Servicetraining Low Voltage – June 2021

ONLINE TRAINING
CONFIDENTIAL AND PROPRIETARY
Any use of this material without specific permission of Torqeedo is strictly prohibited
Contents
Introducing Torqeedo Group
Basics in Electrics
ESD – basic knowledge
Data communication
Battery technology

Service Partner equipment

Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 2
Torqeedo – The Company
§ Climate experts say we need to cut
greenhouse gas emissions by 45% over the
next 11 years
§ Torqeedo focuses on areas where zero-
emission and hybrid drives are already
competitive
§ Torqeedo was founded in 2005
§ Pioneer and global market leader for electric mobility on water
§ More than 100,000 electric propulsion systems in the field
§ Only company that has converted substantial market shares from combustion engines to electric mobility
§ Uncompromising focus on high-tech, maximum efficiency and complete system integration
§ Power classes from 0.4 kW to 200 kW on system level
§ Headquartered in Gilching near Munich (Germany)
§ 200 employees
§ Part of DEUTZ Group since 2017
§ Mechanical design, electronics development, software programming, purchasing, production, marketing, controlling,
sales and service directly in Gilching
§ Since 2012, Dr. Ralf Plieninger has been responsible for the management of Development, Supply Chain and
Manufacturing Processes as Managing Director
§ Dr. Michael Rummel joined Torqeedo as Managing Director in November 2019 and is responsible for Finance,
Marketing, Sales, Service, HR and IT
§ Today, we are active in more than 100 countries and work with more than 2,000 sales, service and boat building
partners.
§ Together, we are changing the way people move around on the water and making this type of mobility cleaner, safer
and more sustainable.
Torqeedo offices

Regional office North America

Regional office Asia-Pacific
Crystal Lake, IL (USA)
Bangkok (Thailand)

Coroporate headquarters and regional office EMEA

Gilching (Germany)
Production facility
Inning (Germany)

7
Service network
 Superior power train engineering

§ Latest brushless motor design with state-of-

the-art electronic commutation

§ Propeller calculation on highest standards

used in commercial shipping

§ Careful design-matching of motor, electronics,

gear, and propeller for superior performance

Source: Torqeedo
 Superior battery technology designed for multiple levels of safety features

§ Superior battery and safety technology

§ Combining performance, comfort and safety
§ Highest level of intelligence
§ Competitive pricing
§ Safe chemistry
§ Using only cells from top tier manufacturers
§ Safe cell casing
§ BMS with redundant safety
§ Additional Pyro Fuse
§ Waterproof IP 67

Source: Torqeedo
Perspective on Performance

Superior Perspective Superior Performance

Overall efficiency in percent

56

Input
Power 30-35

18-20

5-15
Overall efficiency

s
o

ds
s
ed

or

ar
ar

ot
Shaft

qe

o
m
tb

tb
r
To
Power

ou

ou
g
llin
ri c

e
o

in
Tr
ct

ol
e

as
El
Propulsive

G
Power
Record-level overall efficiency of all Torqeedo
outboards provides more speed and range.
Source: Torqeedo
Torqeedo offers a full electric product range from 1HP to 140 HP equivalent power

Cruise 2.0/4.0
Equivalent to
Travel
Equivalent to 5 & 8 HP Cruise 10
Ultralight
Equivalent to 1.5 & 3.5 HP Equivalent to
Deep Blue 25/50
1 & 3.5 HP 20 HP
Equivalent to
40 & 80 HP

Cruise
Pod Deep Blue
Saildrive 25
Equiv. to
5/8/20 HP Deep Blue inboard 50/100 Equiv. 40 HP
Equiv. to 40/80/140 HP

13
Torqeedo High Voltage System Deep Blue
– Designed for Performance and Safety

Onboard computer with contemporary style UI

Electronic throttle, key switch, kill switch

High power, high efficiency motor (max efficiency 98%),

suitable for saltwater cooling, J1939 interface

Connection box, contains hardware based

safety system
Marine Grade
Chargers

Fully integrated, norm conforming system

with professional safety features

Insulation Battery
monitoring damping

Pilot lines Battery

venting
Battery cooperation with
BMW i: high energy density, All components And many
superior quality and safety, waterproof more….
8-year capacity warranty

Source: Torqeedo 14
Electric mobility is feasible for luxury sailing yachts

Application: Luxury sailing yachts

§ Better user experience
- Harvesting energy from solar and hydrogeneration,
therefore less generator run time and silence on board
- Less smell, exhaust, oil/diesel spills
- Abundant clean energy on board
§ More sustainability
§ Low maintenance
Torqeedo in recreational segments

Sailboats Racing

Tenders Green Lakes Kayak fishing Sailing yachts 16

Torqeedo in commercial segments

Ferries & taxis Workboats

Autonomous Surface Vessels Remote areas Multi-purpose boats Rescue / Life Saving 17
And also the Queen relies on Torqeedo electric propulsion with her Royal Boat
Gloriana

Source: Torqeedo 18 18
Torqeedo Production (final assembly)

Torqeedo Gilching I mainly HV products Torqeedo

North America
Torqeedo Gilching II
Torqeedo Asia
Torqeedo Inning Pacific

Central Stock at MATRIUM

Munich/Olching Distributors,
Dealers &
BMZ Battery Assembly Customers
close to Frankfurt a.M.
Karlstein

Other OEMs
suppliers

Source: Torqeedo 19
What is Torqeedo Service?

