Trend Marine Products Limited ___________________________________________________________ Installation Manual INSTALL0009 Sunroof, Chain Driven Issue ECN Date Remarks A B C 870 1018 01728 28 Jun 07 24 Aug 07 04 July 08 D 04841 26 July 12 First Issue Renumbered (was 06STDR101-5005) Corrections REWORKED with diagrams & electrical wiring diagram _______________________________________________________________ INSTALL0009-D Page 1 of 20 Trend Marine Products Limited ___________________________________________________________ Contents Page • Introduction 3 • Handling 4 • How the control system operates 5 • Pre-Installation check 5 • Installation - Mechanical 6 – 11 • Electrical control system fitting 12 – 14 • Control Box: Set-up 15 • Power Failure & Battery Back-up 16 • Maintenance & Cleaning 17 • Chain Tension & Adjustment 18-19 • Contacts details 20 _______________________________________________________________ INSTALL0009-D Page 2 of 20 Trend Marine Products Limited ___________________________________________________________ Introduction Please read installation manual thoroughly prior to installation. If there are any queries arising from the installation process, please contact Trend Marine Products Limited. This manual contains information for safe and complete installation of the product. Incorrect installation may result in a non operable product, failure to work within design parameters or being unsafe for use. It is solely the responsibility of the customer to ensure correct fitment and pre-delivery inspection of the product. Trend Marine Products Ltd does not accept liability for incorrect installation or damage caused due to poor installation. This guide is purely generic. Although some bespoke designs may vary from what is seen or described in this installation guide, the fundamental principles found in this guide should still apply. Please keep this installation guide for future reference. _______________________________________________________________ INSTALL0009-D Page 3 of 20 Trend Marine Products Limited ___________________________________________________________ Handling Care should be taken when handling the Sunroof components and assemblies. The mechanical running components are either stainless steel or anodised aluminium to help prevent corrosion. Therefore care must be taken to preserve this finish during the installation process. Should panels be supplied with the system care must be taken to protect the surface of the panel and any associated glass. Depending upon the supply of the panel, the system is either sent as one complete unit or as a kit of parts. Once installed into the vessel, the system is a rigid unit. Prior to this stage however, due to the nature of their construction, the system can easily be subject to flex and twist during installation. Such actions can cause damage to the surface finish of the unit (e.g. anodising) and permanent deflection will result in a non-functionality of the system. It is the customer’s responsibility to ensure that all relevant health and safety laws and guidelines are adhered to during the installation of Trend Marine Products Ltd. _______________________________________________________________ INSTALL0009-D Page 4 of 20 Trend Marine Products Limited ___________________________________________________________ How the Control System Operates: • The roof is driven open and closed by a geared dc motor. • The motor is controlled by a dc drive card which sends out electrical pulses to the motor for drive in one direction or the other. • Functions on the drive card control; o Speed. o Slow (parking) speed. o Acceleration ramp up to pre-set speed. o Deceleration ramp. o Length of slow down. o Current limit open. o Current limit close. • There is a Datum switch located towards the rear of the starboard rail. This is a magnetically operated reed switch with both N/O and N/C contacts. The magnet is screwed to the underside of the roof panel and is in-line with the sensing face of the Datum switch when the roof is in the open position. The purpose of the Datum switch is to provide a ‘reference position’ for the encoder. • An incremental encoder is fitted to the rear of the motor, and outputs a stream of pulses via two offset channels ‘A and B’. When the motor runs in the opposite direction, the encoder channels output ‘B and A’. It must be noted that the encoder will forget where the roof is if power is removed for any length of time. After a power shut down, the roof needs to be fully opened until it stops over the Datum switch, at this position the system recognises a known reference point. Once the system has been ‘set-up’ (see: Control box set-up), it remembers how many pulses there are between the Datum point (fully open) and the fully closed position. This number is electrically etched onto a memory chip within the controller and is used as part of the slow down functions in either direction. Pre-Installation - Check Prior to fitment into the vessel a pre-installation check needs to be performed to ensure that no damage has occurred during transportation. The customer should carry out the following: • Remove any transportation strops from the system that will prevent / obstruct the panel or carriages from moving over the full length of the tracks. • At this stage do not remove any protection film that is applied to the panel. • Visually inspect mechanism and panel for any signs of damage. Photograph and record any damage observed. • Promptly report any damage to Trend Marine Products Ltd, supported with a written description and photographs. _______________________________________________________________ INSTALL0009-D Page 5 of 20 Trend Marine Products Limited ___________________________________________________________ Installation The rails are supplied pre-assembled and chains pre-tensioned by Trend prior to shipment to the customer. The carriages are also supplied pre-assembled by Trend, along with drive-shafts and the motor/gearbox. Note: The timing of each drive-shaft to be set by the customer on final assembly. Fitting the rails: 1. Slide the two Fixed carriages (no side play) onto the starboard-side rail. Slide the two Floating carriages (with 6-8mm side play) onto the port-side rail. 2. Approximately position both rails and carriages into their respective roof gullies (DO NOT FIX). 