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1. 1 4 LIABILITY Mastervolt can accept no liability for Consequential damage due to the use of the PodMaster Possible errors in the manuals their consequences EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT SAFETY GUIDELINES AND MEASURES 2 SAFETY GUIDELINES AND MEASURES 2 1 WARNINGS AND SYMBOLS The following warning caution and attention symbols are used in this manual WARNING A WARNING refers to possible injury to AN 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 D An ATTENTION sign refers to procedures circumstances etc which deserve extra attention 2 2 USE FOR INTENDED PURPOSE The PodMaster 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 Read 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 power 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 Be aware of your speed The speed is often underesti
2. spi UNE 24 6 MAINTENANCE 25 61 PREVENTIVE MAINTENANCE ttt ttt ttti ttt ttti 25 MAINTENANCE Anu 25 2 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT CONTENTS 6 3 SYNCHRONIZING BATTERY MONIT OR rata diti pecu noe da e ama ee pibe eame 25 6 4 ANODE PROTECTION utate odi esiti nde dre R dee drei e dut decies 25 7 iiie Beeojp cue Dm 26 8 qe RS 27 8 1 TECHNICAL SPECIFICATIONS RR 27 8 2 DIMENSIONS PP EE 28 8 2 1 Seng Ec T 28 8 2 2 MOTOR Eb en Coda he dne d SE a Usate tp PU d ict 29 8 2 3 DIS ge ET 30 9 555 E 31 EN PodMaster 4 2 6 5 amp 10 February 2011 3 GENERAL INFORMATION MASTERVOLT 1 GENERAL INFORMATION 11 USE OF THIS MANUAL Copyright 2011 Mastervolt All rights reserved Reproduction transfer distribution or storage of or all of the contents in this document in any form without the prior written permission of Mastervolt is prohibited This manual contains important safety and operating instructions for the safe and effective operation maintenance and possible correction of minor malfunctions of the PodMaster It is therefore obligatory t
3. MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com MASTERVOLT USER MANUAL PodMaster 4 2 6 5 amp 10 ELECTRIC PROPULSION SYSTEM Copyright 2011 Mastervolt v 0 1 February 2011 CONTENTS MAST E RVO LT CONTENTS eite oS nk OS M EE 4 jd SUSE Or THIS ANAL ever Led ei e lei 4 12 VALDET OF THIS MANUAL Du ea pa D aint feats 4 f GUARANTEE SPECIFICATION int Backs dene o elite ceed Ud Linee nude aed ace 4 HET 4 2 SAFETY GUIDELINES AND MEASURES ccscssssssssssssssssssssssssssssssssssssssssssessssssssssssusssssceeessesesssssssssneseeseeeeseesesssssssssnanseeees 5 24 WARNINGS AND SYMBOLDS 12255224 Deedee E keane str tese 5 22 USE FOR INTENDED 5 2 3 GENERAL SAFETY AND INSTALLATION 21444 5 24 WARNING REGARDING LIFE SUPPORT 5 25 WARNING REGARDING THE USE OF 6 8 HOW 0000 C ee Ce ems 7 3 1 PODMASTER 5 8 1 1 teet ee 7 32 ene S s 7 33 CONTROLLER AND ge 8 3 4 DISPLAY JOYSTICK AND KEY SWI
4. EN PodMaster 4 2 6 5 amp 10 February 2011 13 INSTALLATION MASTERVOLT 5 4 MOTOR A PodMaster electric drive system is quiet and has little vibration when installed correctly In order to achieve this pay close attention to the placement of the Motor Figure 8 The PodMaster motor 1 2 3 4 5 6 The motor must be installed by qualified personnel Below are M10 threaded stud and nut 2x M12 threaded stud and nut 2x Motor Propeller anode 3 blade bronze propeller Angled rubber flange some support guidelines for installation First two preparatory actions need to be taken 1 A sufficiently reinforced hull section needs to be prepared to mount the motor to using the 2 M10 and 2 M12 bolts as indicated in Figure 8 dimensions are given in Chapter 8 2 The angled rubber flange needs to get the proper inclination to ensure most efficient operation of the motor This efficient operation is achieved when the PodMaster motor is placed horizontally in the water in normal operation As the hull might have an angle with respect to horizontal at the location the motor is mounted the inclination of the rubber flange needs to be adjusted to the hull Figure 9 shows how the proper inclination of the flange can be determined the motor horizontally below the hull while the hull is positioned as it would normally be in the water dimensions a and b as indicated in Figu
5. Range ENG DEU Contrast select contrast of LCD module Range 0 80 Backlight always backlight for LCD module Range ON OFF Speaker turn speaker on or off Range ON OFF A Auto return automatically return to main screen Range ON OFF Serial number serial number of the display Read only Firmware version software version of the display unit Read only Page 2 Battery Setup with PIN code Batt Ah C 20 total capacity of the battery pack measured for 20h discharge rate Range 1Ah 1999Ah Peukert rate of discharge affecting remaining charge in the battery Typical value is 1 13 for Lead Acid batteries and 1 02 for Lithium batteries Range 1 00 1 49 Charging ends at voltage voltage at which the display detects end of charging when charging current is lower than end of charging current and restores charging counter to 100 Range 1 0V 340 0V And current current threshold at which the display detects end of charging when charging voltage is greater or equal to charging end voltage and restores charging counter to 100 Range 0 1A 9 9A at 50 battery voltage at which the remaining charge in the battery is at 50 the display has a fixed programmed battery voltage to State of charge relation Range 1 0 300 0V EN PodMaster 4 2 6 5 amp 10 February 2011 21 INSTALLATION MASTERVOLT Page 3 System Setup with PIN code Cha
