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Barrus X05, Operator'S Manual

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Barrus X05 Operator'S Manual Download Page 42

 

 

RDG603B2 

– Issue 1

 

 

 

Page 42 of 88 

 

SECTION 5 

– Maintenance 

 

 

NOTICE: 

REFER TO THE BARRUS MANUAL PRIOR TO CARRYING OUT ANY MAINTENANCE 

WORK. 

 

 

WARNING: 

PRIOR TO CARRYING OUT ANY SERVICE OR MAINTENANCE WORK MAKE SURE 

THE RELEVANT PERSONAL PROTECTION EQUIPMENT IS WORN. 

1.  General 

•

  The person who is to carry out the maintenance of the outboard motor needs to have 

the relevant mechanical and electrical competence to do so. If you do not have the 

relevant skills or tools it is recommended that the maintenance is carried out by your 

local dealer or qualified mechanic. 

•

  The maintenance may involve being in the proximity of moving, hot or electrical parts. 

To reduce the risk of injury always make sure the motor is switched off and the battery 

is disconnected. 

•

  If replacement parts are required always use genuine parts or parts of the equivalent 

design and quality. A list of replacement parts is in 

Section 10 - Spare Parts. 

Please 

contact your local dealer to order the replacement parts. 

•

  Ensure  that  all  installations  and  boat  alterations  comply  with  any  appropriate  local, 

regional, national or international regulations. When installing new propulsion systems 

(that  are  not  identical  to  the  original  ones)  into  existing  craft,  a  new  vessel  Post 

Construction Assessment will be required, and carried out by an independent notified 

body. 

 

 

 

 

 

 

Summary of Contents for X05

Page 1: ...ORIGINAL INSTRUCTION RDG603B2 Issue 1 ELECTRIC OUTBOARD MOTOR OPERATORS MANUAL For the following models X05 X10 ...

Page 2: ...ty alert symbols appear throughout the manual It means attention be alert as your safety is involved Please read and follow the message that appears after the safety alert symbol NOTICE This indicates a situation which can cause damage to the machine personal property and or the environment or cause the equipment to operate improperly CAUTION This indicates a hazardous situation which if not avoid...

Page 3: ...ange of electric outboards are unique in their design Using a permanent magnet three phase D C brushless water cooled 48v electric motor which is mounted directly behind the propeller This gives an efficient and trouble free method of power delivery There is no traditional type impeller to wear out or change Salt silt and sand does not enter the motor and because there is no coolant or water insid...

Page 4: ...hire boat situations No canal river or sea water enters the system No coolant to change No problems in shallow or dirty water No water pump impeller to replace Direct drive no shaft gears or oil changes required Motor overload cut out Spare props of different sizes readily available Spare parts readily available Near silent in operation Optional extras Lithium Ion Polymer batteries available Multi...

Page 5: ...en in this manual are based on the latest information available at the time of publication Barrus reserve the right to change the specification of its products and manuals without prior notice Depending upon the equipment specification of the outboard and accessories fitted there may be discrepancies or differences with the information presented in this handbook No claims may be pursued in this re...

Page 6: ...or makes unauthorised alterations or modifications the warranty coverage will become void Barrus reserves the right to make future warranty coverage possible only with proof of proper maintenance WARRANTY CLAIMS Warranty claims shall be made directly to Barrus or by an authorised dealer The dealer will then arrange for the inspection and any necessary repairs If the repairs carried out are not cov...

Page 7: ...of 88 Damage due to rust or corrosion submersion or unreasonable exposure to the environment such as exposure to high humidity rain fall or seawater or conditions resulting in the freezing of cooling water are also not covered ...

Page 8: ... Remote Control Model Option 17 4 Speed and Direction Control Lever Option 17 SECTION 3 Installation 18 1 Unpacking the Outboard Motor 18 2 Adjusting the Outboard Motor Transom Height 19 3 Mounting of the Outboard Motor 20 4 Adjusting the Outboard Steering Lock 22 5 Adjusting the Outboard Angle 22 6 Battery Selection 23 7 Lithium Ion Polymer LiFePO4 Batteries 23 8 Battery Features EB 4830 EB 4850 ...

Page 9: ... 6 Tilting the Electric Outboard 37 7 Application Downloads and Information 39 SECTION 5 Maintenance 42 1 General 42 2 Installing propeller X05 43 3 Installing Propeller X10 44 4 Controller Alignment 47 SECTION 6 Transportation and Storage 48 1 Transporting 48 2 Storage 48 SECTION 7 Wiring Diagrams 49 1 Wiring Diagram for Electric Propulsion Outboard 49 SECTION 8 Technical Data 50 1 Outboard Data ...

