly, it may be due to a damaged stator winding. To verify the integrity of
the windings in the stator, measure the resistance of the three windings. To do so, use a multimeter
set to 200Ω and measure the resistance of each winding (see Figure 3). You will have three
measurements, which should all fall within the interval of 7Ω to 8Ω. A winding that has a resistance
that is lower than the other windings will have a short circuit. A damaged stator is probably not
worth replacing.

Thruster 110 (6-pin wet mate) Thruster 110HV (7-pin dry mate)

1. 150 VDC RET 1. 300 VDC

2. 150 VDC 2. 15 VDC
3. GND (isolated) 3. GND (isolated)
4. 15 VDC 4. 300 VDC RET
5. Control (0+/-5V) 5. Control (0+/-5V)
6. NC 6. RS-232RX (input)
7. NC

Table 3. Pinout for the thruster bulkhead (or penetrator with connector).

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

2.4 TYPICAL PROCEDURES

Service Parts Procedure

Oil top-up. Thruster oil 4.1 Removing the spring cup
5.10 Topping up and closing with the spring cup
Standard service Front bearing 4.1 Removing the spring cup
Before 500 hrs O-rings
4.2 Removing the end gable and Motor control card
Shaft seal
Thruster oil 4.4 Removing the front gable
4.6 Removing the propeller and propeller shaft
4.8 Drying the stator
5.2 Assembly of the front gable
5.4 Assembly of Front Gable and Rotor Shaft
5.6 Thruster front end assembly
5.8 Thruster back end assembly
5.9 Oil filling with a vacuum pump
5.10 Topping up and closing with the spring cup
6 Thruster testing
Oil top-up
Repairs Rotor shaft Standard service including:
4.7 Removing the shaft from rotor
5.1 Assembly of axel and rotor
Repairs Motor control card Standard service including:
4.3 Removing the motor control card
5.7 Re-attaching the motor control card
Repairs End gable bearing Standard service including:
4.5 Removing the inner gable
5.5 Assembly of the inner gable

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

3 PREPARATION
1. Find a suitable workspace that is clean. This is important, because any contaminants that find
their way into the thruster on assembly can cause leaks or cause short-circuits.
2. Prepare the workspace to protect against electrostatic discharge (see chapter 3.1)
3. You will need a container into which you can spill old thruster oil. Although new thruster oil is
not poisonous, the oil that has been in the thruster will be contaminated and should be
treated as toxic for the environment.
4. Assemble the necessary tools and consumables, of which some are listed in this document (see
chapter 7).

3.1 ELECTROSTATIC DISCHARGE (ESD)

Electrostatic Discharge (ESD)is the sudden flow of electricity between two electrically charged objects
caused by contact, an electrical short. ESD can cause failure of solid-state electronics components
such as integrated circuits. These can suffer permanent damage when subjected to the high voltages
in an electro-static discharge. ESD can occur without the user feeling anything. It is therefore
important to consider the risks of ESD when handling electronic boards and to implement some
simple measures to avoid unnecessary damage to expensive components:

• Do not handle electronic boards without taking measures to avoid ESD.

• Use an ESD wrist strap (Figure 4), grounding mat, or grounding workbench.
• Use only antistatic bags for storage of the electronic boards.
• Do not place electronic boards on surfaces that are not antistatic.

Figure 4. Beware of ESD! The best method of preventing ESD is to use an ESD wrist strap

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

4 THRUSTER DISASSEMBLY

4.1 REMOVING THE SPRING CUP

4.1.1 Use a pair of pliers to pull back the oil piston so that the two holes are visible (in older
versions there is only one hole). Insert a pin into the lower hole to keep the piston in place.

4.1.2 With an Allen key, unscrew the three screws holding the spring cup. Remove the spring cup
and rolling diaphragm.

Figure 5. Procedure for removing the spring cup.

