Marine Roof Marinedach Toit ouvrant Marine Marine schuifdak

Transcription

1 Marine Roof Marinedach Toit ouvrant Marine Marine schuifdak Installation Instructions Einbauanweisung Instructions de montage Montagehandleiding Einbauanleitung Instructions de montage 80 Series 80er Serie Série Series

2 TABLE OF CONTENTS / INHALTSVERZEICHIS / INDEX / INHOUDSOPGAVE English INTRODUCTION OPERATION PRE-INSTALLATION SEAL COMPRESSION INSTALLATION ELECTRICAL CONNECTIONS RESETTING ELECTRICAL DIAGRAM SAFETY SUPPORT TECHNICAL DATA CHECKLIST Deutsch... Français... Nederlands...

3 NOTE For installation and repair of Webasto roofs you will need a special training by Webasto, technical documentation, special tools and special equipment. Do NOT install or repair Webasto roofs, if you have not successfully finished the training by Webasto for acquiring the necessary technical skills. Do NOT install or repair Webasto roofs, if you do not have the necessary technical documentation, tools or equipment. ALWAYS follow the Webasto installation and service instructions and mind all warning indications. Webasto does not assume any liabilities for defects or damages caused by for installation untrained personnel. SYMBOLS On each page you can find a symbol of the kind of tasks explained on that page. Mechanical tasks Electrical connections Special parts of the text are marked with these symbols: Indication of danger of injuries or accidents Indication of danger of damaging the product Indication of another source of information Indication of technically special features 3

4 SCOPE OF DELIVERY Top frame (incl. 2 motors, mechanisms, wiring, rocker switch) Hinge bodies, left and right (incl. sliding mechanism) Rear rails, 2 pcs Rear rail covers, 2 pcs Rear rail end caps, 2 pcs Emergency key (hex key), 2 pcs Installation instructions Installation instructions Operating instructions Panel assembly (according your order) OTHER MATERIALS REQUIRED Hardware to fix top frame and rear rails: screws stainless steel A4, class 70 - M5 pan, dome or round head for rear rails (alternative: self tapping screws) - M6 pan, dome or round head for rear rails (alternative: self tapping screws) Hardware to fix panel to hinge bodies and lever assemblies: screws stainless steel A4, class 70 High quality, acid-free, UV resistant, silicon mastic sealant Loctite 243 or similar thread sealant Grease Isoflex Topas L32 Fuse 40 A Electrical wiring, connectors, etc. NECESSARY TOOLS Drilling machine Drills ø 4.2 and 5 mm Taps M5 and M6 Hex keys Mastic gun Screwdrivers Tools for electrical connections Personnel Perform roof installation with at least 2 persons. This makes the installation easier and reduces the risk of damage. Protection Improper use of tools can lead to injuries or damage to the ship or roof! Thoroughly read tool instructions prior to using. Before using any specialized tools, make sure to know all rules and regulations in your country. Cover interior and exterior of the ship with protection materials (covers, cloths, etc.) to reduce the risk of damage. Also wear protective clothing like ear protection, safety shoes, safety goggles and protective gloves. 4

5 1. INTRODUCTION 80 Series The Webasto 80 Series is an electrically operated sliding roof for comfort purposes. The sliding roof has been designed for use on motor and sailing yachts and can be used in the toughest conditions. It is suitable for fitting in area III (or area II, depending on your order) and usage for ship type with designcategory A (ocean-worthy). All parts are made from high corrosion resistant materials. Note: Several components are customer specific and may be different from corresponding components shown in this document. 2. OPERATION See operating instructions. 5

6 3. PRE-INSTALLATION Marine Roof has to be installed on surface with shape specified below. Deck must be sufficiently strong at installation point. If not, reinforcement must be made. Note: Illustration is an example! Deck shape: - Lengthwise: uncurved, straight. R3 R2 R1 - Cross direction: According your order. W2 L2 L1 - Place top frame in deck. - Center top frame in aperture. A - Fixate top frame to deck near A Aluminium or steel deck: Drill hole ø 4.2 mm and cut thread M5. Important: Do not damage seal when drilling holes, placing and tightening fixing screws. Other deck materials, e.g. GRP (Glass Renforced Plastic): Make your own choice. A - Check if boat center and rear beam of top frame are perpendicular. D B - Fixate top frame to deck near B, same as before (near A ). C - Check if sides of top frame and parallel and perpendicular to rear beam. - Fix top frame to deck near C and D, same as before (near B and A ). - Check if sides of top frame are parallel and perpendicular to rear beam. 6

