vetus 370801.12 E-POD 100 Electric Propulsion System Instruction Manual

vetus 370801.12 E-POD 100 Electric Propulsion System

Product Specifications

• Product Name: E-DRIVE electric propulsion
• Model Number: 370801.12

Product Usage Instructions

1. Safety:
   Ensure all safety precautions are followed during installation and use of the electric propulsion system.

2. Introduction:
   Read through the entire manual to familiarize yourself with the installation process and components.

3. Installation Form:
   Fill out the installation form provided in the manual before proceeding with the installation.

4. Installation:
   Follow the steps below for a successful installation:

5. Electrical System:
   Ensure all electrical connections are secure and follow the wiring diagrams provided.

6. MCVB Boosted Charge Function:
   Understand and utilize the MCVB boosted charge function for efficient charging.

7. Connecting CAN Bus Cables:
   Properly connect the CAN bus cables for control current.

8. Final Installation Check:
   Perform a final check to ensure all components are installed correctly.\

9. Wiring Diagrams:
   Refer to the provided wiring diagrams for accurate connections.

10. Main Dimensions:
    Take note of the principal dimensions for proper installation placement.

11. Battery Capacity, Battery Cable:
    Ensure the battery capacity matches the system requirements and use appropriate battery cables.

Frequently Asked Questions (FAQ):

• Q: What should I do if I encounter issues during installation?
  A: Refer to the troubleshooting section of the manual or contact customer support for assistance.

Warning indications
Where applicable, the following warning indications are used in this manual in connection with safety:

• Danger Indicates that great potential danger exists that can lead to serious injury or death.
• Warning Indicates that a potential danger that can lead to injury exists.
• Caution Indicates that the usage procedures, actions etc. concerned can result in serious damage to or destruction of the engine. Some CAUTION indications also advise that a potential danger exists that can lead to serious injury or death.
• Note Emphasises important procedures, circumstances etc.

Symbols

• Indicates that the relevant procedure must be carried out.
• Indicates that a particular action is forbidden.

Share these safety instructions with all users.
General rules and laws concerning safety and accident prevention must always be observed.

Warning
This product should only be installed and maintained by qualified personnel who have read and understood the instructions and precautions in this manual. Failure to follow the instructions in this manual may result in serious injury or property damage. The manufacturer shall not be liable for any damages resulting from improper installation or maintenance by unqualified personnel.

Introduction

This manual gives guidelines for the installation of the E-POD electric motor.
The quality of the installation is decisive for the reliability of the EPOD system. Almost all faults can be traced back to errors or inaccuracies during installation. It is therefore imperative that the steps given in the installation instructions are followed in full during the installation process and checked afterward.

The E-POD system consists of five modules:

• Propulsion
• Control
• Energy monitoring
• Energy storage
• Energy supply

Several choices and combinations are possible within these modules.

Note Refer to the installation manuals of all components before using the E-POD system.

Unauthorised modifications exclude the factory’s liability for any resulting damage.
Depending on wind area, displacement, propeller, battery pack size and shape of the underwater hull, the power delivered by the electric motor will give a different result on each vessel.
The nominal rated power output is only achievable under optimum conditions:

• During use ensure the correct battery voltage is available.

• The installation is carried out in compliance with the recommendations given in this installation instruction, in particular with regard to:

  • Sufficiently large diameter of the battery cables so that voltage drop is reduced to a minimum.
  • The inflow to the propeller.
  • Alignment of the propulsion and steering system.

• Warning

  • Maximum permissible ambient temperature 50 °C.
  • Maximum permissible external water temperature 30 °C.
  • Keep the system frost-free at all times.

• Warning
  Changing over the plus (+) and minus (-) connections will cause irreparable damage to the installation.

• Warning
  To avoid corrosion problems, absolutely no anti-fouling containing copper oxide should be applied to the E-POD.

Installation form

Go to www.vetus.com and download the installation form.

Note
In order to make a warranty claim, please complete the installation form in full and send the form to: installationforms@vetus.com

Installation

The hull structure around the opening where the E-POD is placed must be sufficiently stiff and able to absorb the forces generated by the movement of the boat in addition to the propulsion forces.

• Take into account the required free space around the E-POD inside the vessel, see main dimensions.
• For the dimensions of the hole in the hull, see main dimensions on page 70.

