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INSTALLATION MANUAL

Installation, power supply, CAN-Joystick and app set-up, operation, maintenance and spare parts for the Max Power Eco Proportional 90 (24 V), 110 (24 V) and 130 (48 V) brushless thrusters, plus the steps to upgrade an existing CT60, CT80, CT100 or CT125 installation.

DocumentMax Power Eco Proportional Series 90, 110 & 130 Installation Manual
FormatPDF · 16 pages · 1.3 MB
LanguageEnglish
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Installation ManualPDF · 16 p.Steps to upgrade from CT to Eco ProportionalPDF · 4 p.
Key DataInstallationElectricalCAN-Joystick & AppOperationMaintenanceCT UpgradeSpare PartsProducts
Max Power Eco Proportional Series 90, 110 & 130 — Installation Manual

Eco Proportional 90 / 110 / 130

Item ECO-PRO 90 24V ECO-PRO 110 24V ECO-PRO 130 48V
Operating voltage (min – max) 21 – 28.8 V 21 – 28.8 V 42 – 57.6 V
Average amperage 260 A 290 A 190 A
Max Power ceramic fuse / ANL fuse 160 A / 150 A 200 A / 175 A 125 A / 125 A
Recommended battery DIN 395, SAE / CCA 700 DIN 535, SAE / CCA 950 DIN 395, SAE / CCA 700

Supply values assume batteries at 100% and in charge at 22 degrees Celsius ambient: 24 V thruster 21.0 - 28.8 V, 48 V thruster 42.0 - 57.6 V. Brushless series need approximately 5% less current than the equivalent brushed models. Delivered with electric motor, controller with mega-fuse preinstalled, CAN panel and CAN cable (10 m).

Tunnel

  • Minimum tunnel position: 139 mm below the waterline. Ideal: at least 185 mm from the waterline to the top of the installed tunnel. As far forward as possible.
  • Mark the tunnel centre on both sides, drill 8 -10mm holes and trace the ellipses with a compass made from a metal rod, 100mm radius.
  • Grind 10 to 15cm around the holes, drill the tunnel before laminating, bond with reinforced fiberglass filler and laminate a minimum of 8 layers of isophthalic resin alternated with mat and roving. Finish 1 to 4 cm with several coats of reinforced filler for hydrodynamic lines, then apply sealant.
  • Do not laminate the area of the tunnel where the motor support will be fixed. Drive leg centred in the tunnel; propellers must never protrude out of it. The propeller should preferably sit on the vessel's centreline and always be accessible from outside.
  • Support the motor whether vertical, inclined or horizontal; the controller generates heat, so the compartment must be dry and ventilated. Batteries charged by both the engine alternator and a charger; a dedicated bank goes close to the thruster.
  • The motor can be set horizontally or at an angle; at an angle, support is absolutely essential to keep leg and motor aligned. Dry, well ventilated area (IP44).

Leg, Motor & Propellers

  • Mark and drill the screw and hub holes with motor support and gasket, keep them clean, dry-fit, dismantle. Coat both sides of the gasket with silicon grease or sealing compound resistant to hydrocarbons and water; no graphite grease. Tighten the two 8mm screws alternately with a 5.5mm Allen key, max. 25 Nm.
  • Make sure no power is supplied. The motor-side coupling is factory set. Push the lower shouldered coupling fully down on the lightly greased leg shaft and place the flexible coupler on it (part #4).
  • Remove the four nuts under the motor without fully removing the four studs (if removed, reinsert them carefully). Set the motor/controller assembly on the motor support and tighten with an 8mm Allen key, max. 40 Nm, in even sequential turns; no Loctite on the studs.
  • Leave 2mm of play (+/- 1mm) between the motor and leg couplings; readjust with the motor side coupling screw using a 2.5mm Allen key. Let air flow freely around the motor/controller.
  • Fit drive pin and propellers and tighten the M12 DIN985 lock nut with a 19mm wrench, max. 25 Nm, for each propeller. Coat shaft and stainless steel cover with silicon grease.
  • Protection grids are recommended against debris but may affect performance.

Power Supply

  • An automatic battery isolator is built into the controller under the plastic cover; Max Power advises a separate manual isolator as well.
  • The integrated mega-fuse protects motor and controller; protect the cables with a separate main fuse near the battery positive terminal, sized from the cable sections, NOT from the motor amperage.
  • Power cables: shortest route, ventilated area, PVC insulation rated at least 105 degrees Celsius; crimped terminals (motor/controller has M10 terminals).
  • Lithium-ion batteries: keep the voltage within 21.0 - 28.8 V (24V) or 42.0 - 57.6 V (48V); consult a marine electrician about discharge and the BMS. With alternator charging, take the charge reference after the diode-splitting block.
  • CAN bus connectors: match the insertion guides before tightening the safety ring.
Total cable length (positive + negative) ECO-PRO 90 ECO-PRO 110 ECO-PRO 130
L ≤ 7 m (3,5 x 2) 50 mm² - 1/0 AWG 70 mm² - 2/0 AWG 50 mm² - 1/0 AWG
7 < L ≤ 14 m (7 x 2) 50 mm² - 1/0 AWG 95 mm² - 3/0 AWG 50 mm² - 1/0 AWG
15 < L ≤ 21 m (10,5 x 2) 70 mm² - 2/0 AWG 120 mm² - 4/0 AWG 70 mm² - 2/0 AWG
22 < L ≤ 28 m (14 x 2) 95 mm² - 3/0 AWG 2 x 70 mm² - 2x 2/0 AWG 95 mm² - 3/0 AWG