§ Technical customer service

§ Management of worldwide service network (selection, training, support)

§ Claim management (own cases + service partner warranty claims)

§ Low voltage service workshops (analysis, repair, maintenance) + spare parts stocks (~800 different articles)

§ High and low voltage field service (Design-in, commissioning, analysis, repair and maintenance)

§ Spare parts management (definition, price calculation)

§ Definition of new aftersales products such as warranty extension, VIP-service, etc.

§ Creation of technical service documents

§ Interface customer / Torqeedo

§ Idea giver for product improvements and new products

Who is Torqeedo Service?

21
 Service KPIs (key performance indicators)

Customer satisfaction is our main KPI!

In 2020, our average service lead time was < 2 days

Source: Torqeedo
Why are you doing this training?

§ After this training you are ready to do service and get access to all necessary spare parts at a discounted price

§ You will know how to maintain, analyze and repair Torqeedo low voltage products

§ Improvement of your after-sales service capabilities

§ Perform warranty services on behalf of Torqeedo and get compensated for it

§ You will learn more about future technologies like electric motors, data communication, lithium batteries and also
about hazardous material and legal background

§ To know each other better and improve our cooperation

Source: Torqeedo
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology

Service Partner equipment

Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 24
Ohm´s law

R=U⁄I
Measuring voltage drop (V)

§ In the example the voltage drop = battery voltage

load
Measuring resistance / continuity ( R )

§ Examples, measuring resistance / continuity

§ Switch
§ Fuse
§ Cable run
Measuring current (A)

§ Reading current is one of the most trickiest as

current is measured in series with the circuit.
load Here you have to physically interrupt the flow of
current and put the meter in line.

§ Torqeedo systems usually contain higher currents

à Clamp meter is needed to read the currents

NB: This has to be a DC A type

Basics Torqeedo electronics

§ Transistor
§ Acts like a switch, which can be controlled by a microcontroller
§ Is only able to handle smaller currents and voltages

§ Mosfet = Field effect transistor

§ Basically same function as transistor but can handle higher voltages and currents
very fast
§ Used in Torqeedo systems controlling for example motor commutation
§ In TQ LV Systems max. Voltage 60V
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology

Service Partner equipment

Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 30
Electrostatic discharge

§ Discharge is caused by connecting two charged surfaces

§ Generation of electrostatic charge (Generation of via a low resistance path

potential differences): § ESD-Damage in electronics

§ Friction of two non-conductive surfaces § Instant damage

§ Material separation § Premature damage / Weakening - Failure

§ à Vulnerability of Electronic circuits

Source: Torqeedo
Electrostatic Discharge

Source: Torqeedo
ESD protection measures

§ Protection policy

§ Establish an ESD protected area § ESD-Transportation and Storage

§ Prevent generation of charges § ESD-Production / Assembly / Service

§ Prevent uncontrolled “violent” discharge § ESD-Protected Product

§ Resistance (antistatic): 100 KΩ bis 100 MΩ (depends on § Applicable standard: IEC 61340-5-1 -2 -…
application)

Source: Torqeedo
ESD-Transportation and Storage

ESD-Carton ESD-Boxes with Cover

Non metallized ESD-bag

Application:
Metallized ESD-Bag Only within ESD protected areas
Source: et-esd.de or within ESD shielded boxes
ESD-Production / Assembly / Service

Everything has to be connected with each other by a defined resistance.

Source: Mini Circuits

Source: esda.org
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology

Service Partner equipment

Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 36
 Data communication in Torqeedo Systems

§ Discussion

§ Imagine we would need one cable for every signal/value

transmitted in our systems – how many cables would that be?
Data communication in Torqeedo Systems

Data communication is just a stream of 1s and 0s. That´s why it´s called a serial bus
Data communication in Torqeedo Systems

§ Programmers love to show binary values as

hexadecimal

§ Hexadecimal is based on 16

§ Sometimes we need to recalculate decimal based

values to

§ Hex – for example when programming serial

numbers

§ Don´t worry – set the Windows Calc to

„programmer“ and just type in
Data communication in Torqeedo Systems

§ Master / Slave System

§ Up to 32 nodes
Data communication in Torqeedo Systems

Travel: Master included in BMS board Pod Drives: Master in Control Box
Data communication in Torqeedo Systems

• Must-have-tool for • CanBus Extension

professional service – the (Kvaser leaf light V2
Combox is an interface available on our shop)
for all Torqeedo products

• The Diagnostic Tool is

configured for all TQ Bus
products
Data communication in Torqeedo Systems

• Invented by Bosch

• ISO 11898

• Standard communication in automotive systems

• 2 Wire Bus Can High Can Low

• Up To 500 kbit/s (250 kbit/s in Torqeedo Lowvolt Systems)

• Since 2018 in Torqeedo Systems

Data communication in Torqeedo Systems

• Gateway and Bus Terminator including each 120 ohm resistor.

