(TEMPORARY) INSTALLATION/USER MANUAL
Contents
1. CONTROLLER ERR 017 CONTROLLER ERR 018 CONTROLLER ERR 019 CONTROLLER ERR 020 CONTROLLER ERR 021 CONTROLLER ERR 022 CONTROLLER ERR 023 DC link charging error Relay error PDPINTA shortcut or mosfet driver error Bad user parameter CRC Bad system parameter CRC Bad flash CRC Wrong parameter version Invalid motor type Autotuning error Boost error Motor over temperature Motor temperature sensor failure Internal error TECHNICAL SPECIFICATIONS GD1 unit Supply voltage 15 60 VDG Supply current Vee lee lee with backlight Icc in sleep mode in normal operation 24V 25mA 153mA 17mA 36V 48mA 119mA 17mA 48V 53mA 120mA 19mA 60V 55mA 121mA 20mA Current measurement range 20A to 600A configurable in Setup Display LCD monochrome 128 x 64 Temperature range 25 C to 60 C Relative humidity 5 95 vapor Dimensions 138 x 90 x 31mm L x W x H Weight 250g Warning this device is susceptible to damage from electrostatic discharge2. propelled vehicles as an add on to one of Mastervolt s AC motor controllers It serves as a graphical user interface between the user and the controller User can set the speed of the motor and see current speed as well as a range of other quantities such as battery voltage battery current motor current remaining time of driving at current consumption etc At the same time GDI unit observes the state of charge of the battery that is how much charge there is left how much was charged and how much discharged It detects when battery is being charged sounds alarm when battery is low etc GDI is linked to one of Mastervolt s motor controllers over CAN bus In addition of sending reference for motor RPM or torque to controlled it also receives various data from it This data is then displayed on screen GDI also has extensive built in safety systems that informs the user of an error in the form of on screen message It also improves energy conservation on board with configurable sleep mode ee sees en AC motor controller r BARD 3 phase AC motor PS Motor temperature sensor Motor CON1 8 speed Tana throttle START switch CON1 G Figure 1 Integration of GD1 unit in 24V 48V systems SAC4 2 INSTALLATION GD1 has two Molex connectors on the backside Figure 3 Backside of GDI unit Connectors have the following pinout 12 PIN MOLEX 1 2 3 4 5 6 Shunt Shunt Motor temperature sens
3. press OK button to confirm them until you will finally return to one of 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 message and the screen will be titled MESSAGE LIST Press UP DOWN to scroll between messages If there are no messages in the list then you will read NO MESSAGES Press OK to exit browsing the messages and to return to main screen Note that when cause of error is removed then the message will automatically be deleted from the list There are various error messages for different problems from problems with CAN bus disconnection of throttle voltage problems etc For list of all messages please see the chapter LIST OF MESSAGES AND ERROR CODES If CAN bus gets disconnected then all the values that depend on successful CAN communication with controller will be masked with signs For example on main screen Screen 0 you will see where RPM value should be displayed 4 2 2 Automatic scrolling to Screen 0 If you are viewing Screen 1 or Screen 2 without pressing any buttons for more than 30 seconds then you will be automatically scrolled to Screen 0 That is the main screen and data presented there is most important and of most interest Exception to this is charging mode when battery is being charged then charging progress is most interesting and there is no automatic scrolling to Screen 0 Before you turn the unit on with S
4. the motor Is turning in forward direction if down then in backward direction 6 Motor current 7 Motor temperature 4 2 OPERATING GD1 Now that you are familiar with user interface and displayed data you must also know how to handle other functions You have already learned that START switch wakes the unit from sleep or puts it into sleep If throttle is in neutral position long enough and there was no action from user then GDI will go into sleep mode This time is configured in Setup In sleep mode LCD display is turned off but GDI still remains active and monitors battery voltage and current Before it goes into sleep mode it also disables the controlled and so saves energy You have also learned that ECONOMY MODE switch limits RPM to allow easier navigation in ports 4 2 1 Notification system Notification system informs you if there is something wrong with any part of the system When such an error occurs there will appear a message on the screen titled NEW MESSAGE When error is related to functionality of GD1 unit then error number will be displayed as well as message itself For example ERR 001 Move throttle to neutral position When error is related to controller then controller error will be displayed followed by message For example CONTROLLER ERR 004 Voltage low at start When you have read new message confirm this with OK button If there are any other messages then they will also be displayed and you will have to
