Propeller Shaft Propulsion AC: 2.5 / 4.0 /6.0 / 10 / 15
Contents
1. 21 8 1 TEGHNIGAL SPESIFAJTEOND 21 8 2 DIMEN SION 22 8 2 1 E NE 22 MOTOR CONTROLLER M 23 AIRONOU MOTI 24 9 ORDERING INFORMA TON ariana una Enna Zaan Zana a annan Eg 26 9 1 JORDE CAR EE M 26 10 EC DECLARATION OF CONFORMITY KE SE ER iux AU P Nan ARR A RU EUR Z ants 27 3 1 GENERAL INFORMATION 1 1 USE OF THIS MANUAL This manual contains important safety and operating instructions for the safe and effective operation of the Bellmarine e propulsion 48 Volt series Also maintenance instructions and possible correction of minor malfunctions of the Bellmarine AC series are included It is therefore obligatory that every person who works on or with a Bellmarine AC system e propulsion is completely familiar with the contents of this manual and that he she carefully follows the instructions and important safety instructions contained herein Installation and maintenance of a Bellmarine AC system may only be performed by qualified and authorized personnel in accordance with regulations and in compliance with the mentioned safety measures Keep this manual in a safe place 1 2 VALIDITY OF THIS MANUAL All of the specifications provisi2. EN Bellmarine AC liquid cooled e propulsion systems 3 2 MOTOR CONTROLLER AND MOTOR The Bellmarine AC motor controller serves to control the speed of the asynchronous induction motor that is specifically designed for low voltage operation The microprocessor control allows the motor to be completely and accurately controlled and monitored The controller software allows various properties of the drive to be set Some of these properties are e Maximum speed Maximum modus economy modus Maximum power Acceleration Deceleration Boost and boost time Joystick performance Battery management These properties and many others have already been set by IDTechnology They can be adjusted to specific wishes by a Bellmarine dealer or by IDTechnology after to connect the system to a PLC with Internet and using the Bellmarine interface 3 2 1 Display E4 or E7 Joystick and contact key The control cable connects the motor controller with the operating instruments the display the joystick and the motor switch The joystick is not included in the system and needs to be ordered separately Various versions are available see chapter 9 3 2 2 Main Switch and Main fuse The Main fuse must be located as close as possible to the batteries to protect the battery and power cable The main switch is mounted between the fuse and the motor controller in order to disconnect the batteries during emergencies and maintenance Main Swi
3. Turn the main switch off Close the Water intake valve of the fresh water cooling 6 Connect the shore connection and make sure it works properly 7 Charge your batteries properly after arrival SS 10 Nov 2013 Bellmarine AC Bellmarine 5 INSTALLATION During installation and commissioning of a Bellmarine AC e propulsion system the safety instructions of chapter 2 must be followed CAUTION The complete set is fully tested and provided with the correct base settings in the factory which means that the proper motor controller always needs to be combined with the proper motor Notes For a proper installation of the Bellmarine AC e propulsion system take note of the following Check the propeller shaft for straightness Use a balanced propeller that is suitable for the system on the boat Provide the balanced propeller if necessary with a so called anti singing edge Pay attention to the position of the propeller in the shaft and the relative position of the rudder A number of optional items to make installation easier can be found in chapter 9 5 1 GENERAL CONSIDERATIONS FOR A SILENT PROPELLER SHAFT SYSTEM wrong Figure 5 1 Propeller system Before installing the propeller shaft system the following three points must be considered to make the electric drive real quiet The points are listed in order of importance Inflow of the water from the propeller For
4. Bollmarine USER MANUAL Propeller Shaft Propulsion AC 2 5 4 0 6 0 10 15 KW 48 VOLT ELECTRIC BOAT PROPULSION SYSTEMS IDTechnology BV Bellmarine Nobelweg 26 NL 3899BN Zeewolde The Netherlands Tel 31 36 5387270 Fax 31 36 5387279 E mail info bellmarine nl www Bellmarine nl Copyright 2013 IDTechnology Bellmarine ACLC nov 2013 Bellmarine CONTENTS GENERAL INFORMATION 4 id USE OF THIS MANUAL 4 1 2 VALIDITY OF THIS MANUAL 4 1 3 GUARANTEE SPECIFICATION 4 D MERI a 4 1 8 IDENTIFICATION LABEL ttt tette tte tte tette ttes 4 SAFETY GUIDELINES AND MEASURES 5 21 WARNINGS AND SYMBOLS 5 22 USE FOR INTENDED ttt ttt tette ttti ttti 5 23 GENERAL SAFETY AND INSTALLATION tentent 5 24 WARNING REGARDING LIFE SUPPORT APBLUCATIONS tentent 5 25 WARNING REGARDING THE USE OF BATTERIES tentent 6 HOW ITAWORKB T 7 34 COMPONENTS 7 3 2 MOTOR CONTROLLER AND MOTOR ttt tette tte 8 3 2 1 DISPLAY E4 OR E7 JOYSTICK AND CONTACT 8 3 2 2 MAIN SWITCH AND MAIN ttti 8 TI OIN RN EE 9 24 VOIP OPIN AND OER 9 4 2 BOOST 9 218 GIS OR We EH REDE 9 ABA DISPLAY BUTTONS 9 4 32 DISPLAY FIELDS 9 433 ALARM ERROR CODES 9 434 PERSONAL PRE
