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THOOSA QUICK GUIDE HANDBOOK

6000, 7000, 7000-HT, 9000

13000 & 17000

ASMO Marine Propulsion Systems

Idition 04 / 2009

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Introduction 3

1. Basic guide before installation in mono hull, displacement boats………….... Checking the purchased material • What to do before installing the Thoosa system • What you can do yourself and what will require authorised people to install. Special tools.

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2. Installation of Thoosa System……………………………………........................... Installing the E-Motor • Installing Motor Controller • Installing the Throttle • Installing Key-Switch • Precautions.

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3. Installation of Accessory parts…………………………………………………..….. Installation of AMC Shorepower Charger • Installation of AM DC/DC Converter • Battery Monitor • Precautions.

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4. Installation of Battery Bank………………………………………………………..… Selection of right battery type for Thoosa Systems • Dimensioning and Installation of Battery Bank • Precautions.

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5. Propeller selection & Change of Standard Gearing……………….…………..… Sizing of Propellers • Propeller types • What parameters to optimize • Change of Thoosa gear reduction • Precautions.

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6. Checking Installation before launching………………………………………...….. Checking electrical installations • Approvals by authorized electrician

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7. Testing the system……………………………………………………………….…… Functionality test of the E-Motor System • Testing low speed and max speed • Messurering of current consuption in different speed modes • Messuring voltage and current on the battery bank during all test manouvres • Messuring the heat developing in the E-Motor • Precautions.

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8. Sailing with electrical propulsion……………...…………………………….……... Precautions

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9. RG Function………………………..……………………………………………………. Advice and guidance in operating

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10. Trouble Shooting....……………………………………………………………………. Table

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11. General Information & Warranty…….……………………………….……………..

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12. Maintenance…………………………………………………………………………….. Thoosa motors, Batteries, Installation.

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13. Data Sheets……………………………………………………………………………… Thoosa Motors, Throttles, Battery Chargers, Battery Monitor, Mechanical drawings, Wiring principles, Sizing & Dimensioning Work Sheets, Battery wiring..

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Contents

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Introduction

Congratulations with your new Thoosa E-Motor system, and welcome to a new generation of energy- and environmentally friendly propulsion systems. The Thoosa motors do not emit any kind of pollutants and you are free of the exhaust fumes, and oil spillage from the noisy diesel engine. The ASMO Marine Thoosa motors are very quiet. Our developing department have made big efforts for making very high efficiency products in the range of 6kW to 17kW. An efficiency that is directly noticeable, by reaching longer motoring distance.

This Thoosa Quick Guide Handbook is a new issue from 2009 and has been completely reworked compared with older issues of Installation Manuals. With this new Quick Guide we will first of all guide you through the basics within the installation of standard parts of the system, and next to give you guideline for how to sail with electrical propulsion.

For those customers who would like to have further details about how to calculate and dimensioning Thoosa systems, battery banks, battery chargers, installation of hybrid systems ect.., you are welcome to contact our marketing department by e-mail info@asmomarine.com.

Should you need further information on our products, please visit www.asmomrine.com or you are welcome to contact us.

We wish you a pleasant sailing…..

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1. RECEIVED GOODS When you have received your THOOSA system, please check that all your ordered materials are delivered, and check if any damaged boxes. If any transport damages or missing collies, please contact the shipping company as soon as possible. Please check the shipment for any missing components/parts within 24 hours and if any discrepancy between your purchase order and delivered parts, you shall contact ASMO Marine within 24 hours by e-mail to: info@asmomarine.com. PLANNING INSTALLATION OF THOOSA SYSTEM Mechanical work We recommend that only authorized boat builders or naval architects are making all the mechanical integration and the THOOSA installation, and to secure that there are being used right quality and sized mechanical accessory parts. Should unauthorized people participating with the mechanical work, this has to be finally approved by the authorized mechanical engineer. Otherwise the warranty of the system will be void. Electrical wiring and installation Only authorized electricians may install the electrical parts and secure all wiring and connections are done proper and according to any local country maritime regulations. Evaluating motor installation Secure that the vessel are in dry environment and free from moisture. If any damages on the hull that can course any entry of sea water into the bilge area when launching the vessel into water again, please get the hull repaired before installing the Thoosa system. Evaluate where the THOOSA motor can be placed and construct a motor bed in bilge area and check the dimensions on the THOOSA drawing. Check that’s possible to get the right declination and direction of dip on motor bed. Check also the angle of shaft struts and shaft bearing (s) will be in line with the THOOSA motor shaft. We recommend to use a propeller shaft with same diameter (30mm) as the THOOSA shaft, because the THOOSA E-Motor has a very high peak torque also at very low speed, and a lot of forces will be put on the shaft so that’s why we recommend not reducing the diameter of the propeller shaft. The THOOSA motor make only small vibrations it self and therefore it should not be necessary to use dampers between the motor bed and the THOOSA motor. But we have had information from customers who had experience with unbalanced propeller shafts and propellers and these inaccuracies were able to course vibrations in whole motor system when going for medium and high power, so to avoid this problem we recommend to use vibration absorbers. Can be purchased as an accessory part at ASMO Marine. Evaluating battery compartment The choice of battery room shall be in a dry area and always be kept free of any sea water, because the batteries will get destroyed due to corrosion and current leakage. The battery room (s) shall be well ventilated because batteries are developing explosive gasses, especially when they are being re-charged. We recommend to dedicate the battery room in centre of boat and centre of gravity as low as possible. That will make better manoeuvring characteristics of the boat. If not possible to have a central battery room, then the battery bank can be split into two separate banks. Example, 48V system: One 24V battery bank placed in each side of the boat and still in centre line. The two separate 24V battery banks shall then be wired in seria to get the 48V battery bank. It’s very important that all DC wires are kept as short as possible due to voltage drop in the cables.