4.2 REMOVING THE END GABLE AND MOTOR CONTROL CARD

4.2.1 Pour out the oil (this oil is contaminated and should be disposed of as hazardous waste).

4.2.2 Remove the cellophane tape attached between the tube and the aft gable.

4.2.3 With a pair of pliers remove the locking string holding the end gable. Then loosen the end
gable and gently pull on the wires to extract the motor control card. If you do not intend
discarding the motor control card, be aware of the risk of ESD (see chapter 3.1).

4.2.4 Pour out the remaining oil.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
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4.3 REMOVING THE MOTOR CONTROL CARD

Be aware of the risk of ESD (see chapter 3.1).

4.3.1 Use a fine soldering iron to remove all the wires from the motor control card. Be careful not
to damage the fine rings on the motor control card that the cables are soldered to.

Figure 6. Removing the end gable and motor control card.

4.4 REMOVING THE FRONT GABLE

4.4.1 Mount a thruster motor bracket (VII) on a table.

4.4.2 With an Allen key remove the three screws fastening the front gable in the thruster tube.

4.4.3 Fasten the thruster on the motor bracket using a hose clamp.

4.4.4 Holding the thruster Nozzle, carefully dislodge the front gable and extract the thruster shaft
and rotor.

Figure 7. Remove the screw holding the front gable. Carefully pull on the nozzle and extract the front gable and
rotor.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

4.5 REMOVING THE INNER GABLE

If the angular bearing has become worn and needs to be replaced, remove the inner gable.

4.5.1 Remove the thruster tube from the motor bracket and place it on a firm surface with space
to avoid pinching the cables (or if the motor control card has been removed, tuck them into
the tube).

4.5.2 Place a suitably sized rod on the angular bearing/inner gable. Lightly tap the rod with a
hammer so that the inner gable dislodges and can be removed.

4.5.3 Clean away the glue remnants from the inside of the thruster tube. Use plastic tools and
electronics cleaner (viii).

4.5.4 Press the angular bearing out of the inner gable (Figure 10). This requires no heating.

Figure 8. (left) place the thruster tube on a firm surface, (centre) dislodge the inner gable with a rod (right) remove
the glue remnants.

4.6 REMOVING THE PROPELLER AND PROPELLER SHAFT

4.6.1 Remove the propeller by holding the rotor and unscrewing the M6 screw in the centre of the
propeller.

4.6.2 Remove the driver pin. And pull the rotor shaft out of the front gable.

4.6.3 Inspect and clean the propeller bushing.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
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Figure 9. (left)hold the rotor and unscrew the bolt holding the propeller, (centre) remove the driver pin.

4.7 REMOVING THE SHAFT FROM THE ROTOR

If the rotor shaft has become worn by the shaft seal or is corroded close to the shaft seal it should be
replaced.

4.7.1 Place the rotor shaft in an oven and heat it to 250 degrees centigrade for 60 minutes. While
the shaft is still hot, place it in the press on a firm surface that has a hole for the shaft to pass
through. Use a rod that has a smaller diameter than the inner diameter of the bearing sleeve
to press the rotor shaft out of the rotor and bearing sleeve (Figure 10).

4.7.2 When the rotor has cooled it needs to be cleaned of all glue remnants. Use a fin grain
sandpaper and a thin rod to clean the inside of the rotor and the bearing sleeve.

Figure 10. (left) Press the bearing out of the inner gable. (right) Heat the rotor and shaft in an oven, then press the
shaft out with a rod.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
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4.8 DRYING THE STATOR

4.8.1 If water has entered the thruster there may be water in the stator windings. To remove this
water the stator is placed in an oven at 75 degrees Celsius for 8 hours (or more).

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
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5 THRUSTER ASSEMBLY

5.1 ASSEMBLY OF THE SHAFT AND THE ROTOR

5.1.1 Identify the rotor-end and propeller-end of the Shaft.

5.1.2 Test the fit of the Rotor and Bearing Sleeve on the rotor-end of the Shaft.

5.1.3 Test the fit of the Angular contact bearing on the propeller-end of the shaft.

5.1.4 Clean the shaft surface (rotor and bearing sleeve seat) thoroughly with Acetone.

5.1.5 Coat the shaft with a thin layer of activator (ii). Do not coat the end of the shaft where the
Bearing sleeve sits. Leave to dry for a minimum of 10-15 minutes.