5. neutral counter clockwise backward forward Figure 4 2 Joystick Bellmarine Refer to the ordering information in chapter 9 for available types 4 5 OTHER OPERATION FUNCTIONS During normal operation the following functions exist and operate autonomously 1 Boost function To accommodate fast maneuvering in the two drive modes the Bellmarine AC e propulsion system is able to deliver an additional amount of power for a limited amount of time when changing direction by the throttle 2 Sleep function Whenever the motor is not spinning for over 60 minutes standard setting the Bellmarine AC e propulsion system will switch to sleep mode limiting the amount of power use To switch back to normal operation switch the system Off and On by using the motor switch 4 6 DEPARTURE Before departure always check the system in Drive mode for correct functioning Follow these steps 1 Disconnect the shore connection 2 Check if the ball head crane of your cooling system is open Turn the main switch on Put the joystick in the neutral position Turn the motor switch on Check if your boat is moored well Check the battery condition Choose the power program maximum or economy Check system carefully in forward and backward direction po co SEP OU die e 4 7 ARRIVAL Follow these steps after arrival Put the joystick in the neutral position Check the battery condition Turn the motor switch off
6. EN Bellmarine 5 8 1 Motor controller connections Bottom view motor controller Figure 5 6 Motor controller the shown motor controller is the AC 34 but same connections exist on the other motor controllers AC 36 and 38 Figure 5 6 gives an overview of the connections on the motor controller The connections include St D M eS qur k O Pole for battery Pole for battery incl main switch and fuse Fuse holder Fuse Slow 3 A Contact key Fuse Holder Fuse Slow 8 A Pump Connection for computer 12 pin connector for display joystick and ignition Motor sensor cable Temp sensor Cooling Pump power cable U wire hole from the motor V wire hole from the motor W wire hole from the motor Service power out 13 8 Volt 250 Watt Service power out 13 8 Volt 250 Watt Cooling inlet Cooling outlet EN Bellmarine AC liquid cooled e propulsion systems 15 5 8 2 Connection of motor cables Figure 5 8 Motor controller the shown motor controller is the AC 34 but same connections exist on the other motor controllers AC 36 and 38 CAUTION Motor cables must not be as short as possible to avoid EMC Connections must be preserved with acid free Vaseline To connect the motor cables and motor sensor cable follow these steps The motor cables are already fixed to the motor 1 Remove the metal cover from the motor controller by r
7. 0 4 kg 0 7 kg 91 kg EN Bellmarine AC liquid cooled e propulsion systems 21 Bellmarine 8 2 DIMENSIONS 8 2 1 Display 11 J1 20 T J2 i I BBD 073 1 10 8734 21 1 137 8 Figure 8 1 Dimensions of display in mm 22 November 2011 HybridMaster Ultra EN Bellmarine Motor controller Motor controller Dimensions Afmetingen in mm Type 34 AC 36 AC 38 A 210 250 450 B 160 205 405 C 295 355 320 D 315 355 355 E 170 185 185 F 225 240 240 G 188 225 425 H 8 8 8 Beware of extra clearance on Frontside in case of cable connections Let op extra ruimte aan de voorzijde in verband met kabel aansluitingen AC 34 gt 150 AC 36 gt 200 AC 38 gt 200 Figure 8 2 Dimensions of AC 34 36 38 motor controller mm EN Bellmarine AC liquid cooled e propulsion systems 23 Bellmarine Asynchronous motor 40MM DN Figure 8 4 Dimensions of N50 6 0 10 kW motor in mm 24 November 2011 HybridMaster Ultra EN Bellmarine 0 KAMM ue uci Figure 8 5 Dimensions of N60 15 kW motor in mm EN Bellmarine AC liquid cooled e propulsion systems 25 9 ORDERING INFORMATION 9 1 ORDERING LIST Part number Description Bellmarine 100789 Self priming pump 100799 Fresh water cool installation kit 100422 ControlMaster Casual single version side mount 10