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Digital Multimeter

Digital Gripper

Multimeter

Torque Spanner

Digital Temperature

Meter

Standard tools and special service tools and measuring instruments Any kind of standard tools are normally available at the ship yard / boat builder, so these will not be mentioned here, but we want to make focus on the special tools that are needed fore making the finale control of the system, before launching the vessel into water and for making the test ride and test rapport. Below you see examples of some of the type of instruments that are needed for an installation.....

Grounding / Bonding of Thoosa systems

The Thoosa propulsion system kit do not have any electrical potential on metal parts and shall not be grounded or bonded to any ground potential onboard. The system shall be installed and operate as an isolated system. The battery bank for the propulsion system shall not have minus pole connected to the boat’s ground potential/ground plate. This to avoid any corrosion or any stray currents. Standard Battery chargers that are connected to battery bank via the Motor Controller Charger socket, have normally 230VAC ground on the chassis and therefore it shall be kept isolated from the Thoosa system, but be installed onboard according to maritime rules for AC power installations.

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2.

BEFORE INSTALLING THOOSA MOTOR

Before mounting the Thoosa motor on the motor bed, please check that the gearing combination is according to what you have required. If your boat data have been changed during the project period or your propeller choice have changed, you will probably need a new dimensioning which can result in change of RPM on propeller shaft.

For change of wheel combination and driving belt, you must contact your loacal dealer or ASMO Marine / technical service.

In Fig.1-4 you can see the different standard wheel combinations available.

The Fig.5, the drawing of how the gear reduction system is mounted.

Fig.1 22-48

Fig.2 22-56

Fig.3 22-72

Fig.4 22-90

Fig.5

ROTATING GEARWHEELS & TIMEING-BELT !

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INSTALLING THOOSA MOTOR

The Motor will generate sparks so therefore the Motor may not be installed in same room as lead acid batteries, because the batteries are developing explosive gasses during charge and discharge conditions and these gasses can be ignited by the sparks created inside the Motor. The Thoosa motor can normally be mounted without vibration absorbers, because the Thoosa motor only make small vibrations itself, but vibrations will occur if the propeller or propeller shaft not are in balance. These vibrations can normally be removed by using vibration absorbers, mounted between the motor bed and the mounting brackets on motor. You can contact ASMO Marine for purchasing these accessory parts.

When using the standard mounting the motor (without absorbers), use 4 x 12mm bolts in each rail (see Fig.6). All 8 bolts must be mounted to secure a solid integration to the hull and to avoid unintended vibrations or the motor to work loose during sailing. If using dampers, then mount 4 pcs in each rail. The motor shall be kept away from water, water dripping and moistur, but must not be covered by any closed housings or other materials that can obstacle the free airflow around the system. The motor is a self cooling system which means that the build-in fan mechanism will secure that heat are being blown away from motor, and will during very hard load currents be able to reach 90ºC, which is also the max allowed temperature on the motor. The standard diameter on the gear shaft is 30mm and we recommend to use the same diameter size for the propeller shaft. Connect the gear shaft and the propeller shaft via two shaft coupling flanges, that shall be bolted together.

Fig.6

NOTE:

For accurate mounting please use the cad drawing ”Thoosa motor console”, found in Chapter 11 !

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INSTALLING MOTOR CONTROLLER

The Motor Controller is fixed mounted (see mechanical details on data sheet, found in Chapter 11) with 2 x 2mtr DC cables for E-Motor, and 2 x 5mtr DC cables for the battery bank. Place the Motor Controller in a dry ventilated room, kept away from: water, water dripping, moister and direct sunshine. Keep the DC cables as short as possible, to avoid inappropriated voltage drops. The Motor Controller contain power relays and therefore the Controller may not be installed in same room as lead acid batteries, because the batteries are developing explosive gasses during charge and discharge conditions and these gasses can be ignited by possible sparks from relay contacts. Fix the Motor Controller with 4 x 8mm bolts and secure that there are min. 10cm free space surround the box. The Motor Controller is forced cooled by fan inside the controller box and the air inlet is in front and air outlet is on rear part. The Motor Controller must not be covered by any external housings or clothes that can obstacle the air circulation. Depending on surrounding temperatures, the controller can easily get up to 40ºC when it’s operating. Start to mount the 2 black DC cables (M1 and M2) to the Thoosa Motor’s pol connections, Fig.7. Tighten the bolts with the torque of 5 Nm. NOTE: Fasten the counternut. When the battery bank has been installed, the DC cables (B+ and B-) shall be mounted, but it will be explained later in Part 4 how to do it.

Fig.7

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INSTALLING THE SIDE MOUNTED THROTTLE

The Throttle is programmed to be placed on starboard side of the boat. If the Throttle shall be placed on the port side, the Throttle software must be re-programmed. Please consult your local dealer for getting the Throttle re-programmed or contact ASMO Marine.

Before starting drilling holes in the bulkhead, secure your selection of right position of Throttle. Cut or drill the holes according to the provided mounting template. If necessary remove the disc knob from the throttle body, by removing the stainless steel locking screw from disc knob. Pull the cable through the O-ring and the cut out for throttle body. Position the O-ring in the recess around the outer edge of the throttle body. Align the stainless steel retaining ring inside the bulkhead with the holes drilled according to the template. Secure by hand or by a couple of pieces of double sided tape. Pull the cable through the cut out in the bulkhead and the retaining ring and insert the 4 screws through the Throttle body and fasten to the retaining ring until tight. Make sure the O-ring stays in place. Align the disc knob with the threaded hole in the shaft and push it in place. Insert locking screw and fasten. (See Fig.8)

Fig.8

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INSTALLING THE SINGLE OR DOUPLE TOP MOUNTED THROTTLE

The Throttle (s), see Fig.9, is programmed to be placed on starboard side of the boat. If the Throttle (s) shall be placed on the port side, the Throttle software must be re-programmed. Please consult your local dealer for getting the Throttle re-programmed or contact ASMO Marine.