Voltage-Drop Check

Thruster running in the water, batteries fully charged and on charge. Measure:

  • At the batteries
  • At the battery cut-off switch
  • At the fuse
  • At the electric motor's connections
  • At the power supply arriving at the thruster control box

Expected between the thruster's connections: approx. 21.0 - 28.8 V (24V) or 42.0 - 57.6 V (48V). If too low:

  • Are the batteries of sufficient capacity and good quality?
  • Are the batteries sufficiently charged?
  • Are appropriate cable sections being used?
  • Are the connections sufficiently tightened?

CAN-Joystick and App

  • The CAN-bus proportional joystick (IP67) has Bluetooth for remote monitoring and troubleshooting from an Android smartphone.
  • ON / OFF: press the Port and Starboard buttons together for 2 seconds; both blink 3 times. The thruster switches off by itself after more than 20 minutes without interaction.
  • Thrust is proportional to the joystick deflection; the lit button shows the direction. A 2 second time delay protects the drive leg when reversing direction; none when thrusting to the same side. Above about 1-2 knots the thruster has little effect: plan ahead.
  • Hold function: deflect the joystick to the desired angle and press the button opposite to the pushed side for 3 seconds; the button blinks 1:4. Any button or joystick movement cancels it.
  • Errors show in the app, by blinking of both joystick buttons and on the controller LED (orange and red signals, under the plastic cover).
  • Reset: push the joystick to the left for 10 seconds.
  • Up to three 10 meter CAN cables via a 3-way "T" connector; only one CAN-Joystick can be used at a time (activating a second one deactivates the first). Keep the area below the dashboard dry.
  • App: Android OS version 8 and above, phone within 5 meters of the joystick; grant Bluetooth and Location permissions, select "Bluetooth connection" and the joystick's name from its side label (RNXXXX – XXXA). The app monitors only (battery voltage and current, motor temperature, motor speed); it gives no command capability.

Joystick Mounting

  1. Drill a 73+0.5 mm hole in the mounting plate (max. plate thickness 10mm).
  2. Place the module in the hole.
  3. Thread both M3 studs through the holding plate's holes.
  4. Tighten with the M3 locknuts provided, max. torque 0.4 Nm.

Operation and Safety

  • The thruster can run continuously as long as there is power. On overheating the controller first limits power to 80%; at the critical threshold it stops, both joystick buttons flash red and the app shows the overheat. It restarts only once the motor has cooled down.
  • When first powered, the small relay on the controller arms automatically for testing: switch the thruster off from the CAN-Joystick when tests are done. Never activate it out of the water; test in the water with batteries at 100% and in charge, engines running.
  • Before use, know your surroundings and have a backup plan; release the joystick before reaching your position; never use near objects, people or animals in the water. Keep the main engine(s) running while thrusting.
  • Turn the main power switch off before any service; the battery isolator must be easily accessible.

Maintenance

  • Before every season, inside: area around the thruster clean and dry, no leaks, connections free of oxidation and tight, batteries in good condition delivering the right voltage, coupling assembly in position.
  • Outside: propellers and tunnel undamaged and free of obstacles, propellers fastened securely, marine growth removed, antifouling on propeller and leg every season (keep paint out of the gap between propeller and leg).
  • The brushless motor needs no maintenance. The drive leg is pre-filled with oil and sealed for life (no oil top-up or anode) and must not be disassembled, even partially (voids the warranty).
  • Each year coat the drive shaft and oil seal stainless covers with silicon grease before refitting the propellers; no aggressive solvents. Worn leg oil seals: replace the drive leg with a standard exchange unit.
  • Never store equipment, sails or ropes in the thruster compartment: after long operation it gets hot enough to damage nearby items or cause a fire, and loose items can pull wiring loose.