5. you battery is at handling large currents Typical value is 1 25 Shunt Current in amperes flowing through shunt resistor that produces voltage drop of 50mV This current is also about the maximum battery current allowed If it is strongly exceeded it will saturate the measuring electronics and therefor affect GDI s ability to asess remainign battery charge Please keep this in mind when selecting your shunt resistor Range of this parameter is 20 600A at 50mV Charging ends at voltage Voltage at which GDI detects end of charging and restores charging counter to 100 You can enter values between 10 0V and 340 OV If your nominal shunt voltage is other than 50mV please recalculate it to 50mV Your shunt states 360A 60mV For the same resistance the equivalent would be 300A 50mV so for such a shunt you should enter 300A 50mV 2 and current lt 3 3 SYSTEM SETUP PAGE 3 SYSTERN Se TUF tes and Serer Ef EA Charging thresh lt UA Disch thresh 1 0A Ubati at EL Odd 6 Low batt alarm 20 Sleep after Hin Se OS 00 Charging thresh Charging ends at voltage parameter works in combination with and current lt parameter see SYSTEM SETUP PAGE 3 Current at which GD1 detects end of charging and restores charging counter to 100 You can enter values between 0 1A and 9 9A Charging threshold current is current at which GD1 considers that battery is being charged You can enter values betw
6. your throttle is measured in small steps called quants Throttle can occupy any of up to 1024 positions or quants To ensure consistency of selected position this calibration can only be done in sequence To start the sequence press OK else press UP or DOWN to move to another page THROTTLE SETUP 4 5 Neutral Throttle positions mt a O1 Su Max forward O300 Has backward DOO Max forward First you must select neutral position In this position motor will be turned off When set press OK to continue with next position Position where motor should have full RPM or torque in forward direction Note that you can select whatever physical direction of throttle you desire This means that you do not have to worry if throttle is mounted on right or left side of cockpit GD1 will recognize this automatically When set press OK to continue with next position Max backward Position where motor should have full RPM or torque in backward direction You will only be allowed to move the throttle in opposite direction of forward range which makes perfect sense You cannot overlap forward and backward range When set press OK to finish calibration For more technical details please read notes below and take a look at Figure 7 Notes Around neutral position there is also a small area that is called backlash While throttle is positioned inside this range it is still considered as in neutral position The motor will stil
7. 0 See Figure 2 CAN bus cables must be shielded twisted pair 3 SETUP Before GDI unit can be used it must be properly configured To enter setup connect GDI to battery and hold OK while you restart GD1 with START switch You will enter first page of setup which requires no PIN code to change parameters Without PIN code you can still view parameters on following pages However you cannot change them You can navigate through setup with all three buttons Press UP or DOWN to select next parameter When you reach last parameter on page press DOWN again to go to next page Or if you reached first parameter on page press UP to go to previous screen To edit a parameter press OK If you have permission to change it then there will appear a gt sign in front of the value You can now change the value using UP DOWN keys If you hold the key for a longer time you will notice that values change faster and faster this will help you select desired value faster When you entered the desired value just press enter to store the value and proceed with other parameters When entering a PIN code press OK to enter edit mode Then select first digit with UP DOWN and press OK to proceed to next digit Repeat until all the digits are entered If you entered valid PIN code you will be granted permission to edit If not you will have to wait 30 seconds to try again Once a valid PIN is entered the field will be masked with checkm
8. MASTERVOLT TEMPORARY INSTALLATION USER MANUAL GD1 DISPLAY CONTROL AND BATTERY MONITORING UNIT MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com This guide is for use with system software version 15 Ts ANFRODUCRION sereen bte temeer rabbit E 3 Ze INSTALLATION ond re re i na en Eide 4 2 SEUP peceren ennen ee 6 3151 5 EM SETUP PAGE Teamammuentlnersnenma E ve ania eh RE 6 32 SYSTEM SSE UP PAGE Z aanmeten teen etten 6 353 SYSTEM SETUP PAGE 3 otoniana T rere ede 7 3 45 STEM SETUP PAGES amen dee emedia aes 8 4 HANDLING AND OPERATION ooo eenen een eeeene eenen 11 del OVERVIEW OF USER INTERFACE carcera eeina e e Ek 11 4 1 1 SCREEN 0 Main screen sssssseeeeeses ke kk e eee eeeeeeeeeeeteeeeeeeeeeeetetanaas 11 4 1 2 SCREEN 1 Battery monitoring SCrEEN cece cee ee eee oeren eeen 13 4 1 3 SCREEN 2 Controller and motor monitoring SCFEEN cece eee ee seen eee e ees 14 de OPERALING SDU resatrsnmtetennte meteen dee 15 42 NOEICAEION SYSTE ini a aa E a E Dee 15 4 2 2 Automatic scrolling to Screen Oss ED aae 16 4 2 3 Charging Discharging Detection cccccecseeeeeeeeeeeueeteneeeeteseeeeeereegs 16 5 ERROR MESSAGES AND ERROR CODES ooo ereen eenn 18 6 TECHNICAL SPECIFICATIONS Germaan nei beet 20 1 INTRODUCTION GDI is a display control and battery monitoring unit It is intended to be used in electrically