On the bottom plate of the throttle (s) is a marking, “forward” and a direction line, showing right positioning. Locate a convenient area for the throttle (s) and cut/drill holes according to the provided mounting template (starboard side or port side). Pull the cable (s) through the cable hole. Align the stand (s) with the holes drilled according to the mounting template. Insert the screws and fasten until tight.

INSTALLING THE KEY-SWITCH

Install the key-switch (see Fig.10) in a central place . Drill a hole of 18mm and mount the switch, but secure that there is enough space in length so the wires and terminals don’t get damaged. The build-in length is 75mm. The switch is connected with a 5mtr. Cable, which shall be mounted in the key-switch socket in front panel of Motor Controller. Turning the key clock wise will activate the Thoosa system.

Fig.9

Fig.10

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INSTALLATION OF AMC 600W/800W/1600W SHORE POWER CHARGER

The installation shall be in a dry and ventilated room, separated from the battery compartment and as close as possible to the Motor Controller, so the DC wires a kept as short as possible. The DC wires are connected with a DC plug that fit into the Motor Controllers charger socket. The charger can be used positioned horizontally on a table or a shelf, but can also be hanged on a wall using the free supplied bracket. No front / rear end parts must be upwards positioned. The charger shall be kept isolated from any groundings onboard, to avoid corrosion problems. The charger has a build-in fan to cool the electronics, and you must secure the air supply don’t get obstructed.

The charger is implemented with ASMO software set-up, so it can charge freely ventilated (open) lead acid batteries and GEL or VRLA (sealed) batteries. The enclosed Charger Manual and Charger Algorithms show the different battery types and Ah sizes. The charger is delivered with a charging set-up that match sealed GEL batteries. If different type battery bank shall be installed, please follow the instruction in the Charger Manual for how to turn the selector switch into right battery type position and charge algorithm.

The chargers can be connected to 110VAC or 230VAC grid. If connected to 110VAC, the output power will be limited according to specified de-rating curve showed in the Charger Manual.

The charger shall be switched off before plugged or disconnected to Motor Controller or battery. If the motor controller or the battery is disconnected without switching off the charger, sparks may be produced. The charger can be switched off by removing the AC plug from AC wall socket.

OPTION: If the charger is delivered with a Temp & Voltage sense unit: mount the cable with Temp sense probe on the battery. The cable with a J-connecter shall be mounted into the charger.

READ THE TECHNICAL MANUAL FOR THE AMC CHARGER CAREFULLY BEFORE TAKING THE CHARGER INTO USE !

INSTALLATION OF AMC 3200W SHORE POWER CHARGER

The installation shall be in a dry and ventilated room, separated from the battery compartment and as close as possible to the Motor Controller, so the DC wires a kept as short as possible. The DC wires are connected with a DC plug that fit into the Motor Controllers charger socket. The charger are designed for wall mounting and fixed horizontal to limit dust and moisture to enter it. The charger shall be kept isolated from any groundings onboard, to avoid corrosion problems. The charger has a build-in fan to cool the electronics, and you must secure the air supply don’t get obstructed.

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The charger is implemented with ASMO software set-up, so it can charge freely ventilated (open) lead acid batteries and GEL or VRLA (sealed) batteries. The enclosed Charger Manual and Charger Algorithms show the different battery types and Ah sizes. The charger is delivered with a charging set-up that match sealed GEL batteries. If different type battery bank shall be installed, please follow the instruction in the Charger Manual for how to turn the selector switch into right battery type position and charge algorithm.

The chargers can be connected to 110VAC or 230VAC grid. If connected to 110VAC, the output power will be limited according to specified de-rating curve showed in the Charger Manual.

The charger shall be switched off before plugged or disconnected to Motor Controller or battery. If the motor controller or the battery is disconnected without switching off the charger, sparks may be produced. The charger can be switched off by removing the AC plug from AC wall socket.

OPTION: If the charger is delivered with a Temp & Voltage sense unit: mount the cable with Temp sense probe on the battery. The cable with a J-connecter shall be mounted into the charger.

READ THE TECHNICAL MANUAL FOR THE AMC CHARGER CAREFULLY BEFORE TAKING THE CHARGER INTO USE !

INSTALLATION OF BATTERY MONITOR

In general please follow the LINK10 manufacturer’s installation manual. But we recommend NOT to place the monitor where it will get exposed for water or moister. Be careful when you mount the monitor, and secure that the wires which are mounted into the monitor connector, don’t break of.

NOTES: The LINK 10 (see Fig.11) is modified for working with ASMO Motor Controller. That means the monitor is fixed with connector that fit into the socket at the motor controller. No pre-scalar, shunt or fuse shall be mounted to the monitor, because it is already installed in the motor controller. Just plug the connector into the motor controller. READ THE TECHNICAL MANUAL

FOR THE BATTERY MONITOR CAREFULLY BEFORE TAKING THE MONITOR INTO USE !

Fig.11

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4.

THEORETICAL CALCULATION OF BATTERY BANK

For making a theoretical sizing of battery bank, please use the “Sizing & Dimensioning Work Sheet” (see Chapter 11). Selection of right battery type for Thoosa systems, please contact our sales & marketing division.