Note

• The motor should be installed in a dry, well-ventilated area.
• The installation must be kept free of bilge water at all times.
• The ambient temperature should not exceed 50 °C. Ensure adequate ventilation. Supply cool air and discharge warm air.
• The part of the hull that the E-POD is installed in must be completely flat.
• The installer must provide a watertight sealing.

The propulsion and steering system components must be correctly aligned to ensure proper operation. The correct positioning is highly important for the sailing characteristics and the electrical consumption.

• Position the E-POD at the correct distance from the rudder and ensure a free flow of water.
• Place the E-POD parallel to or at a slight downward angle to the waterline (WL).
• Place the E-POD in line with, or parallel to, the centre line of the boat.

Electrical System
The electrical wiring between the electric motor and the motor controller has already been installed. The installation has an insulated return. Connect the motor as follows:

• Warning Keeps battery cables free from the E-POD housing and sharp edges
• Warning Connect all negative conductors! A floating negative causes system faults!
• Warning A (system) voltage higher than 60 V causes irreparable damage to the installation!

MCVB boosted charge function
Using the MCVB boosted charge function, the 48 Volt E-POD motor can be used in an (existing) 24 V onboard network.By connecting a 24 Volt battery bank to the MCVB boosted charge connection, the 48 Volt, E-POD, battery bank is charged. An additional charging facility is not required. See page 60 for the connection diagram.

Warning:
The MCVB boosted charge function is only suitable for lead-acid batteries as standard.

Batteries
The battery voltage should be 48 V nominal, with an operating range between ≥44 V and ≤59 V. With an absolute maximum of 60 V.

• The integrated motor controller limits the output as from 44 V and stops at 40 V. This prevents excessive battery discharge.
• Starter batteries are not suitable for an electric propulsion system. Instead, semi-traction or traction batteries should be used.
• VETUS can supply various maintenance-free batteries. For example type AGM (Absorbed Glass Mat), DeepCycle or lithium 4-cell LiFePO4 are suitable for electric propulsion.

Note Balance the voltage of batteries connected in series. Check individual battery blocks and make sure the voltage between them is equal.

Battery capacity
The following points play an important role in determining the battery capacity:

• Boat characteristics (length of waterline, weight, hull shape)
• Sailing style
• Desired range
• Battery type

Table ‘Power consumption indication displacement vessel’ gives an indication of the power consumption (energy consumption) of a displacement vessel at different lengths and speeds. The power consumption can then be used to calculate the sailing time. See example below:

1. Determining battery capacity
   For a boat with a length of 6 meters and a desired sailing speed of 8.8 km/h (4.7 knots) an indicative power input of 2.1 kW applies. The desired sailing time is set at a minimum of 6 hours, continuous sailing. This results in a required battery capacity of 2.1 x 6 = 12.6 kWh.

2. Determine battery pack
   A battery pack of eight AGM batteries, maximum deep discharge of 70%, C20 value 220 Ah, 12 V series parallel (4 x 12 V and 2 x 220 Ah) switched to a 48 V battery pack gives a usable battery capacity of ((220 x 2) x (4 x12) x 70%) = 14.8 kWh.

3. Sailing time calculation (indication)
   Based on the energy consumption of 2.1 kW, this gives a sailing time of (14.8 / 2.1) more than 7 hours.

Power consumption indication displacement vessel

Battery installation
The following points must be taken into account when installing the batteries:

Warning
Always follow the warning and safety instructions as stated in the battery manual.

• Batteries must be installed in a dry, well-ventilated space.
• Ventilation is important because small quantities of explosive gas can be produced while charging. If necessary, install a system of forced ventilation.
• Always install batteries above the bilge water level.
• Batteries must be fixed securely to prevent damage to the casing. Preferably fit batteries in a tray.
• Ambient temperature may not exceed 60 degrees C (140 degrees F). Never place batteries in direct sunlight!
• The batteries must be easily accessible for maintenance.
• Never fit switches or other electrical equipment in the vicinity of batteries; possible sparks could cause an explosion.
• Prevent metal objects from accidentally coming into contact with a battery terminal.

Main current cables

• Connect the motor to the batteries as shown in the diagrams, see page 60.
• Fit the fuse supplied and a main switch in the positive (+) cable.