9. TART switch you must make sure that throttle is in neutral position If not then the unit will inform you of that with an error message This function makes sure that the boat does not start moving if you forgot to move throttle to neutral position and just turned START switch on Similar thing happens if CAN bus gets disconnected You will be notified of this problem and after correcting the error you will be prompted to move throttle to neutral position Again this ensures safe ride Note When GDI unit is connected to battery for the first time the battery voltage is measured State of charge SOC percentage of remaining charge displayed on Screen 1 is then estimated according to battery voltage This estimation also depends on parameter Ubat at 50 see Setup chapter for details Therefore if possible try to connect GDI to battery only after battery has rested for a couple of hours without any load Otherwise SOC value will be correct only after first full charge 4 2 3 Charging Discharging Detection When conditions for charging are met then displays detects charging If START switch is on normal operation then user is notified with two beeps and LCD backlight turns on for 10 seconds if these options are turned on in Setup If START switch is turned off sleep mode then the same happens plus user is presented with Battery monitoring screen Screen 1 There the arrow that symbolizes charged Ah start blinking It keeps bli
10. arks 3 1 SYSTEM SETUP PAGE 1 USER SETUP Language Select desired language Currently English and Language j Contrast German languages are supported Backlight Speaker i Sen Contrast Select contrast of LCD module Serial No _ 2020 Firmware version 14 Backlight Select this option if you want to turn on backlight for LCD module Speaker Turn speaker on or off Serial number Read only Shows serial number of GDI unit Firmware Read only Shown software version in your GDI version unit 3 2 SYSTEM SETUP PAGE 2 SYSTEM SETUP 2 5 Enter write Enter PIN code if you want to edit parameters If Enter write access PIN en SED access PIN you do not enter PIN code you can still view the Penukar i An cad 13 parameters but you cannot change them except BO ag ande ae on Page 1 at voltage 0577 58 Nominal Ah Total capacity of your battery pack meassured for 20h discharge rate If your batteries are Notes 1 For example connected in series enter the capacity of a single battery If connected in parallel enter capacity of a single battery times number of batteries Range of this paramter is 1 999Ah Peukert Peukert s coefficient determines how rate of discharge affects remaining charge in the battery For example if you discharge your battery in short time with higher current it will deliver less charge than if you discharge it over twice the period with only half the current The lower the Peukert s coefficient the better
11. description of Screen 1 Battery monitoring screen Battery is considered to be in discharging mode when Positive discharging current flows for more than 6 seconds This way possible short bursts of discharging are ignored This current must be equal to or greater than current discharging threshold set under Setup Page 3 parameter 3 Disc Thresh Currents that do not satisfy above condition are ignored and do not influence charge counters displayed on Screen 1 Battery monitoring screen 5 ERROR MESSAGES AND ERROR CODES List of all messages and error codes is provided below ERR 001 Move throttle to neutral position ERR 002 Throttle error disconnected ERR 003 CAN bus timeout ERR 004 Battery low ERR 005 Motor temperature high Reducing power ERR 006 High Voltage PCB timeout no link CONTROLLER ERR 001 CONTROLLER ERR 002 CONTROLLER ERR 003 CONTROLLER ERR 004 CONTROLLER ERR 005 CONTROLLER ERR 006 CONTROLLER ERR 007 CONTROLLER ERR 008 CONTROLLER ERR 009 CONTROLLER ERR 010 Over current Over voltage Under voltage Voltage low at start Potentiometer error during operation Potentiometer not zero at start Controller over temperature Controller under temperature Controller temperature sensor error Current offset error CONTROLLER ERR O11 CONTROLLER ERR 012 CONTROLLER ERR 013 CONTROLLER ERR 014 CONTROLLER ERR 015 CONTROLLER ERR 016
