User manual for Exalto windshield wiper Type 280 BS 24 Volt Cat

Parts • Wipers • Bearings • Propulsion

User manual for

Exalto windshield wiper

Type 280 BS 24 Volt

• P.O. Box 40

3370 AA Hardinxveld-Giessendam

The Netherlands

• T +31 (0)184 615800

• F +31 (0)184 614045

• E [email protected]

• I www.exalto.com

Copyright 2013 Exalto

Cat. no. 2178.30 (24 Volt)

version 6 - 2013

Safety

Although Exalto windshield wipers are easy to install, a fair amount of technical knowledge (mechanical and electrical) is required of the technician.

Consult the manual or your vendor in case of doubt on installation or functioning.

Safety symbols

An exclamation mark in front of the text warns, that injury or damage can occur if a procedure is badly performed.

Dangers

The installation and use of Exalto wipers doesn't inflict any personal dangers or damage, provided that installation is done according to the requirements.

 Never remove covers or other safety provisions, unless maintenance is being performed and all safety requirements are obeyed.

 The installer must provide all necessary covers.

 Always isolate the electrical circuit when performing maintenance. Prevent the installation from being started (accidentally) by others.

Safety provisions

Safety provisions protect the user against contact with moving, electrical or hot parts. Some of them must be provided by the installer. There are several safety provisions:

 Cover or panel (compelled): covers moving parts and electrical connections. The installer MUST provide a selfmade cover or place the wiper behind a panel.

 Make sure the wiper has enough ventilation when placing it behind a panel or cover.

 Place a fuse (see specifications) in the main cable.

Safety requirements

Before the Exalto wiper is installed, we strongly recommend the following:

 Read the entire manual before installation.

 Keep your working environment as well as the wiper parts clean.

 Check to be sure no parts are missing or damaged.

 Use only well maintained tools and have them within reach when installing.

 Handle the parts with care.

 Never install or maintain the wiper with the electrical voltage applied, unless this is specifically mentioned in the manual.

 Clear your tools after installation.

1

Use of the manual

Read the entire manual before installation. In this manual you can find the following expressions and symbols:

Hint!

Gives you advice on how to perform a task more easily.

Attention!

Alerts you to possible problems and safety warnings.

Careful!

Warns if the product can be damaged when working carelessly.

Warning!

You can hurt yourself or damage the product severly.

At back of manual

Look at the back of the manual for a drawing.

2

Contents

1 Introduction .......................................................................................... 4

1.1 Introduction ........................................................................................................... 4

1.3 Modified use and guarantee .......................................................................... 4

2 Technical .............................................................................................. 5

2.1 General .................................................................................................................... 5

2.3 Mechanical data ................................................................................................... 5

3 Installation ........................................................................................... 6

3.1 Preparation ............................................................................................................ 6

3.2 Installation of mechanical parts ..................................................................... 6

4.1 Preparation for first use ................................................................................... 10

4.2 Use ........................................................................................................................... 10

5 Maintenance ...................................................................................... 11

5.2 Servicing ................................................................................................................ 11

5.3 Changing the wipe arc and park position ................................................ 11

5.4 Rough determination of wipe arc and wiper blade .............................. 12

6 Troubleshooting ................................................................................. 14

3

1 Introduction

With this user manual we want to guide you in the installation and use of the Exalto windshield wiper. Follow all instructions and install all safety provisions.

1.1 Introduction

The Exalto windshield wipers are especially designed to keep working even with the most extreme weather conditions at sea. All external parts are made of corrosion resistant materials. The housing of the selflubricating bearings is made of bronze. All arms and blades have a black, weather-resistant coating, to prevent reflection.

Wiper type 280 BS is designed to be mounted in the bulkhead. The wiper arc is steplessly adjustable from 40° to 90°. By standard the 280 BS can be supplied for a bulkhead thickness of 25 mm. The pantograph arms are adjustable in length, to set the wipe area accurately. The motor of the 280 BS has IER

(Insulated Earth Return).

1.2 Environmental factors

In the wiper, materials are used that are harmful for the environment (e.g. copper). At disposal of the wiper, parts can be re-used or recycled well. No harmful materials can get off when using or disassembling the wiper.

1.3 Modified use and guarantee conditions

All modifications or defects in the product are subject to the Orgalime General

Conditions of Sale. Contact your vendor if you want to use Exalto wipers for a non-maritime environment or for another application, or in case of any doubt.