5.1.6 Apply glue (i) to the shaft and thread the rotor over the shaft. Rotate the shaft to help spread
the glue evenly.

5.1.7 Press the rotor tightly against the flange.

5.1.8 Wipe off excess glue.

5.1.9 Coat the shaft end with a thin layer of activator (ii). Leave to dry for a minimum of 10-15
minutes. Apply glue (i) to the inside of the Bearing sleeve. Thread the Bearing sleeve onto
the shaft and press it tightly against the shoulder.

5.1.10 Leave to harden for more than 3 hours.

Figure 11. Apply glue to the inside of the rotor. Insert the shaft while turning it to disperse the glue.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
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5.2 ASSEMBLY OF THE FRONT GABLE

5.2.1 Shaft seals assembly

5.2.1.1 There are two shaft seals mounted in the front gable. The outer seal shall have the garter
(steel) spring replaced with the O-ring 11,0. Use an O-ring tool to remove the steel garter.

Figure 12. Oil-side of front gable with shaft seal with steel garter (left), Water-side of front gable with nitrile O-
ring garter (right).

5.2.1.2 Apply some Molykote to the outside of the sealings as lubrication for the assembly. Using
the shaft seal tool (II) insert the shaft seal (with O-ring) into the bore on the water side of
the front gable. The seal shall be inserted so that the garter O-ring is out towards the
water.

5.2.1.3 Apply some Molykote to the outside of the shaft as lubrication for the assembly. Using the
shaft seal tool (II) insert the shaft seal (with steal garter) into the bore on the oil side of the
front gable. The seal shall be inserted so that the steal garter O-ring is inwards to the oil.

Figure 13. Placement of the shaft seals. The seal which is out towards the water shall have had the steel garter
replaced with a nitrile O-ring.

5.2.1.4 Ensure that the seals are tight against the bottom of the bore (straight and level).

5.2.1.5 Fill the gap in-between the seals with Molykote 111. There should be little to no air trapped
between the shaft seals.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.2.2 Angular contact bearing assembly

5.2.2.1 Test the fit of the Angular contact ball bearing in the front gable. If the fit is tight, a press
will be required.

5.2.2.2 The Angular contact ball bearing shall be pressed into place with the bevel facing into the
front gable bore.

5.2.2.3 Make sure that the bearing is straight, level and tight against the bottom of the bore.

Figure 14. Turn the bevel so that it faces down into the bore. Press (or glue) the bearing into place in the front
gable.

5.3 ASSEMBLY OF A NEW PROPELLER

If the propeller needs to be replaced with a new, it will require the fitting of a propeller bushing.

5.3.1 Clean the outer surface of the propeller bushing and the hole in the propeller with Acetone
(iv). Apply a thin layer of Elastofix (vi) to the outside of the bushing. Press the bushing into
the centre of the propeller. Make sure that the bushing is pressed past the diver pin seat
(two notches). Wipe off excess glue. Leave to harden for approximately one hour.

Figure 15. Glue bushing into propeller. Observe the final placement of the bushing in the right-hand picture.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.4 ASSEMBLY OF FRONT GABLE AND ROTOR SHAFT

5.4.1 Insert the front end of the shaft into the angular bearing and through the shaft seals. Be
careful to not dislocate or damage the seals.

5.4.2 Grease the front end of the shaft and the driver pin with Aquashield (xi). Insert the driver pin
into the shaft. Make sure that there is a propeller bushing inserted into the centre of the
propeller. Thread the propeller over the front of the shaft and attach it with a serrated
locking washer (AZ) and M6x16 screw.