12. een 0 1A and 9 9A Disc thresh Discharging threshold current is current at which GDI considers that battery is being discharged You can enter values between 0 1A and 9 9A Ubatt at 50 Battery voltage at which the remaining charge in your battery is at 50 GDI has a fixed programmed slope of relation Ubatt vs State of charge From it it can calculate voltage at 100 and at 0 Range of this parameter is 10 300V Low batt alarm Remaining percent of charge in the battery when low battery alarm should go off Alarm is presented in a form of message on the screen To turn it off set this option to Sleep after Min Sec Note 1 3 4 SYSTEM SET UP PAGE 4 After this time the unit will go into sleep mode if throttle is in neutral position and there is no action from the user LCD display and controller will be turned off and you have to restart the system with START button to wake it up However battery voltage and current will still be measured To turn this timer off set time to This condition works in combination with Charging end at voltage parameter On this page you can calibrate your throttle You can set where is the neutral position of the throttle motor is not running and set how far you must move the throttle to reach full RPM of the motor Note that values on this page can only be changed by moving the throttle itself They cannot be changed with UP DOWN keys Position of
13. l and provides the same charge at high and low discharge currents It can be configured in Setup Typical value is 1 25 For example Your battery has stated capacity of 100Ah for discharge rate of 20 hours This means that if you discharge it with 5A C 20 you will be able to extract 100Ah This will happen in 20 hours This however does not mean that discharging it with 20A will provide you the same 100Ah in 5 hours time In reality you will be able to extract much less How much can be determined with above equation Peukert equation holds true only for discharging and not also for charging From these 3 values you can determine physical charge that was charged to or extracted from the battery And you can also see approximately how full your battery still is 4 1 3 SCREEN 2 Controller and motor monitoring screen 1 Indicator of screen number 2 Throttle position 3 Controller temperature 4 Input power 6 Motor current 0022 Hin 5 Motor RPM direction and RPM value HOE T 7 Motor temperature EFEEK 1 Indicator of screen number 2 Throttle position Upper number represents position in quants lower number represents position as percentage range forward positive sign or backward negative sign 3 Controller temperature 4 Input power This is a product of battery voltage and current through shunt resistor 5 Motor RPM direction and RPM value If circular arrow is pointing up then
14. l be turned off Purpose of this area is to compensate for mechanical construction of throttle and also to allow comfortable selection of neutral position when driving Value of backlash is by default 1 8 of range forward or backward whichever is smaller and is set after throttle calibration sequence is finished Backlash can also be manually corrected on next page of setup and can be set up to 1 4 of described range Neutral position has a limited range as can be seen in Figure 7 For security reasons however you must move throttle for at least 16 quants from neutral position to produce enough forward range A part of range is reserved to detect when throttle is disconnected Note that with throttle you can command either RPM of the motor or the torque on shaft This option can be selected elsewhere in the setup THROTTLE throttle_neutral POSITIONS throttie min b d _ throttle min fwd A D QUANTS oh Fn Ben ri E i 3 ba y Kal hs Fall ut Pa Ma Fa igs E i throtle max_bwd a k k throttle_backlash throttle max fwd rl nar max 970 PE ai throttle may hud max 1000 i throttle_neutral min 30 throttle_max_hwd min 8 ie disconnected lt 8 disconnected gt 1000 A D 0 A D 1023 A D 1023 reversed dir A D 0 reversed dir Torque RPM Controller quants Nm min sent to controller over CAN 999 9 9999 65535 error disconnected Eg 2500 40960 A D q
15. nking until charging takes place After that GDI returns to sleep mode Because GD1 must detect various types of charging regardless of whether battery is full or empty or if different types of chargers are used there exists a set of rules that describes charging Battery is considered to be in charging mode if Negative charging current flows for more than 6 seconds This way possible short bursts of charging current from induction of motor are ignored This current must be equal to or greater than current charging threshold set under Setup Page 3 parameter 2 Charging thresh Or for more than 6 seconds battery voltage is greater than voltage set in Setup Page 2 parameter 5 Charging ends at voltage This ensures that charging will still be detected in case that baterry is already full and there flows almost no current If controller is turned off and there flows negative charging current 6 seconds margin is Skipped and battery is immediately considered as being charged Battery is considered to be charged to full when For more than 10 minutes flows current smaller than the value set in Setup Page 3 parameter 1 and current lt And for more than 10 seconds battery voltage is higher than voltage set in Setup Page 2 parameter 5 Charging ends at voltage When battery is charged to full then State of charge SOC counter percent of remaining capacity in the battery is set to 100 see