Page 10: ...N 13 Declarations 60 1 Declaration of Conformity for Recreational Craft Propulsion Engine with the requirements of Directive 2012 53 EU 60 2 Declaration of Conformity for Recreational Craft Propulsion Engine with the requirements of the Recreational Craft Regulations 2017 UKCA Marking 62 3 LiFEP04 Battery TUV Safety Data Sheet 64 ...

Page 11: ...WILL FALL ON YOU CAUSING SERIOUS INJURY OR DEATH Note Suitable safe lifting equipment must be used to lift move and mount the outboard onto the boat The batteries used for the outboard will be heavy Make sure safe lifting procedures or suitable cranes or hoists are used when moving and installing them 3 Rotating Parts WARNING SEVERE HAZARD KEEP HANDS AND OTHER BODY PARTS AWAY FROM MOVING ROTATING ...

Page 12: ...st be switched off If the propeller is damaged it may become unbalanced and cause either bad vibrations or the outboard to fail Do not use the outboard in this situation 5 Electrics CAUTION Do not touch any electrical parts while operating the motor The electrical parts may cause shock or electrocution Ensure all electrical connections are insulated against accidental short circuit 6 Batteries DAN...

Page 13: ... FIRST and re connect it last If charging the battery ensure that the charger is switched off before connecting and disconnecting Do not tip the battery on its side Please see label on battery or manufacturer s instructions for specific information A battery master on off switch must be installed in the system Lithium ion batteries have other safety features that must be followed refer to Section ...

Page 14: ...hich will start the motor again Continue at a reduced speed until the initial cause of the overload has been resolved 9 Modifications Do not attempt to modify the outboard motor as this is likely to reduce safety and reliability Any modifications will mean that the outboard will not be liable for warranty and maybe illegal to use 10 Boat Ensure the boat that the outboard motor is being fitted to h...

Page 15: ...e to do so can result in poor performance system failure terminal overheating or in some cases melting of plastic terminal plugs or even fires 13 Applicable Standards Ensure that the fitting and installation of the electric outboard motor batteries battery storage cables and control systems comply with all relevant local national and international standards ...

Page 16: ...at are not shown here Note The serial number can be found on the top of the control unit Note The On Off Power Button is illuminated green when it is in the on position Description 1 Outboard Cowl 2 Tiller Control 3 Transom Mounting Bracket 4 Leg 5 Anti Cavitation Plate 6 Motor 7 Propeller Description 1 Speed Control Twist Grip 2 Direction Display 3 Safety Lanyard 4 Mode Switch 5 On Off Power Butt...

Page 17: ...4 Speed and Direction Control Lever Option Figure 5 Speed and Direction Control Lever Figure 6 Extension Cable Description 1 Steering Wheel 2 Speed and Direction Control Lever 3 Steering Cable 4 Electric Outboard Description 1 Safety Lock 2 Control Grip 3 Connecting Cable 4 Safety Lanyard 5 Mode Switch 6 On Off Power Button 7 Extension Lead Connecting Plug 8 Extension Cable 3 1 Metres ...

Page 18: ...suitable personal protective equipment for unboxing Figure 7 How the outboard motor will arrive Use a screwdriver to open the wooden box carefully Do not damage the wooden box Make sure to remove all screws and or staples from the sides of the box Figure 8 Opening the wooden box Check to make sure the following parts are in the box 1 Outboard Motor 2 Safety Key 3 Anderson Connector 4 Hexagonal Spa...

Page 19: ...te The outboard has an adjustable transom height system there are a number of positions to choose from between short and long shaft Prior to fitting the outboard motor make sure the correct transom height is chosen for the hull of the vessel see 3 Mounting of the Outboard Motor To adjust the transom height open the quick release clip and move the shaft up or down to the required height then close ...

Page 20: ...unted so that the boat is balanced For single engine boats mount the outboard motor on the centre line keel line of the boat Figure 10 Centre Line Keel Line Mount the outboard motor ensuring the anti cavitation plate is 25mm 1 below the bottom of the boat Figure 11 Mounting Height Centre Line ...

Page 21: ... of maximum potential speed If it is mounted too low it will cause excessive drag in the water using more power In shallow water it may become restricted and hit the bottom causing damage to underwater components Fit the outboard to the boat securing with the thumb screws on the transom Holes are provided to drill through and enable additional bolts to secure the outboard to the transom Figure 12 ...

Page 22: ...y tightened to maintain stability during transport and initial assembly Figure 13 Steering Lock Bolt 5 Adjusting the Outboard Angle This is much easier to do before the boat is put into the water Open the quick release handle rotate the motor so the pins line up with the desired holes close the quick release handle There are 4 angles to choose between Figure 14 Adjusting angle of the outboard Stee...

