MODEL 540

DC BRUSHLESS TUNNEL THRUSTER

• 500w bi-directional tunnel thruster develops over 21lbf (9.5 kgf) forward & reverse thrust in
an extremely compact and lightweight package.
• Powerful direct drive DC brushless motors for low noise in noise sensitive applications.
• Magnetically coupled propeller drive eliminates all rotating shaft seals for optimum reliability.
• High stainless steel propeller gives uniform thrust in both directions and is available in both
RH and LH direction of rotation.
• Speed & direction control using +/-5v analog signal.
• Rated to 2,800 ft (850m) or optional 5,000 ft (1,500m) depth with 1 atmosphere housings or
full ocean depth with oil filled, pressure balanced housings.
• Available with hard anodized 6061-T6 aluminum, Type 316 stainless steel or 6Al4V titanium
housings.
• Available with motors for 24vdc, 30vdc, 48vdc, 60vdc, 75vdc, 100vdc, 130vdc, 150vdc,
200vdc, 230vdc or 260vdc. Other voltages optional.

Bollard Output Input Weight Depth Rating

21lbf (9.5kgf) forward & 500w at 24vdc, 30vdc, 4-6lbs (1.8-2.7kg) in 2,800ft (850m) &
reverse thrust, 48vdc, 60vdc, 75vdc, air, 5,000ft (1,500m) with
using RH & LH invest- 100vdc, 130vdc, 150vdc, 3-5lbs (1.4-2.3kg) in 1 atm housings, full
ment cast stainless 200vdc 230vdc or 260vdc, water, depending on ocean depth when oil
steel propellers. +/-5v analog speed configuration. filled (PBOF).
(specifications subject to change
control. without notice)

03/25/14 1
 MODEL 540
DESCRIPTION

Introduction Depth Rating Options

The Model 540 is a tunnel thruster based upon The standard configuration is rated to 850m depth
Tecnadyne’s highly successful Model 521 thruster. and places the electronics controller within the 1-at-
The Model 540 develops over 9.5kg thrust in both mosphere motor housing. An extra cost option, using
the forward and reverse directions, yet weighs less titanium pressure components, is rated to 1,500m
than 1.4kg in water. Using the same advanced using self-contained electronics in the motor’s 1-at-
technology as all Tecnadyne thrusters, of which mosphere housing. For full ocean depth rating, the
over 4,000 units have been delivered to customers electronics module is installed in a remote, one atmo-
worldwide, the Model 540 is ideally suited as a lat- sphere housing ( either the customer ’s housing
eral or vertical thruster on inspection class ROV’s, or one supplied by Tecnadyne) and the thrust-
AUV’s and manned submersibles. er is oil filled and pressure balanced using
Magnetic Propeller Coupling electrical cabling of flexible Tygon tubing.
As with all Tecnadyne thrusters, the propeller of the Voltages Supported
Model 540 is magnetically coupled. With this design, The Model 540 is available for operation at voltag-
a magnet array is fitted inside the hub of the propel- es of 24vdc, 30vdc, 48vdc, 60vdc, 75vdc, 100vdc,
ler; and this magnet array is driven by a matching 130vdc, 150vdc, 200vdc, 230vdc and 260vdc. DC
magnet array attached to the motor inside the sealed power must be supplied by a well filtered battery
pressure vessel. By eliminating the rotating drive shaft bank, rectified and filtered AC or a regulated DC
and shaft seals that always seem to leak over time, power supply with less than 10% voltage ripple.
the Model 540 achieves extremely high reliability. Analog Speed Control
Additionally, the magnetic coupling will ratchet if
The Model 540 controller accepts a +/-5v an-
overloaded, preventing damage caused by objects
alog speed and direction control signal that
jammed in the propeller. And since the water lubri-
can be supplied by a computer with D/A card
cated propeller bearings are external to the pres-
or a simple joystick. Additionally, the Model
sure housing, they can be easily replaced in a
540 returns a digital speed feedback signal.
matter of minutes.
Model 541 Option
High RPM Motor & Planetary Gearbox
The Model 541 has back-EMF filtering capacitors in
The Model 540 uses DC brushless motors that are
a slightly longer housing section which reduce the
manufactured to the ISO 9001:2008 quality stan-
need for external back-EMF filtering. The Model 541
dard. These high RPM, low inertia motors are cou-
has identical performance to the Model 540.
pled to 6/1 ratio planetary gearset, assembled us-
ing hardened, high precision spur gears. This motor Other Options
/ gearbox combination delivers maximum reliability, Optional configurations include: strut or blade
efficiency and power in an extremely compact, light- mounting; the 11 available buss voltage choices pre-
weight and easy to maintain package. viously mentioned; housings of hard anodized alu-
Custom Designed Bi-Directional Propeller minum (standard), Type 316 stainless steel or 6Al4V
titanium; several bulkhead type or cable end subsea
The newly designed, high efficiency Type 316 stain-
connectors; and RH or LH rotation propellers.
less steel propeller develops approximately the same
thrust in both the forward and reverse directions. This Please note that the specifications are subject to change
is ideal for use as a lateral or vertical thruster in a without notice. Additionally, Model 540 thrusters for op-
wide range of ROV, AUV and manned submersible eration to depths greater than 1,000 meters are subject to
applications. U.S. Government export controls.

