DriveMaster Ultra
Contents
1. L 16 54 19 59 1 LO oo LO mi AHHA 11 0 68 li E ll yy y y l 8 11 NS Figure 30 Dimensions of DriveMaster Ultra 5 motor in inches 136 375 Masvervour 7 5 kW 5 36 420 N 498 R5 17 10 Figure 31 Dimensions of DriveMaster Ultra 7 5 motor in mm Side pv 755 kW R0 20 0 68 0 39 st co c CN Oo ro CN O N 206 226 Front 9 O LM LM at O N Re r 8 11 8 90 Figure 32 Dimensions of DriveMaster Ultra 7 5 motor in inches I EE cc NN zi 682 Figure 34 Dimensions of DriveMaster Ultra 10 motor in inches 184 wil Side 419 7 23 al P 584 712 m 4 irn 16 49 22 99 28 05 1 34 0 39 10 71 11 50 Figu2. note of the length of the motor cables since you can not shorten or extend these cables 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 Figure 10 Motor controller mounting The motor controller must be mounted by using four bolts as shown in Figure 10 See chapter 8 for the controller dimensions 14 March 2011 DriveMaster Ultra EN MASTERVOLT INSTALLATION 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 indoor arrangement The display requires a rectangular 138 mm by 92 mm width by height panel cut out See 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 not continuously be in contact with water Position the joystick carefully
3. E 9 42 USEOFTHE DISPLAY all ee 9 43 JJUSEOFTHEJOYSTIOK aces a No oe eret dern 10 44 DEPAHTURE tete Bo eoo Eten 10 AL Me ete 10 5 INSTALLATION vereen NT Bei dep teen ib heee 11 5 1 GENERAL CONSIDERATIONS FOR A SILENT PROPELLER SHAFT 11 59 COMPONENTS sens ere NB eene ttti s br deet 11 5 MOTOR c 0 11 54 TRICE COUP 12 5 41 HOMOKINETIC JOINT 12 5 4 2 THRUST GU 13 55 eub 14 15 gt Em 15 oo 15 SET MOTOR CONTROLLER CONNECTIONS ccccsssssccssssseccsssssecesssssescssssnscecssssscensssneessssssneecsssnscensenie 17 8 2 OF MOTOR CABLES ssssssscsosssssccssssecesssssseessssseccssssseccsssssecccsssncensssssesessssseecssssnees 17 5 8 3 CONNECTION OF SIGNAL CABLES 18 584 CONNECTION OF POWER CABLES 18 59 CME ATON o oom 19 nuo COMMISSIONING EIE LM 19 67 aa 20 PREVENTIVE MAINTENANCE aD AU LN EN 20 por MAINTENANCE OI LIEU E E ee 20 7
4. 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 5 8 WIRING Each system has the following wiring Main battery power connections Control cables including preassembled connectors Preassembled motor cables including clamp connection U V W Motor sensor cable including preassembled connectors The power cables for connecting the batteries to the motor 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 chapter 3 and the wiring diagram in Figure 11 EN DriveMaster Ultra March 2011 15 INSTALLATION MAST E RVO LT J J Display Joystick Motor controller Main switch Motor sensor cable Battery Motor Figure 11 Wiring diagram the shown motor controller belongs to the DriveMaster Ultra 3 5 but the same connections exist on the other systems The battery and joystick are not included in the system For ordering information see chapter 9 16 March 2011 DriveMaster Ultra EN MASTERVOLT INSTALLATION 5 8 1 MOTOR CONTROLLER CONNECTIONS Figure 12
5. March 2011 DriveMaster Ultra EN 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 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 Ix ATTENTION mn An ATTENTION sign refers to procedures circumstances etc which deserve extra attention 2 2 USE FOR INTENDED PURPOSE A DriveMaster Ultra 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 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 aware of your speed The speed is often underestimated because of the lack of sound alert to your surroundings silent sail means that others can hardly hear you 2 4 WARNING REGARDING LIFE SUPPORT APPLICATIONS
6. Figure 21 Dimensions of DriveMaster Ultra 3 5 motor controller in mm Front Side 11 61 seio Figure 22 Dimensions of DriveMaster Ultra 3 5 motor controller in inches Front Side Figure 23 Dimensions of DriveMaster Ultra 5 and 7 5 motor controller in mm Front Side 9 06 Figure 24 Dimensions of DriveMaster Ultra 5 and 7 5 motor controller in inches Front Side 404 TERT 1 Figure 25 Dimensions of DriveMaster Ultra 10 and 20 motor controller in mm Front Side 15 91 Soo 17 87 Top Figure 26 Dimensions of DriveMaster Ultra 10 and 20 motor controller in inches 8 2 3 ASYNCHRONOUS MOTOR Side Front 407 ee 195 217 250 16 03 Figure 28 Dimensions of DriveMaster Ultra 3 5 motor in inches 136 Side Front ERVOLT 5 kW 5 36 D HTH lt lt 4 ec 17 10 Rs ec O N 206 2 226 d Figure 29 Dimensions of DriveMaster Ultra 5 motor in Side Front 15 02 Manservant