INSTALLATION OF BATTERY BANK

Before connecting the battery blocks in a serial connection, secure the single blocks are fully charged. For charging a single 12V block, use a 12V battery charger. The battery bank shall be placed in a separate dry, dark and well ventilated room, and because the weight of lead acid batteries are very heavy, we recommend to place the batteries as low as possible but above maximum bilge water level and in the centre lines of the boat, to secure maximum efficient manoeuvrability. Batteries can develop explosive gasses during discharge and recharge, so no Thoosa motor, motor controller or other electronic equipment can be installed in same compartment as the batteries. Secure an efficient air flow through the battery compartment so it’s getting ventilated to atmosphere to avoid any accumulated gasses. If the battery blocks are mounted inside a box with a lid, this box must be equipped with venting holes for sufficient ventilation direct to atmosphere. Batteries that are of open/flooded version, shall be mounted on a try that will contain any spillage of electrolyte caused by any inclination angels of the boat. The battery blocks / battery boxes shall be secured so they don’t move at any inclination angels, and that can be done by straps or restraining brackets across the battery top. The positive (+) pole on the battery bank shall be mounted with a 300A fuse as close as possible to the battery. If using a short cable (maximum 20cm) between the + pole and the fuse, the cable size shall be of same type and dimension as the DC battery cables coming from motor controller. Some fuses on the market allow to be mounted directly on the pole bolt. Any battery poles shall be protected and isolated by plastic or rubber caps, so any short circuits can be avoided.

The DC cables, + and -, coming from the Motor Controller (battery bank input) shall run parallel to each other and as straight as possible, for minimizing any kind of interference or radiation. Cable bend radius shall be a minimum of 6x cable diameter. The cables shall be protected from any mechanical damages, and if they are passing through interior walls the cables must be protected by cable transit bushings. The battery cables shall be kept free from water in bilge area. Prepare the minus (-) cable with a battery terminal that fit the minus (-) post on the battery bank, and crimp an end lug to the plus (+) cable, so it fit into the fuse holder mounted to plus (+) post on battery bank. DO NOT CONNECT THE PLUS (+) CABLE BEFORE YOU HAVE GONE THROUGH THE “CHECKING INSTALLATION BEFORE LAUNCHING”. SEE ALSO BATTERY WIRING PRICIPLES IN CHAPTER 13, “DATA SHEETS”

WORKING WITH BATTERIES IS DANGEROUS. EXPLOSIVE GASSES WILL BE DEVELOPED WHEN BATTERIES ARE BEING DISCHARGED OR RECHARGED. BATTERY COMPARTMENTS MUST BE PROPERLY VENTILATED !

SERVICE TOOLS SHALL BE ISOLATED !

BATTERY POLES MAY NOT BE SHORT CIRCUIT !

BATTERIES CONTAIN HIGHLY CORROSIVE LIQUIDS. ANY SPILLAGE MUST BE REMOVED IMMEDIATELY !

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5.

PROPELLER SELECTION AND REDUCTION GEAR

The selection of right propeller size and pitch is quite significant, and therefore it’s recommended that you before making a purchase, try to make an agreement with the propeller supplier, that he make the calculation of propeller size and pitch to your boat. If possible also to get an agreement, that it will be possible for you to make an exchange of propeller with other characteristics and different pitch.

Because the Thoosa motors have a very high torque at very low rpm’s, it’s possible to use a bigger propeller than standard for diesel motors and by this making the best use of the energy, taking from battery bank. On the other hand, if a too big propeller with a too high pitch is mounted on the shaft and the motor get it difficult to swing the propeller, it can result in overload of the Thoosa motor (too high current through the system), and the controller system will react immediately by limiting the power to the motor. Therefore it’s needed to make a prop calculation so future problems get avoided.

If it because of practical reasons not is possible to mount a propeller with bigger diameter due to limitation in space between rudder and propeller or a requirement for low draught, it can be necessary to make a compromise and choose a smaller prop diameter. A 3-blade prop will make a good balance between small diameter, thrust and efficiency. The 3-blade prop can also accept higher rpm’s because it have reduced vibrations.

As a guideline for calculating the propeller size, you can use following method of calculation for minimum propeller diameter and pitch:

Dmin = 13,35 (Bwl x Hd)0,5

where

Bwl = beam water line length in meters Hd = draft in meters, without ballast keel

P = (Kts x 1250,6) / [Rpm (1 – slipA)]

where

Kts = required max speed in knots Rpm = max prop shaft rpm’s per minute SlipA = 0,45 (estimation for sailboats)

Change in reduction gearing:

If calculations are showing that the rpm’s on prop shaft must be changed, please contact your local dealer or ASMO Marine Technical Service.

WRONG REDUCTION GEARING AND WRONG DIMENSIONING OF PROPELLER DIAMETER AND PITCH, CAN COURSE OVERLOAD OF THE SYSTEM, AND IN WORST CASE CAUSE DESTRUCTION OF THE MOTOR DUE TO OVERHEATING !

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6.

CHECKING INSTALLATION BEFORE LAUNCHING.

Before launching the boat into water, it’s important to make a double check of the mechanical and electrical installations.

Mechanical

¨ Check the Thoosa motor is fastened safe to the motor bed. All screws mounted into motor bed.

¨ Check the Thoosa gear shaft and propeller shaft are screwed together by the two flanges. Check that dimensions of bolts are correct according to flange holes, and no bolts are missing.

¨ Control the free rotating of the shaft.

¨ Control that Thoosa motor and gear system are free of any foreign objects, and there are free ventilation surround the system.

¨ Control the ASMO Motor Controller is fastened safely with screws.

¨ Check that Throttle are fastened in right position and the handle is working without being obstacle by any foreign elements.

¨ Control the battery charger and battery monitor are mounted properly.

¨ Control the battery bank are clamped to the hull and each block is fixed with brackets so they can not move.

¨ Check for any spillage of acids / electrolyte from battery blocks.

¨ Control that selected propeller is matching the Thoosa motor size and rpm’s.

Electrical

¨ Control that all DC cables are free of any damages.

¨ Control all DC cables are fastened correct to boat construction.

¨ Check DC cable connections to Thoosa motor are fastened properly.

¨ Control right plugs are connected correctly to sockets at the motor controller.

¨ Check that 300Amp battery fuse is mounted properly to + pole of battery bank.

¨ Control that black DC cable (-) is mounted correct to the – pole on the battery bank.