6. Table 1 Default parameter settings Parameter Page 1 User Setup Language Contrast Backlight Speaker Auto return Serial Number Firmware version Page 2 Battery Setup Batt Ah C 20 Peukert Charging ends at voltage And current Ubatt at 50 Page 3 System Setup Charging threshold Discharging threshold dU dt threshold Shunt Standby after Page 4 Low battery SOC alarm SOC alarm ON SOC alarm OFF Min On Time Max On Time Enable MSG Enable ECO Enable RE2 Page 5 Batt Low Voltage Alarm Alarm ON Alarm OFF On delay time Min ON Enable MSG Enable ECO Enable RE2 Page 6 Joystick Setup 1 2 Neutral Max forward Max backward Backlash Q filtering Page 7 Joystick Setup 2 2 Fwd speed Bwd speed ECO speed FWD torque BWD torque Torque ctrl mode Default setting System dependent System dependent System dependent 4 0A System dependent 3 0A 1 0A 00 300 A 50 mV disabled 1800rpm 1800rpm 1200rpm 20 0 Nm 10 0 Nm OFF Page 8 Regen Setup OV speed trip Regen torque Max batt volt Gain Generator mode 1500 rpm Press to calculate System dependent 16 OFF Peukert values 1 02 MLI 1 15 AGM 1 27 Gel 1 27 2V Gel Default parameters The default parameter settings for the PodMaster are given in Table 1 Some values are indicated as System dependent as their value should be set according to the installed battery pack CAUTION Never set the param
7. MAINTENANCE 6 1 PREVENTIVE MAINTENANCE Check your whole system regularly on the following points Check the bilge and controller 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 Check the anodes regularly Always keep the system connected to the shore connection even in winter storage This will keep the batteries in 10096 condition and prevents self discharging of batteries If the system is not going to be used for a long time and a permanent shore connection is not available charge the batteries for 100 and remove the fuse 6 2 MAINTENANCE The PodMaster is a low maintenance system However you should be alert for moisture and salt which can permanently damage your system The controller can be cleaned with a dry or slightly damp cloth Never use water or a solvent to clean the controller Always contact your dealer if you notice strange noises vibrations or non traceable error messages on the display Have the whole system checked by a qualified installer every two years This will keep the system in optimal condition 6 3 SYNCHRONIZING BATTERY MONITOR It is important to regularly synchronize the battery monitor with the battery in order to keep the battery monitor delivering accurate information Therefore perform a complete charge cycle on the battery The charge cycle is
8. by moving the joystick itself They cannot be changed with the UP and DOWN keys The position of the joystick is measured in small steps called quants The joystick can occupy any up to 1024 positions of the quants Calibrate the joystick in the following way 1 Put the joystick in the physical neutral position 2 Select the Neutral parameter in the joystick setup mode and press OK 3 Put the joystick in the desired forward position ATTENTION When calibrating the display will recognize automatically if the joystick is mounted on the right or left side of the boat 4 Select the Max forward parameter in the joystick setup mode and press OK 5 Put the joystick in the desired backward position ATTENTION It is only allowed to move the joystick in the opposite direction of the forward position 6 Select the Max backward parameter in the joystick setup mode and press OK The joystick is now calibrated and ready for use Setting the backlash The small area near the neutral position is called backlash The purpose of this area is to compensate for mechanical construction of the joystick After calibrating the joystick the settings of the backlash area is compensated automatically z Neutral 131 Backlash T 2 Forward Backward Figure 15 Setting the joystick backlash 20 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT INSTA
9. complete and the battery is full when the charging current drops below the set parameter parameter page 2 and current and the battery voltage is higher than the set parameter parameter page 2 charging ends at voltage The State of charge readout will be set to 100 6 4 ANODE PROTECTION The motor housing and propeller shaft are protected with sacrificial anodes Check the anodes for corrosion on a regular base at least once every year Replace the sacrificial anodes when half of the anode has been lost to corrosion CAUTION Never coat anodes with paint or anything else for it will lose its function EN PodMaster 4 2 6 5 amp 10 February 2011 25 TROUBLE SHOOTING MASTERVOLT 7 TROUBLE SHOOTING In case of a failure the PodMaster 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 Mastervolt Service Centre See www mastervolt com Make sure you have the article and serial number close at A leakage in a seal can be detected by either Oilin the water or water on top of the oil in the rudder trunk A leaking seal is not directly damaging for the motor as long as there is enough oil left in the motor but it should be replaced as soon as possible hand when contacting the Mastervolt Service Centre CAUTION To prevent a leaking seal at the propeller shaft connection or at the rudder