Page 23: ... different hull shape length displacement speed and daily operating cycle requirement Only one 48V Barrus battery module is required to run the X series outboards Additional battery modules can be added to increase the range Battery modules can be easily connected in parallel to form a larger capacity battery bank If using batteries from other manufacturers or sources these may be either 12v or 24...

Page 24: ...RDG603B2 Issue 1 Page 24 of 88 display Voltage Figure 15 Voltage Display Current Draw Figure 16 Amps Display Amp Hours Figure 17 Amp Hours Display Battery Percentage Figure 18 Battery Percentage Display ...

Page 25: ...the battery to the outboard harness as per Figure 19 48V 30Ah EB4830 48V 50Ah EB4850 Weight 16kg 27kg Nominal Voltage 48v 48v Charge cut off voltage 58 0 5v 58v 0 5v Overcharge cut off voltage 59v 59v Normal charger current 3 Amps 7 Amps Normal charge time 10 Hours 7 Hours Max charge current 30 Amps 25 Amps Fast charger time Optional extra 1 Hour 2 5 Hours Normal discharge current 30 Amps 80 Amps ...

Page 26: ...fferences in the charge condition of batteries wired in series can cause high compensatory currents or overloads which can damage the cables connectors or battery In extreme situations this can cause fires and injuries 8 Battery Features EB 4830 EB 4850 Battery Management System Built into the battery structure This prevents damage by over charging and over discharging Also in the case of a short ...

Page 27: ...cted to the outboard at the same time using the connector Figure 20 If two or more 48v batteries are connected together in parallel it is not a problem they will equalise the charge whilst in use Note 48V batteries only to be used with the multi plug connector If two or more batteries are charged together they can be connected and either all be charged with a charger each or one charger for all of...

Page 28: ... table below shows an example of how long the outboard motor can be used in a specific application before the batteries will require charging Please note that boat sizes hull shapes and battery sizes will give different results This means longer travel times can be achieved depending on the application The following values are based on a 16ft Cabin Cruiser Model Battery Supply Battery Capacity Ava...

Page 29: ...nals to insulate them 10 Lithium Ion Polymer LiFePO4 Batteries Warnings EB 4830 EB 4850 Do not immerse the battery in water and keep the battery in a cool dry environment Do not leave the battery near a heat source Use the correct charger for the battery Do not reverse the positive and negative terminals Do not connect the battery directly to a mains power electrical outlet Do not connect the posi...

Page 30: ...s RDG206A48 Note See Section 1 12 safety precautions referring to terminal crimping 14 Battery Installation Ensure the batteries are stored in a well ventilated compartment that complies with the requirements of the R C D recreational craft directive or other appropriate regulations They must be covered to prevent damage and accidental short circuit of the cells connections and batteries Batteries...

Page 31: ... charged and isolated from the electric outboard 16 Connecting Speed and Direction Control Lever Option The outboards are available either as tiller operation or as an inboard with remote shift control These either come as standard or can be fitted as an option The plug on the Control Lever is connected to the plug on the outboard motor Figure 24 Ensure locating arrows are aligned before connectin...

Page 32: ...RDG603B2 Issue 1 Page 32 of 88 Figure 24 Control Lever connected to Outboard Motor ...

Page 33: ...r or other electrical items in water Only run the electric outboard when the propeller is under water If the outboard is run in the air the shaft sealant rings for sealing the motor to the propeller can be damaged When the electric outboard is mounted the tiller electronics are splash proof only The tiller and shaft head are not designed to be submerged as this can damage the electronics beyond re...

Page 34: ...ode you want to use Sport Normal or Economic on the mode switch Note The outboard has 3 modes Sport S Normal N and Eco E which have different speeds that are a percentage of the maximum throttle The default settings are Economic 25 Normal 60 and Sport 100 These can be altered using the EZ Outboard Application See 7 Application Downloads and Information Press the power button The light on the power...

Page 35: ...g The outboard will not operate if the safety lanyard is not mounted in its correct location Note The lever must be installed to move the boat forwards when the lever is moved forward Press the power button The light on the button will illuminate green Press the locking safety button on top of the lever down Slowly push the speed and direction control lever in the direction required forwards or ba...

Page 36: ... the neutral position using the speed control twist grip This will stop the propeller Press the power button The light on the button will go off 5 Stopping Procedure Outboard motor with speed and direction control lever Put the speed of the motor to the neutral position using the control lever This will stop the propeller Press the power button The light on the button will go off ...