¨ Secure the battery bank are fully charged and measure the battery voltage.

¨ Check Thoosa system is matching the battery bank voltage.

¨ Connect the red DC cable (+) to the 300Amp battery fuse holder.

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COPY OF TEST RIDE & APPROVAL SHEET FOR THOOSA SYSTEMS.

(ORIGINAL DOCUMENT WILL BE ENCLOSED EACH THOOSA SYSTEM WHEN DELIVERED).

REQUIREMENTS FROM CUSTOMER DATE OF PURCHASE (dd.mm.yy.): DATE OF TEST: (dd.mm.yy) CUSTOMER: TEST AREA: (sea, lake, harbor, river) PHONE NUMBER: THOOSA PRODUCT: FAX NUMBER: SERIAL NO: CONTACT PERSON: SERIAL NO: E-MAIL: GEAR / REDUCTION: INSTALLATION COMPANY: MAX. PROPELLER SHAFT RPM: E-MAIL: WIND SPEED: AUTHORISED ENGINEER/TECHNICIAN: AMBIENT TEMPERATURE (°C):

BOAT TYPE: LOA: (mtr or foot) BEAM: (mtr or foot) DRAFT: (mtr or foot) DISPLACEMENT FULL: (kg) PROPELLER SIZE: (diameter, pitch) PROPELLER TYPE: BATTERY BANK SIZE AND TYPE:

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PRE-TESTING THE THOOSA MOTOR

For checking the right propeller direction, press the throttle in forward position and control that the propeller turns in the right direction. If not, interchange the two black DC cables on the Thoosa motor. Check again for right propeller direction.

TEST RIDE & APPROVAL

When the boat is launch into water, there must be carried out a test of the Thoosa system according to the ASMO Test Ride specifications.

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Authorised Engineer / Technician to carry out below tests, and fill in the forms with the meassured figures.

TEST 1. / 6 MINUTES / HALF THROTTLE SPEED FORWARD Product Voltage (VM) Voltage (VB) Amp (A) Temperature °C (T) Speed kt Comments

Thoosa E-Motor Battery Bank

TEST 4. / 6 MINUTES / HALF THROTTLE SPEED REVERSE Product Voltage (VM) Voltage (VB) Amp (A) Temperature °C (T) Speed kt Comments

Thoosa E-Motor Battery Bank

TEST 2. / 6 MINUTES / FULL THROTTLE SPEED FORWARD Product Voltage (VM ) Voltage ( VB ) Amp (A) Temperature °C (T) Speed kt Comments

Thoosa E-Motor Battery Bank

TEST 3. / 15~20 MINUTES / HALF THROTTLE SPEED FORWARD Product Voltage (VM) Voltage (VB) Amp (A) Temperature °C (T) Speed kt Comments

Thoosa E-Motor Battery Bank

A) The air temperature at ventilation holes on the motor shall be measured by digital temp probe instrument (T). The temperature must never exceed 80°C.

B) One analog voltmeter (VM) directly on motor terminals (measuring the DC level of 16kHz square pulses from controler). And one digital voltmeter (VB) directly on battery pol bolts.

C) One amp meter (A) in serial connection with the DC cable between Motor Controller and Thoosa motor. E.g. a clamp meter. TEST: Secure that voltage and amp limits not exeed specified values listed in the table. If unusual high temperature, or too high current consumption occur on products during this test, please interrupt the test.

Problem:

• Propeller RPM is too high. Wrong gear reduction • The pitch is too high • Combination of both

Remedy:

• Make new propeller calculation, according to the boat data/specifications and the size of motor (in kW) installed. • Make new propeller RPM calculation.

CONSTANT CURRENT CONSUMPTION FOR CONTINUOUS USE – NOT TO BEE EXCEEDED ! THOOSA 6000 THOOSA 7000 THOOSA 7000-HT THOOSA 9000 THOOSA 13000 THOOSA 17000

VM A VM A VM A VM A VM A VM A 12V 80A 12V 80A 12V 80A 12V 100A 48V 150A 48V 150A 24V 100A 24V 100A 24V 100A 24V 130A 60V 165A 60V 165A 36V 120A 36V 120A 36V 120A 36V 150A 72V 180A 72V 180A 48V 125A 48V 140A 48V 140A 48V 1) 200A 84V 190A 84V 190A 54V 130A 54V 150A 54V 150A 54V 2) 200A - - 96V 200A

1) <40 sec. when accellerating the boat. Continuously limited to 170A

2) <40 sec. when accellerating the boat. Continuously limited to 180A

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ASMO Marine finale approval of installation

Date:_____________________

_______________________________________________

(signature & stamp)

(Copy will be send to customer by e-mail)

NOTES:

_____________________________________________________________________________________________

______________________________________________________________________________________________

______________________________________________________________________________________________

______________________________________________________________________________________________

______________________________________________________________________________________________

______________________________________________________________________________________________

______________________________________________________________________________________________

(To bee filled out by the authorized test engineer. For finale approval, please return to ASMO Marine the completed TEST RIDE & APPROVAL SHEET FOR THOOSA SYSTEMS included pictures (JPEG format) of the physical installation of the Thoosa system (s) onboard.)

Thoosa System has been field tested according to the above ASMO Marine requirements.

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8.

PRACTICAL SAILING WITH THOOSA ELECTRICAL PROPULSION SYSTEM

When starting to sail electrically, there are always the 3 most important parameters to focus on. These are:

- motoring distance - motoring speed - motoring time

All 3 parameters are related to the Ah capacity on main battery bank for the propulsion system, and because lead acid batteries are quite heavy, it’s very important to know how much weight it’s allowed to carry onboard without deterioration the manoeuvrability of the sailboat. The battery capacity (Ah) is the “fuel” for an electrical propulsion system, and as a help to economize on the battery power it’s very important that a battery monitor is installed together with Thoosa motor system, and that the skipper keep an eye on this monitor when adjusting the throttle. Because the Thoosa motor is almost silent, it’s very easy to make that mistake by giving the sailboat too much throttle when cruising around and it will create high power consumptions from battery bank. Similar to the problem first time when driving an electrical car or electrical scooter, so in fact it’s a matter of getting experience and confidence with the system in form of “learning-by-doing”. In the next part we will give you a short guideline for how you can operate the Thoosa system and keep an acceptable power reserve in the battery bank.