7. Communication CAN open Nodes 2 0 Standard ID type 11 bit Baud rate 500 Kbps Safety Undervoltage 19V 38 V Overvoltage 63 V 126V Current Maximum allowed value is programmable Motor power Maximum allowed value is programmable Motor speed 1400 rom 1400 rom 1400 rom 222 1400 rom 1400 rom Related torque 24Nm 34Nm J 5iNm 68Nm 136Nm Thermal safety Shuts down the controller when overheated Coupling limitation Adjustable via software Environment Temperature 40 50 C Protection class motor controller electronics IP 65 Display upper side 65 Weight Motor 872kg 65kg 69kg 118kg 176kg Shaft flange 0 7 kg 0 7 kg 0 7 kg 0 8 kg 0 8 kg Motor cable U V W standard length 2 5 m 1 8 kg 2 2 kg 2 2 kg 2 2 kg 2 2 Motor controller 97kg 43132 206kg 206kg Display 04kg 04 04kg 04kg Wiring assembly motor controller display 0 7kg 07kg 07 2 07kg Total weight system 505kg 81 9kg 8590 1427kg 200 7 22 March 2011 DriveMaster Ultra EN 8 2 DIMENSIONS 8 2 1 DISPLAY J1 J2 4 T PEELE datgeen Figure 19 Dimensions of display in Ji J2 T u 12 Hops oo oo 0 34 mi 0 83 5 42 Figure 20 Dimensions of display in inches 8 2 2 MOTOR CONTROLLER Front Side 214 280
8. Maximum shaft speed 5 000 rom Length homokinetic shaft 155 25 mm Propeller shaft diameter 25 30 amp 1 11 4 The given values are for sailing with less than 100 hours at full load For commercial applications 60 80 of these values are to be considered maximum load 5 4 2 THRUST BEARING Due to the high torque of DriveMaster Ultra systems and the associated high thrust the thrust force of the propeller shaft on the motor always needs to be absorbed by a thrust bearing The thrust bearing carries the thrust of the propeller directly to the ship s hull instead of the motor This is done via absorbing plastic bushings The mounting of the cylindrical propeller shaft in the thrust bearing is a solid bush Figure 8 Thrust bearing The thrust bearing should be mounted on a plate that is strong enough to transfer the thrust from the propeller to the hull The thrust is calculated by means of the following formula Fin 300 x P Fin thrust N P power kW 10 N thrust equals 1 kgf Example P 10kW Fin 300 x 10 3000 N this equals 300 The mounting plate must be positioned at an angle of 90 compared to the propeller shaft The tolerance is lt 2 Take note of the following when installing the thrust bearing rubber shock absorbers are to be installed both sides of the thrust bearing bolts should be tightened so that the rubbers are slightly rounded An exact torque is no
9. The DriveMaster Ultra 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 DriveMaster Ultra 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 DriveMaster Ultra in life support equipment EN DriveMaster Ultra March 2011 SAFETY GUIDELINES AND MEASURES MASTE RVO LT 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 protection and clothing protection Avoid touching eyes while working near a battery f 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 vici
10. 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 4 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 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 4 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 1596 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 rudd
11. CONTROLLER bl MOTOR DISPLAY PROPELLER Figure 1 System block diagram 3 1 DRIVEMASTER ULTRA SYSTEM The diagram of Figure 1 gives a simplified view of a DriveMaster Ultra system The main parts of the system are the battery and controller supplying the motor with energy and the motor with propeller providing the thrust for the propulsion The system is operated by the joystick and the motor switch with a key The joystick sends speed and direction information to the controller which transmits the right amount of power to the motor The motor switch is used to turn the system on and off and select its operating mode Information about battery voltage remaining power thrust power and possible malfunctions is shown on the display Furthermore there is a fuse for protection and a main switch for powering on and off The motor controller is the key element in the system It manages operation protection and information 3 2 COMPONENTS A DriveMaster Ultra comes with the following components Motor controller Asynchronous motor with premounted flange on shaft Display Motor switch with key Main switch Main fuse and main fuse holder Connection cable display joystick and contact key and battery connectors Please check the contents of the box before you start with the installation If any of the items is missing please contact your supplier 3 2 1 MOTOR CONTROLLER AND MOTOR The DriveMaster Ult