10. console of the boat The location of the display is not critical but it is important that rain water does not stay on the display but can run off Vertical or diagonal installation is recommended This does not apply to an indoor arrangement The display requires a rectangular 122 mm by 76 mm width by height panel cut out 1 Place the display in the cut out panel see Figure 11 2 Fix the U shaped bracket at the back side of the display on the two threads using nuts 3 Tighten the nuts until the display is well fixated to the panel Figure 11 Mounting the display See chapter 8 for the display dimensions EN PodMaster 4 2 6 5 amp 10 February 2011 15 INSTALLATION MASTERVOLT 5 6 JOYSTICK The joystick can be mounted at any desired location Note the following The Mastervolt joysticks are splash water proof only Therefore the joystick may not be continuously in contact with water Position the joystick correctly The lever has to be able to rotate freely in both directions Choose the location carefully so the risk of accidental turning the lever is minimal The joystick is not included in the system For ordering information see chapter 9 5 7 WIRING Each system has the following wiring Pre assembled motor cables Pre assembled signal cable Main battery power connections including the shunt fuse and main switch The power cables for connecting the bat
11. 5 amp 10 February 2011 MAST E RVO LT TECHNICAL DATA 8 TECHNICAL DATA 8 1 TECHNICAL SPECIFICATIONS Model PodMaster 4 2 6 5 10 Article number 140600420 140600650 140601000 MOTOR Type AC synchronous Nominal power 4 2 kW 6 5 kW 10 kW Speed 1500 1500 1800 Rated torque 27 Nm 38 Nm 52 Nm Motor efficienc 94 94 94 System efficiency 90 90 90 Motor weight 35 kg 35 35 ae a E N CONTROLLER Nominal battery voltage 48 V Minimal input voltage 19V Maximum input voltage 57 6V Switch off input voltage low 19V Switch off input voltage high 63 V Rated output current 200 A Maximum output current 300 A Rated power 11 2 kVA Maximum power 19 5 kVA IP enclosure rating IP44 Weight 5 8 kg DISPLAY Type Graphic LCD monochrome 128 x 64 pixels Operating voltage range 18 0 to 75 0 VDC Maximum operating current 26 5 mA 48 V Standby current 2 9 mA 48 V Current measurement method SHUNT Current measurement range 20 0 to 600 0 configurable Backlight Low power white LED Panel cutout 122 mm x 76 mm Mating connector Molex Mini Fit 12 pin Female Crimp Terminals Molex Mini Fit 10 pin Female Crimp Terminals ENVIRONMENT Temperature range 25 C to 35 C Relative humidity 9 to 95 vapor Enclosure protection IP65 face IP40 rear EN PodMaster 4 2 6 5
12. EN PodMaster 4 2 6 5 amp 10 February 2011 11 OPERATION MASTERVOLT 4 4 DEPARTURE Before departure always check the system for correct functioning Follow these steps before departure 1 Disconnect the shore connection 2 Turn the main switch to the ON position 3 Putthe joystick in the neutral position 4 Turn the key switch ON and choose the power program Drive or Economy 5 Check the battery condition 6 Check the system s forward and backward 4 5 ARRIVAL Follow these steps after arrival Put the joystick in the neutral position Check the battery condition Turn the key switch to the OFF position Optional Turn the main switch to the OFF position Connect the shore connection and make sure it works properly 6 Recharge the batteries after arrival fue 4 6 CHARGING BATTERIES When charging the batteries the display will give two confirmation beeps and will present the Battery Information screen see page 10 Charging can be recognized from the blinking arrow that symbolizes charged Ah After the charging is completed the display returns to the standby mode ATTENTION Only connect the system to the batteries D after they have rested for a couple of hours without any load Otherwise the SOC value will only be correct after the first full charge 12 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT INSTALLATION 5 INSTALLATION During insta
13. LLATION 5 9 COMMISSIONING PIN code To edit parameters you have to enter the Write access PIN code on the second page Without the PIN code you can still browse through the parameters on these pages However you cannot change them Only page 1 can be edited without a PIN code The PIN code for the PodMaster is 4134 To enter the PIN code 1 Press OK to enter the edit mode 2 Selectthe first digit with UP and DOWN 3 Press OK to proceed to the next digit 4 Repeat until all the digits are entered If you entered a valid PIN code you will be granted permission to edit If not you have to wait 30 seconds to try again Once a valid PIN code is entered the field will show OK Edit the parameter If you have permission to change the parameters the edit sign in front of the parameter value will be shown Edit the parameter 1 Press OK to edit the parameter The value to be edited will appear inverted 2 Change the value using the UP and DOWN keys 3 Press OK to store the value 4 Perform steps 1 til 3 to proceed with other parameters Not all parameters can be directly edited with the UP and DOWN keys An open arrow sign in front of the parameter value indicates a value needs to be calibrated When an ON OFF parameter is selected just press OK to change the value The value is ON when the box is checked Page 1 User Setup without PIN code Language choose language of preference