8. involved in an accident Ensure adequate and secure mounting and always use suitable handling equipment for transportation Bellmarine Nov 2013 Bellmarine AC EN Bellmarine 3 HOW IT WORKS 3 1 COMPONENTS Bellmarine AC e propulsion system comes with the following components Motor controller AC 34 AC 36 AC 38 Liquid cooled Asynchronous motor water cooled IP66 with pre mounted flange on shaft motor mounting bracket integrated temp sensor and rotary position sensor Option Self priming pump Fresh water installation kit including water inlet outlet 1x Ball Valve crane 5 meter water hose 15 mm and cooling fresh water filter or Closed loop cool unit Forced air cooled including integrated pump and 5 meter water hose 15 mm Option LCD Display EA E7 or l control Incl Connection cable set display joystick contact key cooling pump and battery power connectors to motor controller Motor switch with key Main fuse and main fuse holder Main power switch Option Motor Flange Propeller shaft coupler Shaft size 25 mm Motor Flange Propeller shaft coupler Shaft size 30 mm Please check the contents of the box before you start with the installation If any of the items is missing please contact your supplier Electrical installation kit motor controller Battery Selfpriming pump installation kit Closed loop cool unit incl pump and fan
9. protection and clothing protection Avoid touching eyes while working near a battery If battery acid contacts skin or clothing wash immediately with soap and water If acid enters the eye immediately flood the eye with cold running water for at least 10 minutes and get medical attention immediately NEVER smoke or allow a spark or flame in the vicinity of a battery or engine Do not short circuit batteries as this may result in an explosion and fire hazard Take extra care to reduce the risk of dropping a metal tool onto a battery It might spark or short circuit the battery or other electrical part and it may cause an explosion Remove personal metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current that is high enough to weld a ring or anything like it to metal causing a severe burn NEVER charge a frozen battery Excessive battery discharge and or high charging voltages can cause serious damage to batteries Do not exceed the recommended limits of the discharge level of your batteries If it is necessary to remove a battery always remove the grounded terminal from the battery first Make sure all accessories are off so as not to cause an arc Be sure that the area around the battery is well ventilated while the battery is being charged Refer to the recommendations of the battery manufacturer Batteries are heavy It may become a projectile if it is
10. 0423 ControlMaster Sport single version side mount 100424 ControlMaster Sport T single version top mount 100542 ControlMaster Sport TD double version top mount 100790 ControlMaster Sport Tc single version top mount compact 100791 ControlMaster Sport TDc double version top mount compact 26 November 2011 HybridMaster Ultra EN Bellmarine 10 EC DECLARATION OF CONFORMITY We Manufacturer IDTechnology BV Bellmarine Address Nobelweg 26 389BN Zeewolde The Netherlands Declare under our sole responsibility that the products Electric boat propulsion systems Bellmarine AC liquid Cooled 2 5 N30 Bellmarine AC liquid Cooled 4 2 N30 Bellmarine AC liquid Cooled 6 0 N50 Bellmarine AC liquid Cooled 10 0 N50 Bellmarine AC liquid Cooled 15 0 N60 are in conformity with the provisions of the following EC directives Electromagnetic Compatibility EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC The following harmonized standards have been applied EMC Emission standard for industrial environments EN 61000 6 4 2007 EMC Immunity standard for industrial environments EN 61000 6 2 2005 General Safety Information Technology Equipment EN 60950 1 2006 Furthermore we hereby declare that the same products are intended to be incorporated into other machinery and must not be put into service until the relevant machinery into which it is to be incorporated has been declared in conformity with the essen
11. FERENCES AND BATTERY CAPACITY sscssssesssssesssseessseesssesssseesssteetsneeteee 10 44 10 45 OPERATION FUNCTIONS 10 46 DEPARTURE En E rasaan err rnesa aerer rn 10 47 10 INSTALLATION 11 5 1 GENERAL CONSIDERATIONS FOR A SILENT PROPELLER SHAFT 11 5 2 COMPONENTS 11 JH euo m 12 54 MOTOR CONTROLLER 12 o SRI T 12 DISPLAY Cm 14 EE E EE EE E E eee ere 14 14 581 MOTOR CONTROLLER 15 5 8 2 CONNECTION OF MOTOR CABLES 16 583 CONNECTION OF SIGNAL CABLES 16 584 CONNECTION OF POWER 16 5 9 CONTROLLER ttt rtt ttt ttti 17 5 10 COMMISSIONING tnter ttt tte ttt tt ttt ttt ttt 18 19 61 PREVENTIVE MAINTENANCE 19 TOME V TANTAN 19 63 19 Nov 2013 Bellmarine AC EN Bellmarine EN Bellmarine AC liquid cooled e propulsion systems 7 5 _ 2 e 20 8 TECHNICAL DATA rran