4

2 Technical data

2.1 General

 Product ................................................... Exalto windshield wiper

 Types ....................................................... 280 BS – 24 Volt

 Catalogue numbers 24V .................. 2178.30

2.2 Electrical data 24 Volt

 Torque (max.) ....................................... 80 Nm

 Voltage ................................................... 24 Volt

 Current ................................................... 3,2 A

 Power consumption (max.) ............ 77 W

 Number of revolutions ..................... Low 30 rpm, high 45 rpm

 Recommended cable ........................ 5 wires, 1½ (16 g) or 2½ mm

2 (14 g)

.................................................................... up to 10 m long

 Recommended fuse .......................... 10 A slow blow

 Grounding ............................................. Insulated earth return

2.3 Mechanical data

 Dimensions ........................................... l x w x h = 547 x 160 x 180 mm

 Bearing diameters .............................. Drive shaft Ø27 /support shaft Ø27 mm

 Mounting ............................................... In bulkhead (25 mm)

 Bearing ................................................... Bronze housing, self-lubricating

 Wiperarms ............................................. Model P12 up to 1500 mm

 Wiperblades ......................................... Up to 1200 mm

 Wipe arc ................................................. Slotted lever 40°-90° steplessly

.................................................................... adjustable

 Weight .................................................... approx. 9,7 kg

5

3 Installation

Read the chapter on safety. Check before installation if the parts are all present and undamaged. In case of errors, contact your vendor.

3.1 Preparation

The complete wiper, with packaging, can be handled and transported by hand. Leave the wiper in the packing, until you're ready to install it; this to reduce the risk of damage. Make sure all parts, tools and other means are ready.

3.2 Installation of mechanical parts

1. If your wiper is supplied with the wipe arc lever and motor lever uninstalled, please follow steps 5.3 and 5.4 to set the wiping arc prior to installation.

Determine the position where the wiper is to be installed. The dimensions are shown below. The wiper can be installed in any position.

6

Attention!

When installing the wiper, reserve space for a housing or cover.

2. Place the windshield wiper in the pre-drilled holes of the bulkhead (see figure). A nitrile plate must be placed at both sides of the bulkhead.

7

3.3 Electrical installation

4. Install a wiper switch in the dashboard.

Wiring diagram 280 BS 24 Volt

5. Connect the wiper to the ship's electrical installation; see the schemes above. Use a cable consisting of 5 wires with cross-sections of at least 1½ mm 2 (16 g) up to a maximum of 10 m. Use larger cross-sections when using longer cables.

6. Place a slow blow fuse of 10 A (24 Volt) in the main cable.

7. Connect the switch to the wiper (refer to that specific manual for installation).

3.4 Final installation

8. Testrun the motor briefly. Wait until the motor stops after turning the switch off. If the wiper is well installed, the motor will be in park position.

The standard park position is shown in the figure on page 12.

Hint!

If you have doubts regarding the park position, make a vane with tape to simulate the position of the arms.

Attention!

The 280 BS is suitable for wiper arms model P12 up to

1500 mm and matching blades up to 1200 mm. tape

8

9. Place the wiper arms with the blade on the shafts. Fasten the nuts onto the shafts, but not too tight yet.

10. Testrun the motor again to check the wiped area.

11. If the wipe arc is correct, adjust the position and the length of the arm if necessary. Tighten the nuts properly now.

12. To complete the installation, the wiper must be enclosed by means of a panel or cover. Provide the wiper with sufficient ventilation.

Place a protection cover or panel.

Provide sufficient ventilation.

9

4 Operation and use

4.1 Preparation for first use

If the wiper has been installed and been adjusted, the system can be prepared for first use. We recommend a thorough inspection of the system to ensure proper operation.

Check:

 if there are no leaks where the bearings go through the window;

 if the set wipe arc cleans the entire window;

 if the park position is correct.

If the wipe arc or the park position is wrong, adjust them again. Follow the procedure in section 5.3.

4.2 Use

All Exalto windshield wipers are provided with the following functions:

 low speed;

 high speed;

 self parking.

Don't run the wiper on a dry window; excessive wear of the blades and the motor can occur. Clean the wiper frequently (see also paragraph 5.1).

Because of the big variety of wiper switches, refer to the user manual of the chosen switch to learn about the functions of that specific switch.

10

5 Maintenance

5.1 General maintenance

To keep the Exalto wiper in good condition, you are advised to:

 clean wiper, arms and blades with fresh water after every journey in salt water ( to prevent salt from clogging moving parts);

 prevent running the wiper on a dry window.

5.2 Servicing

As long as the wiper system functions normally and is kept in good shape (see section 5.1), servicing the drive is not necessary. Check yearly (monthly when used intensively) if the wiper blades are worn. Replace blades when worn or when the blades leave many stripes across the glass. In case of failure or adjustments, have servicing done solely by qualified mechanics. In chapter 6,

“Troubleshooting”, a listing is given of possible troubles.