3. Lower the roof onto the four carriage pins, then jack the pins (using T-key supplied) to ensure the top of the roof is approximately level with the top of the boats’ GRP aperture. 4. Position the starboard-side rail with 67mm (2 5/8”) gap between the back of the sprocket plates and the GRP gulley as shown below. 5. Push the roof open enough to access the 1st (front) fixing hole. 6. Place four equal thickness packers between the corners of each side of the roof and the GRP gullies to centre the roof side to side as shown over. _______________________________________________________________ INSTALL0009-D Page 6 of 20 Trend Marine Products Limited ___________________________________________________________ EQUAL PACKERS HERE EQUAL PACKERS HERE 7. Once centred, drill the 1st (front) hole of the starboard-side rail and fit a fixing screw. Next drill the hole in the rail directly behind the roof panel, again fit a fixing screw. 8. Now move the roof panel further back (approx’ ¾ open), reposition the four equal packers, and drill the rear hole in the starboard-side rail and add a fixing screw. At this stage, only the starboard-side rail is fixed. Remove the packers and check the roof moves freely forward and aft, remaining central within the aperture. 9. Move the roof to approximately the ½ open position, then using the ‘trammel set’ (spanning beam) set the port-side rail parallel to the starboard rail at the pre-set distance. Ensure the back edge of the sprocket plates to the GRP gulley is set to 67mm as per the starboard side. 10.Carefully drill the front and rear fixing holes in the rail then screw down. Move the panel forward to drill and fix the middle holes. CHECK the panel moves freely. 11.Slide the roof panel forward or back to access the remaining fixing holes. Drill and fit screws to all remaining fixing holes in both rails. CHECK the panel moves freely. _______________________________________________________________ INSTALL0009-D Page 7 of 20 Trend Marine Products Limited ___________________________________________________________ 12.Check and reset the height of the carriage pins (if required) to ensure the top of the roof is level with the top of the boat GRP aperture. When set, fit the four large washers, the M6 retaining screws using ‘ScrewLock’ then torque down to 8Nm (6ft lbs). 13.Finally, fit the black plastic D-shaped caps. Note: The plastic caps must be fully sealed to prevent water ingress using only black silicon as shown below. FILL AROUND RECESS & UNDER CAP WITH BLACK SILICON HERE. 14.Notes: • Remove all burrs. • Clean both sides of swarf and GRP dust prior to fixing. • Fill all rail fixing holes with silicon (to prevent water ingress) before fitting screws. _______________________________________________________________ INSTALL0009-D Page 8 of 20 Trend Marine Products Limited ___________________________________________________________ Fitting the Geared Motor & Drive-Shafts: 1. Fit the motor/gearbox in the central location ensuring that the motor is securely mounted and is protected from effects of water ingress. 2. Fit the drive shafts to the motor/gearbox and side rail assemblies ensuring that the U/J assemblies are correctly assembled with shaft keys and grub screws tightened correctly and Loctite ‘screw-lock’ applied to the screws. See picture below. 3. Final roof alignment: The slip couplings allow for timing of the chains to be accurately aligned to each other. These adjustments allow the roof panel to be set as square as possible to the aperture. To adjust one or both of the slip couplings, slacken the three screws and nuts in the coupling and rotate the outer half-shaft within the slots to the position required. Once set, mark a line across both halves of the coupling and tighten the nuts and screws. See the following two pictures for clarification. _______________________________________________________________ INSTALL0009-D Page 9 of 20 Trend Marine Products Limited ___________________________________________________________ ROTATE FOR TIMING ALIGNMENT SLIP COUPLING SLIP COUPLING – CLOSE-UP SLACKEN NUTS & SCREWS TO ADJUST _______________________________________________________________ INSTALL0009-D Page 10 of 20 Trend Marine Products Limited ___________________________________________________________ Datum Switch Adjustment: The gap between the underside of the magnet which is fixed to the lower face of the roof panel and the Datum switch needs to be set to 3mm (1/8”). 1. Move the roof back to the fully open position with the magnet over the top (sensing) face of the Datum switch. 