12. DEPARTURE Before departure always check the system for correct functioning Follow these steps Disconnect the shore connection Turn the main switch on Put the joystick in the neutral position Turn the motor switch on Check the battery condition Choose the power program maximum or economy Check system forward and backward a he 4 6 ARRIVAL Follow these steps after arrival Put the joystick in the neutral position Check the battery condition Turn the motor switch off Turn the main switch off Connect the shore connection and make sure it works properly 6 Reload the batteries after arrival ne Q p gt 10 March 2011 DriveMaster Ultra EN MASTERVOLT INSTALLATION 5 INSTALLATION During installation and commissioning of a DriveMaster Ultra 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 Check the serial number of the motor controller and that of the motor they must be identical Notes For a proper installation of the DriveMaster Ultra 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
13. MASTERVOLT USER MANUAL DriveMaster Ultra MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com 3 5 5 7 5 10 amp 20 ELECTRIC PROPULSION SYSTEMS Copyright 2011 Mastervolt v 0 5 March 2011 CONTENTS MASTERVOLT CONTENTS cinere E bat p tU 4 MEE TS MANU Nr em 4 io SADDITYSOF THIS MANUAL ctore ese M bt iUe suc 4 13 GUARANTEE SPECICATION EI LU E 4 eon 4 2 GUIDELINES AND MEASURES dle se uiae needa eee 5 B4 a EM UE 5 22 _USBFORINTENDED PURPOSES NI oen 5 23 GENERAL SAFETY AND INSTALLATION PRECAUTIONS ssseererettenrn tnnt 5 24 WARNING REGARDING LIFE SUPPORT 5 25 WARNING REGARDING THE USE OF BATTERIES 6 2 0080 Ci ot 7 31 DRIVEMASTER ULTRA SYSTEM 7 82 4COMPONEN TS neemen A AER XE o 7 321 MOTOR CONTROLLER AND MOTOR 7 3 2 2 DISPLAY JOYSTICK AND MOTOR SWITCH em open 8 3 2 3 MAIN SWITCH AND FUSE Qe edi e 8 477 OPERATION sesam tener d m 9 41 SWITCHING ON AND
14. Motor controller the shown motor controller belongs to the DriveMaster Ultra 3 5 but the same connections exist on the other systems Figure 12 gives an overview of the connections on the motor controller The connections include Pole for battery Pole for battery incl main switch and fuse Fuse holder Fuse Fast 4 Connection for computer 12 pin connector for display joystick and ignition Motor sensor cable U wire hole from the motor V wire hole from the motor W wire hole from the motor OOo Oy ELSE Tues 5 8 2 CONNECTION OF MOTOR CABLES Figure 13 Connecting points for motor cables the shown motor controller belongs to the DriveMaster Ultra 3 5 but the same connections exist on the other systems CAUTION Motor cables must not be shortened or extended 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 removing the screws marked x y and z in Figure 13 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 13 Install the cables using the s
15. TROUBLE SHOOTING ocho diac UN 21 8 _ ronnie neten Queda irte a tee Rn toan e an 22 81 TECHNICAL SPECIFICATIONS 22 2 March 2011 DriveMaster Ultra EN MASTERVOLT CONTENTS 9 8 2 DIMENSION MET 23 8 2 1 DISREA d es 23 8 2 2 MOTOR CONTROLLER po CPI 24 8 2 3 ASYNCHRONOUS MOTOR artes 27 ORDERING INFORMATION ad a Xu ee CoU 32 EN DriveMaster Ultra March 201 1 GENERAL INFORMATION MASTERVOLT 1 GENERAL INFORMATION 1 1 USE OF THIS MANUAL Copyright 2010 Mastervolt All rights reserved Reproduction transfer distribution or storage of part 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 of the DriveMaster Ultra series Also maintenance instructions and possible correction of minor malfunctions of the DriveMaster Ultra series are included It is therefore obligatory that every person who works on or with a DriveMaster Ultra is completely familiar with the contents of this manual and that he she carefully follows the instructions and important safety instructions contain
16. ed herein Installation and maintenance of a DriveMaster 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 provisions and instructions contained in this manual apply solely to standard versions of the DriveMaster Ultra series 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 1 4 LIABILITY Mastervolt can accept no liability for Consequential damage due to the use of a DriveMaster Ultra system Possible errors in the manuals and their consequences
17. er 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 5 3 MOTOR A DriveMaster Ultra 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 and the entire propeller shaft system EN DriveMaster Ultra March 201 1 11 INSTALLATION MASTERVOLT Figure 5 Mounting the motor The motor must be mounted directly on an existing foundation or by using the optional support bracket The motor must be fixed by using four bolts as shown in Figure 5 CAUTION In a propulsion system using a propeller a thrust bearing must always be present to transmit the large forces generated by the motor to the hull The motor can be installed with or without a homokinetic coupling If no homokinetic coupling is used the motor has to be 100 in line In combination with a homokinetic coupling the motor must be placed slightly out of line This is to guarantee the lubrication of the homokinetic joint During installation of the motor pay attention to the following Check that all bolts are tightened after positioning the motor and propeller shaft system sure that the motor is well protected and prepare for unforeseen circums
18. high Motor controller Standard security to prevent overloading the battery When the cannot operate regeneratively battery can take up current again the regeneration will automatically start 28 Motor temperature too high gt 135 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 Put joystick in neutral the system Errors are reset with the motor switch by turning it off and on again EN DriveMaster Ultra March 2011 21 TECHNICAL DATA MAST E RVO LT 8 TECHNICAL DATA 8 1 TECHNICAL SPECIFICATIONS Model DriveMaster Ultra 3 5 5 7 5 10 20 Article number 140300350 140300500 140300750 140301000 140302000 Battery Nominal battery voltage 48 V 96 V Battery voltage 25 2 60 0 V 50 4 120 V Minimal battery capacity 200Ah 300Ah 45 600Ah 6004Ah AC Number of phases 3 Nominal phase current 85 A 150A 150A 225A OBA Maximum phase current 250A 350A 35 450A 450A PWM operating frequency 10 kHz Maximum encoder frequency 15 kHz Output frequency 0 300 Hz Control adjustment Motor type Asynchronous Maximum motor power 8 55kW 2 5kW lt 75 lt 10KW 20kW S1 51 62 120 min 51 52 120 min Sensor SKF sensor bearing Encoder pulses per rotation 64 Read motor parameters Automatic via Auto fine tuning Standby mode Blocked by software
19. hing on the power 1 Check all 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 CALIBRATION The main calibration is done in the factory Every time the system is turned on it will perform a diagnosis first Follow these steps 1 Putthe Joystick in the neutral position 2 Turnon 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 5 10 COMMISSIONING The factory settings of the DriveMaster Ultra are optimal for most installations For some applications however it is desirable to change these settings Therefore several adjustments can be made If your DriveMaster Ultra is not new you have to take into account that previous users may have changed the settings Let a certified installer set the DriveMaster Ultra to your preferences in case of doubt To change the controller software a computer or laptop or the Curtis 1311 Handheld Programmer can be used This 1311 Handheld Programmer simplifies adjustment
20. my Two power programs are available Maximum the full power of the motor is available Economy 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 is running Be aware that switching from Economy to Maximum will increase the speed of the motor and that of the boat instantly is possible to remove the key in the economy reduced power position for safety reasons The system is switched off by turning the key counter clockwise to the off position 4 2 USE OF THE DISPLAY After switching on the motor the display lights up 9 9 OD 6 Figure 2 Display Display buttons 6 Up menu navigation button 7 Down menu navigation button 10 Select menu button The buttons are used for switching between 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 leave in the lower left corner 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 Motor power in kW opeed motor pr
21. n 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 keep your system in optimal condition 20 March 2011 DriveMaster Ultra EN MAST E RVO LT TROUBLE SHOOTING 7 TROUBLE SHOOTING In case of a failure the DriveMaster Ultra display shows At the right side of the display is a LED alarm triangle see an error code to help you find the cause If you cannot Figure 2 This triangle displays the following colours in solve a problem with the aid of the fault finding table case of an alarm below contact your local Mastervolt Service Centre See Yellow low battery level www mastervolt com Red alarm error code system The number of the alarm is shown in the Make sure you have the article and serial number close at display see Figure 18 hand Figure 18 Display showing error code The following table shows the most common errors 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 signal Battery voltage too low Power is automatically reduced Charge batteries as soon as possible 24 Battery voltage too