5.3 Changing the wipe arc and park position

If the wiped area is not optimal, the wipe arc and park position can be changed. Always arc ranges isolate the electrical circuit before opening the housing.

Adjusting the wipe arc

 Isolate the electrical circuit;

 move the screw of the motor lever to the correct wipe arc range (see the upper connection lever motor lever smaller arc figure);

 move the screw in the slot from the wipe

shaft lever away from the shaft for a smaller and towards the shaft for a larger wipe arc;

 fasten the nut again (max. 33 Nm / 24.34 ft.lbs);

 run the motor briefly to park it;

 place the motor lever in the desired park position (see the text below). wipe shaft lever larger arc

55°-90°

40°-55°

30°-40° connection lever

Adjusting the park position

 Place the motor lever loose on the shaft, parking right or left (see the drawing in paragraph 3.4 and the picture on page 12 for reference);

 place the motor lever in such a way that it forms an almost straight line with the connection lever (see the drawing on page 12);

 tighten the motor lever well now;

11

 place the wiper in the bulkhead;

 adjust the wiper arm to the correct length, if necessary. motor connection lever smaller arc larger arc wipe shaft lever

33 Nm /

24.34 ft.lbs

(standard) park position 1 wrong connection lever motor lever park position 2 arc ranges

55°-90°

40°-55°

30°-40°

  

5.4 Rough determination of wipe arc and wiper blade

With this method the wipe arc and the wiper blade can be determined roughly. Contact your vendor to determine your configuration more accurately.

 Determine length of pantograph arm (L): L = E + D

 get the maximum wiped area width (W): W = ±0.9 * GW

 find the intersection of L en

W in the diagram below;

1000

Wipe arc

GH

H

W

GW

D

E

L

D = distance top side

glass to center

of spindles

E = eye height

GH = glass height

GW = glass width

H = height displacement

L = length of arms

W = width of wiped area

Determination of wipe arc

40° 45° 50° 55° 60° 65° 70° 75° 80° 85° 90°

900

800

700

600

EXAMPLE

500

400

300

300 400

Units in mm

500 600 700 800 900 1000 1100 1200 1300 1400

Wiped area width (W)

12

 the wipe arc-line closest to the intersection, shows the wipe arc;

 find in the table below the vertical displacement of the blade (H);

Determining the vertical displacement of the wiper blade

Armlength (L)

40°

45°

50°

55°

60°

65°

300

19

23

26

34

40

47

350

21

27

33

40

47

55

400

25

30

36

45

54

63

450 500 550 600

26

35

43 47 52 56

51 57 62 66

60

71

30

38

67

79

34

42

74

86

37

46

80

94

650

40

50

61

74

87

102

700

43

53

66

79

94

110

750

45

57

70

85

100

117

800 850 900 950 1000

48

61

51

65

54

68

57

72

60

76

75 80 84 89 94

90 96 102 107 113

107 114 121 127 134

125 133 141 149 157

70°

75°

80°

85°

55

62

70

79

63

73

82

92

73

83

94

105

81 90 100 109

93 104 114 124

105 117 129 140

119 132 145 158

118

135

152

171

127

145

164

184

136

155

175

197

145 154 163 172 181

165 176 186 196 207

187 199 211 222 234

210 223 236 250 263

90° 86 103 117 132 146 161 176 190 205 220 234 249 264 278 293

Units in mm Vertical displacement of the blade (H)

 Now the wiper blade can be calculated:

Length of wiper blade = 0.9 * 2 * (E - H)

5.5 Disassembly and assembly

Prevent injuries when disassembling: isolate the wiper from the electrical installation. Keep all necessary tools within reach and remember the chapter on safety. Provide a protecting packaging, if you're going to stock or transport the wiper.

5.5.1 Removing the wiper assembly from the bulkhead

1. Isolate the electric circuit and disconnect the wires.

2. Remove the wiper arms.

3. Remove the nuts and rings on the outside.

4. Remove the wiper out of the holes in the bulkhead.

5. For replacing the wiper, follow chapter 3.

5.5.2 Removing the motor from the wiper assembly

1. Isolate the electrical circuit, disconnect the wires and remove the wiper.

2. Disassemble the motor lever (see 5.5.2).

3. Unscrew the motor and remove it.

4. When replacing, screw the motor on the housing. Follow section 5.3 to install the motor lever in the right park position.