Troubleshooting

Problem Check
The CAN-joystick does not activate
  • CAN cable connected behind the joystick and at the thruster; remove the plastic cover and check all connections are sound and free of oxidation
  • Battery main switch ON
  • Main power fuse near the battery positive terminal not burnt
  • Battery voltage: 24 V bow thruster 21.0 - 28.8 V; 48 V bow thruster 42.0 - 57.6 V
The motor is running but the thruster is not working or thrust has decreased
  • Propellers fitted correctly, undamaged, propeller pin not broken
  • Coupling assembly: replace if damaged
  • Tunnel not obstructed, propellers free: remove marine growth
  • Rotate the leg's upper shaft by hand: if not smooth and all else is fine, replace the drive leg
  • Motor or controller overheated and running at reduced power
Electric motor does not operate
  • Battery main switch ON
  • Mega-fuse inside the controller and main power fuse near the battery not burnt
  • Connections tight and free of corrosion
  • Battery voltage: 24 V bow thruster 21.0 - 28.8 V; 48 V bow thruster 42.0 - 57.6 V
  • Alerts in the Android app
  • Count the red and orange signals under the controller cover and contact Max Power
  • Reset: push the joystick to the left for 10 seconds

Upgrading from CT to Eco Proportional

  • The Eco Pro 90 (24V), 110 (24V) and 130 (48V) fit existing CT60, CT80, CT100 and CT125 tunnel installations: drive leg, propellers and lower mounting base stay, so the tunnel needs no modification.
  • Check the space: Eco Pro units are more compact but may touch equipment onboard; make a mock-up and set it on the existing installation first. Dry, well ventilated area, away from flammable material.
  • The Eco Pro has a megafuse and battery isolator above the controller: the CT automatic battery isolator (if present) can be removed; keep a manual isolator near the battery positive terminal.
  • The charging system and power supply circuit may need modification (battery coupler, charger, etc.) depending on onboard and Eco Pro voltages; this is the installer's responsibility. Existing cables and battery bank in good condition and larger than advised in the manual need no change.
  • The command circuit is CAN Bus: replace the existing command harness completely. The kit includes one CAN-Joystick and a 10 meter CAN-Cable; up to three CAN-Joysticks per thruster.

Steps

  1. Turn off the main power switch of the thruster.
  2. Remove all cables (label positive and negative).
  3. Remove the 4x screws securing the CT motor on the existing mounting base.
  4. Remove the CT motor.
  5. Clean the installation area.
  6. CT60/CT80: insert the 1x 312211 key into the drive leg.
  7. CT60/CT80: position the upper mounting base on top of the existing lower mounting base.
  8. CT60/CT80: tighten the 4x 634133 screws in sequential, even turns, max. torque 33Nm.
  9. CT60/CT80: install the coupling assembly and position the brushless motor as described in the installation manual (key on the motor shaft).
  10. Connect the power supply cables to the motor.

Parts Needed for the Upgrade

Part no. Existing model Description
313714 CT60 / CT80 Motor support compo reinforced MP08 Ask us to source it →
634133 CT60 / CT80 Screw socket head DIN912 8x55 A4 (4 needed) Ask us to source it →
630487 CT60 / CT80 Coupling hub PG56 Ø20 alu 165/225 View part →
633743 CT60 / CT80 Coupling sleeve PG56-SF 165/225 View part →
633746 CT60 / CT80 Coupling hub PG56 Ø16 alu shoulder View part →
312211 CT60 / CT80 Key 15X5X18 shoulder coupling View part →
636677 CT60 / CT80 / CT100 / CT125 Eco 90 motor kit View part →
636678 CT60 / CT80 / CT100 / CT125 Eco 110 motor kit View part →
636679 CT60 / CT80 / CT100 / CT125 Eco 130 motor kit View part →
636838 CT165 / CT225 Eco 15kW motor kit 24V Ask us to source it →

Dimensions (mm, as printed)

Model Eco Pro A Eco Pro B Eco Pro C Eco Pro D CT A CT B CT C CT D CT E
CT 60 306 350 6 to 7 185 210 140 275 185 6 to 7
CT 80 306 350 6 to 7 185 210 140 275 185 6 to 7
CT 100 306 350 6 to 7 185 250 200 356 185 6 to 7
CT 125 306 350 6 to 7 185 250 200 365 185 6 to 7
CT 165 391 382,5 7 to 8 250 250 200 430 250 7 to 8
CT 225 391 382,5 7 to 8 250 270 200 405 250 7 to 8

Spare Parts

Max Power Eco Proportional 90 / 110 / 130 exploded view with part numbers

Part no. Ref. Description
636677 1 Max Power thruster Eco 90 motor kit View part →
636678 1 Max Power thruster Eco 110 motor kit View part →
636679 1 Max Power thruster Eco 130 motor kit View part →
N/A 2 Key (included in part number #1) Ask us to source it →
630487 3 Coupling motor View part →
633743 4 Coupling PG56 View part →
633746 5 Coupling drive leg View part →
313714 6 Upper motor assembly Ask us to source it →
313715 7 Lower motor assembly Ask us to source it →
310254 8 Leg gasket View part →
312211 9 Key 15X5X18 View part →
35035 10 Composite leg (includes n° 8, 9, 11, 12) View part →
N/A 11 M12 lock nut DIN985 A4 Ask us to source it →
312053 12 Propeller pin View part →
636576 13 Propeller Ø185 (nut version) View part →

Warranty: two (2) years; register within 3 months for 1 extra year (3 years in total); non-pleasure use limited to one year.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual