PodMaster 6.5 & 10 PROFESSIONAL
Contents
1. dil ED ED 8 3 2 EE E T 8 3 3 CONTROLLER AND MOTOR meme eee 9 3 4 DISPLAY JOYSTICK AND KEY SWITCH dafim RR 9 3 5 MAIN SWITCH FUSE AND SHUNT 9 09e eA 9 3 6 CONNECTION CABLES 48 9 4 Slgzr We 10 4 1 SWITCHING ON AND QOFF ffffu 10 4 2 USE OF THE DISPLAY ARA WA 10 4 2 1 SETUP PERSONAL PREFEBRBIICES 9 10 4 2 2 NORMAL OPERATION 7 B _ 11 4 2 3 ALARM ERROR 12 4 3 USE OF THE a 12 4 4 DEPARTURE icc ue u 13 4 5 n p AA oto O nnb lom 13 4 6 CHARGING BATTERIES 13 5 INSTALLATION dd ce ea ipt de ao OR uccide 14 5 1 GENERALE O T RIDE RATIO D iiai a a2. synchronous Nominal power 6 5 kW 10 kW Speed 1200 RPM 1000 RPM Rated torque 51 Nm 100 Nm Motor efficiency 96 97 System efficiency 9290 9390 Motor weight 29 37 Total system weight 35 kg 43 kg Forces torque on rudder trunk Steering force on lever arm CONTROLLER Nominal battery voltage 48 V Minimal input voltage 19 V Maximum input voltage 57 6 V Switch off input voltage low 19 V Switch off input voltage high 63 V Rated output current 200A Maximum output current 300 Rated power 11 2 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 Q 48 V Current measurement method SHUNT Current measurement range 20 0 to 600 0 A 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 Relative humidity 9 to 95 vapor Enclosure protection IP65 face 1 40 rear EN PodMaster 6 5 8 10 Professional February 2011 29 TECHNICAL DATA MASTERVOLT 8 2 DIMENSIONS 8 2 1 CONTROLLER Front Figure 17 Dimensions of the controller in mm Front Figure 18 Dimensions of the
3. EN PodMaster 10 Professional February 2011 MASTERVOLT HOW IT WORKS 3 CONTROLLER AND MOTOR The PodMaster Professional 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 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 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 several types of joysticks available which is why the joystick is not a standard part of the s
4. Never install a controller near or in the same location a so called wet open battery sure that there is adequate ventilation and do not cover up the intake and outlet opening 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 14 EN PodMaster 10 Professional February 2011 MASTERVOLT INSTALLATION 5 4 MOTOR A PodMaster Professional 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 NS E 2 ge Figure 8 Mounting the motor Lever arm Supporting ring Supporting ring Rudder trunk Mounting flange for fixating to the hull Motor Flange for connecting additional fin Propeller shaft OP te Ol See The motor must be installed by qualified personnel Below are some support guidelines for installation 1 Drill a hole in the boat hull with the diameter of the rudder trunk at the desired location 2 Remove the lever arm and supporting rings from the rudder trunk see Figure 8 item 1 2 and 3 3 From under the boat pull the rudder trunk through the hole in
5. 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 ATTENTION Tax An ATTENTION sign refers to procedures m circumstances etc which deserve extra attention 2 2 USE FOR INTENDED PURPOSE The PodMaster Professional 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 The PodMaster is not intended for use in any medical equipment that is intended for use as a c
6. MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com MASTERVOLT USER MANUAL PodMaster 6 5 amp 10 PROFESSIONAL ELECTRIC PROPULSION SYSTEM Copyright 2011 Mastervolt v 0 3 February 2011 CONTENTS MASTERVOLT 2 EN PodMaster 10 Professional February 2011 MASTERVOLT CONTENTS CONTENTS 1 GENERAL INFORMA HON cocirar 5 1 1 USE OF THIS NAINBALD iena a a A a e A desee 5 1 2 VALIDITY OF TAIS MANUAL EE O E Eaa 5 1 3 GUARANTEE SRFECIRICATION gcc a dat cee E eee eee 5 1 4 eet hed TEN 5 2 SAFETY GUIDELINES AND MEASURES ioni xat iino iai Saan Aaaa SANNAA 6 2 1 WARNINGS AND SYMBOLES udo pu re ret err eI into Eo ete Pott emitur teme DRM HMM a ition ates 6 2 2 USE FOR INTENDED PURPOSE th iostahtscsu coda eheu bib oett oai edet 6 2 3 GENERAL SAFETY AND INSTALLATION 6 2 4 WARNING REGARDING LIFE SUPPORT 6 2 5 WARNING REGARDING THE USE OF BATTERIES EAR IO 7 3 HOW IT WO PRS OE edr conce a n He a CES ik Ec vu CI cul N eau MeV GG ec 8 3 1 PODMASTER