14. ORKS INCLUDED IN THE PODMASTER SYSTEM MOTOR SWITCH WITH KEY JOYSTICK SWITCH SHUNT FUSE Figure 1 System block diagram 3 1 PODMASTER SYSTEM The diagram of Figure 1 gives a simplified view of the PodMaster system The battery pack supplies energy The controller is the key element in the system It manages operation protection and information The motor with propeller provides the thrust for the propulsion The motor consists of a seawater resistant aluminum bogy The system is operated by the joystick and the key switch The joystick gives speed and direction information to the controller so it can give the right amount of power to the motor With the key switch the system is turned on and off and its operating mode is selected Information about the motor speed remaining battery charge estimated remaining time of sailing battery voltage controller and motor monitoring and more is shown on the display Furthermore there is a fuse for protection and a main switch for powering on and off The shunt measures the current from and to the controller CONTROLLER L 4 MOTOR E DISPLAY PROPELLER 3 2 COMPONENTS The PodMaster has the following components Controller Submerged pod AC synchronous motor complete with 3 blade bronze propeller Display Key switch Shunt Fuse Main switch a Several connection cables Please check the contents of the box b
15. TCH ale 8 3 5 MAIN SWITCH FUSE AND SHUNT s e B 8 36 CONNECTION CABLES o e AEN 8 4 OPERATION RE T Hd TERR 9 41 9 SWITCHING ON AND OPE ioo e NM Neo eee oreet 9 42 USE OF THE e 9 4 2 1 SETUP PERSONAL PREFERE ICES 9 4 2 2 NORMAL OPERATION 2 10 4297 ALARM Eoo VEL o ooo ooo oem eet nsi m 11 USE OF THE JOYS CK A NE o NS oor th 11 44 1 NB O lc ea o betae etes sitet 12 ARRIVAL S s o NB ie obe dre tete ettet 12 6 CHARGING BATTERIES WEE Dent better 12 5b JNSIALLATION c NE A ooo ooo eie teat 13 Di pese 13 5or COMPOR NTSGE ave aah hme 13 5 3 Au CWENMEE 13 WHO UON Umm 14 DEM ANDE PROTECTION Arar aioin aa eset ente 15 15 D Ww EMEN TT 16 S RING PR TU 16 M CONNECTIONS TO CONTROLLER cue p ue LIO 18 CONNECTING MOTOR CABLES cote ul ie ce ee ettet 18 5 737 CONNECTING SIGNAL GABLE a LL LAU p 18 574 CONNECTING BATTERY CABLES n E 19 5 7 5 BEFORE SWITCHING ON THE POWER emm dde 19 5o SAU BRATION du aii cate tse ettet iiic Urt 20 59 21 540 REGENERATION REGEN 2
16. amp 10 February 2011 27 8 2 DIMENSIONS 8 2 1 CONTROLLER Front Side 149 Figure 18 Dimensions of the controller in inches 8 2 2 MOTOR Side Back 590 Top Sg 3 Q N E GG cg B gt gt Figure 19 Dimensions of the motor in mm Side Back 23 23 Top Figure 20 Dimensions of the motor in inches 8 2 3 DISPLAY Back 133 121 2 0 2 86 75 2 0 2 Top Figure 21 Dimensions of the display in mm Back 5 24 4 77 0 008 3 39 2 96 0 008 Top Figure 22 Dimensions of the display in inches 27 3 1 07 Side Side 9 ORDERING INFORMATION Part number Description 141500010 ControlMaster Casual single version side mount 141500030 ControlMaster Sport single version side mount 141500120 ControlMaster Sport T single version top mount 141500220 ControlMaster Sport TD double version top mount 142000734 Rubber flange for PodMaster 4 2 6 5 amp 10 1cm height difference 142000735 Rubber flange for PodMaster 4 2 6 5 amp 10 2cm height difference 142000736 Rubber flange for PodMaster 4 2 6 5 amp 10 3cm height difference
17. bolt nut combinations 5 7 3 CONNECTING SIGNAL CABLE After the display joystick and key switch have been installed they have to be connected The signal cable provides the following connectors At one end For the display Molex 12 pin and Molex 10 pin connector For the key switch Molex 6 pin connector For the joystick 3 pin connector At the other end For the temperature sensor cable Molex 6 connector For the controller 19 pin plug see Figure 14 CAUTION Make sure you do not mistake the connector of the joystick for the 3 pin Molex connector of the Ubatt Display key switch joystick Connect the display joystick and key switch with the pre assembled Molex connectors The Molex connectors on the display can be found on the back side Controller Connect the 19 pin plug see Figure 14 with the 19 pin connector at the front side of the controller see Figure 13 number 4 Lock the connector by turning the chrome ring a quarter of a stroke Figure 14 Connector for signal cable CAUTION CAN bus control signals are transferred through this cable Therefore never run this cable along power cables or 230 Volt wiring Secure cables properly loose cables can eventually cause malfunctions 18 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT INSTALLATION 5 7 4 CONNECTING BATTERY CABLES WARNING Make sure that when connecting the battery and the co
18. e 1 9999 RPM WARNING ECO speed must always be lower than any AN other maximum speed value ECO speed does not apply when sailing in the Torque drive mode FWD torque torque of motor when full forward torque is selected with joystick Only active when Torque ctrl mode is set Range 0 1 999 9 Nm BWD torque torque of motor when full backward torque is selected with joystick Only active when Torque ctrl mode is set Range 0 1 999 9 Nm Torque ctrl mode drive motor torque instead of speed mode RPM Range ON OFF WARNING If the Torque drive mode is switched OFF make sure that the Forward and Backward AN speed have correctly been configured If the Torque drive mode is switched ON make sure that the Forward and Backward torque have correctly been configured Page 8 Regen Setup with PIN code Ov speed trip maximum allowed motor speed during generator mode Range 1 9999 RPM Regen torque maximum braking torque during REGEN mode Range 0 1 999 Nm CAUTION The REGEN torque should be lower than the nominal motor torque to prevent motor damage Max batt volt maximum voltage for braking torque Range 0 1 399 9V Gain rate at which applied braking torque to the motor is reduced Default value is 16 Range 1 255 Generator mode Enables REGEN mode Range ON OFF EN PodMaster 4 2 6 5 amp 10 February 2011 23 INSTALLATION MASTERVOLT