• Total Bus resistance = 60 Ohm

Data communication in Torqeedo Systems

• Drive Enable – High when • Can High + Low -> Inverted

driving and non inverted bus signal

• Charge Request – set high by • V-Bus – Bus voltage for

charger, wakes up batteries to powering
charge
• On – high when on button
• Emergency off – high when triggered
triggered (batteries blink red,
E34 on screen)
Data communication in Torqeedo Systems

• Translation TQ Can to TQ Bus

• Network management

• Charger management

• Master of the canbus system

Data communication in Torqeedo Systems

Possible entry point for combox

All nodes need battery power

Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology

Service Partner equipment

Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 48
Battery technology – basic knowledge

• Voltage U [V]

• Definition: the difference in electric potential between two points

• Current I [A]

• Definition: the rate of flow of electric charge past a point

• Power P [W] = U x I [V x A]

• Definition: the rate, per unit time, at which electrical energy is transferred by an electric circuit

• Capacity C [Ah] = I x t [A x s] 1h = 3600s

• Definition: the ratio of the change in electric charge of a system, to the corresponding change in its electric
potential

• Energy E [Wh] = P x t [W x s] 1h = 3600s

• Definition: energy equivalent to one watt (1 W) of power expended for one hour (1 h) of time
Battery technology – basic knowledge

• Most common batterie types:

Technology Energy Safety Nominal Self-Discharge Cycles
density V
WH/kg
NiCd 50 High 1,2V 20%/Month 500-800
Ni-MH 85 High 1,2V 30%/Month 300-800
Li Fe Po 4 100 Medium-High 3,3V 3-5%/Month 7000

Li-Io 180 Medium 3,6V 1-5%/Month 800-1500

Li-Po 200 Low 3,7V 1-5%/Month 1000
Pb 30 High 2,0V 3-20%/Month 500-800
 Battery technology – basic knowledge

• State of charge („SOC“, not identical to • Self-discharge

capacity!)
• If a battery is not in use, the battery will have
• Typically shown in % a self-discharge, depending on SoC and

• 100 % is a full battery, 0% is end of temperature.

discharge, not 0 V. • Typically less than 2% a month on Torqeedo

• Torqeedo voltage range is between 3,0 and batteries (incl. electronics).

4,15V. If a battery cell is below 2V, the cell • Optimal storage battery storage
can‘t be used in a save way anymore and the
• Li-Ion: SoC 40-60 %, temperature 15-20 °C
battery has to be disposed.
• Lead based batteries: SoC 100 %; cool as
possible, but no frost

• NiMH: SoC 40 %; temperature 20 °C

• NiCd: SoC 40 %; temperature 20 °C

Battery technology – basic knowledge

Source: Torqeedo
Battery technology – basic knowledge

Source: Torqeedo
Confirmation of compliance of battery service steps

• Use isolated tools • Charge batteries only on fire

resistant surfaces (Stone, flag,
• Use ESD protection
Fermacell, …)
• Do not wear any metal (such as • Charge only under permanent
watches, chains, metal zipper, control
…)
• Use only sand or fire
• Keep your working place clean extinguisher for metal to fight
from anything you do not use
against a fire of the batteries
• Keep any end of any wire either • Either drop a burning/smoking
soldered to a fixed point or battery into a huge amount of
isolated with a tape water (>1m³) or do not use any
• Disconnect the core pack from water
the PCB always in the following • Do not leave anything on the
order: Plus wires, balancing opened battery
connector, minus wires
• Follow strictly the steps in the
• Connect the core pack always in service manual
the following order: Minus wires,
balancing connector, plus wires
Battery technology – basic knowledge

Source: Torqeedo
Battery technology – basic knowledge

Charging

V A
overcharged

4,15

Normal 3,6
range

3,0

discharged

2,0

R.I.P.
0

t
Battery technology – basic knowledge

Discharging

4,15

Li Ion (k=1,05)

3,0

2,0

Pb (k=1,3)

C1 C2

0
C10 C20 C50

Peukert Factor / rate capacity effect

Battery technology – basic knowledge

Battery wiring

+ -
12V

+ -
12V
+
Motor
(48V)
+ - -
12V

+ -
12V

Source: Torqeedo
Battery technology – basic knowledge

Battery wiring

+ - + -
12V 12V
+
Motor
(24V)
-
+ - + -
12V 12V

Source: Torqeedo
Battery technology – basic knowledge

Battery / charger wiring

12 + 12 = 24
24V Charger
11 + 13 = 24

+ - + -
12V 12V
+
Motor
(24V)
-
+ - + -
12V 12V

12V Charger 12V Charger

Source: Torqeedo
Battery technology – basic knowledge

Corrosion

1. Electrochemical corrosion: iron nail in the water à rust

2. Galvanic corrosion: two different (chemical properties) metals in the water à

one metal destroys the other one

Source: Torqeedo
Battery technology – basic knowledge

Corrosion

3. Electrolytical corrosion: 10.000x faster than galvanic corrosion!

+ -
Radio 12V

+ -
12V
Delta = 36V ! +
Motor
(48V)
+ - -
12V

+ -
12V

Source: Torqeedo
Battery technology – basic knowledge

Corrosion

3. Electrolytical corrosion: 10.000x faster than galvanic corrosion!

+ -
12V

+ -
12V
+
Motor
(48V)
+ - -
12V

+ -
Radio 12V

Delta = 0V
But the risk of a disbalanced battery bank!
Source: Torqeedo
Battery technology – basic knowledge

Use zinc saver / galvanic isolator!

EN ISO 13297 / ABYC

Source: www.tbbecker.de
Battery technology – how to destroy aluminum
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology

Service Partner equipment

Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 66
Service Partner equipment

What do you need to do service?