Warning
When calculating the cable cross-sections, take into account a maximum permissible voltage drop of 5%. Never use smaller cable cross-sections than indicated in the table below.

When the batteries are not being used or not charged, it is recommended that they are disconnected from each other using an isolating switch.

Warning

• NEVER fit the fuse, main switch or isolating switches in the battery space!
• When installing the electrical installation, always consult the locally applicable regulations.

Take the following points into account when installing the battery cables:

• Fit the cables in the shortest possible way from batteries to motor.
• With a long cable length, bundle the ‘+’ and ‘-’ cables together.
• Install the ‘+’ and ‘-’ preferably in such a way that the total length of each cable is the same. This ensures an equal load on each battery.
• Ensure that the cables do not run through any bilge water.
• Ensure that the cables cannot come into contact with any sharp edges.
• Fix the cables in such a way to prevent wear or abrasion caused by vibration.
• Use cable terminals to connect the cables to switches, fuse and motor.
• Preferably fit cable terminals by crimping.
• Use good quality battery terminals to connect the cables to the battery posts.
• Tighten bolts securely to ensure a good connection.
• Do not use spring-loaded battery terminals!
• Grease the battery posts and battery terminals with Vaseline to prevent corrosion.
• Never change over the connector cables.
• Before leaving, check the charge status of the batteries just as you would check the tank capacity of a diesel engine.

Warning
Changing over the plus (+) and minus (-) connections will cause irreparable damage to the installation.

Warning
NEVER short-circuit the batteries by connecting the plus (+) pole to the minus (-) pole.

Connecting the main current cables

• Switch all electrical equipment off.
• Prevent any short circuits caused by tools, for example.
• Connect the positive (+) cable first, then the negative.

Internal fuse
There is an internal fuse on the controller in the connection box. This fuse protects the controller and the motor against short circuits or overload.

Note
Always replace a defect fuse by a fuse of the same value.

Configuration of one or more motors
If two E-POD motors are installed, only the port E-POD motor needs to be configured.

Danger
Only work on the system when the motor is stopped and the electrical system is switched off.

• Remove the E-POD cover.
• Locate the CAN bus connector on the MCVB.
• In a propulsion system with two E-POD motors, only cut the red wire of the port side motor.
• Make sure that both ends cannot make contact. For example, use an insulated cable end sleeve.
• Replace the cover.

Note
The direction of rotation of the motor can be set on the control panel.

Connecting CAN bus (control current) cables
See diagrams from page 63 if multiple panels have to be connected.

Note
The CAN bus power supply must always be connected to 12 Volt (≥10 V, ≤16 V). Use the E-DRIVE MPE1KB key switch as power supply.

Caution
As required by international standards, all neutral (negative) conductors of the DC system must be connected to one central point. This prevents not only dangerous situations and corrosion problems, but also error messages in the CAN bus system.

Final installation check

• Note
  Check for possible leakage immediately after the ship has been launched.

• Note
  After the installation of the system, before commissioning, check the following points:

  • All cable connections, bolts, nuts and swivels.
  • The correct operation of all panels.

Wiring diagrams

1. E-POD motor/MCVB
2. Battery
3. Main fuse
4. Main switch
5. Charger
6. Inverter
7. Boost charge
8. connection

Note:

• The CAN bus is a chain to which the E-POD motor and panels are connected.
• The power supply (4) can, via the Hub, be connected to the chain at several points. A terminator (7) must be connected to both ends of the chain!

One E-POD motor, One helm station

1. E-POD motor (A/B)
2. Bow thruster
3. Motor control, motor (A / B)
4. CAN-bus supply
5. Control voltage fuse
6. Connection cable
7. Terminator
8. Key switch
9. Switched power supply (12 V, 15 A)
10. CAN-bus hub
11. Monitor panel
12. Bow thruster panel

One E-POD motor, one bow thruster, one helm station. The diagram can be extended to up to four helm stations.

Two E-POD motors, one bow thruster, two helm stations.

Dimensiones principales

Battery capacity, battery cables

Fokkerstraat 571 – 3125 BD Schiedam – Holland
Tel.: +31 (0)88 4884700
sales@vetus.com
www.vetus.com

Printed in the Netherlands
370801.12 2023-09

References

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