Figure 16. Carefully insert the shaft through the shaft seals. Grease with Aquashield, insert driver pin, thread the
propeller over the shaft end and attach with locking washer and screw.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.5 ASSEMBLY OF THE INNER GABLE

5.5.1 Using the press tool (IV) insert the Spring pin into the hole on the Inner gable.

5.5.2 Verify that the Angular contact ball bearing fits in the bore of the Inner gable.

5.5.3 Apply a small amount of thread locker (iii) to the inside of the Inner gable and press the
Angular contact ball bearing into place, making sure that it is straight, level, and tight against
the bottom of the bore.

5.5.4 Verify that the Inner gable (pin outwards) fits in the thruster tube. There are two shoulders in
the thruster tube (end gable side with cables) close to the stator. The Inner gable shall pass
over the first shoulder and rest against the second.

5.5.5 Clean the inside of the thruster tube with acetone (iv).

5.5.6 Apply activator (ii) to the outside of the inner gable and leave to dry for 10 to 15 minutes.

5.5.7 Apply glue to the inside of the thruster tube. Apply the glue on tube, between the shoulders
and in the area corresponding to the plastic cover on the stator.

5.5.8 Insert the inner gable (pin outwards) and press it tightly against the inner shoulder.

5.5.9 Leave to harden for 3 hours.

Figure 17. (left) inserting the Spring pin, (centre) Applying a small amount of thread locker, (right) the two
shoulders are visible close to the stator.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.6 THRUSTER FRONT END ASSEMBLY

5.6.1 Mount a thruster motor bracket on a table.

5.6.2 Fasten the thruster tube, with inner gable, on the motor bracket with a hose clamp.

5.6.3 Fasten the O-ring protection tool (V) on the thruster tube with a hose clamp.

5.6.4 Assemble the front gable with the Nozzle, Nozzle spoke spacers x 3 using the M4x40 screws.

5.6.5 Place one spring plate and two shims 0.5 mm, 0.2 mm on the bearing sleeve.

5.6.6 Holding the Nozzle, carefully insert the rotor into the thruster tube until the bearing sleeve is
pressed into the bearing.

5.6.7 With one hand on the Nozzle, hold the Front gable pressed against the tube. With the other
hand test the axial fit of the rotor axel. There should be no play in the rotor axel and the
shoulder on the Front gable shall rest against the tube end. If there is axial play in the shaft,
add shims, if the front gable shoulder is not against the tube, remove shims. Repeat this
process until you are satisfied with the fit.

5.6.8 Remove the rotor from the tube.

5.6.9 Using the adhesive gum (ix) thoroughly clean the rotor magnet and the inside of the stator
from dirt and particles. It is very important that the inside of the thruster tube and the rotor
are perfectly clean.

5.6.10 Inspect the O-ring grove on the front gable and ensure that it is clean. Grease a 42 mm O-ring
with Molykote (v) and thread onto the front gable.

5.6.11 Holding the Nozzle, carefully insert the rotor into the thruster tube until the bearing sleeve is
pressed into the bearing. Then turn the front gable so that the holes line up. Insert the M4x8
screws and tighten them firmly without overtightening them (steel in plastic).

5.6.12 Remove the O-ring protector tool.

Figure 18. (left, centre) spring plate and shims on bearing sleeve, (right) inserting the rotor into the stator to test
axial fit.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.7 RE-ATTACHING THE MOTOR CONTROL CARD

5.7.1 Study the relevant drawing and the motor control card (Figure 20, Figure 21 and Figure 22).
Identify the attachment points for the wiring from the stator windings, hall element switches
and the Subconn bulkhead connector.

3.1).

5.7.2 Fasten the motor control card in a holder. Start with the wires from the Subconn bulkhead.
Insert the wires into the hole form the top of the card and solder the wire into place from the
opposite side.

5.7.3 When all the wires are in place, double-check that they have been soldered to the correct
hole on the motor control card.

5.7.4 Continue with the wires from the stator and hall element sensors. Thread them into the
holes from underneath the motor control card and solder them from the top side.
Thruster 110HV motor control card has a 5-pin connector for the hall element sensors.