• Service training

• Spare parts

• Tools (Hardware + Software)

• Service manuals / Service documentation à Service Website

• Experience

• Support

Source: Torqeedo
ESD-Production / Assembly / Service

Source: esda.org
Servicepartner Equipment – leak tester
Servicepartner tools

x
Service tools

• Good Quality METRIC

Tool Set
• Torx
• Allen
• Socket Wrench
• Spanners

• Circlip Tools
• Plier set
• Etc.
Service tools

OR
Service Partner equipment

20kg Sledge Hammer Torque Driver

Just kidding

Torque Wrench

Soft hammer

Shaft Seal grease

??
Contact Cleaner Inter dental brush
Thread locker
Anti seize

Source: Torqeedo
Service Partner equipment

• Selfmade Cruise 2/4 reference shafthead

• Makes life easier when diagnosting cruise

Source: Torqeedo
Service Partner equipment

• One of Torqeedo´s test pools • Good base for a selfmade test tank

• A testing tank is required • Good for Travel but rather to small for cruise 4/10

Source: Torqeedo
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 76
Technical training product overview

Travel 503/1003 & 1103

Travel 503/1003 facts

• Integrated on-board computer • Power In .5/1kW

• GPS Module • Thrust 1.5/3 hp

• Efficiency 48%

• Gear Ratio 1:7

• Transom bracket with manual trim • Weight: 33-34lbs

• Voltage 29.6V
• Pylon

• Rotor

• Stator

• Gearbox

• Power output stage

• Motor Communication
Travel 1103 facts/603

• Integrated on-board computer • Power In 1.1kW

• Thrust 4 hp

• Efficiency 49%

• Gear Ratio 1:1

• Transom bracket with manual trim • Weight: 38-39lbs

• Voltage 29.6V

• Pylon

• Rotor

• Stator

• Power output stage

• Motor Communication
Travel / Frequently Asked Questions, Errors

E06 Defect of the power supply (mostly battery, but can also be the cable)

E23 Tiller calibration

E30 Communication error battery - motor.

Check cables (corrosion, dirt, cable breakage, bad connection)

E43 Battery empty, charge and try again.

E45 Defective motor electronics

Source: Torqeedo

80
Technical training Travel 503/1003

• Travel 503/1003 • Internal short visible

• Problem: E45 damage

shorted PCB/water • Cable connection

damage issues

• Problem: E30 • Display foil not

continuity cable adhering properly
break/broken
pin/dirty contacts

• Problem: E22 water

damage display foil
lifting
Technical training Travel 503/1003

• Travel 503/1003 • Corrosion

• Broken tilt lever

• Bent tilt lever

• Casting damaged
Technical training Travel 603/1103

• Travel 603/1103

• Problem: E36 wrong capacitor type

installed (production problem)

• Problem: E30 continuity cable

break/broken pin/dirty contacts

• Problem: E22 water damage

display foil lifting

• Leak at the pipe threads

Travel / UL 1103 leakage test

• Adaptor for Travel pylon testing • Proper connection to the pylon

Travel/ Ultralight batteries

Travel 503/1003/1103 batteries

Source: Torqeedo
Travel/ Ultralight batteries

• Travel / Ultralight battery < 2015 • Max power before failure:

• Estimated lifecycle: 6-8years • I > 69A @ 1ms

• Cells: fixed in bottom housing • I > 55A @ 200ms

• BMS: external, changable • I > 45A @ 2s

• Note: Not available anymore

• Fuses for charger input:

• Use 80V fuses not 12V!

Source: Torqeedo
Travel/ Ultralight batteries

• >2015 One piece corepack and BMS

• Battery fully readable and flashable with the

combox.

Source: Torqeedo
Travel/ Ultralight batteries

• The Travel service tool has still some german

expressions…. Let us explain….

• Kap_relativ = SOC

• Kap_voll = full capacity => this is a dynamic value and is

learned by the BMS in tiny steps. If you got claims
concerning low range compare this value to the design
capacity of the battery

• i_akku_mittelwert: average outgoing current

• i_in charge: charging current – used for charger

diagnostic

Source: Torqeedo
Travel/ Ultralight batteries

• Firmware, Parameter file

• Firmware: • Parameter file:

• Travel / UL Battery firmware • Tells the battery which

contains the software of the designed capacity the
master for controlling the battery has
bus and motor • Sometimes a new battery
• Contains Software to contol could have a wrong
the battery states parameter file installed

• (remember the last slide –

capacity)

Source: Torqeedo
Travel/ Ultralight batteries

Source: Torqeedo
Travel/ Ultralight batteries

Source: Torqeedo
Travel/ Ultralight batteries

Source: Torqeedo
Travel/ Ultralight batteries

Source: Torqeedo
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 94
Ultralight 403/1103

Source: Torqeedo
Ultralight 403/1103

Ultralight – a great motor for waterhiking or kayak fishing

Source: Torqeedo

96
Ultralight 403/1103

Ultralight 402/403

Ultralight 403A 1103A

Source: Torqeedo

97
Ultralight 1103AC

Source: Torqeedo

98
Ultralight 403/1103

Source: Torqeedo 99
Products / Error FAQ

E03/E04 (Nur UL 403) Try to operate motor while tilted up – sometimes a sensor failure, try to unstuck the sensor by
gently hitting the shaft

E05 Blocked motor – Fishingline?

E30 Communication error between motor and battery – cable problem?