12. Turn the couplings one stroke counter clockwise The cable is now secured and cannot get loose as a result of vibration 3 Place the couplings on the controller Refer to the manual of the battery supplier for more information about the connection and location of the battery Follow these steps after installation and before switching on the power 1 Check connections again 2 Check the voltage of the battery 3 When you are convinced that everything has been connected properly turn the main switch on 5 9 CONTROLLER CALIBRATION The main calibration is done in the factory Every time the system is switched on it will perform a self diagnosis first Follow these steps 1 Putthe Joystick in the neutral position 2 Turn on the system with the motor switch The display lights up and the main relay in the motor controller will close if everything is connected correctly 3 Move the joystick forward and backward to check the system and the rotation of the propeller 4 Check the system for unwanted noise and vibration CAUTION Steps 3 and 4 must be done carefully so that the bearings of the shaft will not be damaged in case the propeller shaft is not properly lubricated EN Bellmarine AC liquid cooled e propulsion systems 17 5 10 COMMISSIONING The factory settings of the Bellmarine AC e propulsion systems are optimal for most installations For some applications however it is desirable to change th
13. an be cooled in a several way s 1 Fresh water cooling Only fresh water 2 Closed loop in combination with heat exchanger and forced air cooling 2 Closed loop in combination with heat exchanger and fresh water cooling Important in the cooling system flow the motor controller must be first in line followed by the motor CAUTION Beware of temperatures below zero freezing can damage your system During freezing fill your system with coolant to protect it See maintenance and service in chapter 6 12 Nov 2013 Bellmarine AC EN JU el marine ITTTT EF He Fresh water Cooling system Inlet waterschep 3 Filter Pump pomp Controller Motor Outlet Afvoer gu mn WM KA Figure 5 4 Cooling system Fresh water EN Bellmarine AC liquid cooled e propulsion systems 5 6 DISPLAY The display is usually mounted on the control console of the boat The location of the display is not critical it is important that rain water does not remain on the display and can run off Upright or slightly slanted installation is recommended This does not apply to an indoor arrangement The display requires a rectangular 138 mm by 92 mm width by height panel cut out Refer to chapter 8 for the display dimensions 5 7 JOYSTICK The joystick is mounted for instance vertically on the control console Note the following joystick is splash proof only Therefore the joystick should no
14. de Weight Motor Shaft flange Stainless steel 316 Motor cable U V W standard 2 0 m Motor controller Display Wiring assembly controller display Total weight system 23 kg 0 55 kg 2 0 kg 9 7 kg 0 4 0 7 kg 36 4 kg AC liquid cooled 25 48 V _25 2 60 0 200 Ah lt 2 5 kW S1 1450 rpm 20 Nm 2 0 kW 81 5000 rpm 34 58A 110A 10 kHz 15kHz 0 300 Hz N30 Asynchronous 4 2 kW 1 1450 rpm 29 Nm 8 kW 81 5000 rpm 4 2 300 AC 34 3 95A 175A N30 _ Hall sensor electronic 64 Standard 11 bit lt 500 Kbps 19V 63V Maximum allowed value is programmable Maximum allowed value is programmable Shuts down the controller when overheated Adjustable via 40 50 C IP 66 65 25kg 0 5kg 2 0kg 13kg 0 4 0 7 kg 384 software 450 Ah lt 6 0 kW 51 1450 rpm 47 Nm lt 4kW 51 5000 rpm 36 137 270A N50 bbkg _0 7 kg 13 kg 0 4 kg 0 7 kg 69 8 10 600 Ah lt 10 kW 1 1450 rpm 65 Nm 7 5 kW S1 5000 rpm AC 36 230A 430A N50 59 kg 0 8 kg 18 kg 0 4 kg 0 7 kg 74 kg 800 15 kW 81 1450 97Nm 10 kW S1 5000 rpm AC 38 950A 1 500A N60 76 kg 0 8 kg 18kg
15. emoving the screws marked x y and z in Figure on both sides of the controller 2 Pull the three cables through the corresponding holes at the front of the controller Make sure that the U V and W cables are placed in the correct location 3 Connect the three motor cables labeled U V W onto the correspondingly marked connections on the motor controller see Figure 5 8 Install the cables using the supplied M8 bolts and tighten them with 9 6 0 9 Nm Use a torque wrench 4 Close the cover carefully and tighten the screws The motor sensor cable is already connected to the motor controller 5 Connect the motor direction 4P and temp sensor 2P cable from the motor controller to the motor with the preassembled cable with 2 x IP 66 connector Bellmarine 5 8 3 Connection of Signal cables Figure 5 9 Signal cable connector 12P Follow these steps to connect the display joystick and motor switch to the motor controller 1 Determine the position of the display joystick and motor switch 2 Bring the supplied signal cable to this position 3 Connect the display joystick and motor switch with the preassembled plugs 4 Connect the 12 pin plug at the other end of the cable with the 12 pin connector that is located at the front of the motor controller 5 Lock the plug by turning the chrome ring a quarter of a stroke CAUTION CAN bus control signals are transferred through this cable Therefore never r