19. efore you start with the installation If any of the items is missing please contact your supplier EN PodMaster 4 2 6 5 amp 10 February 2011 HOW IT WORKS MASTERVOLT 3 3 CONTROLLER AND MOTOR The PodMaster controller is used to control and monitor the operation of the synchronous motor that is specifically developed for low voltage The controller also has software that allows various properties of the drive to be set Some of these properties are Maximum speed in various operation modes Joystick calibration A Auto tuning and self test functions Battery management These properties and many others have already been set by Mastervolt 3 4 DISPLAY JOYSTICK AND KEY SWITCH The display serves as a graphical interface between the user and the controller The user can set and monitor a range of parameters such as Current motor speed Battery voltage Battery current Motor current Remaining time of sailing at current consumption etc At the same time the display tracks the state of charge SOC of the battery and has a built in safety system that informs the user of errors The key switch is a three position switch that switches between the operation modes Off Drive Eco Regeneration The joystick is a lever which can be turned clockwise and counter clockwise to move forward or backward The settings can be adjusted to the preferred location in the boat There are s
20. eters to values other than indicated in the Default parameter settings table without consulting your Mastervolt distributor 5 10 REGENERATION REGEN MODE The generator principle allows recharging of the batteries from mechanical power obtained from the motor shaft The application is suited for sailing boats During sailing periods the REGEN mode can be enabled on the display section 3 4 Successful setting of the REGEN mode is indicated on the display by showing REG on the status line in the main screen Figure 3 item 6 When the REGEN mode is enabled on the display the Economy most clockwise position of the key switch will become the REGEN mode position The Economy mode cannot be enabled manually When the REGEN mode is enabled both on the display and with the key switch the amount of regeneration is controlled by the joystick as shown in Figure 16 With turning the joystick further clockwise the regeneration torque and thus braking will increase Neutral Backlash J 100 Figure 16 Controlling regeneration torque ATTENTION Do not fake the regeneration mode by setting the motor to a low RPM in the normal D Drive mode while sailing faster The excessive energy will charge up your batteries However there is no battery monitoring possible battery will therefore be overcharged and damaged 24 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT MAINTENANCE 6
21. everal types of joysticks available which is why the joystick is not a standard part of the system In this manual a standard joystick is used as an example Refer to the ordering information in chapter 9 for alternative types 3 5 MAIN SWITCH FUSE AND SHUNT The main switch is mounted between the fuse and the motor controller in order to disconnect the batteries during emergencies and maintenance The fuse is connected to the plus pole of the battery The shunt is mounted between the minus pole of the battery and controller The shunt measures the current power consumption which is used by the display to show the current performance battery state of charge and remaining sailing time 3 6 CONNECTION CABLES Figure 1 gives a simplified view of the components of the PodMaster with its cabling connections EN PodMaster 4 2 6 5 8 10 February 2011 MASTERVOLT OPERATION 4 OPERATION 41 SWITCHING ON AND OFF The motor is switched on by turning the key clockwise in the key switch and the system is switched off by turning the key counter clockwise to the off position The key switch has three positions From left to right position Off the motor is switched off Drive the full power of the motor is available Economy Regeneration in Economy mode the maximum speed of the motor is reduced as well as the maximum power WARNING It is possible to switch between the two power programs while the motor
22. h 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 involved in an accident Ensure adequate and secure mounting and always use suitable handling equipment for transportation EN PodMaster 4 2 6 5 8 10 February 2011 MASTERVOLT HOW IT WORKS 3 HOW IT W
23. hat every person who works on or with the PodMaster 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 the PodMaster systems may only be performed by qualified and authorized personnel in accordance with regulations and compliance with the mentioned safety measures Keep this manual in a safe place 1 2 VALIDITY OF THIS MANUAL All of the specifications provisions and instructions contained in this manual apply solely to standard versions of the PodMaster delivered by Mastervolt For other models see other manuals available on our website www mastervolt com 1 3 GUARANTEE SPECIFICATION Mastervolt 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