22. ng a smooth and low noise propulsion system and absorbs all axial forces that need to be dealt with Low friction ensures a long life propulsion system and the ability to operate a more powerful engine and propeller Homokinetic joint The homokinetic joint is mounted between the thrust bearing and the motor flange Its purpose is to ensure installation of motor and propeller shaft without centering problems After mounting the homokinetic joint provides a few millimeters of movement to the front and the back of the center axle ATTENTION opecify the propeller shaft diameter when ordering 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 142000355 Extension cable set 6 metres
23. nity of a battery or engine 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 lf 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 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 6 March 2011 DriveMaster Ultra EN MASTERVOLT HOW IT WORKS 3 HOW IT WORKS INCLUDED IN THE DRIVEMASTER 3 5 SYSTEM MOTOR KEY SWITCH JOYSTICK BATTERY MAIN FUSE MAIN SWITCH
24. opeller LED Attention triangle Economy or Maximum mode Screen 1 Calculated remaining time Screen 2 blank 9 Total number of operating hours goo Alarm error codes The LED attention triangle Figure 2 7 flashes several times when an error occurs followed by a short rest period The number of times the LED flashes and the colour of the LED is an indication of the malfunction Meaning of LED colours 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 See chapter 7 for a description of the error codes 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 Press the Select menu button marked 10 in Figure 2 for three seconds and the preferences menu will appear 2 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 3 Confi
25. ra motor controller serves to control the speed of the asynchronous induction motor that is specifically developed for low voltage operation he 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 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 Mastervolt They can be adjusted to specific wishes by a Mastervolt dealer EN DriveMaster Ultra March 201 1 HOW IT WORKS MASTERVOLT 3 2 2 DISPLAY JOYSTICK AND MOTOR SWITCH 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 3 MAIN SWITCH AND FUSE The main switch is mounted between the fuse and the motor controller in order to disconnect the batteries during emergencies and maintenance March 2011 DriveMaster Ultra EN MASTERVOLT OPERATION 4 OPERATION 41 SWITCHING 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 econo
26. re 36 Dimensions of DriveMaster Ultra 20 motor in inches 9 49 2 76 1 50 9 ORDERING INFORMATION Part number Description 3D motor mounting set 142000260 DriveMaster Ultra 3 5 142000261 DriveMaster Ultra 5 and 7 5 142000262 DriveMaster Ultra 10 142000263 DriveMaster Ultra 20 The DriveMaster can be mounted in the boat with a support bracket that is adjustable in height width and angle The support bracket has a total weight of 11 3 kg for the 3 5 13 8 kg for the 5 and 7 5 15 8 kg for the 10 and 18 kg for the 20 The support bracket is delivered with 4 motor adjust feet and vibration absorbers Figure 37 Support bracket 142000440 A flex thrust bearing homokinetic coupling 425mm 142000441 A flex thrust bearing homokinetic coupling 30mm Characteristics of an A flex coupling Production of sound and vibration has decreased by 90 Simplification of motor propeller shaft systems Lining procedure is easy by self targeting clamping hub in the thrust bearing absorb lining differences of up to 2 x 8 A complete set consists of homokinetic drive shaft thrust bearing with sleeve optional adapter bolts nuts and washers See the ordering details Thrust bearing The thrust bearing carries the high torque of DriveMaster Ultra systems and the associated high thrust force of the propeller shaft on the motor directly to the ship s hull instead of the motor The thrust bearing aids in realizi
27. rm your choice with the Select menu button 10 4 Repeat steps 2 and 3 for the settings you want to change EN DriveMaster Ultra March 201 1 OPERATION MASTERVOLT 5 Go to Exit to leave the settings menu and confirm with the Select menu button 10 6 Press the Select menu button 10 for three seconds to leave the menu The settings have now been changed 43 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 3 shows the joystick with default forward clock wise and backward counter clockwise operation neutral counter clockwise clockwise backward forward Figure 3 Joystick Refer to the ordering information in chapter 9 for available types 4 4 OTHER OPERATION FUNCTIONS During normal operation the following functions exist and operate autonomously 1 Boost function To accommodate fast maneuvering a DriveMaster Ultra 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 throttle is in neutral position for over 60 minutes standard setting the DriveMaster Ultra 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 5