7. 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 stainless steel body Steering of the boat is done with the lever arm which is directly attached to the motor through the rudder trunk 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 INCLUDED IN THE PODMASTER 10 PROFESSIONAL SYSTEM CONTROLLER 5 MOTOR DISPLAY PROPELLER 3 2 COMPONENTS The PodMaster Professional has the following components Controller Submerged pod AC synchronous motor complete with lever arm rudder trunk and mounting components Display Key switch Shunt Fuse Main switch A Several connection cables Please check the contents of the box before you start with the installation If any of the items is missing please contact your supplier
8. controller in inches 30 EN PodMaster 10 Professional February 2011 MASTERVOLT TECHNICAL DATA 8 2 2 SYNCHRONOUS MOTOR 10KW Front Side 297 Figure 19 Dimensions of the motor in mm Front Side E 11 68 2 36 52 20 54 7 2 E Figure 20 Dimensions of the motor in inches EN PodMaster 6 5 amp 10 Professional February 2011 31 TECHNICAL DATA MAST E RVO LT 8 2 3 SYNCHRONOUS MOTOR 6 5KW Back Side Figure 22 Dimensions of the motor in inches 32 EN PodMaster 10 Professional February 2011 MASTERVOLT TECHNICAL DATA 8 2 4 DISPLAY Back 133 121 2 0 2 86 fee HA Top Figure 23 Dimensions of the display in mm Back 5 24 4 77 0 008 3 39 2 96 0 008 Figure 24 Dimensions of the display inches 27 3 1 07 Side Side EN PodMaster 6 5 8 10 Professional February 2011 33 ORDERING INFORMATION MASTERVOLT 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 34 EN PodMaster 10 Professional February 2011
9. er ee 14 5 2 Soge aN S E O A A E 14 5 3 CoN Ein ARR 14 5 4 M l eR 15 5 4 1 PNW PROTEC MON mmm 16 5 5 PO dEi m d 16 5 6 PONS TIOR qm CC 17 5 7 iiiter Cc M 17 5 4 1 CONNECTIONS TO CONTROLLER dept traten olere Drei eee tovs 19 5 72 CONNECTING MOTOR GABLES eenaa tide aae 19 5 7 3 CONNECTING SIGNAL CABLE EE EEEE 19 5 7 4 CONNECTING BATTERY GABEES 20 5 7 5 BEFORE OWL CHING ONS THE PO VE isco 20 5 8 CGAHBRATION m 21 5 9 eer esce Dede ee edie 22 5 10 BEGENERATIONAREGEN MODE 25 6 27 6 1 PREVENTIVE MAINTENANGE ea thoi oes dune bi tu pst en 27 6 2 MAINTENANCE 27 PodMaster 6 5 8 10 Professional February 2011 3 CONTENTS MASTERVOLT 6 3 SYNCHRONIZING BATTERY MONITOR nahen nied etaed ior petto eeu 27 6 4 ANODE FROTEGTION 24 oS nc tiun does e Iu beue alee des 27 7 TROUBLE SHOOTING 28 8 aa e a aaa eaaa e A a
10. mode ATTENTION Only connect the system to the batteries Ix 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 EN PodMaster 6 5 amp 10 Professional February 2011 13 INSTALLATION MASTERVOLT 5 INSTALLATION During installation and commissioning of the PodMaster 10 Professional 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 For a proper installation of the PodMaster use balanced propeller that is suitable for the system on the boat Bolts must be tightened crosswise if possible and with an even pressure Do not remove any protection covers or protection material during the trial sail 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 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
11. the hull 4 Bolt the rudder trunk to the hull by using the 4 holes in the mounting flange see Figure 8 item 5 5 Fit the rudder trunk using a reinforced housing in the hull similar to when placing a conventional rudder This housing needs to ensure that forces torques on the rudder trunk see chapter 8 are well absorbed by the hull An example of a construction that could be used is given in Figure 9 and Figure 10 ANC N N M d i J ll Q lt Figure 9 Reinforced housing Overview with part of the boat hull Figure 10 Reinforced housing top view with part of the boat hull After installation fill the motor with bio oil included in the package through the top opening of the tube that is connected to the motor The required oil level is 5 cm from the top edge of the tube See chapter 8 for the motor dimensions EN PodMaster 6 5 amp 10 Professional February 2011 15 INSTALLATION MASTERVOLT 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
12. 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 N 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 Hegen 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 24 EN PodMaster 10 Professional February 2011 MASTERVOLT INSTALLATION Table 1 Default parameter settings Parameter 65 10 Page 1 User Setup Language Contrast Backlight Speaker Auto return Serial Number Firmware version Page 2 Battery Setup Batt Ah C 20 System dependent Peukert Syst