16. ese settings Therefore several adjustments can be made If your Bellmarine AC e propulsion system is not new you have to take into account that previous users may have changed the settings Let a certified installer dealer set the Bellmarine AC e propulsion system to your preferences in case of doubt To change the controller software settings a computer or laptop with Curtis 1314 4402 interface and software or the Curtis 1311 Handheld Programmer can be used See figure 5 13 This 1311 Handheld Programmer simplifies adjustments programming testing and diagnosing It provides a fast and easy interface to the motor controller The connector for the computer or Handheld Programmer can be found on the front of the motor controller it is marked 4 in Figure Please refer to the Curtis 131 1 Handheld manual for further operating instructions Figure 5 12 1311 Handheld programmer e Bellmarine DEPLAY DATA NOEL KEY 18 Nov 2013 Bellmarine AC EN Bellmarine 6 MAINTENANCE 6 1 PREVENTIVE MAINTENANCE Check your whole system regularly on the following points Check the bilge and motor compartment for unwanted moisture or water Check the operation of the automatic bilge pump Check the system for irregularities such as abnormal noise vibration and wear Keep the system always connected even in winter storage to the shore connection This will keep the batteries in 100 conditi
17. example a propeller with a 2 4 KW drive moves about 280 liter water per second The water inflow should be disrupted at a minimum and the water should flow horizontally through the propeller If the boat has a keel from which the propeller protrudes then the keel must be narrowed above and below the propeller shaft to get the inflow to the propeller as smooth as possible See Figure The view of the keel shows the difference between a straight keel and a keel that is narrowed There must be enough space at least 15 of the propeller diameter between the propeller and the hull The same applies when a heel is mounted that supports the rudder When designing the heel it is important that the inflow of water is not disrupted A curved piece of flat steel can cause tremendous turbulence in the water causing noise and loss of efficiency There must be sufficient space between the propeller and the rudder It is an advantage that the rudder is drop shaped en is not made out of a flat plate This drop shaped design is also called a NACA profile 5 2 COMPONENTS See the block diagram in chapter 3 and the wiring diagram in section 5 8 EN Bellmarine AC liquid cooled e propulsion systems 11 5 3 MOTOR A Bellmarine AC e propulsion system is quiet and has little vibration when installed correctly In order to achieve this pay close attention to the placement of the motor and the entire propeller shaft system Figure 5 2 M
18. l Battery voltage too low Power is automatically reduced Charge batteries as soon as possible 24 Battery voltage too high Motor controller cannot operate regenerative Standard security to prevent overloading the battery When the battery can take up current again the regeneration will automatically start 28 Motor temperature too high gt 110 Power is automatically reduced by the motor controller until the temperature has dropped to a safe value 47 Joystick is not in neutral during switch On of the system Put joystick in neutral Errors are reset with the motor switch by turning it Off and On again 20 Nov 2013 Bellmarine AC EN Bellmarine 8 TECHNICAL DATA 8 1 TECHNICAL SPECIFICATIONS Model Article number Battery Nominal battery voltage Battery voltage Minimal advised battery capacity Performance Maximum motor drive power Maximum motor drive speed Maximum motor drive torque Maximum motor regeneration power Maximum motor regeneration speed Controller Number of phases Nominal phase current Maximum phase current PWM operating frequency Maximum encoder frequency Output frequency Motor Motor type Sensor Encoder pulses per rotation Communication CAN open Nodes 2 0 ID type Baud rate Safety Under voltage Over voltage Current Motor power Thermal safety Torque limitation Environment Temperature Protection class motor controller Display upper si
19. n label on the Bellmarine AC 34 motor controller similar on other models 36 38 The identification labels are found on the Bellmarine AC motor and motor controller see Figure 1 1 Important technical information required for services maintenance and secondary delivery of parts can be derived from the identification label z ATTENTION Never remove the identification labels Nov 2013 Bellmarine AC EN Bellmarine 2 SAFETY GUIDELINES AND MEASURES 21 WARNINGS AND SYMBOLS The following warning caution and attention symbols are used in this manual WARNING A WARNING refers to possible injury to persons if the user does not carefully follow the procedures CAUTION A CAUTION sign refers to possible significant damage to the equipment if the user does not carefully follow the procedures restrictions and rules ATTENTION An ATTENTION sign refers to procedures circumstances etc which deserve extra attention 2 2 USE FOR INTENDED PURPOSE A Bellmarine AC e propulsion system may only be used for ship propulsion and according to the installation operation and maintenance instructions of this manual 2 3 GENERAL SAFETY AND INSTALLATION PRECAUTIONS Head this manual thoroughly before installing and or using the electric components Follow the assembly instructions carefully Only work with the controller when the drive is switched off It is important to switch off the powe