Example of installation:

Thoosa 7000 system, included a lead acid battery bank of 48V/250AhC20 / semi traction type. Total weight of system is calculated to be ~ 365kg. The system is installed into a sailboat for near coast sailing, sailing on lakes and rivers and the motor system will be used when sailing in and out of harbours, harbour manoeuvres, small cruising when no wind available ect…

A lead acid battery have certain rules to follow for discharge, otherwise the battery cells inside the battery blocks will be damaged and shorten the life time drastically. A thumb rule is to let the standard batteries be discharged 50% (DOD) and max. 60%. Special expensive traction types do allow up to 70% DOD. But in this example of installation there has been a chosen standard lead acid semi traction deep cycle battery. So, the 48V/250Ah battery bank will in fact have 125Ah available for the propulsion, which now shall be used in the most reasonable way. Here are some guidelines for a sailing pattern: (activate the battery monitor and select Amp mode. Discharge is shown as negative number)

Out from mooring place / harbour manoeuvres

These operations are normally done in very slow speed mode, forward and reverse directions and the operating time short. The current consumption can vary between 10Amp and 20Amp. The figures at the battery monitor will change values very rapidly according to adjusting of the throttle. Because the Thoosa motor have high torque already at very low rpm’s on the prop shaft, it makes the manoeuvring very quick and quiet. Estimated time consumption for these manoeuvrings ~ 5 minutes and estimated current consumption from battery bank ~2Ah.

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Out of harbour

Depending of how the harbour is constructed, we estimate the distance and time as average values, round a ride of 10 minutes. Adjust the current consumption by the throttle to be between 20Amp and 30Amp max. This will drain the battery bank with ~5Ah.

Until now it has only cost us a small amount of the available Ah in the battery bank, so there should be plenty of Ah / time for cruising, even we have to think about a safe home ride the same day.

Normal cruising mode

If you have decided to go to another port, you can calculate theoretical motoring time available and distance, by following formal:

Left capacity on battery bank (Ah) Current consumption by cruising (Amp)

If we assume the boat will make a speed of 4kts/hour at a current consumption of 40Amp, we can now calculate the theoretical distance to reach in flat water:

Hours available (h) x Speed (miles per hour) = 3 x 4 = 12 nautical miles = 22km = total discharged battery bank.

This was the theoretical calculations, but then there have not been mentioned any emergency situations, current conditions in the water, wind conditions, ect…, so for safety reasons it’s better to make the calculations by only using 2/3 of the hours available. In this case it means 2h, and which will give round 8 miles distance at cruising speed, before entering the destination port.

Emergency, man over board situation or evasive manoeuvre

In this situation it’s very important that the battery bank can deliver the max current (Amp) required by the Thoosa motor, if the throttle is pushed full forward or reverse. In such a situation the Thoosa 7000 motor will consume 140Amp, and if we assume it will take 5 minutes to solve the emergency problems, the total current consumption from the battery bank will be in the range of 12Ah; not much, but anyway the battery blocks have been exposed for an extremely heavy drain in these minutes and depending on the state-of-charge of the battery bank, the battery voltage can drop drastically and be close to the voltage level where all discharge automatically will be stopped by the motor controller. To secure that the Thoosa system don’t stop in emergency situations, the motor controller software has been adjusted so it allow the motor to operate even the battery voltage level are below cut-off limits. The motor controller will switch of at 40V. Too many operations of this kind will of course reduce the life time of the battery bank, but on the other hand it’s better to win in an emergency situation.

After this operation mode, it’s recommended that the batteries get allowed to recover within the next 15 minutes, so it’s better to reduce the cruising speed so discharge current is round 10A~15A in that period.

= Hours available = 118 40

= ~ 3 hours

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Into harbour, harbour manoeuvres, into mooring place

Calculate the same time and current consumption for going into harbour as when going out of harbour. If you don’t know the destination port, then calculate with a bit more safety margin, by reducing the speed to 3kts. A thumb rule is, that for each 1kts increase of speed, it will double the current consumption from battery bank.

Recharge of battery bank from shore power charger

For recharging a total discharged 48V/250Ah lead acid battery bank, with a 48V/30A 3-step charger, will take about 10 to 14 hours. A lead acid battery must be recharged with 120%, to get 95~98% capacity out again, so that’s why the recharge time can get up to 14 hours.

Things that will have influence on power consumption from battery bank

- hull construction, sea fouling on hull surface - displacement full - propeller size and pitch - wind, tidal currents, waves - speed

9.

RG-function

RG stands for “regeneration of power”, which means that it is possible to use the Thoosa motor as a battery charger when the boat is going for sail and the propeller is spinning. Before going into more details about how to use and trim the system in RG mode, it’s important to explain from beginning, that there can be big differences in how efficient the regeneration can be, due to different physical parameters like….

- propeller type - propeller size - place of propeller - sailing speed when going for sail - hull construction - hull performance and the hydrodynamics

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Not all propellers are able to use for regeneration, because in general propellers are designed so they present minimum of drag when the boat is being leaded through the water by the wind in the sails, which is the opposite of what is required when we want the motor to spin maximum and generate power to the battery bank. The level of water pressure at the blades back of propeller is essential for RG efficiency. See fig.12. Many sailboats are mounted with a 2-blade folding propeller, but it’s worth to know that some folding propellers are not able to stay open in regeneration mode, so the blades will fold together if sailing speed is too low. We don’t have the recipe for which propeller type that is the best for regeneration, but a fixed 2- or 3-blade propeller have much bigger chance to regenerate than a folding propeller. But we have done some tests with a 2-blade folding propeller, which will be showed later in this chapter (see Fig.14 & 15), just to prove that it’s possible to make regeneration with a folding propeller.