Figure 19. (left) Thruster 110 motor control card facing the stator, (right) Thruster 110 motor control card facing
the spring cup. Please observe that the Thruster 110HV has a 5-pin connector for the Hall element switches, and
that the three capacitors (C4, C28, C29) are not labelled.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

Stator windings Motor Control Board

RED
MA (K9)
WHT
MB (K10)
6-pin Subconn
BLK Connector (M)
MC (K11)
BLK
(K2) HVRET 1
WHT
(K1) HV 2
RED
BLU (K4) GND 3
HA HB HC +5H (K12)
GRN
GRN (K3) +15V 4
H0 (K16)
ORG
BRN (K7) IN 5
HA (K13)
BLU
ORG 6
HB (K14)
N.C.
Hall effect switches YEL
HC (K15)

Figure 20. Drawing over Thruster 110 motor control card connections.

Stator windings Motor Control Board

RED
MA (K9)
WHT
MB (K10)
7-pin CRE
BLK penetrator
MC (K11)
(K1) HV 1

(K3) +15VDC 2

BLU (K4) GND 3

HA HB HC 1 (PIN 1)
GRN (K2) HVRET 4
2 (PIN 2)
BRN (K7) IN 5
3 (PIN 3)
ORG (K7) TXD 6
4 (PIN 4)
N.C. 7
Hall effect switches YEL
5 (PIN5)

Figure 21. Drawing over Thruster 110 HV motor control card connections.

5.7.5 When the wires have been soldered to the motor control card, double-check that the wires
are connected to the correct points on the motor control card, in accordance with the
relevant drawing (Figure 20, Figure 21).

5.7.6 Double check the wiring with the following measurements:

With a Multimeter set to the Diode check function (symbol for diode), measure:

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

6-pin wet-mate bulkhead (Table 3) Measurement

Pin 1 (HVRet) to Pin 2 (HV) ≈ 0.7-0.8 V
Pin 2 (HV) to Pin 1 (HVRet) 0V
Pin 3 (GND) to Pin 4 (+15V) ≈ 0.5 V
Pin 4 (+15V) to Pin 3 (GND) ≈ 0.8 V

7-pin dry connector (Table 3) Measurement

Pin 4 (HVRet) to Pin 1 (HV) ≈ 0.7-0.8 V
Pin 1 (HV) to Pin 4 (HVRet) 0V
Pin 3 (GND) to Pin 2 (+15V) ≈ 0.5 V
Pin 2 (+15V) to Pin 3 (GND) ≈ 0.8 V

With a Multimeter set to Ohm measurement:

6-pin wet-mate bulkhead (Table 3) Measurement
Pin 2 (HV) to screw on tube >10 MΩ
Pin 3-5 ≈ 10 kΩ
Pin 5-3 ≈ 10 kΩ

7-pin dry connector (Table 3) Measurement

Pin 1 (HV) to screw on tube >10 MΩ
Pin 3-5 ≈ 10 kΩ
Pin 5-3 ≈ 10 kΩ

5.8 THRUSTER BACK END ASSEMBLY

5.8.1 Place the thruster on an even surface. Hold the motor control card and turn the thruster
approximately 3 turns to twist the wires.

5.8.2 Look into the thruster tube and locate the spring pin on the inner gable. Locate the hole in
the bottom of the motor control card (aluminium cooling ring). Line up the pin and the hole,
then insert the motor control card into the thruster tube. Ensure that the hole on the cooling
ring is threaded over the spring pin. When correctly assembled, it should not be possible to
rotate the motor control card, and the distance between the capacitor (see Figure 19 (right),
C4, C28, C29) and tube rim shall be at least 14 mm.

Figure 22. (left) tube - motor control card - end gable, (centre) turn 3 times, line up pinhole and insert, (right) card
should not rotate and the distance between capacitor and tube rim shall be at least 14 mm.