13. aa aa aa aaa aaa aaaea 29 8 1 TECHNICAL SPECIFICATION S urras e Een dero beu bte ted E e A OM 29 8 2 DIMENSIONS cd A A bia den AE 30 8 2 1 CONTROLLER mter 30 8 2 2 SYNCHRONOUS MOTOR TOKW uice Rn Ee nona boe 31 8 2 3 YNGHRONOUS MOTOR G OKW E E ESAR 32 8 2 4 a wt 33 9 ORDERING INFORMATION E Edi a e v eed uh ar oe 34 4 EN PodMaster 10 Professional February 2011 MASTERVOLT GENERAL INFORMATION 1 GENERAL INFORMATION 1 1 USE OF THIS MANUAL Copyright 2011 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 maintenance and possible correction of minor malfunctions of the PodMaster Professional It is therefore obligatory that every person who works on with the PodMaster Professional 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 menti
14. attery charge State of 4 Battery current 5 Estimated remaining time of sailing 6 P di b gt g A P ond ion c REG mode 2 pos Background lights indicator 8 pos display supply voltage ATTENTION After not pressing any buttons on the Battery Ix or Controller Information screen for 30 seconds it will automatically return to the Main Screen This can be changed on parameter page 1 auto return Battery information Charged charge Ah 4 Remaining charge indicator Used charge Battery measurements SOC remaining State of EE in 96 pU ue Power inkW voltage in Volts current in A Low Mov indicator Figure 5 Controller information screen 1 Controller status Bridge on status indicator red light Temperature in C 2 Motor direction indication Arrow pointing up forward Arrow pointing down backward 3 Motor measurements Speed in RPM Temperature in C RMS current in A 4 Joystick position position in quants position forward positive or backward negative in percentage EN PodMaster 6 5 amp 10 Professional February 2011 11 OPERATION MASTERVOLT 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
15. ays 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 Range ON OFF Enable RE2 low battery alarm RE2 output Range ON OFF Page 6 Throttle Joystick Setup 1 2 with PIN code Ix 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 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 EN PodMaster 6 5 amp 10 Professional February 2011 23 INSTALLATION MASTERVOLT 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 Range 1 9999 RPM WARNING ECO speed must always be lower than any N 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
16. be edited without a PIN code The PIN code for the PodMaster Professional is 4134 To enter the PIN code 1 Press OK to enter the edit mode 2 Select the 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 Range ENG DEU Contrast select contrast of LCD module Range 0 80 Backlight always on backlight for LCD module Range ON OFF Speaker turn speaker on or off Range ON OFF automatically return to mai
17. but 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 Professional system one sacrificial anode is included to protect the propeller This is a zinc anode and is to be placed on the shaft ATTENTION To protect the stainless steel motor housing a second sacrificial anode needs to be placed on the boat near the motor housing and it needs to be electrically connected to that motor housing This anode 16 not Ix provided with the system as the proper choice of metal depends on environment water conditions In general we recommend using zinc anodes for salt water and aluminum anodes for fresh water but it is wise to consult a local expert 5 5 DISPLAY The display is usually mounted in the control 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 f
18. d 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 clockwise backward forward Figure 6 Use of the joystick 12 EN PodMaster 10 Professional February 2011 MASTERVOLT OPERATION 4 44 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 Put the 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 Checkthe 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 Las oor pe cm 4 6 CHARGING BATTERIES When charging the batteries the display will give two confirmation beeps and will present the Battery Information screen see page 11 Charging can be recognized from the blinking arrow that symbolizes charged Ah After the charging is completed the display returns to the standby