20. on and prevents self discharging of batteries If the system is not going to be used for a long time anda permanent shore connection is not available charge the batteries for 100 and remove the fuse Check the condition of your V belts regularly also after a longer period of not sailing 6 2 MAINTENANCE The Bellmarine liquid cooled e propulsion systems basically don t need maintenance However you should be alert for moisture and salt which can permanently damage your system The body of the motor and motor controller can be cleaned with a dry or slightly damp cloth Never use water or a solvent to clean the motor or motor controller Always contact your dealer if you notice strange noises vibrations or non traceable error messages on the display Have your whole system checked by a qualified installer every two years This will help keeping your system in optimal condition 63 WINTERSTORAGE The Bellmarine Liquid Cooled e propulsion systems with an open fresh water cooling system must be protected in case freezing Temperatures below zero can damage the motor or controller To protect the system it is necessary to fill the system in winter time with cooling liquid How to protect Close the water inlet valve open the fresh water Filter unit switch on the e propulsion system Disconnect the 2 pole temperature sensor on the motor and the pump will start Put the winter cooling fluid into the freshwate
21. ons and instructions contained in this manual apply solely to standard versions of the Bellmarine AC series delivered by IDTechnology For other models see other manuals available on our website www idtechnology nl 1 3 GUARANTEE SPECIFICATION IDTechnology guarantees that this unit has been built according to the legally applicable standards and specifications Should work take place which is not in accordance with the guidelines instructions and specifications contained in this user manual then damage may occur and or the unit may no longer meet its specifications All of these matters may mean that the guarantee becomes void The guarantee is limited to the costs of repair and or replacement of the product Costs for installation labor or shipping of the defective parts are not covered by this guarantee During production and before delivery all equipment is tested and inspected The standard warranty period is two years after purchase See chapter 10 for the EC Declaration of Conformity Bellmarine 1 4 LIABILITY IDTechnology can accept no liability for Consequential damage due to the use of a Bellmarine AC e propulsion system Possible errors in the manuals and their consequences 1 5 IDENTIFICATION LABEL Bellmarine MOT 3 M 81 2 COD KW C S Nm n COS H 2 RPM I ll I Manufactured in the Netherlands Figure 1 1 Identificatio
22. ounting the motor The motor must be mounted directly onto an existing foundation The motor must be fixed by using eight bolts as shown in Figure 5 3 During installation of the motor pay attention to the following Check that all bolts are tightened after positioning the motor and propeller shaft system Make sure that the motor is well protected and prepared for unforeseen circumstances like leakage Suggestion place a automatic bilge pump Refer to chapter 8 for the motor dimensions 5 4 MOTOR CONTROLLER Note the following when installing the motor controller motor controller must be mounted at a dry well protected and accessible location in the boat note of the length of the motor cables install the controller as close as possible to the motor Never install a controller near or in the same location as a so called wet open battery controller must be able to take in enough cool air make sure there is adequate ventilation Ensure that the intake opening cannot be blocked and do not cover up the outlet hole After the most suitable location in the boat has been determined the controller can be mounted in place Bellmarine Figure 5 3 Motor controller mounting The motor controller must be mounted by using four bolts as shown in Figure 5 3 Refer to chapter 8 for the controller dimensions 5 5 COOLING The Bellmarine liquid cooled e propulsion systems c