Page 37: ...ease handle Figure 28 Tilt Lock Lever Lift and tilt the electric outboard up Lift and tilt the outboard until the lift latch engages and this will hold the leg in the raised position To adjust the trim angle When the quick release handle Figure 28 is open the motor can be moved to adjust the trim angle Figure 29 Trim Pin Closing the quick release handle will move the pin back into the slot ...

Page 38: ...lease the lever Figure 30 Outboard release lever being pulled out to lower the motor Set the tilt lock lever to the locked position When running the tilt lever must be in the locked position Failure to do this will result in the outboard leg lifting out of the water if reverse astern direction is engaged This is potentially very dangerous as the propeller will be rotating ...

Page 39: ...ogged can be shown in either km h or mph This is particularly useful if not using the Barrus EB 4830 EB 4850 LiFePO4 batteries as alternative batteries are unlikely to have the visual display gauge on top See figures 15 16 17 and 18 The Bluetooth adaptor dongle should already be in place when the outboard arrives If it is not in place Ensuring your electric outboard is turned off and disconnected ...

Page 40: ...similar on the in app Bluetooth menu Note The app may appear in a different layout on the iPhone version The log section of the app allows users to download a spreadsheet with information about the outboards speed current and power as well as the motor and controller temperatures The time interval in seconds between logs can also be adjusted using the settings tab ...

Page 41: ...ton at the bottom This can be seen in the picture below Once uploaded the motor will continue to beep constantly until it has been restarted Doing this sets the maximum outboard speeds for each mode limit Figure 35 Setting Outboard Speeds Once the settings have been uploaded to the outboard they will not change unless modified through the app even if the battery is disconnected or the Bluetooth do...

Page 42: ...e maintenance may involve being in the proximity of moving hot or electrical parts To reduce the risk of injury always make sure the motor is switched off and the battery is disconnected If replacement parts are required always use genuine parts or parts of the equivalent design and quality A list of replacement parts is in Section 10 Spare Parts Please contact your local dealer to order the repla...

Page 43: ...Issue 1 Page 43 of 88 2 Installing propeller X05 Insert cylindrical pin into the upper hole of the motor shaft Figure 36 Cylindrical Pin X05 Fit propeller and nylon washer Figure 37 Fitment of the Propeller X05 ...

Page 44: ...sue 1 Page 44 of 88 Fit stainless steel washer slotted nut and split pin Figure 38 Fitment of Propeller Nut X05 3 Installing Propeller X10 Fit ceramic bearing to the motor shaft Figure 39 Propeller Bearing Fitting ...

Page 45: ...Issue 1 Page 45 of 88 Fit washers and bearing in the order shown in Figure 40 Figure 40 Ceramic Bearing Fitting Insert the cylindrical pin through the upper hole of the motor shaft Figure 41 Cylindrical Pin X10 ...

Page 46: ...RDG603B2 Issue 1 Page 46 of 88 Fit propeller and nylon washer Figure 42 Fitment of the Propeller X10 Fit stainless steel washer slotted nut and split pin Figure 43 Fitment of Propeller Nut X10 ...

Page 47: ...RDG603B2 Issue 1 Page 47 of 88 4 Controller Alignment Ensure the controller unit base is parallel to the motor Figure 44 Alignment of the Controller Unit ...

Page 48: ...porting When the outboard motor is removed from the boat lay it down horizontally or put the outboard motor back in the original box 2 Storage Store the outboard motor in a well ventilated dry storage area The outboard motor should ideally be kept upright on a rack or trolley ...

Page 49: ...RDG603B2 Issue 1 Page 49 of 88 SECTION 7 Wiring Diagrams 1 Wiring Diagram for Electric Propulsion Outboard Figure 45 Outboard Wiring Diagram X05 X10 ...

Page 50: ... Rated Voltage Vdc 48 48 Input Current A 65 138 Max Propeller Speed r min 2000 2600 Propeller in 10 x 7 10 x 7 Thrust Ib 130 185 Trim and Tilt System Mechanical Mechanical Control System Tiller Remote Tiller Remote Dry Weight of Electric Outboard Model Dry Weight kg X05 20 X10 24 Model Total Shipping Weight kg Dimensions cm EZ X05T 32 107 x 52 x 27 EZ X05R 34 5 107 x 52 x 27 EZ X10T 38 107 x 52 x ...

Page 51: ...RDG603B2 Issue 1 Page 51 of 88 4 Outboard Dimensions Figure 46 X05 Outboard Motor Dimensions ...

Page 52: ...RDG603B2 Issue 1 Page 52 of 88 Figure 47 X10 Outboard Motor Dimensions ...