E43 Undervoltage battery

E45 Short in motor pcb (high voltage on battery)

Source: Torqeedo

100
Products / Error FAQ

„My motor spins but doesn´t have any

thrust“

Main issue:
Drive pin defective (Ultralight and Travel)

Source: Torqeedo

101
Products / Error FAQ

A big success for Torqeedo has been Travel/ Ul

series 401/801 and UL402 as well as Base
Travel

Source: Torqeedo

102
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 103
Technical training product overview

Cruise 2.0 / 4.0 R/T/FP

Cruise 2.0 / 4.0 R/T/FP facts

• Power In 2/4kW
• Shafthead
• Thrust 6/9 hp
• Master PCB
• Efficiency 56%
• Power Supply (Softstart)
• Gear Ratio 1:5
• Transom bracket with manual trim • Weight: 33-42lbs OB
34lbs Fixed Pod
• Pylon
• Voltage 24-48V
• Rotor

• Stator

• Gearbox

• Power output stage

• Motor Communication
Battery operational modes

Depending on the battery type, a Cruise motor can be operated in so-called smart mode or in lead acid mode (dumbmode).
The Smart mode is only possible with original Torqeedo batteries

Smartmode Dumbmode

Data connection required Only + and - connected to the battery

Pairing (enumeration) required during initial commissioning Capacity adjustment required at initial commissioning.

Precise range determination Accuracy depends on many factors (type, age)

Hydrogeneration possible No hydrogeneration

Source: Torqeedo

106
Example Cruise 2 in "Smart mode"

Source: Torqeedo

107
Example Cruise 2 in "Dumb mode"

Source: Torqeedo

108
Technical training Cruise 2.0 / 4.0

• Parts of the Cruise 2.0 / 4.0 R/T

• Top Cover

• Head Frame

• Transom Bracket

• Pylon
Technical training Cruise 2.0 / 4.0

• Parts of the Cruise 2.0 / 4.0 FP

• Electronic Box

• Flange

• Trimmable Adapter Block

• Profile

• Pipe Coupling

• Cable Gland

• Pylon FP
Technical training product overview

• Running of a Genset without buffer battery

Technical training product overview

• Master PCB commands, power

• Turns System on and off reduction, self

diagnostics
• Communication to all
devices • <2021 TQ BUS

• >= 2021 TQ LINK (TBA)

• Controls Speed

• Fixed Pod Control Box

• Softstart PCB • Voltage, Current
measuring
• Precharge for reducing
current peaks • Temperature measuring
for power supply

• GPS Module • Speed over water

• Outboard Shaft head • Range calculation
Cruise 2/4/ Frequently Asked Questions, Errors

E23 Tiller / Remote calibratation

E30 Communication error Control => motor. Check data cables to and from the control box.

E43 Battery empty, charge and try again

E47, E07 Defect of the motor electronics

E84 Communication battery(s) motorà enumeration error

Source: Torqeedo

113
Technical training Cruise 2.0 / 4.0

• External rotor

• Interanal stator with temperature sensor

• Power output stage with integrated communication

board in front of stator

• 2009-2016 shaft has actuation pin

• 2017 - now shaft with splined shaft

Stator
Technical training Cruise 2.0 / 4.0 Rotation reference

• This magnet ring is the reference for • The magnet ring has to be fixed on
the motor´s rotation encoder (located the shaft. The picture on the right
on pcb) side shows a failure on the motor.

• Motor has to be calibrated after The ring is not in rotation with the

replacing the pcb (Service tool) shaft, a proper motor control ins not
possible.
• Ability for exact rotation speed
calculation / motor circuit control • Fix magnet and run Calibration.
Technical training Cruise 2.0 / 4.0

•MOSFETs
• Cruise 2.0/4.0 motor

• Problem: Shunt-diode defective

• Problem: MOSFET defective

•Video –sound on
• Problem: Loose magnets

•Shunt-diode
Technical training Cruise 2.0 / 4.0 Water ingress

• Rubber buildup on shaft • Worn seals or incorrect grease • Corrosion buildup on PCB
Technical training Cruise 2.0 / 4.0

• Damaged Master PCB • E06 (soft start) or cable

set or faulty on/off
• Damaged Soft Start
switch)
• Damaged Remote
Throttle or Tiller

• Damaged Shaft Head

data cable
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4

Power 26-104 / 24-3500

Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 119
Safety concept Torqeedo Power 26-104 / Practice

Power 26-104 / 24-3500

Source: Torqeedo
Power 26-104 / 24-3500
Safety concept Torqeedo Power 26-104 /24-3500

• Power 26-104 • Power 24-3500

• The maximum energy is: • The maximum energy is: 139.2Ah x 25,2V = 3,507Wh

• 48 cells in parallel a‘ 2,25Ah = 108Ah x (7 cells in series • Power consumption is below 0.5W (Battery on)
a‘ 3,7V = ) 25,9V = 2797,2Wh. • Power Off timer prevents deep discharge on later
models
Power 26-104 24-3500 Storage

Batteries with this stickers turn off automatically after 48h

The 48h counter starts when charge or discharge <1A
Third party consumers like DC/DC converters might block this function

Servicepartners can disable the 48h auto off function (for use with
Bilgepump etc)
Warranty on deep discharge will be void!
Safety concept Torqeedo Power 26-104 / Practice

• No Cruise connected: negative loop needed

• Cruise connected: no negative loop needed

 Safety concept Torqeedo Power 26-104 / Practice

• Power 26-104 Corepack

• 7-CGR18650-48

• Short circuit currents over 3000 Ampere

• Welding currents

• Don’t wear conductive watches or jewellery

• Use insulated tools

 Safety concept Torqeedo Power 26-104 / Practice

• Power 26-104

• Upper Shell Spare part

se
Pyro fu
He
at
sin
k

Re
rts
Data po

co
ve
ry
di
od
e
CB
Signal P
CB
Power P
Safety concept Torqeedo Power 26-104 / Practice

When is the pyro switch activated?