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03/25/14 2
 MODEL 540
REPRESENTATIVE THRUSTER CONFIGURATIONS

MODEL 540
540-AAA-LMG6FS-XX-0850-AL-SCLX-ST-A-RH

4X 8-32 SOCCKET HEAD

SeaCon CAP SCREWS SUPPLIED
LMG-6-FS
5.90 [149.9]

Ø2.25 [57.2]

1.35 [34.3]
6.00 [152.4]
WEIGHTS 5.20 [132.2] 5.48 [139.1]
3.7lb [1.7kg] in air
2.7lb [1.2kg] in water

SCALE 1:4

Download STP solid model of this thruster here:

[Link]

MODEL 541
541-AAA-LMG6FS-XX-0850-AL-SCLX-St-A-RH

SeaCon
LMG-6-FS
5.90 [149.9]

Ø2.25 [57.2]

1.35 [34.3]
6.00 [152.4]
WEIGHTS 5.20 [132.2] 6.98 [177.2]
4.2lb [1.9kg] in air
3.2lb [1.5kg] in water

SCALE 1:4

Download STP solid model of this thruster here:

[Link]

03/25/14 3
 MODEL 540
REPRESENTATIVE THRUSTER CONFIGURATIONS

MODEL 540
540-AAA-LMG6FS-XX-OFRE-SS-HPF(R)X-ST-A-RH

WEIGHTS
IMPULSE MHDG-8-CCPOF
3.9lb [1.8kg] in air
3lb [1.4kg] in water

4X 8-32 SOCKET HEAD

5.90 [149.9] CAP SCREWS SUPPLIED

2.25 [57.2]

2.89 [73.3] 5.20 [132.2]

6.00 [152.4]

SCALE 1:4

Download STP solid model of this thruster here:

[Link]

MODEL 540
540-AAA-LMG6FS-XX-0850-AL-SCLX-BM-A-RH

WEIGHTS
3.8lb [1.7kg] in air
3lb [1.4kg] in water
0.26  0.55
  0.51 X 82°
SeaCon 1/4-28 UNF-2B ON BACKSIDE
LMG-6-FS
0.88 [22.2] 2.89 [73.4] 0.38 [9.5]

1.50 [38.1]

2.25 [57.2]

3.85 [97.9] 6.83 [173.4] 5.90 [149.9]

SCALE 1:4

Download STP solid model of this thruster here:

[Link]

03/25/14 4
 MODEL 540
REMOTE ELECTRONICS OPTIONS

REMOTE ELECTRONICS MODULE, HPFX CONFIG

USED IN THE HPFX CONFIGURATION & INSTALLED IN CUSTOMER FURNISHED
PRESSURE VESSEL. 1.68 [42.7]
To Motor Hall Sensors

0.14 THRU 2X
FOR MOUNTING USING
2.25 [57.1] SOCKET HEAD SCREWS
0.36 [9.0]

0.20 [5.0] 2.625 [66.68]