24. is running Be aware that switching from Economy to Drive will increase the speed of the motor and thus of the boat instantly 4 2 USE OF THE DISPLAY Mes VOLT 4 Figure 2 Display buttons and information area Display buttons and information area 1 Button UP 2 Button DOWN 3 Button OK 4 Information area Standby mode After the battery power is initialized the display will be in the standby mode From this standby mode there are two operating modes Setup personal preferences Normal operation Drive Economy mode Sleep mode 4 2 1 SETUP PERSONAL PREFERENCES Before the display can be used it must be properly configured to suit personal preferences To enter the setup mode press the OK button Figure 2 and hold it while you re start the system with the key switch To leave the setup mode turn the key switch to the off position Navigation through parameter pages Navigation is done using UP and DOWN Figure 2 to select the next parameter The parameter with focus will have a browse sign gt in front of the value When you reach the last parameter on the page press DOWN again to go to the next page Or if you have reached the first parameter on the page press UP to go to the previous screen Holding UP or DOWN longer will let you jump to the next page directly without stepping through the parameters Edit the parameter To edit parameters you have to enter a Write access PIN c
25. llation and commissioning of the PodMaster the safety instructions of chapter 2 must be followed 5 1 GENERAL CONSIDERATIONS The following points must be considered for safe installation and to make the electric sail real quiet There must be enough space at least 15 of the propeller diameter between the propeller and the hull Bolts must be tightened firmly and with an even pressure 5 2 COMPONENTS See the block diagram in chapter 3 and the wiring diagram in section 5 7 5 3 CONTROLLER Note the following when installing the controller The controller must be mounted in a dry and accessible location in the boat Make sure that the controller is well protected Prepare for unforeseen circumstances like leakage Suggestion place a bilge pump note of the length of the motor cables since these cables must not be shortened or extended Never install a controller near or in the same location a so called wet open battery Make sure that there is adequate ventilation and do not cover up the intake and outlet opening The controller must be able to take in enough cool air Ensure that the intake opening cannot be blocked After the most suitable location in the boat has been determined the controller can be mounted in place Figure 7 Mounting the controller The controller must be mounted using four bolts as shown in Figure 7 See chapter 8 for the controller dimensions
26. mated because of the lack of sound Be alert to your surroundings silent sail means others can hardly hear you 2 4 WARNING REGARDING LIFE SUPPORT APPLICATIONS The PodMaster is not intended for use in 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 Mastervolt Such agreement will require the equipment manufacturer either to contract additional reliability testing of the PodMaster 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 Mastervolt responsible for any claims arising from the use of the PodMaster in life support equipment EN PodMaster 4 2 6 5 amp 10 February 2011 SAFETY GUIDELINES AND MEASURES MASTERVOLT 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 battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye 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 wit
27. ntroller the fuse has been removed and or the main switch is switched off Notice the following when connecting the cables to the batteries The positive terminal is marked with a plus sign on the controller and the negative terminal is marked with a minus sign The main switch must be mounted at an accessible location between the fuse and the controller so that the system can be disconnected from the battery in case of an emergency or in case of maintenance The fuse must be placed as close as possible to the battery to ensure maximum wiring protection The cable runs from the battery to the fuse and the cable runs from the battery to the shunt Refer to your battery manual for more information about the connection and location of the battery The power cables are connected to the controller by M6 bolt nut combinations 5 7 5 BEFORE SWITCHING ON THE POWER Follow these steps after installation and before switching on the power 1 Check all connections again 2 Check the voltage of the battery 3 After you are convinced that everything has been properly connected turn the main switch on EN PodMaster 4 2 6 5 amp 10 February 2011 19 INSTALLATION MASTERVOLT 5 8 CALIBRATION On Page 6 of the parameter setup see page 22 the joystick can be calibrated The neutral position of the joystick and how far you must move the joystick to reach full RPM can be set The values can only be changed
28. ode on the second page Without the PIN code you can still browse through the parameters on the pages However you cannot change them Only page 1 can be edited without a PIN code ATTENTION For a detailed description of the parameters see chapter 5 9 Edit the parameter 1 Press OK to edit the parameter The value to be edited will appear color inverted 2 Change the value using the UP and DOWN keys 3 Press OK to save the value 4 Perform steps 1 til 3 to proceed with other parameters When an ON OFF parameter is selected just press OK to change the value The value is ON when the box is checked EN PodMaster 4 2 6 5 amp 10 February 2011 OPERATION 4 2 2 NORMAL OPERATION Drive Economy mode The Drive or Economy mode is switched on and off using the key switch without pressing any buttons while switching D Make sure that the joystick is in the neutral position when you start the system If not In the drive mode the display area has three different information pages which can be scrolled between with the UP and DOWN keys Main screen Figure 3 Main information screen Lx or Controller Information screen for 30 4 e ATTENTION the unit will show an error message Main screen Battery information screen Controller information screen RENT Charge in 30 3A Speed value RPM Speed direction and econom Arr