Page 53: ... propeller is blocked by foreign matter 4 HALL protection HALL input is abnormal 5 MOSFET Transistor protection MOSFET self checking is abnormal 6 Phase winding disconnect protection One of motor wires is disconnected 7 Self checking error protection Self checking is abnormal if internal system power is on 10 Controller over heat protection Controller operation temperature is higher than the defau...

Page 54: ...etooth Adaptor GM BL0001 GM BL0001 Laptop Connecting Lead GM PI 400VEC GM PI 400VEC Propeller in GM X10P7 10 x 7 GM X10P7 10 x 7 Anti Ventilation Cavitation Plate GM AX0501 GM AX1001 Skeg GM SG0002 GM SG0002 Transom Mounting Bracket GM MBL0001 GM MBL0001 Steering Bush Set GM20 007 312 GM20 007 312 Battery Master Switch RDG2199938 RDG2199938 Anderson Type Connector RDG206A48 RDG206A48 Anderson Type...

Page 55: ...RC 010L GM TRC 010L Remote Throttle Set Right Hand GM TRC 010R GM TRC 010R Remote Throttle Cable 3m GM RT0002 GM RT0002 Inboard Shifter Mounting Brkt RDG401A431 RDG401A431 Steering Linkage GM DL00L1 GM DL00L1 Steering Tube Extensions GM DL00L3 GM DL00L3 Remote Steer bracket GM DL00L4 GM DL00L4 Cowl GM20 007 501 GM20 007 501 Quicksilver 2 4 C Multipurpose Marine Lubricant 92 8M0121966 92 8M0121966 ...

Page 56: ...0 Thick walled stainless steel lock Includes a STAZO plus cylinder and security card Easy to install Figure 48 STAZO Nutlock 2 STAZO Security Chain Part Numbers 42 117 315 1 5m Chain 42 117 325 2 5m Chain Lasso security chain with square shackles Made of hardened steel Includes STAZO protective cover As set with STAZO ART lock Figure 49 STAZO Security Chain ...

Page 57: ...AZO Bracket Nut Part Number 42 117 361 M8 Stainless steel Easy installation Figure 50 STAZO Bracket Nut 4 STAZO Outboard Lock Part Number 42 117 002 Solid stainless steel lock Dimensions 40 x 40 x 300mm Figures 51 52 STAZO Outboard Lock ...

Page 58: ...RDG603B2 Issue 1 Page 58 of 88 5 Talamex Outboard Motor Lock Part Number 42 130 100 AISI 316 cylinder lock anti rattle Packed in blister Dimensions 300 x 40 x 35mm Figure 53 Talamex Outboard Motor Lock ...

Page 59: ...must recycle WEEE in accordance with your local authority or recycling centre Battery recycling Batteries should not be disposed of in your domestic waste You must recycle batteries in accordance with your local authority or recycling centre Unwanted packaging materials should be sorted and taken to a recycling centre so they can be disposed of in a manner which is compatible with the environment ...

Page 60: ...e Outboard Motor Power Source Electric Voltage 48 Volts Identification of Engine s covered by this Declaration of Conformity Barrus Engine Models Factory Family Code Shire EZ X05T EZ X05T Shire EZ X05R EZ X05R Shire EZ X10T EZ X10T Shire EZ X10R EZ X10R Is in conformity with the standards listed below EN 61000 6 3 2007 Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standard ...

Page 61: ...are in conformity with the type s for which above mentioned EC type examination or type approval certificate s has have been issued and will meet the requirements of Directive 2013 53 EU when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that this these engine s must not be put into service until the recreational craft which it is they are...

Page 62: ...wer Source Electric Voltage DC 48 Volts Identification of Engine s covered by this Declaration of Conformity Barrus Engine Models Factory Family Code Output Shire EZ X05T EZ X05T 3kW Shire EZ X05R EZ X05R 3kW Shire EZ X10T EZ X10T 6 5kW Shire EZ X10R EZ X10R 6 5kW Essential Requirements Standard s Other normative document metho d Technica l file Specify in more detail Mandatory standard Engine Ide...

Page 63: ...n or type approval certificate s has have been issued and will meet the requirements of the Recreational Craft Regulations 2017 when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that this these engine s must not be put into service until the recreational craft which it is they are to be installed has been declared in conformity with the r...

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Page 88: ...ess Tel Email Dealer Name Address Tel Email Product Model Serial Number Rental Use Yes No Location Date of Delivery Owner signature Dealer signature Please return this form by post to Special Products Division Warranty E P Barrus Ltd Glen Way Launton Road Bicester Oxfordshire OX26 4UR OR by email to Richard Cooke barrus co uk l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l ...

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