MotoCrane Ultracap Power Core User manual
UPC Operation Manual v1.0
December, 2019
To minimize risk of serious injury, death or
damage, before using MotoCrane UPC, all
drivers and operators must read this
Operation Manual and all on-product labels.
All practices and procedures stated herein are
required for the proper and safe operation of
the UPC.
If there are any questions, please contact
MotoCrane Support at
Keep this Operation Manual near your UPC for
future reference.
Safety Signal Words
This manual and the safety labels attached to this equipment utilize signal words that
signify safety hazards with different levels of severity. The words are preceded by a
triangle signifying that these are safety related. Below are the words used and the
definitions for these words:
● indicates a hazardous situation which, if not avoided, could result
in death or serious injury or damage
● indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury or damage
● is used to address practices not related to physical injury
The terms IMPORTANT and NOTE are also used to describe ideas for better and more
efficient use of the UPC.
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Contents
Safety Signal Words 2
Contents 3
Before the First Drive 4
IMPORTANT PRODUCT AND SAFETY INSTRUCTIONS 5
Safety 5
IMPORTANT: Restricted Use Statement 5
Disclaimer and Limitations of Liability 5
Limited Warranty 6
Intellectual Property 6
Parts of the UPC 7
UPC System Overview 7
Setting up the UPC 8
Setup Process 9
Using the UPC 11
UPC Interface 11
Known Hazards 13
Transporting the UPC 13
Troubleshooting 13
Diagnosing with COM and CHARGE LEDs 13
Diagnosing with GUI Warning and Error Messages 14
Maintenance 18
Weather & Water 18
Specifications 18
Mounting/Dimensions 19
UPC Connection Diagram 20
Revision History 21
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Before the First Drive
Do the following before using the UPC for the first time.
1. Read this Operation Manual
2. Read the Warranty in the Terms of Sale
3. Watch any available video tutorials at www.motocrane.com/support
4. Recommended: Attend MotoCrane Training for in-person demonstration
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IMPORTANT PRODUCT AND SAFETY
INSTRUCTIONS
Safety
The MotoCrane UPC is not a toy and can cause serious injury, death or damage if not
used properly. You must exercise caution during use of the UPC to ensure a safe
filming environment for everyone. This Operation Manual describes safe operation and
should be read in conjunction with the applicable online training videos or additional
in-person training.
IMPORTANT: Restricted Use Statement
The UPC must only be used by trained operators 18 years of age or older. Only
appropriate motor vehicles driven on a closed course with paved or finished surfaces
(for example, asphalt, concrete, or tarmac) or moderate off-road (for example, gravel or
dirt roads) conditions may be used. In addition, the speed and acceleration of the
motor vehicle must not exceed system ratings for MotoCrane products as set forth in
this Operation Manual.
Do not modify or adjust the UPC. The UPC has been calibrated before it is shipped to
you. No modification or adjustment to the UPC is allowed without the express written
approval of MotoCrane, LLC.
Disclaimer and Limitations of Liability
You agree that you are responsible for your own conduct and any content created
while using the UPC, and for any consequences thereof. You agree to use this product
only for purposes that are proper and in accordance with local laws, regulations or
other legal requirements.
You also agree:
1. Any part of this disclaimer is subject to change without prior notice. Refer to
www.motocrane.com/support for the latest version.
2. MotoCrane, LLC reserves the right of final interpretation of this disclaimer.
3. MotoCrane, LLC has no control over the use, setup, assembly, modification or
misuse of the UPC, and therefore no liability shall be assumed or accepted by
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MotoCrane, LLC for any resulting damage, death, or injury incurred directly or
indirectly from the use of the UPC. By the act of use, setup or assembly, the user
accepts all resulting liability.
Limited Warranty
The UPC has a limited manufacturer's warranty on parts and assembly. See the Terms
and Conditions of Sale for your UPC for a complete description of this limited warranty.
This Limited Warranty is incorporated by reference into this Operation Manual.
Intellectual Property
MotoCrane™, UPC, and are trademarks of MotoCrane, LLC. You may
not use the trademarks of MotoCrane, LLC without express written permission. All
rights reserved.
