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INSTALLATION MANUAL

How to wire the Max Power 12/24 V Battery Coupler, which runs a 24V thruster from two 12V batteries charged by a 12V system: power cabling and control connections for Composite tunnel thrusters, VIP 150 electric, VIP 150 / 250 hydraulic and R 200 hydraulic thrusters.

DocumentMax Power 12/24 V Battery Coupler Installation Manual
FormatPDF · 12 pages · 6.7 MB
LanguageEnglish
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WarningsComposite TunnelVIP & R 200DrawingsProducts
Max Power 12/24 V Battery Coupler — Installation Manual

Read This First

  • This model (Blue, Black & Brown control wire inputs) only works with thrusters fitted with an electronic control box. For 24V thrusters without an electronic controller use the previous coupler model (Blue, Red & Brown inputs).
  • Installation by a qualified marine electrician; read the whole document and the drawings first.
  • Works only with a 12 Volt charging system, maximum charging current 100 Ampere.
  • Coupled batteries: same manufacturer, same model and capacity – different battery types can cause serious damage.
  • Treat the coupled batteries as an independent bank, never connected directly to any other bank. Protect the charger against reverse current (most marine chargers have a diode; or take the charging positive after a diode splitting block).

Composite Tunnel Thruster Range

Power Cabling (drawing BC 01)

  • Size the charging cables C1 & C2 for minimum voltage drop and the maximum 100A charging current.
  • Cables S+ & S- the same size as the thruster motor circuit (see the thruster manual).
  • Fit a power fuse and a manual battery isolator in the positive power cable of the thruster motor.

Control Connections, Standard 24V Unit (24V motor, 24V relay, electronic controller)

Option 1 – keep the 24V relay (BC 02)

  1. Unplug the negative (black) bridge wire from the controller at the bottom male spade connectors of the two thruster relay coils.
  2. Cut it and connect it with proper fittings to the negative (black) going to the battery coupler relay coils.
  3. Connect the negative bridge with diode, supplied with the coupler, between the motor negative terminal (A1) and the bottom spade connectors of the relay coils.
  4. Connect the blue and brown wires going to the coupler to the unused spade connectors of the relay coils.
  5. Take the control circuit / controller supply from points A & B of the coupler battery bank.

Option 2 – fit a 12V relay (BC 03)

  1. Replace the 24V relay supplied with the thruster by a 12V relay.
  2. Connect the blue, brown & black wires going to the coupler to the unused spade connectors of the relay coils.
  3. Supply the control circuit / controller from a separate 12V battery bank, not one of the coupled batteries.

VIP 150 Electric (BC 01, BC 04)

  • Power cabling as BC 01.
  • Remove the negative (black) bridge wire of the loom from the two bottom spade connectors of the relay; fit the coupler's negative bridge with diode between motor terminal A1 and those connectors.
  • Use a 12 V electric battery isolator in the motor positive cable.
  • Replace the standard 24V up/down motors with 12 V models.
  • Connect blue, brown and the black (negative common) from the control card to the coupler control wiring; control supply from points A & B of the coupler bank.

VIP 150 / 250 Hydraulic and R 200 Hydraulic (BC 05, BC 06, BC 07)

  • Charging cables C1 & C2 sized for 100A; S+ & S- the same size as the electro-hydraulic pump circuit; power fuse and manual isolator in the pump positive cable.
  • Directional Control Valve (DCV) solenoids must be 12 V – replace them if not.
  • Use a 12 V electric battery isolator and power relay.
  • VIP: replace the 24V up/down motors with 12 V models. R 200: replace the 24V motor on the up/down RAM with a 12 V model.
  • Connect the blue, brown & black wires going to the DCV to the coupler control wires.
  • Supply from a separate 12 V bank (advised) or from one of the 12 V banks used by the coupler.

Drawings in the Manual

Drawing Content
BC 01 Power cabling for Composite Tunnel & VIP, 24V models (coupler MPOP3180, 12V electric battery isolator, power fuse; charge 12V, maximum 100A)
BC 02 Composite Tunnel control connections, Option 1 (control supply 2 × 2 mm², depending on cable length)
BC 03 Composite Tunnel control connections, Option 2
BC 04 VIP 150, 24V control connections
BC 05 Power cabling for VIP 150/250 & R 200 hydraulic
BC 06 VIP 150/250 hydraulic control connections
BC 07 R 200 hydraulic control connections

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