19. e parameters on the pages However you cannot change them Only page 1 can be edited without a PIN code ATTENTION Ix For a detailed description of all 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 till 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 M 10 EN PodMaster 10 Professional 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 ATTENTION Make sure that the joystick is in the neutral position when you start the system If not the unit will show an error message 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 Battery information screen Controller information screen Main screen min o0 1 30 130 Figure 3 Main information screen 1 Speed value RPM b A 2 Speed direction and economy mode Arrow pointing up forward Arrow pointing down kaoa Economy mode 5 A 3 Remaining b
20. em dependent Charging ends at voltage System dependent And current 4 0A Ubatt at 5096 System dependent Page 3 System Setup Charging threshold 3 0A Discharging threshold 1 0A dU dt threshold 00 Shunt 300 50 mV Standby after disabled 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 See 5 8 Max forward See 5 8 Max backward See 5 8 Backlash 25 Q filtering ON Page 7 Joystick Setup 2 2 EU Fwd speed 1000rpm Bwd speed ECO speed FWD torque BWD torque Torque ctrl mode Page 8 Regen Setup OV speed trip Regen torque Max batt volt 1500 rpm Press to calculate System dependent Gain 16 Generator mode ON Peukert values 1 02 MLI 1 15 AGM 1 27 Gel 1 27 2V Gel Default parameters The default parameter settings for the PodMaster Professional 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 parameters 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 sha
21. ft 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 o E s f H9 ido Figure 16 Controlling regeneration torque ATTENTION Do not fake the regeneration mode by setting the motor to a low RPM in the normal I Drive mode while sailing faster The excessive energy will charge up your batteries However there is no battery monitoring possible The battery will therefore be overcharged and damaged EN PodMaster 6 5 amp 10 Professional February 2011 25 INSTALLATION MASTERVOLT 26 EN PodMaster 10 Professional February 2011 MASTERVOLT MAINTENANCE 6 MAINTENANCE 6 1 PREVENTIVE MAINTENANCE Check your whole system regularly on the following points Check the bilge and controller compartment for unwanted m
22. ixated to the panel GS Figure 11 Mounting the display See chapter 8 for the display dimensions 16 EN PodMaster 10 Professional February 2011 MASTERVOLT INSTALLATION 5 6 JOYSTICK The joystick can be mounted at any desired location Note the following Mastervolt joysticks are splash water proof only Therefore the joystick may not be continuously in contact with water Position the joystick correctly 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 Temperature sensor cable including pre assembled connectors The power cables for connecting the batteries 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 EN PodMaster 6 5 8 10 Professional February 2011 17 INSTALLATION MASTERVOLT i Display Key swi
23. l increase the speed of the motor and thus of the boat instantly 4 2 USE OF THE DISPLAY So 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 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 code on the second page Without the PIN code you can still browse through th
24. librate 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 Ix 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 Neutral Max Forward Max Backward Figure 15 Setting the joystick backlash EN PodMaster 6 5 8 10 Professional February 2011 21 INSTALLATION MASTERVOLT 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
25. n 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 batter 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 28 EN PodMaster 10 Professional February 2011 MAST E RVO LT TECHNICAL DATA 8 TECHNICAL DATA 8 1 TECHNICAL SPECIFICATIONS Model PodMaster Professional 6 5 10 MOTOR
26. n 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 A 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 Ubatt 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 22 EN PodMaster 10 Professional February 2011 MASTERVOLT INSTALLATION Page 3 System Setup with PIN code Charging 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 thresh
27. oisture 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 10096 and remove the fuse 6 2 MAINTENANCE The PodMaster Professional 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 complete and the battery is full when the charging current drops below the set parameter parameter page 2 and current and battery