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Parts of the UPC
●UPC Module
●10’ Power Output Cable
UPC System Overview
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Setting up the UPC
UPC Setup at a Glance
Below is the proper start-up sequence of the UPC. A summary of this procedure is also
indicated on the front panel of the UPC (labeled “STARTUP SEQUENCE”):
1. Confirm all switches are in the OFF position.
2. Connect the charge input power source (48V input socket or 4 V-Mount
batteries on the top lid).
3. Select the appropriate power source with the INPUT SELECT SWITCH, make
sure the voltmeter shows expected voltage.
4. Connect the UPC output cable to the PSU. Make sure the PSU MAIN PWR switch
is in the OFF position.
5. Turn the CHARGE INPUT SWITCH ON.
6. Turn the 48V POWER OUTPUT SWITCH ON to begin charging the
ultra-capacitors. Allow around 4min to charge. Once the READY LED turns
green, Turn ON the PSU MAIN PWR switch. Make sure that the PSU voltmeter
displays 48V and that the COM LED on the UPC turns on.
: Failure to follow these instructions and those below can result in serious
injury, death or damage.
These instructions will be demonstrated in our training videos and found online at
www.motocrane.com/support. All terminology is referred to in the above diagrams.
8
Setup Process
NOTE: UPC setup should occur before the MotoCrane Power Supply Unit (PSU)
setup. See ULTRA Operation Manual for more information.
There are three switches on the UPC front panel, as shown below:
To properly power on ULTRA with the UPC, the switches must be activated in the
following sequence:
1. Choose input with the INPUT SELECT SWITCH
2. Turn on the COM circuitry with the CHARGE INPUT SWITCH
3. Charge the ultra-capacitor bank with the 48V POWER OUTPUT SWITCH
The INPUT SELECT SWITCH allows the user to select between two power sources:
●an external 48V input (such as the 12VA)
●the BATTERY ARRAY (V-Mount) input.
To select the 48V external input, 48V power source must be connected to the 48V
INPUT socket (under the switch) and the INPUT SELECT SWITCH must set towards the
48V socket. At this stage, the input voltmeter should display the input voltage (48V).
To select the BATTERY ARRAY input, all four V-Mount batteries must be connected to
their mounting plate on the top lid of the UPC and the INPUT SELECT SWITCH must
be set towards the BATTERY ARRAY label. The input voltmeter should display the
series voltage of the four V-Mount batteries (from 50V to 67V, depending on the
charge levels of the batteries).
While BATTERY ARRAY input is selected, the UPC will not turn on without
4 V-Mount batteries connected.
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The CHARGE INPUT SWITCH turns on the circuitry that allows the UPC to
self-diagnose and communicate with ULTRA. This gives the user insight on the different
UPC parameters (input battery voltage levels, ultra-capacitor temperatures and charge,
power consumption etc..). Refer to the ‘UPC Features’
section to see all the UPC
parameters and data displayed on the ULTRA controller.
The 48V POWER OUTPUT SWITCH electrically separates the ultra-capacitor bank to
the rest of the UPC. To begin charging the bank, turn this switch to the ON position.
When the ultra-capacitors are charging, the CHARGE LED will be yellow. The LED will
clear once the ultra-capacitors are fully charged. Note that the ultra-capacitor bank
does not need to be charged to its maximum voltage (29V) to power on ULTRA. Once
the bank reaches a voltage of 21V, the UPC is ready to power ULTRA through the PSU.
The READY LED will turn green when the ultra-capacitor bank reaches 21V, notifying
the user that the UPC is ready to power up ULTRA (the PSU switch MAIN power can be
turned on).
Wait until the READY LED turns green before turning on the PSU.
During normal operation, the UPC will expend energy stored in the
ultra-capacitors, causing the yellow CHARGE LED to turn on. This is normal but can
indicate a temporary decrease in performance until recharging is complete. Please
refer to the indicators on the controller to determine state of charge.
NOTES ON ULTRA-CAPACITOR CHARGING
The time it takes to charge the ultra-capacitors depends on the initial voltage level of
the bank. If the UPC has not been used for more than a day, the voltage levels of the
ultra-capacitors should be relatively low (less than 6V) and it will take around 4 minutes
to charge to 21V (READY LED turns on) and around 5 minutes to charge to 29V
(maximum voltage).