23. r supply of the electric drive with the main switch Remove the key and keep it with you so that nobody else can turn it back on aware of your speed The speed is often underestimated because of the lack of sound Be alert to your surroundings silent sail means that others can hardly hear you 2 4 WARNING REGARDING LIFE SUPPORT APPLICATIONS The Bellmarine AC e propulsion system is not intended for use any medical equipment that is intended for use as a component of any life support system unless a specific written agreement pertaining to such intended use is executed between the manufacturer and Bellmarine Such agreement will require the equipment manufacturer either to contract additional reliability testing of the Bellmarine AC and or to commit to undertake such testing as a part of the manufacturing process In addition the manufacturer must agree to indemnify and not hold Bellmarine responsible for any claims arising from the use of the Bellmarine AC e propulsions systems in life support equipment EN Bellmarine AC liquid cooled e propulsion systems 2 5 WARNING REGARDING THE USE OF BATTERIES Pay attention to the following when working with batteries Someone should be within hearing range or close enough to come to your aid when you work near a lead acid AGM or gel or Li lon battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye
24. r filter and make sure the complete system motor and controller will be filled with this Switch of the system reconnect the temp sensor connection on the motor and close the fresh water filter again Don t forget in spring time before using the system again to open the water inlet valve EN Bellmarine AC liquid cooled e propulsion systems 19 7 TROUBLE SHOOTING In case of a failure the Bellmarine AC e propulsion system display shows an error code to help you find the cause If you cannot solve a problem with the aid of the fault finding table below contact your local Bellmarine Service Centre See www idtechnology nl Make sure you have the article and serial number close at hand FAULT 24 160 0 h2 MODE MAX Figure 7 1 Display showing error code The following table shows the most common errors Bellmarine At the right side of the display is a LED alarm triangle see Figure 4 1 This triangle displays the following colors in case of an alarm Yellow low battery level Red alarm error code system The number of the alarm is shown in the display see Figure 7 1 Code Error Solution 16 Controller overheated gt 95 Let motor controller cool down and check the cooling of the housing 22 Controller too hot gt 85 Power to motor is automatically reduced until the temperature has dropped to a safe value 23 Low voltage warning yellow LED signa
25. t continuously be in contact with water Position the joystick carefully lever has to be able to rotate freely in both directions Choose the location so that the risk of turning the lever in the unwanted direction is minimal Battery Power main Switch Main fuse Pump Battery Display Joystick Bellmarine 5 8 WIRING Each system has the following wiring Main battery power connections Control cables including preassembled connectors Preassembled motor cables 2 5 and 4 2 kW including clamp connection U V W Motor sensor cable including preassembled connectors Pump power cable including preassembled connector The power cables for connecting the batteries to the motor controller and Motor power UVW cables gt 4 2 kW are not included in the delivery The connection of the cables is explained in the following sections Connect the cables in the following order 1 Connect the motor cables 2 Connect the signal cables 3 Connect the battery power cables See the block diagram in chapter 3 and the wiring diagram in Figure 5 7 E Motor switch Contact key Motor Figure 5 5 Wiring diagram the shown motor controller is the AC 34 controller but same connections exist on the other motor controllers AC 36 and 38 The battery and the joystick are not included in the system For ordering information refer to chapter 9 14 Nov 2013 Bellmarine AC
26. tch Motor controller Bellmarine Nov 2013 Bellmarine AC EN Bellmarine 4 OPERATION 41 SWITCHING ON AND OFF The motor is switched on by turning the key clockwise in the motor switch The motor switch has three positions off maximum and economy Two power programs are available e Maximum the full power of the motor is available Economy the maximum speed of the motor is reduced as well as the maximum power It is possible to switch between the two power programs while the motor is running Be aware that switching from Economy to Maximum will increase the speed of the motor and that of the boat instantly It is possible to remove the key in the economy reduced power position for safety reasons The system is switched off by turning the key counterclockwise to the off position 4 2 POWER BOOST Moving the Joystick Throttle from neutral to Forward or Backwards the system will apply an extra 10 power to the motor for 8 seconds to increase acceleration and maneuverability Every time passing the neutral position of the joystick this power boost function will be available 4 3 USE OF THE DISPLAY E4 After switching on the motor the display lights up YO IDA 8X7 6 Figure 4 1 Display 4 3 1 Display buttons 6 Up menu navigation button 7 Down menu navigation button 10 Select menu button The buttons are used for switching between