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without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.8.3 Use Molykote (v) and grease a 42 mm O-ring. Thread it over the end of the end gable and
into the O-ring groove.

5.8.4 Attach the O-ring protection tool (VI) to the thruster tube (use a hose clamp to hold it in
place during assembly or hold it tightly). Turn the thruster 3 times and then insert the end
gable into the thruster tube. Line up the Subconn or CRE bulkhead with the slit made for the
locking thread.

5.8.5 Insert the locking thread to lock the end gable into place.

Figure 23. (left) turn the thruster 3 times to twist the wires, then insert the end gable into the tube. (right) line up
the Subconn or CRE bulkhead with the slit.

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without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.9 OIL FILLING WITH A VACUUM PUMP

5.9.1 Place the thruster on an even surface. Ensure that the end gable is clean. Place the filling
cylinder on the end gable and ensure that it seals tightly. Open all the ball valves (Figure 24-
nr 1, 2, 3). Start the air pump. Carefully close the ball valve nr 2 so that the oil is slowly
sucked into the cylinder and fills the thruster. When the oil reaches 10-15 mm over the
bottom of the filling cylinder (Figure 24- Max oil level) open ball valve nr 2, to stop the filling,
and then close ball valve nr 3, to shut off the oil supply. Close the ball valve nr 2 to vacuum
pump the filling cylinder. Keep the vacuum pump running between 5 and 10 minutes (until
bubbles stop rising from the oil). To assist in the removal of air from the oil, turn the
propeller and tilt the thruster slightly back and forth. When there are no air bubbles rising in
the oil, open ball valve nr 2 and turn off the vacuum pump. Remove the filling cylinder (oil
will spill).
Ball valve 2

Presure
Meter

Ball valve 1 Oil separator Ball valve 3

Max oil level

Air Pump
Filling cylinder
Oil

Figure 24. Oil filling system

Figure 25. Using the filling cylinder and a vacuum pump fill the thruster with oil and remove the air.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.10 TOPPING UP AND CLOSING WITH THE SPRING CUP

5.10.1 Thread the Spring over Piston pin and insert the pin into the Spring cup. Lock it in place by
inserting a piece of locking string into the hole in the pin.

5.10.2 Place the Rolling diaphragm over the piston and work it into place. Use a plastic tool to
ensure that there is only one even fold in the rolling diaphragm.

5.10.3 Stand the Spring cup on its end. Then fill the fold in the Rolling diaphragm with thruster oil (x)
and ensure that there is no air trapped in the fold.

Figure 26. (left) Rolling diaphragm, Piston, spring and Spring cup. (centre) Assembled Spring cup. (right) Fill the
fold in the Rolling Diaphragm with thruster oil to expel all the air.

5.10.4 Insert the Nut plate into the slot in the End gable.

5.10.5 Ensure that the thruster is overfilled with oil and that the Rolling diaphragm is overfilled with
oil. Now with a swift movement, that does not spill out the oil, place the Spring cup over the
end gable end press it down. Insert the three M4x20 screws and tighten them firmly, without
overtightening.

5.10.6 To test that there is no air in the thruster, press down on the piston. If the piston sinks in and
springs back, there is probably air in the thruster, which must be removed (Go back to point
3 in this chapter).

5.10.7 Measure the length of the piston (oil at room temperature). The length of the piston should
measure between 14 and 16 mm.

5.10.8 If the pin is longer than 16 mm, some oil must be removed. Do this by loosening the three
screws slightly so that oil can very slowly seep out when pressure is applied to the piston.

5.10.9 Wipe away the excess oil. Clean the thruster with Propanol (viii) then use Acetone (iv) to
clean the closest to the joint between the end gable and the thruster tube.

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without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

5.10.10 Cut a piece (13 cm) of Polyester film (vii) and tape the joint, between the end gable and the
thruster tube, beginning at the locking string slit and ending on the opposite side. The
purpose of the tape is to keep the aft gable from turning and twisting the cables.