29. ow pointing up f Arrow pointing dow Economy mode Remaining batter Battery current Esti mai Figure 5 Controller information screen 1 Controller status Bridge on status indicator red light Temperature in C Normal operation Regeneration mode IP Over voltage protection active 2 Motor direction indication Low battery m Arrow pointing up forward E A pos B ckground lights indicator Arrow pointing down backward 3 pos display supply voltage 3 Motor measurements m Speed in RPM Temperature in C RMS current in A Joystick position position in quants position forward positive or backward negative in percentage After not pressing any buttons on the Battery seconds it will automatically return to the Main Screen This can be changed on parameter page 1 auto return 10 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT OPERATION Sleep mode If there was no action from the user and the joystick is in the neutral position than the display will go into sleep mode after a set period of time This set period of time can be configured on parameter page 3 see chapter 5 9 but as a standard the sleep mode is disabled In the sleep mode the display is turned off but it still remains active and monitors the battery voltage and current Before it goes into sleep mode it also disables the controller to save energy Re
30. re 9 the rubber flange is taken off during this measurement The height difference over the length of the rubber flange should be the same as b When the proper inclination of the rubber flange has been determined there is two ways to get the right it onto the flange Machining it with a saw The saw needs to have sufficiently large teething in order to prevent the rubber polyurethane material from clogging the teeth during the cutting Buying a standard 1cm 2cm or 3cm inclined rubber flange through Mastervolt see Chapter 9 for details Figure 9 Measuring optimal inclination for rubber flange After these preparations mounting the motor is done as shown in Figure 10 3 Place the motor with the rubber flange on top below the hull and fix it to the hull by the 4 nuts on the threaded studs Figure 10 Mounting the motor See chapter 8 for the motor dimensions 14 EN PodMaster 4 2 6 5 amp 10 February 2011 MASTERVOLT INSTALLATION 5 4 1 ANODE PROTECTION When two different metals are physically or electrically connected underwater a current will flow between these two metals The electrons that make up that current are supplied by one of the metals giving up bits of itself in the form of metal ions This is called galvanic corrosion and it destroys underwater metals The most common galvanic corrosion is present in case of a bronze or aluminum propeller on a stainless steel shaft b
31. rging threshold current at which the display considers that the battery is being charged Range 0 1A 9 9A Discharging threshold current at which the display considers that the battery is being discharged Range 0 1A 9 9A dU dt threshold reserved for future use Shunt current flowing through shunt resistor that produces voltage drop of 50mV You should never overload the shunt resistor Range 20 600A Standby after set time for sleep mode Range mm ss 00 01 59 59 Off Page 4 Low Battery SOC Alarm with PIN code SOC alarm ON remaining charge in the battery when low battery alarm should go on Range 00 9096 Set 00 for Off SOC alarm OFF remaining charge in the battery when low battery alarm should go off When it is set lower than the SOC Alarm on the parameter is ignored Range 00 90 Min On Time minimum time alarm stays activated Range hh mm 00 01 12 00 Max On Time maximum time alarm stays activated Range hh mm 00 01 12 00 Enable MSG low battery SOC alarm message display Range ON OFF Enable ECO ECO mode with low battery SOC alarm Torque mode must switched Range ON OFF Enable RE2 low battery alarm 2 output Range ON OFF Page 5 Battery Low Voltage Alarm with PIN code Alarm ON when the battery voltage has fallen below this value the low battery alarm will be activated Range 0 0 340 0V Alarm OFF batte
32. ry voltage threshold when low battery alarm is released Range 0 0 340 0V On delay time time the low battery alarm ON condition must be met before the alarm is activated Range 0 300s Min on minimum time that the alarm relay stays activated Range hh mm 00 01 12 00 Enable MSG low battery voltage alarm message display Range ON OFF Enable ECO ECO mode with low battery voltage alarm Torque ctrl mode must be switched on Range ON OFF Enable HE2 low battery alarm RE2 output Range ON OFF Page 6 Throttle Joystick Setup 1 2 with PIN code D ATTENTION For actual calibrating see section 5 8 Neutral neutral position for joystick Range 1 1023 forward full RPM or torque in forward position Range 1 1023 Max backward full RPM or torque in backward pos Range 1 1023 Backlash manual correction of joystick backlash Range 0 99 Q filtering when enabled small changes of joystick value due to electric noise are ignored Range ON OFF 22 EN PodMaster 4 2 6 5 8 10 February 2011 MASTERVOLT INSTALLATION Page 7 Throttle Joystick Setup 2 2 with PIN code Fwd speed speed of the motor when full forward is selected with joystick Range 1 9999 RPM Bwd speed speed of the motor when full backward is selected with joystick Range 1 9999 RPM ECO speed speed of the motor when ECONOMY mode is selected Rang