If a fault occurs while the ultra-capacitors are charging, the CHARGE LED
will change from yellow to RED. Do not power on the PSU if the CHARGE LED is RED,
and immediately turn the 48V OUTPUT POWER SWITCH to the OFF position.
If ULTRA is not connected to the UPC when the fault is occuring, the UPC
will beep. Otherwise, the controller will beep.
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Using the UPC
The UPC is a high power device, capable of providing power to MotoCrane ULTRA,
even during the most demanding applications. The UPC is designed to provide a user
experience continuous with that of a conventional battery. However, with the UPC
there are some features and protections that the user should recognize in order to
ensure safe and reliable operation. The UPC has built in intelligence and
self-diagnostics, just like the rest of the ULTRA system. The user can access UPC
diagnostics and real-time information from the ULTRA Controller GUI. Please see the
‘UPC Interface’ section for reference on the information contained within the UPC
Diagnostics portion of the GUI.
UPC Interface
The upgraded ULTRA Controller GUI redirects all DIAGNOSTICS buttons to a new
DIAGNOSTICS sub-menu, shown below. The standard ULTRA DIAGNOSTICS can be
entered by pressing the button on the left, while the new UPC DIAGNOSTICS can be
accessed by pressing the button on the right. SYSTEM LOG information about both
pieces of the system can be accessed through the SYSTEM LOG button on the
DIAGNOSTICS sub-menu. For further information about standard ULTRA
DIAGNOSTICS features and general GUI organization, please refer to the ULTRA
Operation Manual.
The UPC DIAGNOSTICS page is shown in the following figures. Depending on the
configuration of the UPC, the V-Mount battery gauges may or may not be present. If
you are using the 4 V-Mount batteries as the power input source of the UPC, you will
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see real-time battery level information. If you are using the 12VA as an input source,
the battery gauges will be absent. Note the differences in the following figures:
***Numeric Battery Array voltages should be used for reference only, as actual voltage
may differ by up to 300mV (.3 volts)
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Known Hazards
The following list represents a list of known hazards that exist when
operating the UPC. This is not exhaustive, but represents some common hazards to
watch out for.
●UPC mounting. The UPC should not be subject to movement relative to
the vehicle during operation. Make sure the UPC is secured and does not
slide. Keep any moving objects away from the UPC switches.
●Input power source. Make sure the power source input is robustly
connected to the UPC. For the 48V external input, make sure the power
source is properly mounted (no sliding). For the Battery Input source,
makes sure the V-Mount batteries are correctly installed on the mounting
plates.
●User awareness. The user should be aware of the different UPC
parameters, warnings and errors displayed on the controller. If the
controller is not connected to the UPC, the user should pay close
attention to the LEDs on the UPC front panel.
●Capacitor charge level. The user should be monitoring the ultra-capacitor
charge level gauge at all time. Do not let the ultra-capacitors discharge
below 0%. The ULTRA controller will notify the user with a warning/error
when the charge level is getting too low.
Transporting the UPC
●All switches must be in the OFF position,
●48V external input and/or V-Mount batteries should be disconnected from the
UPC
●storage temperature between -40°C and 70°C
Troubleshooting
Diagnosing with COM and CHARGE LEDs
The UPC contains three LEDs to assist in operating the unit safely, as well as to assist
with debugging in the event that an issue arises. The COM LED will turn on when the
UPC electronics are successfully communicating on the CAN-bus with the other parts
of the ULTRA system. Keep in mind that the 48V POWER OUTPUT SWITCH needs to
be turned ON for the electronics in the UPC to function. For the COM LED to be
present, the following conditions must be satisfied:
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1. The UPC is connected to the ULTRA PSU, and the ULTRA system is fully
connected (i.e. all cables are connecting the ULTRA modules to the PSU)
2. INPUT SELECT SWITCH is set to the correct source of power (e.g. set to
‘BATTERY ARRAY’ if 4 V-Mount batteries are connected)
3. CHARGE INPUT SWITCH is turned ON
4. 48V POWER OUTPUT SWITCH is turned ON
5. Ultracapacitor bank is charged to at least 21V
6. The ULTRA PSU MAIN POWER INPUT SWITCH is turned ON
If all of these conditions are satisfied, and the COM LED is off, this indicates that either
the electronics in the UPC have stopped functioning properly, or a wiring issue has
developed that prevents normal communication to occur. If COM LED issues are
occurring elsewhere in the ULTRA system, please refer to the ULTRA Operation Manual
for further debugging.