Fig.12

Sailing direction

Now, for those who would like to understand a bit more of the background for the Thoosa motor to regenerate, we have to talk a little bit of technical issues (see fig.13). When the throttle is put into RG position and the prop shaft is spinning, the Thoosa motor will generate an electromagnetic field, which will create a certain DC output voltage that goes to the Motor Controller. In the motor controller the recharge current to battery bank is set-up to 60A maximum, and this setting will have a braking effect on the propeller shaft. So, if not the propeller shall stall, it’s absolutely necessary to keep a high sailing speed. When the sailing speed , when going for sail, is 100%~120% the maximum speed when going for motor, there will be generated power back to the battery bank. The motor controller will take care of stepping up the voltage so it gets high enough so it can be used for charging the battery bank.

Fig.13

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Activating the RG function:

When you have reached an acceptable sailing speed for sail, 100% ~ 120% of maximum speed when going for motor, you can activate the RG function by following:

1) Push the throttle forward, close to max. position and the back again to first click position, 15° from neutral position. This manoeuvre serves two useful purpose, namely to get the shaft spinning and for a folding propeller also to open the blades.

2) If the battery monitor is activated and put into Amp mode, you can see how much current that is being generated back to battery bank. Charging is shown as a positive number (unsigned). Discharge from battery bank is shown as a negative number.

3) If the propeller stalls, bring the throttle back to neutral position and repeat phase 1), but leave the throttle e.g. in 20° to 30° position or in a position where the propeller don’t stall. You can fine adjust the regeneration current by adjusting the throttle; but don’t get below the first click position, because that will stop the RG function.

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THROUBLE SHOOTING THOOSA SYSTEM

LED FAILURE INDICATIONS ON ASMO MOTOR CONTROLLERS Steady On System is switched on and all is OK. 1 flash Voltage Low or voltage High. 2 flashes High temperature. Heat sink temperature >54°C. 3 flashes Thermal shutdown. Heat sink temperature >87°C. 4 flashes High current shut down. 5 flashes Fan failure. 6 flashes NTC failure X flashes of 0,8 sec, pause 0,8 sec after each flash, then pause of 2 sec.

THOOSA MOTOR CONTROLLERS VOLTAGE WINDOWS Thoosa 6000 48V system. Min. Voltage 40V. Max. Voltage 61V Thoosa 7000 48V system. Min. Voltage 40V. Max. Voltage 61V Thoosa 7000HT 48V system. Min. Voltage 40V. Max. Voltage 61V Thoosa 9000 48V system. Min. Voltage 40V. Max. Voltage 61V Thoosa 13000 72V system. Min. Voltage 60V. Max. Voltage 92V Thoosa 17000 96V system. Min. Voltage 80V. Max. Voltage 123V

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Problem Cause Remedy

No power, no light in LED Check main switch Switch on Main fuse or fuse in front defect Replace fuse w. same type

Wrong propeller direction

Wrong connection of DC cables on motor terminals.

Interchange DC cables on Thoosa motor

Throttle mounted in oppesite position.

See throttle instructions

Thoosa motor showing reduced power

Throttle mounted in oppesite position and wrong connection of DC cables on motor terminals.

Check and re-mount throttle. Check throttle instructions. Interchange DC cables on Thoosa motor

Controller in power limit mode. Thoosa motor overloaded

Check propeller for free spinning Re-calculate reduction gearing, and change to lower gearing. Carry out a new Test Ride, according to specifications

Propeller too big Change propeller . Carry out a new Test Ride, according to specifications

Wrong pitch settings

Change propeller or adjust pitch. Carry out a new Test Ride, according to specifications

Battery voltage on battery bank below min. voltage.

Check battery voltage Recharge battery bank 100% and make new sailing test.

Thoosa motor loosing power very fast

Propeller problems See earlier remedy

Battery voltage is dropping fast Check battery voltage Recharge battery bank 100% and make new sailing test

Wrong battery type

Make calculation of battery size, according to Size & Dimensioning Work Sheet. Change battery bank.

Sailing distance too short

Motoring speed too high. (high current consumption) Reduce motoring speed

Battery bank capacity is too small. Battery bank have lost capacity and must be replaced

Replace battery bank. Follow instruction for replacing battery bank.

Sea fouling on hull surface Clean the hull for fouling

Nearly full throttle, high current consumption and only low speed

Wrong propeller (too small) Change propeller

Too small Thoosa motor installed

Change to bigger Thoosa motor. New dimensioning required. Ask your local dealer or contact ASMO technical service.

THROUBLE SHOOTING THOOSA SYSTEM If any problems occur, please check this list before contacting customer service.

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Problem Cause Remedy

Battery voltage on battery bank is dropping faster than earlier

Fouling on hull surface Clean hull for fouling

Not fully charged battery bank Recharge battery. Check charge voltage from battery charger.

Corrosions on battery cells (inside battery blocks) Replace battery bank

“Dead” Thoosa motor

Blowed battery fuse Replace battery fuse, w. right type.

Main key-switch defect Motor Controller defect

Replace key-switch Contact service organization for repair of Motor Controller

Bad cable connections Repair and tighten all screws on DC cables

Defect throttle Replace throttle

No or only little power left in battery bank

Battery bank discharged by external components

Disconnect the battery system when left unused in longer time. Secure proper recharge / maintenance charge every month.

Leakage current somewhere in the electrical system. Moister and dirt on battery terminals or between DC connections.