To Motor Phases Control Signal Input
Black, Phase A White, +/-5v Analog Control Signal
Red, Phase B Blue, Isolated Control Signal Return
White, Phase C (#20, 0.5m length)
(#16, 0.5m length) Optional Feedback Signal
Purple, Digital Speed Feedback Signal
Power Input
Red, + Power
Black, Return
(#16, 0.5m length)
2.87 [72.8] SCALE 1:2

Download STP solid model of this electronics module here:

[Link]

REMOTE ELECTRONICS MODULE, HPRX CONFIG

USED IN THE HPRX CONFIGURATION & INSTALLED IN CUSTOMER FURNISHED
PRESSURE VESSEL.

0.25 [6.4] To Motor Phases

Black, Phase A
0.25 [6.4] Red, Phase B
White, Phase C
Power Input (#16, 0.5m length)
Red, + Power
Black, Return
(#16, 0.5m length)
To Motor Hall Sensors

Control Signal Input

White, +/-5v Analog Control Signal
Blue, Isolated Control Signal Return
2.370 [60.20] (#20, 0.5m length)
Must be fitted into 2.25 [57.1] Optional Feedback Signal
cylindrical pressure Purple, Digital Speed Feedback Signal
vessel with I.D. shown.
Thermal heat transfer
compund must be used. SCALE 1:2

Download STP solid model of this electronics module here:

[Link]

03/25/14 5
 MODEL 540
CONFIGURATIONS & PART NUMBERING

540 - AAA - BBBBB - XX - CCCC - DD - EEEE - FF - HH - JJ

AAA - Buss Voltage Option (Consult factory for other voltages)
24 - 24vdc 60 - 60vdc 130 - 130vdc 230 - 230vdc
30 - 30vdc 75 - 75vdc 150 - 150vdc 260 - 260vdc
48 - 48vdc 100 - 100vdc 200 - 200vdc

BBBBB - Subsea Connector Option (Consult factory for other connectors)

LMG6FS - SeaCon LMG-6-FS, cable end, for SCLX only
MCIL5M - SeaCon MCIL5M, cable end, for SCLX only, no speed feedback
MCIL6M - SeaCon MCIL5M, cable end, for SCLX only
MCBH5M - SeaCon MCBH5M, bulkhead mount, SCLX only, no speed feedback
MCBH5M - SeaCon MCBH6M, bulkhead mount, SCLX only
IL6M - SeaCon IL6M, cable end, for SCLX only
MHDG8CCP - Impulse MHDG-8-BCR, oil filled tubing, for HPFX or HPRX, all voltages
MCPBOF8M - SubConn MCPBOF8M, oil filled tubing, for HPFX or HPRX, all voltages
for technical details on the referenced connectors please go to [Link], [Link] & [Link]

XX - Cable Length Option (Does not apply to BCR or FCR style connectors)
XX - Cable Length in X.X meters - leave as XX if no cable installed

CCCC - Maximum Operating Depth Option

0850 - 850 meters (2800 ft)
1500 - 1,500 meters (5,000 ft), (extra cost option)
FOD - Full Ocean Depth (Requires Oil Filled Pressure Compensated option, above)

DD - Material of All Wetted Metallic Surfaces Option

AL - 6061-T6 Aluminum, Hard Anodized Black
SS - Type 316 Stainless Steel, Passivated
TI - 6Al4V Titanium

EEEE - Self Contained or Remote Electronics Option

SCLX - Self Contained Electronics (electronics in housing with motor)
HPFX - Remote Electronics, Square heat plate electronics, 1 Atmosphere Motor Housing
HPRX - Remote Electronics, Round heat plate electronics, 1 Atmosphere Motor Housing
the Model 1020 can also be supplied with the RSOF or the RROF electronics from the Model 1060