7 - Drill remaining holes ø 4.2 mm and cut thread M5. - Remove top frame. Important: Do not damage seal when drilling holes. - Apply bead of sealant along contour of roof aperture. Also around fixing holes. - Place top frame again. - Aluminium or steel deck: Place and tighten fixing screws. Important: Do not damage seal when placing and tightening fixing screws. - Make electrical connections. See chapter 6. For GRP panels: - Attach the 2 forks (these are customer specific) to panel. x x - With mechanism in tilt position, 10 ~ 20 cm open: Place panel assembly on top of top frame and attach forks to LH and RH lever assemblies with 2 hexagon socket head screws M6 and 2 bushings. Just hand-tight. Note: Levers must be centered between forks. 7

8 For other panels (glass, sandwich,...): - Attach the 2 forks (these are customer specific) to panel. - With mechanism in tilt position, 10 ~ 20 cm open: Place panel assembly on top of top frame and attach forks to LH and RH lever assemblies with 2 hexagon socket head shoulder screws M6 and 2 Nylon spacers. Just hand-tight. - Attach 2 hinge bodies (these are customer specific) incl. sliding mechanisms to panel. - Slide rear rails through sliding mechanisms. Close sliding roof completely. Position rear rails. 60 mm front With closed sliding roof: - Ensure that rear rails are parallel and perpendicular to rear beam of top frame. - Measure distance between rear rails near sliding bracket. 8

9 - Drill fixing holes H1 (front holes in rear rails only) ø 5 mm and cut thread M6 in deck (LH and RH). Place fixing screws in holes H1, just hand-tight. Use pan, dome or round head screws. Alternative fixation with self tapping screws: - drill holes with correct diameter - place screws in holes H1 H1 front 310 mm H1 - Open sliding roof completely. If necessary, close roof a bit, until last hole in each rail can be accessed. - Check if distance between rear rails is same as measured before. X Y X Y - Check if sliding roof is well aligned with deck: X=X Y=Y sliding roof in center of deck 9

10 - Drill rear fixing holes H2 ø 5 mm and cut thread M6 in deck. Place fixing screw in each hole, just hand-tight. Alternative fixation with self tapping screws: - drill holes with correct diameter - place screws in holes H2 rear H2 H2 10

11 4. SEAL COMPRESSION 12 mm - Close sliding roof completely. - Measure distance between top frame and panel assembly. Ideally, this is 12 mm. 11

12 5. INSTALLATION - Drill remaining fixing holes ø 5 mm and cut thread M6 in deck. Alternative fixation with self tapping screws: drill holes with correct diameter - Remove rear rails. - Apply bead of sealant around all fixing holes. - Place rear rails and all fixing screws. Tighten fixing screws. grease grease - Apply thin layer of grease (Isoflex Topas L32) to inside of rear rails to ensure smooth sliding. 12

13 For GRP panels: - Place panel assembly again. Push sliding mechanism into back side rear rails. x x - With mechanism in tilt position, 10 ~ 20 cm open: Attach forks on panel assembly to LH and RH lever assemblies with 2 hexagon socket head screws M6 and 2 bushings. Tightening torque 4 Nm. Lock threads with Loctite 243 or similar. Note: Levers must be centered between forks. For other panels (glass, sandwich,...): - Place panel assembly again. Push sliding mechanism into back side rear rails. - With mechanism in tilt position, 10 ~ 20 cm open: Attach forks on panel assembly to LH and RH lever assemblies with 2 hexagon socket head shoulder screws M6 and 2 Nylon spacers. Tightening torque 4 Nm. Lock threads with Loctite 243 or similar. - Place rear rail end caps in backside of rear rails and tighten set screws. Tightening torque 1 Nm. rear 13

14 - Press rear rail covers into rear rails and cut excessive length. A A Check if there is grease on inside of rear rails (A) and tracks (B). If not, apply a thin layer of grease (Isoflex Topas L32) to inside of rear rails (A) and tracks (B) to ensure smooth sliding. B grease B (A) grease grease (B) Trim interior of boat. Ensure that 2 motors and connectors can be reached if necessary. E. g.: - Manual operation of roof in case power supply is shut off. - Replacement of motors and control units. IMPORTANT: Ensure that the hex keys / emergency keys to open the sliding roof manually are always ready to hand for crew / passengers. Finish the installation and check the function of the marine sliding roof. 14