Clean batteries and all DC connections. Measure leakage current by instrument

Defect blocks in battery bank Replace complete battery bank.

Shore power charger don’t charge.

Check the fuse, AC and DC wires. If ok, repair or replacement of shore power charger is required.

If flooded batteries, the blocks are missing water

Refill with distilled water and recharge batteries

Battery monitor showing wrong data.

Software error Reset monitor Defect monitor or cable Replace monitor

General low capacity in battery bank. Replace battery bank

Turn the key-switch to off. Disconnect the DC wires at the battery poles, and take out the battery blocks. Put in new battery blocks. NOTE: All blocks must be of same type, voltage and Ah capacity !

BRING THE DEFECT BATTERIES TO RECYCLING !

THROUBLE SHOOTING THOOSA SYSTEM

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GENERAL INFORMATION

ASMO Marine sahll in no event be liable for loss, damages or costs arising from use of ASMO Marine products, or in any way connected with faulty installation, improper operation or incorrect utilization and maintenance. ASMO Marine shall in no event be liable for any direct, indirect, damages, disablement or death on persons who:

- Install or works with ASMO Marine products - Integrate ASMO Marine products for operating with other kind of units - Participating in any sailing activities

ASMO Marine reserves the right to improve the design, change technical specifications or change this General Information without prior notice. This ”INSTRUCTION” serves as a guideline for safe and effective operation, for maintenence and for possible correction of minor malfunctions of the products. It is therefore obligatory that all persons who works on or with the products are completely familiar with the content of this ”INSTRUCTION”and follow the contained herein. Installation of and work on the product may only be carried out by qualified, authorized and trained personal, familiar with the locally applicable standards and taking into consideration the safety guidelines and measures.

Safety Guidelines:

- According to Thoosa Quick Guide Handbook - Only allow changes in your electrical system to be carried out by qualified personnel . - Do not short circuit the battery poles when working with batteries. They contain very

high power and by a short circuit, the batteries can explode. Never smoke or allow a spark or flame in vicinity of a battery.

- Do not reverse the battery cables on the battery. It can result in instantaneous damages of the product. Such damages are not covered by the Warranty.

- Do not change the cable size or replace the cables. If you need to replace the cables, contact your local dealer or contact ASMO Marine technical service.

- When installing products with 230VAC, you have to install an RCCB (gound leakage) switch in serial with the 230VAC wires.

WARRANTY

- The Warranty period is 24 month from day of delivery. During the Warranty period, ASMO Marine will repair the products. When having problems with your ASMO Marine products, please contact your local dealer or ASMO Marine technical service.

- A repaired product will not be given a prolonged or renewed warranty period. - The cost for transportation and insurance on items returned for service, is the

responsibility of the customer. - The Warranty becomes void if:

• ASMO Marine have not signed the ”Test Ride & Approval Sheet For Thoosa System”.

• Improper installed, unauthorized repaired, wrong battery polarity connection, abnormal used or used in violation of the ”INSTRUCTION”.

INSTRUCTION

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THOOSA MOTOR SYSTEM

Brushes

Lifetime: Yearly: Replacement

Up to 5.000 hours during normal conditions. Brushes should be checked. If Thoosa motor have not been used for a long period of time ≥1 Year, brushes should be checked for moisture and expansion. Check the brushes are free to move in the brush holder. Can be checked with a feeler gauge of 0,25mm, inserted on one side of each brush. Clean the bushes. Run the motor for 30 min. at the lowest possible speed. After 30 min. increase the speed in 5 steps (with 10 min. intervals) from min. to max. This is done to ensure that any moisture absorbed by the brushes is dried out without damaging the motor or the brushes. After 3.000 hours it’s recommended to replace the complete brush holder module. Make a positioning mark of brush holder module so you can recognize the brush holder position. Loosen the 4 x 4Mx16 screws which hold the brush holder in position. Remove the brush holder module and replace it with a new one. Turn the brush holder to the marked position and tighten the 4 screws. Fine tuning: Measure the current by a clamp meter, and adjust the bushes (brush holder) for lowest current.

Motor Gearing Timeing Belt

Lifetime: Yearly: Replacement

Up to 5.000 hours during normal conditions. Check for wear and tear. Check that it’s tight. After 3 Years it’s recommended to replace the Timeing Belt. Remove the safety cover, and loosen the screws on the front of the console. Replace the Timeing Belt, and lift the motor until the Timeing Belt is tight. Fasten the screws and put on the safety cover.

Throttle Yearly: No need for maintenance.

Motor Controller

Yearly: No need for maintenance, but check from time to time that the air-outlet on the back of controller box not is blocked. If the air-outlet is blocked, the controller can heat up and start reducing the output power until it has reached the operating temperature again.

Accessory parts Yearly: Check the local manuals.

Battery bank

Yearly: Check according to battery manufacturer’s technical manual. or.. Contact ASMO Marine for request of “Battery Guide”

MAINTENANCE

BEFORE DOING ANY KIND OF WORK WITH OR AROUND THE MOTOR, TURN OFF THE KEY-SWITCH AND REMOVE THE + WIRE FROM BATTERY BANK !

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- THOOSA 6000 - THOOSA 7000 - THOOSA 7000HT - THOOSA 9000 - THOOSA 13000 - THOOSA 17000 - SIDE MOUNTED THROTTLE - SINGLE TOP MOUNTED THROTTLE - DUAL TOP MOUNTED THROTTLE - MOTOR CONTROLLER - BATTERY MONITOR - AMC BATTERY CHARGER - CAD DRAWINGS, MOTOR, CONSOLE, GEAR SYSTEM - WIRING DIAGRAM - QUICK INSTALLATION DIAGRAM - SIZE & DIMENSIONING WORK SHEET - BATTERY WIRING 48V SYSTEMS - BATTERY WIRING 72V SYSTEMS - BATTERY WIRING 96V SYSTEMS

DATA SHEETS