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6 Troubleshooting

In this chapter, several malfunctions are mentioned combined with possible causes. Please leave servicing to qualified mechanics.

6.1 Wiper doesn't run after switching on

 Possible causes:

1. Wiper switch has failed.

2. Burned or incorrectly sized fuse.

3. Electrical connections are miswired or damaged.

4. Motor failed.

 Solutions:

1. Test and replace it. Check if the current is (and keeps being) too high.

2. (See solution 1).

3. Test for a charge on the motor and check all connections.

4. Replace the motor and check for drag or a current that is too high.

6.2 Wiped area or park park position wrong

 Possible causes:

1. The wiper arms were placed without parking the motor first.

2. The wipe arc is set wrong or changed due to high loads (e.g. spring tension arms to high, drag).

3. The wires are connected wrong.

 Solutions:

1. Remove the wiper arms. Run the motor shortly to park it and re-install the arms according to chapter 3.

2. Determine the wipe arc if needed (see section 5.4) and set the wipe arc again (see chapter 5.3).

3. Check and reconnect the wiring (see the scheme in section 3.3).

6.3 Motor runs, but arms don't move

 Possible causes:

1. Mechanical joints are loose.

2. Parts are broken.

3. Grooves of shafts are worn.

 Solutions:

1. Check if the arms are well fastened. If not, open the housing (follow chapter 5) and check all joints and parts to see if they are loose, broken or worn.

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7 Declaration of conformity

MANUFACTURER’S DECLARATION according to Appendix II sub B of Directive 89/392/EEG (Machines)

Exalto B.V.

Nijverheidsstraat 12

3371 XE Hardinxveld-Giessendam

The Netherlands

 +31 (0)184-61.58.00

Fax: +31 (0)184-61.40.45 hereby declares that

Exalto windshield wiper type 280 BS

 is intended to be built into another machine or as a component, or is to be integrated with other machines to a machine where Directive 89/392/EEG applies to;

 does not fully comply to the requirements of mentioned Directive;

 complies to the following harmonised standards:

Pleasure yachts

 NEN-EN-ISO 10133 Extra-low voltage D.C. installations (1997)

(regarding color codes)

…and declares that the sub-assembly in question shall not be set into operation until the complete machine, into which the sub-assembly is fitted, shall be complete and conforms to all aspects of Directive 89/392/EEG.

Hardinxveld-Giessendam

04-15-2013 (m-d-y)

15

8 Parts list

Pos. Qua Description

1 1 Motor 80Nm 2100.PM3-0004

3

4

4 Locking washer Ø8mm

3 Hexagon bolt ISO 4017

M8 x 20-S-A4

M8 2100.091

M8×20 933140080020

5

6

7

1 Hexagon Bolt ISO 4017

M8 x 35-S-A4

1

9

Motor crank 280BS

Washer 10mm din125

8 2 Rod M10

M8×35 933140080035

M10

9 5 Hexagon nut M10 din934

10 1 Threaded end

M01

M10

11 1 Nylon tubing Ø10

12 1 SS Hexagon bolt M10 ISO4017 M10

2197.077

2197.092

2197.070

2197.090

0975140101000

211210

093388010040

15 2 SS Hexagon bolt M10 ISO4017 M10×30

16 4 Washer Ø25×16×1mm SS

17 1 Flanged nut M10 M10

18 1 SS Hexagon bolt M10 ISO4017 M10×45

19 1 Nut

20 1 Support spindle WD25

M8

2100.938

2197.082

093388010030

2100.353

2100.069

093388010045

2100.460

2197.083

22 2 Rubber Sealing plate

23 1 Stainless steel sealing plate

24 8 Nut M27×1,5mm SS

2100.511

2100.521

M27×1,5mm 2100.352

25 2 Circlip for shafts Ø16 din471

27 2 Locking washer 10mm M10

M10

2100.411

2100.359

2100.092

2100.074

16

9 Drawings and schemes

9.1 Assembly overview

17

9.2 Internal wiring diagram

The following diagram is to help understand the principle of the wiper motor. code

Switch code

Cable

(since 6-1999) high speed + low speed +

53b

53

H

L white yellow earth - 31b black common leg self parking +

53e

53a

P

B blue red

18

Parts • Wipers • Bearings • Propulsion

User manual for

Exalto windshield wiper

Type 280 BS 24 Volt

• P.O. Box 40

3370 AA Hardinxveld-Giessendam

The Netherlands

• T +31 (0)184 615800

• F +31 (0)184 614045

• E [email protected]

• I www.exalto.com

Copyright 2013 Exalto

Cat. no. 2178.30 (24 Volt)

version 6 - 2013