Figure 27. Insert the nut plate, overfill the thruster slightly with oil. Pour oil in the rolling diaphragm. Place the
spring cup on the end gable without letting any air get into the thruster. Tighten the screws into the nut plate.
Clean the thruster and tape the joint between the tube and end gable.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

6 THRUSTER TESTING

6.1 BENCH TEST

For bench testing the thruster, the following setup can be used. Use the 0-5VDC to control the
thruster. Be very careful with the control signal voltage (0-5VDC). Do not apply voltages above 5VDC
since this can damage the motor control circuits. Only test the thruster at low RPM for short periods
of time, since running the thruster out of water will wear out the shaft seal.

Linear DC Power Supply (eg 0-30 VDC)

DC Power Supply 150 VDC 15VDC/0,5A 0VDC/0.1A

150 VDC/1.5A

+ - + - + -

Subconn 6-pin
bulkhead

2. 150 VDC
1. 150 VDC RET
6 2
4. 15 VDC
1 3. GND
5 3 5. 0-5 VDC
6. NC
4

Figure 28. Bench test setup for thruster 110. Please observe that the pin-out numbering is not in numerical order.

Linear DC Power Supply (eg 0-30 VDC)

DC Power Supply 300 VDC 15VDC/0,5A 0VDC/0.1A

300VDC/1.5A

+ - + - + -

CRE 7-pin
bulkhead

1. 300 VDC
1
4. 300 VDC RET
6 2
7
2. 15 VDC
5 3 3. GND
4 5. 0-5 VDC
6. NC
7. NC

Figure 29. Bench test setup for Thruster 110HV. Please observe that the pin-out numbering is not in numerical
order.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

6.2 IN-WATER TEST

It is advised to do an in-water test of the assembled thruster. It is also advisable to have separate test
equipment to test the thrusters with to avoid damage to the ROV if something is wrong.

When the thrusters have been run for approximately 4-8 Hrs, measure the piston length (oil at room
temperature). It will probably have sunk 1-2 mm. Top-up the oil level.
When the thrusters have been run for approximately 24 Hrs, measure the piston length (oil at room
temperature). If it has sunk in again (<2 mm), there may be a problem with a bad seal.
Measure the HV insulation:
Subconn bulkhead Measurement
Pin 2 (HV) to screw on tube >10 MΩ Ω

CRE penetrator with connector Measurement

Pin 2 (HV) to screw on tube >10 MΩ Ω

If the insulation measurement is <10 M Ω the thruster may have contaminants or water in the oil.
Begin by emptying the oil and re-filling the thruster (point 3 in this chapter). If this does not help, the
thruster must be dismantled, the stator dried in an oven and assembled again using new seals and O-
rings.

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

7 PARTS, TOOLS AND CONSUMABLES

If required, the listed tools and consumables can be purchased from Ocean Modules.

7.1 SPECIAL TOOLS

Name Product nr. Illustration

I. Vacuum pump 99-99007-01

II. Tool for inserting sealing.

III. Sealing removal tool

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without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

IV. Press

V. O-ring protection tool (Front gable) 06-00020-01

VI. O-ring protection tool (Aft gable) 06-00021-01

VII. Thruster bracket X 40-00705-01

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

7.2 CONSUMABLES

Name Product nr. Illustration

i. Loctite 638 (Glue)

ii. Loctite 7649 (Activator)

iii. Wurth Threadlocker (Medium strength)

iv. Acetone (For cleaning)

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

v. Molykote 111 (For greasing)

vi. Wurth Elastofix (Rubberised super glue)

vii. 3M SGH12 (Polyesterfilm)

viii. Propanol/Isopropyl
Electronics cleaner

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB
 Revision EM&I 01

ix. Adhesive gum

x. Thruster oil (Shell Ondina X 420)

xi. Aquashield

This document and the information contained herein is the property of Ocean Modules Sweden AB and must not be used, disclosed, or altered
without the prior written consent of Ocean Modules Sweden AB