Current > 365A
Temperature > 130C
Cell Voltage > 4.350mV
Discharge >1A when turned off
 Safety concept Torqeedo Power 26-104 / Practice

• The 2nd Protection will trigger the PSS.

• After activation, the PSS must be replaced (only by Torqeedo!)

• If activated, the voltage at the PSS socket will be > 12V.

• A red LED on the signal PCB will indicate this state.

R = Mohm or OL
U = >12V
RED LED on PCB
Safety concept Torqeedo Power 26-104 / Practice
Safety concept Torqeedo Power 26-104 / Practice
Safety concept Torqeedo Power 26-104 / Practice
Safety concept Torqeedo Power 26-104 / Practice

• Troubleshooting

• Service manuals

• Videos

• Diagnostics with Service Tool / Combox II

Cruise 2 4 PCB Change

https://www.youtube.com/watch?v=D1WTBwOaXyE
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 134
Technical training product overview

Cruise 10.0 R/T/FP/SD

Cruise 10 facts

• Power In 10kW
• Shafthead
• Thrust 20hp
• Master PCB
• Efficiency 56%
• Power Supply (Softstart)
• Gear Ratio 1:5
• Trim control board
• Weight: 132-139lbs OB
73lbs Fixed Pod
• Transom bracket with electrohydraulic trim
• Voltage 48V
• Pylon

• Rotor

• Stator

• Gearbox

• Power output stage

• Motor Communication
Cruise 10.0 battery options

• Currently two model years:

• < 2021 => Compatible with all battery types (gateway
required for TorqLink)
• => 2021 => Only compatible with Power 48-5000 (no
gateway required) not totally true

• Minimum configuration to operate the Cruise 10.0

• 2x Power 48-5000
• 4x Power26-104 / 24-3500
• 4x Conventional 12V battery (double the number
recommended to achieve a reasonable range)

Source: Torqeedo

137
Technical training Cruise 10.0

• Parts of the Cruise 10.0 body

• Transom bracket • Lower body parts and pylon • Bracket front

Technical training cruise 10

• Master PCB • Controls Speed

• Turns System on and off commands, power

reduction, self diagnostics
• Communication to all
devices • < 2021 TQ BUS

• > 2021 TQ LINK

• Fixed Pod Control Box
• Softstart PCB measuring

• Precharge for reducing • Temperature measuring

current peaks for power supply

• Voltage, Current

• Tilt PCB • Controls hydraulic pump

• Outboard Shafthead
for tilt and trim
Cruise 10 Frequently Asked Questions, Errors

E23 Tiller / Remote calibration

E30 Communication error Control => motor. . Check data cables to and from the control box.

E43 Battery empty, charge and try again

E47, E07 Defect of the motor electronics

E84 Communication battery(s) motor. Enumeration needed

Source: Torqeedo

140
Technical training Cruise 10 Motor

• Internal rotor • Communication board at the rear

• Outer stator with temperature • 2016-2019 gearbox with straight

sensor gears

• Power output stage at the rear • 2019- now low noise gearbox
(compatible)

• Clamp • Gearbox
• Stator

• Rear ball bearing

• Rotor
Technical training Cruise 10

• Communication PCB

• Internal CAN BUS

• Communicates with Master PCB

Technical training product overview
Technical training Cruise 10

• New Cruise 10 main switch 2021

Technical training Cruise 10
Technical training Cruise 10
Technical training Cruise 10
 Preview repair C10 Pylon

§ Rear view of the new mounting plate

§ Signal PCB and power stage removed

 Preview repair C10 Pylon

§ Take your time to install the new thermal pad

§ Wrong installed pads can lead to shorts or

bad heat transport
 Preview repair C10 Pylon

• Conductive rear side of motor pcb

• When reinstalling clean that side
remove thermal pad residue
Preview repair C10 Pylon

• Installation material is going to be

delivered in a kit.
 Preview repair C10 Pylon

• Using the correct

installation order and
torque settings is extremly
important!

• Service manual and videos

will be available soon
 Preview repair C10 Pylon

• Be careful! There are lots of sensitive

SMD parts on the PCB!
 Preview repair C10 Pylon

• Spacers and connectors

for the signal pcbs.

• Hardest part to install!

Technical training Cruise 10

• Some shafthead covers are not fitting well and let water go past the seal:

• Improvement:

• Shorter screws needed!

• New foam shafthead sealing

Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 156
Power48-5000

§ Power 48-5000 the ideal battery for the Cruise 4.0

since it is straight 48V
§ Replaces i.e. 2x Power 24-3500 in series or 4x12V
conventional lead acid traction batteries
§ Motor requires an additional "translator / gateway".