28. old 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 90 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 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 ctrl mode must switched Range ON OFF Enable RE2 low battery alarm RE2 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 battery 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 st
29. omponent 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 10 Professional February 2011 MASTERVOLT SAFETY GUIDELINES AND MEASURES 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 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 red
30. oned safety measures Keep this manual in a safe place 1 2 VALIDITY OF THIS MANUAL All of the specifications provisions instructions contained in this manual apply solely to standard versions of the PodMaster Professional 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 See page Error Bookmark not defined for the EC Declaration of Conformity 1 4 LIABILITY Mastervolt can accept no liability for Consequential damage due to the use of the PodMaster Professional Possible errors in the manuals and their consequences EN PodMaster 6 5 amp 10 Professional February 2011 SAFETY GUIDELINES AND MEASURES MASTERVOLT
31. ontroller 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 Temperature sensor cable One end of the temperature sensor cable has already been connected to the motor and the other end to the signal cable near the controller plug Connect the two Molex 6 pin connectors to each other 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 EN PodMaster 6 5 amp 10 Professional February 2011 19 INSTALLATION MASTERVOLT 5 7 4 CONNECTING BATTERY CABLES WARNING Make sure that when connecting the battery and the controller 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
32. 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 Return 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 lf 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 I 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 an
33. tch Joystick Temperature Sensor Cable E d iix Main switch Battery Figure 12 Wiring diagram The battery joystick and propeller are not included in the system For ordering information see chapter 9 18 EN PodMaster 10 Professional February 2011 MASTERVOLT INSTALLATION 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 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 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 Forthe key switch Molex 6 pin connector Forthe joystick 3 pin connector At the other end For the temperature sensor cable Molex 6 pin connector For the c
34. 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 20 EN PodMaster 10 Professional February 2011 MASTERVOLT INSTALLATION 5 8 CALIBRATION On Page 6 of the parameter setup see page 23 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 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 Ca
35. uce 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 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 6 5 8 10 Professional February 2011 HOW IT WORKS MASTERVOLT 3 HOW IT WORKS MOTOR SWITCH WITH KEY JOYSTICK BATTERY MAIN SWITCH Figure 1 System block diagram 3 1 PODMASTER SYSTEM The diagram of Figure 1 gives a simplified view of the PodMaster Professional system The battery pack supplies energy
36. 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 6 5 8 10 Professional February 2011 27 TROUBLE SHOOTING MAST E RVO LT 7 TROUBLE SHOOTING In case of a failure the PodMaster Professional display A leakage in a seal can be detected by either shows an error code to help you find the cause If you Oilin the water or cannot solve a problem with the aid of the fault finding water on top of the oil in the rudder trunk table below contact your local Mastervolt Service Centre See www mastervolt com A leaking seal is not directly damaging for the motor as long as there is enough oil left in the motor but it should Make sure you have the article and serial number close at 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 trunk connection replace the seals every four years The following table shows the most common errors Error Code Error Solutio
37. ystem 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 Professional with its cabling connections EN PodMaster 6 5 8 10 Professional February 2011 OPERATION MASTERVOLT 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 is running Be aware that switching from Economy to Drive wil
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