15 6. ELECTRICAL CONNECTIONS Webasto customer rt or gn/ge 40A Determine switch position and install it. Connect battery 12 V DC. Red: + 12 V DC, continuous, fused with 40A. Orange: + 12 V DC, continuous, fused with 40A. Green/yellow: (minus) br rt sw br = brown ge = yellow gn = green or = orange rt = red sw = black Attach connectors wiring harness to motors. See electrical diagram (chapter 8.) Note: There should be an amperage of at least 40 A available. Note: In case there s a 24 V DC power supply, use a 24 V - 12 V DC convertor that can handle at least 40 A. Note: All wiring must be able to handle 40 A. rt sw gn or br If desired, switch can be illuminated. In that case, make 2 additional connections (see illustration): - Orange: + 12 V DC - Green: (minus) Other wires: - Red: Motors close - Black: Motors (minus) - Brown: Motors open br gn or rt sw = brown = green = orange = red = black 15

16 Different switch: In case another switch is used to operate the roof, it must be switched minus from the motors. Connect the wires as follows: - Black and red => close roof - Black and brown => open roof 7. RESETTING When necessary, the marine sliding roof can be operated manually. The driving shafts of the 2 motors can be turned with hex keys to open or close the roof. Important: When operating the roof manually, do not operate the roof electrically with the switch! A If the roof is operated manually with hex keys (A), the control system has to be reset. Reset procedure: Note: There should be an amperage of at least 40 A available. - Press and hold button (close) to close the roof as far as possible. - Release button (close). - Press and hold button (close). After approx. 10 sec the roof moves with small steps until it s completely closed and the motors produce a loud "click" sound. - Now, release button (close). The system has been reset. From now on, the roof will function normally. 16

17 8. ELECTRICAL DIAGRAM 1 2 Webasto customer rt or gn/ge 40 Amp 3 4 rt br 5 sw 1 = motors with control units 80 Series 2 = connector 3 = fuse 40 A 4 = battery 12 V DC 5 = switch 80 Series Red wire: + 12 V DC, continuous, with fuse 40 A Orange wire: + 12 V DC, continuous, with fuse 40 A Green / yellow wire: (minus) Cut and lengthen wires if necessary. All wiring must be able to handle 40 A. br ge gn or rt sw = brown = yellow = green = orange = red = black 17

18 9. SAFETY Sliding roof must not be used as escape hatch. Ensure that another hatch is accessible for emergencies. Do not to stick out any limbs when closing the roof! Not designed as walking surface! 18

19 10. SUPPORT For more details and updates, please check Webasto's technical website: TECHNICAL DATA X = direction of travel of boat Z X Y R3 R2 R1 W1 L2 L1 L3 19

20 Description 80 Series General Part no. According your order Operation Continuous electric Operating voltage 12 V DC, 40 A Control panel Rocker Switch Installation method Frame and rear rails screwed on deck Average installation time 8 hours Frame materials AlMg Si 0.5 Surface treatment (depending on colour) Anodised and/or powder coated (according your order) Panel To be developed by customer Allowable weight Max. 80 kg, including panel weight Not designed as walking surface Allowable temperature -10 to +75 ºC Possibility to use as escape hatch No Aperture dimensions According your order / CAD file Panel dimensions According your order Optics Colour panel Exterior (depending on colour) Interior Panel fixation According your order According your order Anodised Bolted on mechanism 20

21 12. CHECKLIST Check installation and functionality. See also Operating Instructions. INSTALLATION Clean All parts clean before operating roof. No dirt, dust and small particles. Examples: - No small particles in rear rails, front rails or mechanism (from drilling holes for fixation top frame and rear rails): causes damage and corrosion of rear rails. - No dust in mechanism (e.g. from sanding wooden parts). Grease Isoflex Topas L32 grease on inside of tracks and rear rails. Thread sealant Loctite 243 or similar thread sealant on threads of 2 pcs. screws M6 (fixation panel assembly to lever assemblies. Fuse Correct fuse in wiring Alignment rear rails Position rear rails in accordance with Installation Instructions exactly in line with roof and aperture parallel Sealing Panel assembly must compress seal at complete outline of roof When closed, distance between top frame and panel = 12 mm. FUNCTION Roof must run smoothly. Must open and close completely and correctly. Open Close 21

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24 Im Fall einer mehrsprachigen Version ist Englisch verbindlich. In multilingual versions the English language is binding. Dans le cas d'une version redigee en plusieurs langues, l'anglais est alors la langue qui fait foi. Bij een meertalige versie is de Engelse versie bindend. Webasto Product International NL Constructieweg 47 NL BC Kampen The Netherlands Phone: +31 (0) Fax: +31 (0) info-nl@webasto.com Internet: Ident-No B 08/11 Errors and omissions excepted Printed in The Netherlands Webasto AG, GCS 2011