27. tems 4 3 4 Personal preferences and battery capacity The display can be set to suit personal preferences Both power and speed scale can be set using the installed motor and program settings In the same menu also the battery capacity C20 that is installed in the system can be set This value is important for the battery status indication and remaining time calculation To change the settings 1 Pressthe Select menu button marked 10 in 2 Figure 4 1 for three seconds and the preferences menu will appear 3 Move the slider to the setting you want to change with the Up and Down buttons on the right 8 and 9 With the help of these buttons you can step up and down through the list of options you can change including the battery capacity C20 rating 4 Confirm your choice with the Select menu button 10 5 Repeat steps 2 and 3 for the settings you want to change 6 Go to Exit to leave the settings menu and confirm with the Select menu button 10 7 Pressthe Select menu button 10 for three seconds to leave the menu The settings have now been changed 4 4 USE OF THE JOYSTICK While in the Maximum or Economy drive mode the desired power and speed can be adjusted in forward and backward direction with the joystick by turning it over the full stroke This happens without intermediate steps Figure 4 2 shows the joystick with default forward clock wise and backward counter clockwise operation
28. tial requirements of the following EC directive Machinery Directive 2006 42 EC The following harmonized standards have been applied Rotating electrical machines EN 60034 1 2004 Zeewolde 22 October 2013 Marien Schoonen CEO IDTechnology BV Bellmarine EN Bellmarine AC liquid cooled e propulsion systems 27
29. two screens and navigation and control in the calibration and settings menu In normal operation two screens are available in the display To toggle between the screens press the Up and Down buttons on the right 8 and 9 Screen 1 is recognized by the image of a battery in the lower left corner Screen 2 is recognized by the image of a clover leave in the lower left corner 4 3 2 Display fields 1 Screen f Battery condition indicator showing battery State of Charge in percentage Screen 2 Eco meter showing relative economy of current operation in percentage related to the speed of the boat Motor power in KW Speed motor propeller LED Attention triangle Economy or Maximum or Hybrid mode Screen 1 Calculated remaining time Screen 2 blank 9 Total number of operating running hours 5 4 3 3 Alarm error codes The LED attention triangle Figure 4 1 7 flashes several times when an error occurs followed by a short rest period The number of times the LED flashes and the color of the LED is an indication of the malfunction Meaning of LED colors in case of an alarm error Yellow low battery level Red alarm error code system The alarm number is shown in the display The display will show a large text block in the upper section with the error code displayed Us See chapter 7 for a description of the error codes EN Bellmarine AC liquid cooled e propulsion sys
30. un this cable along motor power cables or 230 Volt wiring Secure cables properly loose cables can eventually cause malfunctions 5 8 4 Connection of power cables WARNING Make sure that when connecting the battery and the motor controller the fuse has been removed and the main switch is turned off 2 Figure 5 10 Quick connect couplings for power cable Notice the following when connecting the cables positive terminal is clearly marked with a red mark on the motor controller main switch must be mounted at an accessible location between the fuse and the motor controller so that the system can be disconnected from the battery in case of an emergency or in case of maintenance 16 Nov 2013 Bellmarine AC EN Bellmarine properly sized fuse must be placed as close as possible to the battery to ensure maximum wiring protection cable runs from the battery to the fuse and the cable runs from the battery to the pole of the controller Specifications for connecting the motor power cables Power rating 4 2 kW 8 kW 10 kW Cable size 235 mm gt 50mm 270 mm Two quick connect couplings are included for connection to the motor controller see Figure 5 11 Figure 5 11 Quick connect couplings for motor controller Follow these steps to connect the quick connect couplings 1 Install the couplings with care at the ends of the cables 2
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