33. teries to the controller 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 Figure 2 and the wiring diagram in Figure 12 16 EN PodMaster 4 2 6 5 8 10 February 2011 MASTERVOLT INSTALLATION J 9 Display Key switch Joystick Signal cable Controller o T a Main Battery Figure 12 Wiring diagram The battery and joystick are not included in the system For ordering information see chapter 9 EN PodMaster 4 2 6 5 amp 10 February 2011 17 INSTALLATION MASTERVOLT 5 7 1 CONNECTIONS TO CONTROLLER Figure 13 Connecting the controller Figure 13 shows an overview of the connection points on the controller These connections are 1 Pole of battery 2 Motor connection 3 Fuse holder 4 19 pin connector for display joystick and key switch 5 Motor connection 6 Motor connection 7 Pole of battery 5 7 2 CONNECTING MOTOR CABLES CAUTION Motor cables must not be shortened or extended CAUTION Connections can be preserved with acid free Vaseline Connect the pre assembled motor cables to the three motor connections L1 L2 and L3 on the controller The ends of the cables can be mounted to the controller by M6
34. trunk connection replace the seals every four years The following table shows the most common errors Error Code Error Solution ERR 001 The joystick is not in the neutral position Move the joystick to the neutral position ERR 002 Joystick error disconnected ERR 003 CAN bus timeout ERR 004 Battery low Charge the battery ERR 005 Motor temperature high Power will be reduced ERR 006 High voltage PCB timeout no link CONTROLLER ERR 001 Over current CONTROLLER ERR 002 Over voltage CONTROLLER ERR 003 Under voltage CONTROLLER ERR 004 Voltage low at the start CONTROLLER ERR 005 Potentiometer error during operation CONTROLLER ERR 006 Potentiometer not at zero at the start CONTROLLER ERR 007 Controller over temperature CONTROLLER ERR 008 Controller under temperature CONTROLLER ERR 009 Controller temperature sensor error CONTROLLER ERR 010 Current offset error CONTROLLER ERR 011 DC link charging error CONTROLLER ERR 012 Relay error CONTROLLER ERR 013 PDPINTA shortcut or mosfet driver error CONTROLLER ERR 014 Bad user parameter CRC CONTROLLER ERR 015 Bad system parameter CRC CONTROLLER ERR 016 Bad flash CRC CONTROLLER ERR 017 Wrong parameter version CONTROLLER ERR 018 Invalid motor type CONTROLLER ERR 019 Auto tuning error CONTROLLER ERR 020 Boost error CONTROLLER ERR 021 Motor over temperature CONTROLLER ERR 022 Motor temperature sensor failure CONTROLLER ERR 023 Internal error 26 EN PodMaster 4 2 6
35. turn from sleep mode to drive mode The sleep mode has to be switched off with the key switch to return to the stand by mode before it can be switched on again for the drive mode 4 2 3 ALARM ERROR CODES The notification system informs you if there is something wrong with any part of the system When such an error occurs a message will appear on the display screen titled NEW MESSAGE When you have read the new message confirm this with the OK button see Figure 2 If there are any other messages they will also be displayed You will have to press OK to confirm them until you will finally return to one of the three screens If you wish to see which errors are still present press OK on any of the screens You will now be able to browse the messages The screen will be titled Message List Press the UP and DOWN keys to scroll between the messages ATTENTION D When the cause of the error is removed the message will automatically be deleted from the message list See chapter 7 for a list of all error messages 4 3 USE OF THE JOYSTICK 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 6 shows the joystick with the default forward clockwise and backward counter clockwise operation neutral counter clockwise QN backward forward Figure 6 Use of the joystick
36. ut other metal motor housings are also at risk The best way to prevent galvanic corrosion is to add a third metal into the circuit one that is potentially more reactive than the other two metals This piece of metal is called a sacrificial anode With the PodMaster system one sacrificial anode is included to protect the propeller This is an aluminum anode and is to be placed on the shaft ATTENTION To protect the seawater resistant aluminum AIMg 5 motor housing a second set of sacrificial anode s needs to be placed on the boat near the motor housing and needs to be electrically connected to that motor housing This anode is not provided with the system as the proper choice of anode depends on environment water conditions D and other material use on the boat In general we recommend in fresh water magnesium anodes in brackish water aluminum anodes Mil A 24779 SH in salt water zinc anodes Mil A 18001K Nevertheless it is always recommended to directly consult an expert Mastervolt or your local expert on anode protection on the specific situation at hand CAUTION Beware that properly placing a sacrificial anode on your boat to protect the aluminum motor housing is essential and failure to do so might cause severe damage to your System Damage to the motor caused by galvanic corrosion is not covered by our product warranty 5 5 DISPLAY The display is usually mounted in the control

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