Source: Torqeedo

157
Power 48-5000

§ Loads the Power 48-5000 from 0 to 100% in a maximum of 10

hours

§ The Power 48-5000 system can consist of up to two parallel

connected batteries. Up to three chargers can be connected to
the Power 48-5000 system for faster charging

§ Waterproof IP65

§ Charging current 13 A

§ Charging current 50 A

§ Charges one Power 48-5000 from 0 to 100% in < 2 hours,

§ Waterproof IP65

§ When using the aluminium throttles (1949-00, 1950-00,

1951-00, 1952-00) or the TorqLink throttle (1976-00), the
charging power can be adjusted via menu setting

Source: Torqeedo

158
Example Cruise 4 im „Smartmode“ mit Power 48-5000

Source: Torqeedo

159
160 Technical specifications

Data Power 48-5000

Property Value
Nominal voltage 44.4 V
Charging cut off voltage 50 V
Discharging cut off voltage 36 V
Maximum voltage at the terminals 50 V
Maximum discharge current 200 A
Ambient temperature, storage -25°C to 60°C
Ambient temperature, charging 0°C to 45°C
Ambient temperature, discharging -10°C to + 50°C
Nominal energy 5275 Wh
Usable energy 5000 Wh
Series connection Not allowed ** more batteries
only via special
Parallel connection Max. 2 batteries with TQ CAN Network and Torqeedo gateway kit **
release from
IP-Protection IP 67
Torqeedo
Data charger Application Engineering
Charger 650-Watt 2213-00 Charger 2900 Watt 2212-00
Property Value Value
Input voltage 100-240 V A C / 50-60 Hz 100-240 V A C / 50-60 Hz
Frequency 50-60 Hz 50-60 Hz
Power consumption 3,33 A 16 A
Output max. (with 100 V input 650 Watt 2900 Watt by 185 V A C
voltage) (650 Watt) (1400 Watt)
Battery type Power 48 5000 Li Ion Power 48 5000 Li Ion
Charger starting voltage 36 V 36 V
Efficiency 93% 93%
Refrigeration passive Active cooling unit with an integrated fan
IP-Protection IP 65 IP 65
 Battery
Source: Torqeedo
161 fixation
 LED display

Smart mode: white LED at an interval of 0,5 seconds

Source: Torqeedo
164

Operating modes

• Boot mode (bootloader)

This mode allows a firmware update to be carried out. In this mode no discharging or charging is
possible.

• Active mode (application)

In this mode the battery is in use, which means that it can be discharged or charged, or it prevents
this in the event of an error.

• Deep Sleep mode (supply and CPU switched off)

The battery has switched off in order to consumes as little power as possible, for example during
storage or undervoltage. In this mode no discharging or charging is possible. After waking up - for
example by the charger - the battery changes to active mode.

• Shipping mode

This mode should allow storage periods after production of up to 1,5 years.
Specified at 30% SOC and 25°C ambient temperature.
 Safety
Source: Torqeedo
165 concept
 Safety
Source: Torqeedo
166 concept overcharging

Double overcharging safety system

1. Charger voltage and current are primarily regulated via communication.

2. In the event of any fault, the 2nd protection of the battery HW then independently disconnects the
charging circuit.
Power 48 – leakage test

• Leakage testing for Power48-5000 is only possible as a vaccum test

• Our leakage tester can´t handle the membrane water test.

Hardware Versions

• V3

• First version in series

• Often had problems with balancing

currents (red light error)
Hardware Versions

• V3.5

• Improved Version, Capacitor

prevents circuit damage due to high
balancing current
Hardware Versions

• V4

• Newest Version

• Additional Fuse

• Revision B
FAQ KNOWN PROBLEMS

• Battery LED is fixed RED

• Disbalancing between batteries causes high currents

• Tilting Cruise 10 while battery is boot sequence

• Using DC/DC converters (actually not allowed)

• Pyrofuse blown

• Charger does not charge, shows Error

• Often on first operation – customer uses wrong charging sequence

• E84/82

• Installation of batteries with different voltages

• Gateway disconnects battery for balancing

• Battery does not turn on

• Battery deep discharged

• Button or key switch defective

Corepack voltage deep discharge

• If the battery does not turn on anymore it

could have the following reasons:

• Button defective

• Electronic problem

• Corepack voltage under security level (deep

Discharge)

• Minimum voltage for recharging: 21V ???

• Recharging can be done using a adjustable

power supply.

• Note: Charging current is proportional to

charging voltage. Set the voltage 1.5V higher
than the corepack voltage and readjust after
the current sinks under 1A. As soon the
battery electronics turns on again you can use
the original charger.
Power 48-5000 Hardware Versions

• E82 Problem

• Wanted behavior if gateway turns

battery off for balancing

• with Gateway >2.029 this battery is

hidden from the master -> E82 +
E84

• Unwanted behavior due to

calibration problem (SOC does not
fit pack voltage)

174
Power 48-5000 chargers

• Two charging modes: Smartmode with gateway, Dumbmode without gateway.

• Charge request set to high when plugged in -> wakes up battery and gateway

• System has to be switched off when charging in Smartmode

• Uses batt. Voltage when operated in dumbmode

• Uses commands from gateway when operated in smartmode

• Known failures

• Customer uses wrong plug-in sequence

• Charger does not charge to full – wrong calibration parameters (Models 2018)

• Charger gets hot and does not charge to full (production failure 2001-xxxx)

Source: Torqeedo
Power 48-5000 chargers

• Display problem. Chargers are not waterthight -> Warranty

Source: Torqeedo
Fastcharger Power48

• Charging current 60A

• Consumes 14A @ 230V !