16. or ECONOMY MODE switch GND Supply voltage Do not connect m Throttle f 8 9 10 Tl 12 9 GND 10 Do not connect 11 START switch 12 External relay oo DUS WN FE 4 PIN MOLEX 1 CAN busA GND CAN bus B BR WN e It is recommended you use original set of cables supplied by the company Notes Shunt cables must be shielded twisted pair If you do not use shunt resistor please short SHUNT and SHUNT and connect them both to GND For details on the selection and configuration of motor temperature sensor please see SAC4 SAC40 user s guide Economy mode switch has internal pull up and connects to ground when active The purpose of this switch is additional limitation of RPM torque It is useful for example as additional safeguard when navigating your boat in a port It is recommended that you use company supplied throttle as shown in the picture below Figure 4 Example of speed throttle as supplied by the company If you want to use your own throttle connect slider of throttle potentiometer to Molex 12 pin 8 Other side of potentiometer must be connected to GND via 50E resistor 1 10K THROTTLE pin SOE Polarity of potentiometer does not matter You can configure in Setup which direction is forward backward START switch wakes the unit from standby when supply voltage is delivered to this pin Has internal pull down External relay connection controls DC link charging at SAC4
17. ry current Current is positive when it is flowing from battery to load Remaining battery charge State of charge Status line is showing e Motor direction When arrow symbol in status line is pointing up then the motor is spinning forward When it is pointing down then the motor is spinning backward e Presence of ECONOMY MODE When you turn ECONOMY MODE switch on status line will show ECONOMY When you are driving in economy mode you have additional limitation of RPM This lower limit is configured in setup and is the same for forward and backward speed see setup section of this document Estimated value of RPM speed When arrow symbol in status line is pointing up then the motor is spinning forward When it is pointing down then the motor is spinning backward Speed RPM indicator Gives you visual feedback of your current speed 4 1 2 SCREEN 1 Battery monitoring screen 1 Indicator of screen number 30 4h a en Sah 2 Charge charged 3 Amount of remaining charge 4 Battery current 5 Battery voltage 6 6 Charge used 1 Indicator of screen number 2 Charge charged Displays amount of charge that was charged into the battery and is obtained using the simple integral of current It can only be increased or reset to zero Ah charged gets reset at the beginning of charging and Ah used at beginning of discharging By partial charges when battery was not fully charged see chapter Operating GD1 this co
18. uants 5 he a8 hk AZ B Eg 1500 27851 999 9 9999 10 Figure 7 Relation of throttle position and A D quants Effectively bottom figure displays relation of throttle position vs motor speed or torque 4 HANDLING AND OPERATION If you have correctly installed the GD1 module and have also configured all the parameters then you can start using GDI unit When you turn START switch on you will see logo on the screen for a few seconds If there are no errors then you will see the main screen Screen 0 There are a total of 3 screens and you can scroll between them with UP DOWN keys Description of elements on each screen is provided below 4 1 OVERVIEW OF USER INTERFACE NIEZEN i iui IN MAIN gt DOWN BATTERY gt 4 DRIVE gt OK 0 0 Display Control and Battery Monitoring Unit DISPLAY AREA 4 1 1 SCREEN O Main screen 1 Indicator of screen number 2 Estimated remaining time of driving 3 Battery current 4 Remaining battery charge State of charge 5 Status line 3 02 08 1 2 7 Speed value RPM ar ECONOMY 4 5 7 3 8 Speed indicator RPM Indicator of screen number Estimated remaining time of driving at this current consumption After this time battery will probably be empty This value is masked with if e motor has less than 50 RPM e no current flows from the battery or current flows into battery e remaining time is greater than 10 hours Batte
19. unter only get incremented up to max value 3 Amount of remaining charge expressed in percent This value is also referred to as a State of charge SOC and is calculated using Peukert s equation Please refer to the note below for more information 4 Battery current Current is positive when it is flowing from battery to load 5 Battery voltage 6 Charge used Displays amount of charge that was extracted from the battery And is obtained using the simple integral of current It can only be increased or reset to zero Ah used gets reset at the beginning of discharging By partial charges when battery was not fully charged see chapter Operating GD1 this counter only get incremented up to max value Note SOC is calculated using Peukert s equation which provides a more realistic calculation of remaining charge QO t t discharge time t n n Q discharge current I Q tn nominal discharge time usually taken as 20 hours Qn 20 or i more commonly named C 20 Qn nominal battery charge battery capacity C This is the capacity stated on your battery If your battery is rated for 20 hours and you discharge it with just the right current so that it will be empty after 20 hours you will be able to extract nominal charge or the stated capacity n Peukert coefficient It determines how rate of discharge affects remaining charge in the battery The more it approaches 1 the more is your battery idea
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