2. The datum switch can be adjusted up or down by either screwing it in or out of its’ carrier block, or by slackening the two clamping screws and sliding the carrier and switch up or down. Once set, tighten the clamp screws or the white Nylon lock nut (if used) on the switch. CHECK the gap and re-adjust if necessary. _______________________________________________________________ INSTALL0009-D Page 11 of 20 Trend Marine Products Limited ___________________________________________________________ Electrical control system fitting: The control system consists of two boxes, the interface box (160 x 80 x 55) and the main control box (240 x 160 x 90) that require installation and initial set-up prior to final commissioning. The interface box needs to be located within 0.5 metres of the motor and in a dry location. The main controller needs to be located within 3 metres of the main supply, in a dry location, and not to exceed operating temperatures in excess of 50°C. The location must also allow access to the front of the control box to enable the set-up button and fault indication LEDs to be accessible / visible. The Control boxes lead set needs to be connected in accordance with the wiring diagram (06STDR101-9001). For 12V Systems, the supply voltage must NOT reduce to less than 10.5V, and a charging voltage of 13.5 Volts is required to charge the back-up battery. See wiring diagram 06STDR101-9001 page 13. See Control Box details: page 14. See Control box SET-UP: page 15. _______________________________________________________________ INSTALL0009-D Page 12 of 20 Trend Marine Products Limited ___________________________________________________________ _______________________________________________________________ INSTALL0009-D Page 13 of 20 Trend Marine Products Limited ___________________________________________________________ _______________________________________________________________ INSTALL0009-D Page 14 of 20 Trend Marine Products Limited ___________________________________________________________ _______________________________________________________________ INSTALL0009-D Page 15 of 20 Trend Marine Products Limited ___________________________________________________________ Power Failure / System Shutdown Should the system experience a power failure, set-up does not have to be re-instigated unless the roof has been moved manually. If the system has been operated on the battery back-up system or was not fully in the closed position the set-up button does not need reactivating however the roof will travel at the reduced set-up speed until the panel reaches the datum switch. Battery Back-up In the event of a power failure with the roof in the open or partially open position the system has a battery back-up that will allow the roof to be closed only. The battery back-up system is intended for emergency use only and can’t be used to operate the roof for normal operation. When the back-up system is activated the roof will travel forward to the closed position at set-up speed. It must also be noted that the battery will only charge when the roof is in its fully closed position. Also whilst in battery mode the anti-nip safety feature will not operate. Notes: • Upon initial set-up the battery will require 18-24 hrs to fully charge. • In the event of power failure and the roof is required to be closed via the battery back-up this operation must be completed within 2 hours of the initial failure. • Batteries have a limited life and to avoid any potential failures should be replaced every two years. _______________________________________________________________ INSTALL0009-D Page 16 of 20 Trend Marine Products Limited ___________________________________________________________ Maintenance and Cleaning The only substance that is recommended for cleaning the sunroof system is a mild solution of soap and water, which should be liberally used to remove any salt deposits etc that may have accumulated whilst at sea. The sunroof can then be dried off using a suitable absorbent leather cloth. When dry, the panel can be buffed up with a dry clean soft cloth. On no account should any aggressive materials be used for this purpose, they may affect the surface finish of the panel and any adhesive which is used to retain the glass into the panel or retaining the sealing gaskets. Should the vessel not be used for any period of time then a light lubricant such as ‘WD40’ should be applied to the full length of the drive chain in both rails. Once the system has been lubricated the system should be cycled for 6 full operations to ensure that the chains are fully lubricated. The tension in the drive chains needs to be checked annually. This checking and adjustment should only be carried out by a member of Trends’ staff, or a competent Engineer. The checking and adjusting procedure is listed on pages 18-19. _______________________________________________________________ INSTALL0009-D Page 17 of 20 Trend Marine Products Limited ___________________________________________________________ _______________________________________________________________ INSTALL0009-D Page 18 of 20 Trend Marine Products Limited ___________________________________________________________ _______________________________________________________________ INSTALL0009-D Page 19 of 20 Trend Marine Products Limited ___________________________________________________________ Appendix Electrical Wiring Diagram • 06STDR101-9001 : Sunroof – Electrical Diagram Potentiometer settings • Customer Pot Settings.pdf Fault Diagnosis Chart • G-104-10-FDC-A Contact Trend Marine Products Ltd Sutton Road Catfield Great Yarmouth Norfolk NR29 5BG United Kingdom Telephone: +44 (0) 1692 581307 Sales Fax: +44 (0) 1692 582550 General Fax: +44 (0) 1692 582993 E-mail us at the following: sales@trendmarine.com brochure@trendmarine.com enquiry@trendmarine.com spares@trendmarine.com _______________________________________________________________ INSTALL0009-D Page 20 of 20