• Charging power reduction with TQ Link

throttle

• Known failures:

• Charger only operates with gateway

Version > 2.028

• Gateways with lower software cause

A69

Source: Torqeedo
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 178
Tillers an Throttles

Source: Source Arial Nova Light 9 pt plain 179

Tillers and Throttles

• Tiller used for Travel/Cruise 2/4 • Tiller PCB. Main part of

since 2010 tiller/throttle. Contains display,
buttons, hall sensor for magnetic
pin and logicboard

Source: Torqeedo
Tillers and Throttles

• Throttle 1918-00. Used for Travel

and Cruise models. Basically the
same as the tiller but pcb not
replacable.

• The earlier mentioned problem of

suddenly stopping motors only
appear with the throttle, not with the
tiller.

Source: Torqeedo
Tillers and Throttles – Parts and malfunctions

• Metal round – placed under the magnetic key gap. Sometimes falls off

• -> Magnetic key does not stay on place anymore. Can be fixed with adhesive

• Diametric magnet + rotary encoder. Missing magnet or

• defective encoder can cause E22 and E23 Errors

• Membrane – defective membrane causes water ingress – test for

watertightness!

• Cable failures can cause communication problems

Source: Torqeedo
Tillers and Throttles – Parts and malfunctions

Source: Torqeedo
Tillers and Throttles – Leakage testing

Source: Torqeedo 184

Tillers and Throttles

• TQ Link throttles

• Can Communication (Gateway set needed for TQ-BUS Motors)

• For TQ-CAN Cruise Motors and Deep Blue without gateway

• Same firmware for all types

Source: Torqeedo
Tillers and Throttles / Malfunctions

• E34 / E85 on startup, shutdown >> Softwarebug,

update cruise
• E34 – Emergency off triggered
• No Display light -> Software bug -> Update
• Throttle can´t be calibrated after replacing
display -> changed rotary encoder 2019 ->
Replace encoder
• Lock button on side mount throttle stuck -> bad
material -> replace button
• Tilt does not work -> Tilt on throttle only works
for Deep blue (Not entirely correct)

Source: Torqeedo
Tillers and Throttles / Malfunctions

• Twin throttles need a neutralisation of the potential between port and starboard
batteries

• Situation: Minus side of starboard and port batteries are not connected
via a 35mm² cable.

• If only one battery bank is activated it can cause a potential

balancing over the twin throttles electronic.

• This causes electric failures of the throttle electronic

• Indicators:

• Weird error messages

• Flickering leds

• Slow canbus reaction

• Buzzing sounds.

Source: Torqeedo
Throttle / Malfunction Twin Cruise Systems
Tillers and Throttles

• Defective displays due to high pressure on the screen

• Mostly customer fault

Source: Torqeedo
Tillers and Throttles

• New TQ Link throttle 2021

• Has bus terminator inside

• Works only for cruise 10 TQ Link - yet!

This throttle is completely closed. No repairs on pcb possible

• No known failures anymore

Source: Torqeedo
Repair Video Tiller

https://www.youtube.com/watch?v=xzPB-9mIPb4
Very Helpful New Trouble Shooting Manual
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 193
Torqeedo Service Website (Preview)

www.torqeedo.com https://service.torqeedo.com/
Torqeedo Service Website Going forward

How you can help me to help you?

Please send me an e-mail officially

requesting full access to the Service Partner Web
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 196
 HAZMAT

Postponed to next session in July

Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 198
Warranty Conditions

Warranty ≠ Warranty (Guarantee)

We have to distinguish between two kinds of warranty:

1. Manufacturer Warranty (voluntary)

2. Legal Warranty / Guarantee (mandatory)

Torqeedo
Warranty Conditions

Source: Torqeedo 199

Legal Warranty (German law) – typical questions for the daily business

(1) How often can we repair the same problem?

It depends on the complexity of the repair, but regular 2 times.
(2) What is a reasonable time for repair?
Up to 2 months if the customer gave us a deadline. If we break this deadline we
have to inform and explain the customer why it takes so long. Basically the
customer has the right to give the product back or to get a reduction of the price.
(3) Does the warranty start again after repair?
There is no clear legal practice! We offer a maximum of 6 months after the end
of the 2 year warranty for the repaired part.
(4) Can we use used parts for repair?
Yes, if they work in the same way like new ones. à e.g. parts from upgrade offers
(5) How long do we have to keep spare parts for products which we do not sell anymore?
There is no clear legal practice! The recommendation is 5 years if the costs to
do this are not disproportionately.

à There can be different laws in your country!

Source: Torqeedo 200
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 201
New Service Partner Agreement

?
Contents
Introducing Torqeedo Group
Basics in Torqeedo electronics
ESD – basic knowledge
Data communication
Battery technology
Service Partner equipment / Service Website
Travel 503/1003/603/1103 incl. battery
Ultralight 403/1103
Cruise 2/4
Power 26-104 / 24-3500
Cruise 10
Power 48-5000
Tillers/Throttles
Servicepartner website
Hazardous material (HAZMAT)
Legal background
Service Partner contract
Feedback, Discussion 203
Feedback

How was the training?

What was good?

What could have been better?
Any other questions please via the
messaging function or raise hand
Your contact to Torqeedo

Now:
[email protected]
Phone: +6596222100

Soon:
email: [email protected]
Phone: +6596222100

205
THANK YOU FOR YOUR TIME AND ATTENTION

206