28. s 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 marked 4 in Figure 12 DISPLAY SCREEN MENU KEY DATA INCIDEC KEY Figure 17 1311 Handheld programmer Please refer to the Curtis 1311 Handheld manual for further operating instructions EN DriveMaster Ultra March 201 1 19 MAINTENANCE MASTERVOLT 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 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 10096 and remove the fuse 6 2 MAINTENANCE The DriveMaster Ultra basically does not 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 clea
29. t available Check the tension after approximately one month and tighten the bolts with one stroke The propeller shaft should slide into position in the thrust bearing easily without friction EN DriveMaster Ultra March 2011 13 INSTALLATION MASTERVOLT 1 Plastic bushings 2 Propeller shaft 3 Thrust bearing 4 Sleeve Figure 9 Propeller shaft in the thrust bearing Take the following steps 1 Mount the thrust bearing by using the bushings marked 1 2 Lubricate the propeller shaft 2 and the exterior of the sleeve 4 with oil and grease 3 Insert the propeller shaft 2 into the sleeve 4 until it sticks out approximately 5 to 10 mm 4 Tighten the bolts of the clamping device inside the thrust bearing 3 crosswise and diagonally by hand until they are properly fastened 5 Tighten the bolts crosswise and diagonally with a torque wrench with half a stroke each time M6 17 Nm The sleeve has two extra holes This allows the sleeve to be removed To do so follow these steps 1 Loosen all bolts 2 Use two M6 bolts and screw them in the two pin holes 3 Remove the bolts crosswise until the sleeve pops off the shaft The propeller shaft in the thrust bearing is not included in the delivery 5 5 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
30. tances like leakage Suggestion place a bilge pump Clockwise rotating is forward See chapter 8 for the motor dimensions 5 4 A FLEX COUPLING ATTENTION The homokinetic joint and thrust bearing are not part of the delivered system and must be ordered separately They can be ordered separately at Mastervolt See the ordering information in chapter 9 5 4 1 HOMOKINETIC JOINT The homokinetic joint is mounted between thrust bearing and the motor flange The homokinetic joint is properly fitted if after mounting the center axle can be moved a few millimeters to the front and back Figure 6 Tightening order of bolts The bolts 2 x 6 M8 must be tightened crosswise as shown in Figure 6 First tighten bolt 1 then bolt 2 and so on Use a torque wrench M8 41 Nm CAUTION The homokinetic joint may never be 100 in line It must be a minimum of 1 out of line per homokinetic joint The maximum mounting angle depends on the rpm of the propeller shaft 8 angle for each homokinetic joint gt maximum 1200 rpm 6 angle for each homokinetic joint gt maximum 1500 rpm 5 angle for each homokinetic joint gt maximum 2000 rpm 12 March 2011 DriveMaster Ultra EN MASTERVOLT INSTALLATION Figure 7 Homokinetic joint Figure 7 shows the homokinetic joint marked 1 and the thrust bearing marked 2 WARNING Specifications Maximum thrust 4 300 N Maximum torque 485 Nm
31. uick connect couplings for power cable Notice the following when connecting the cables The 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 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 power cables Motor controller gt 35 mm Fuse T 225 Ampere Power 3 5 kW Voltage 48 Volts Two quick connect couplings are included for connection to the motor controller see Figure 16 Figure 16 Quick connect couplings for the motor controller Follow these steps to connect the quick connect couplings 1 Install the couplings with care at the ends of the cables 2 Place the couplings on the controller 3 Turn the couplings one stroke counter clockwise The cable is now secured and cannot get loose as a result of vibration Refer to the manual of the battery supplier for more information about the connection and location of the battery 18 March 2011 DriveMaster Ultra EN MASTERVOLT INSTALLATION Follow these steps after installation and before switc
32. upplied 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 sensor cable from the motor controller to the motor with the preassembled cable with bayonet plug 6 Turn the chrome ring clockwise until the bayonet ring is locked EN DriveMaster Ultra March 2011 17 INSTALLATION MASTERVOLT 5 8 3 CONNECTION OF SIGNAL CABLES Figure 14 Signal cable connector 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 run this cable along 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 Figure 15 Q
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