FF - Mounting Option
ST- Strut Mount BM - Blade Mount

HH - Propeller Handing Option

RH - Right Hand, Stainless Steel Propeller LH - Left Hand, Stainless Steel Propeller

03/25/14 6
 MODEL 541
CONFIGURATIONS & PART NUMBERING

541 - AAA - BBBBB - XX - CCCC - DD - EEEE - FF - HH - JJ

AAA - Buss Voltage Option (Consult factory for other voltages)
24 - 24vdc 60 - 60vdc 130 - 130vdc 230 - 230vdc
30 - 30vdc 75 - 75vdc 150 - 150vdc 260 - 260vdc
48 - 48vdc 100 - 100vdc 200 - 200vdc

BBBBB - Subsea Connector Option (Consult factory for other connectors)

LMG6FS - SeaCon LMG-6-FS, cable end, for SCLX only
MCIL5M - SeaCon MCIL5M, cable end, for SCLX only, no speed feedback
MCIL6M - SeaCon MCIL5M, cable end, for SCLX only
MCBH5M - SeaCon MCBH5M, bulkhead mount, SCLX only, no speed feedback
MCBH5M - SeaCon MCBH6M, bulkhead mount, SCLX only
IL6M - SeaCon IL6M, cable end, for SCLX only
MHDG8CCP - Impulse MHDG-8-BCR, oil filled tubing, for HPFX or HPRX, all voltages
MCPBOF8M - SubConn MCPBOF8M, oil filled tubing, for HPFX or HPRX, all voltages
for technical details on the referenced connectors please go to [Link], [Link] & [Link]

XX - Cable Length Option (Does not apply to BCR or FCR style connectors)
XX - Cable Length in X.X meters - leave as XX if no cable installed

CCCC - Maximum Operating Depth Option

0850 - 850 meters (2800 ft)
1500 - 1,500 meters (5,000 ft), (extra cost option)
FOD - Full Ocean Depth (Requires Oil Filled Pressure Compensated option, above)

DD - Material of All Wetted Metallic Surfaces Option

AL - 6061-T6 Aluminum, Hard Anodized Black
SS - Type 316 Stainless Steel, Passivated
TI - 6Al4V Titanium

EEEE - Self Contained or Remote Electronics Option

SCLX - Self Contained Electronics (electronics in housing with motor)
HPFX - Remote Electronics, Square heat plate electronics, 1 Atmosphere Motor Housing
HPRX - Remote Electronics, Round heat plate electronics, 1 Atmosphere Motor Housing
the Model 1020 can also be supplied with the RSOF or the RROF electronics from the Model 1060

FF - Mounting Option
ST - Strut Mount BM - Blade Mount

HH - Propeller Handing Option

RH - Right Hand, Stainless Steel Propeller LH - Left Hand, Stainless Steel Propeller

03/25/14 7
 MODEL 540
THRUST PERFORMANCE CURVES

Model 540 Thruster

Input Power & Thrust vs. Propeller RPM
500 30
Watts, Forward
475 Watts, Reverse 28.5
Thrust, Forward, 0 knot
450 Thrust, Forward, 1 knot 27
Thrust, Forward, 2 knots
425 Thrust, Forward, 3 knots 25.5
Thrust, Forward, 4 knots
400 Thrust, Reverse, 0 knot 24

375 22.5

350 21

325 19.5

300 18
Input Power, Watts

275 16.5

Thrust, lbf
250 15

225 13.5

200 12

175 10.5

150 9

125 7.5

100 6

75 4.5

50 3

25 1.5

0 0
150 300 450 600 750 900 1050 1200 1350
Propeller RPM

Model 540 Thruster

Thrust vs. Voltage Change
50
24vdc Winding, Forward 75vdc Winding, Forward 200vdc Winding, Forward
45 24vdc Winding, Reverse 75vdc Winding, Reverse 200vdc Winding, Reverse
30vdc Winding, Forward 100vdc Winding, Forward 230vdc Winding, Forward
40 30vdc Winding, Reverse 100vdc Winding, Reverse 230vdc Winding, Reverse
48vdc Winding, Forward 130vdc Winding, Forward 260vdc Winding, Forward
35 48vdc Winding, Reverse 130vdc Winding, Reverse 260vdc Winding, Reverse
Thrust, lbf

60vdc Winding, Forward 150vdc Winding, Forward

60vdc Winding, Reverse 150vdc Winding, Reverse
30

25

20

15

10

5
0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300
Volts

03/25/14 8
 WHAT WERE YOU DOING 30 YEARS AGO?
In 1985 Tecnadyne delivered its first thrusters, six Model 1020’s that were installed on the original RTV-500 built by Mitsui Engi-
neering & Shipbuilding (MES) of Tokyo. Since that time, we have manufactured and delivered over 6,000 thrusters, including more
than 600 of the Model 1020. And even though the Model 1020 that we build today incorporates over 32 design revisions to improve
reliability, efficiency and maintainability – that thruster is still 100% compatible with the Model 1020 that was installed on that first
RTV-500 system more than 30 years ago. This means that, after 30+ years, MES (or any of our customers) can still purchase or re-
pair a Model 1020 thruster to keep its fleet of ROV’s working. And in those 30 years, the Model 1020 thruster has powered vehicles
to the Titanic, that discovered JFK’s PT-109 in the Pacific, that participated in record depth wellhead completions off the coast of
West Africa, that discovered lost cities in the Black Sea, that have scoured the world’s oceans for mines, and that have successfully
completed thousands of routine subsea missions. And the Model 1020 thruster is still being installed on new ROV and AUV systems
worldwide.
And, like the Model 1020, Tecnadyne’s twenty-one other thruster models have also served the offshore community with reliability,
high performance and cost effectiveness – but none for quite as long as the Model 1020’s 30 years. Tecnadyne is constantly devel-
oping and releasing new thruster models, with 4 new models released in 2010 and 4 models being released in 2013.
It is Tecnadyne’s commitment to its customers and to the subsea community that no vehicle system, be it an ROV, an AUV, a
manned submersible or any other subsea system, will ever be made obsolete because the Tecnadyne thrusters installed on that
system are no longer available for a reasonable and competitive price.
So, for your next ROV, AUV or manned submersible build or purchase, be sure to specify only genuine Tecnadyne thrusters. You,
your operators, your technicians and your customers will be glad you did – for the next 30 years.

QUALITY ASSURANCE
Tecnadyne operates under a Quality Plan that is fully ISO 9001:2008 compliant. All electrical soldering is performed
by technicians certified to the IPC J-STD-009 & IPC-A-610 standards.

FINAL TEST & INSPECTION

All Tecnadyne products undergo a rigorous set of final test procedures. Each thruster is operated at reduced power
and full power in both directions for extended time periods. Each thruster is pressure tested and then subjected to
an insulation breakdown test to identify leaks or other problems. Prior to shipment to the customer, each thruster is
certified to perform correctly and to factory specifications.

EXPRESS LIMITED WARRANTY

Subsea thruster motors manufactured by Tecnadyne are warranted to the original Purchaser for a period of one
year from the date of shipment from the factory to conform to Tecnadyne’s specifications at the time of purchase
and to be free of mechanical, electrical and physical defects in material and workmanship if the products have been
installed, electrically connected, operated and serviced in accordance with Tecnadyne’s instructions as listed in the
Operations & Maintenance Manual accompanying the thrusters.

Except for the express warranty set forth herein, Tecnadyne makes no other warranties or guarantees, express,
oral, implied or statutory, regarding its subsea thruster products. All such warranties are expressly disclaimed to the
extent allowable by law.

BUILT WITH PRIDE IN THE U.S.A.

9770 Carroll Centre Road, Suite C

San Diego, CA 92126, USA
Voice & Fax: 1-858-586-9660
Ext 101 for Sales, Ext 104 for Service, Ext 113 for Deliveries

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[Link] [Link]/tecnadyne @tecnadyne [Link] company/tecnadyne

03/14