Under normal situations the CHARGE LED will be either a yellow color (while charging),
or completely off. If a problem arises within the UPC that affects the charging circuit,
the CHARGE LED will turn RED. If this happens, please turn OFF the 48V POWER
OUTPUT SWITCH and contact MotoCrane Customer Support for further debugging
and diagnostic procedures.
Note that if a fault occurs when ULTRA is not connected to the UPC (PSU is not
connected), the CHARGE LED will buzz in addition to turning RED.
Diagnosing with GUI Warning and Error Messages
ULTRA has multiple internal sensors and an error reporting system built into the GUI.
The UPC shares this error and warning reporting infrastructure and allows the user to
monitor these events via the Controller GUI. If an active error or warning is present, the
respective red or yellow icon will be displayed. A yellow icon indicates a warning, and
the controller will beep once to alert the user. A red icon indicates an error, and the
controller will beep repeatedly until the icon is touched or the DISARM physical switch
is pressed by the user. Touching the error or warning icon will bring you to the Status
page, where you can see a list of active errors and warnings. If you are experiencing an
intermittent issue, and the warning or error is not currently active, you can review
events by navigating to the System Log, which is accessible through the Diagnostics
page. The System Log will also provide a list of errors and warnings that have occurred,
along with the time since the event occurred (in 2 minute increments). Note that the
System Log will only hold the most recent 10 events. Note that the system log events
are retained upon power cycle, but all time information is lost. From either the Status
or System Log page, you can access the Code Lookup Table, which will provide you
with a short description of the error or warning and a recommended first step for
troubleshooting and clearing the issue. For reference, the ‘Controller - GUI’ section of
the ULTRA Operation Manual shows the location of the System Log and Code Lookup
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buttons within their respective pages. More detail is given below about each error
message along with a description of what to try if the first step does not work.
**When debugging any error or warning, first ensure that all cables are properly
connected and check the status of the COM and CHARGE LEDs
Code
Description
Service
Details
142
Power
Accessory Input
Voltage
Warning
●Ensure correct voltage
of input power source
If using 4 V-Mount batteries, this warning
will be triggered if the input voltage is
below 51V or if a single V-Mount
battery’s input voltage is below 12.8V. If
using the 48V input, this warning will be
triggered if the input voltage is below
46V.
143
Power
Accessory Input
Voltage Error
●Ensure correct voltage
of power source
If using 4 V-Mount batteries, this warning
will be triggered if the input voltage is
below 49.5V or if a single V-Mount
battery’s input voltage is below 11.9V. If
using the 48V input, this warning will be
triggered if the input voltage is below
45V.
147
Power
Accessory
Over-Current
Error
●Disarm system and
remove power source
●Ensure the proper
power source is being
connected
The main UPC processor communicates
with the current-limiting charging circuitry
to ensure that the charging current
amplitude never exceeds a certain level
(9A). If this threshold is exceeded, this
error will be triggered. If this error
persists, contact Customer Support.
152
Power
Accessory
Over-Voltage
Error
●Disarm system and
remove power source
●Ensure the proper
power source is being
connected
The main UPC processor communicates
with the current-limiting charging circuitry
to ensure that the charging voltage
amplitude never exceeds the maximum
allowed voltage for the ultra-capacitor
modules. If this threshold is exceeded,
this error will be triggered. If this error
persists, contact Customer Support.
154
Power
Accessory
Ultracap Level
Warning
●Reduce use until the
Ultracaps have the
chance to charge more
To ensure that the UPC is outputting 48V
to power ULTRA, the ultra-capacitor bank
must be within a certain window of
voltages (21-29V). The percentage gauge
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on the ULTRA controller shows that
voltage window mapped from 0 to 100%.
If the percentage goes below 25%, a
warning will be triggered.
155
Power
Accessory
Ultracap Level
Error
●Discontinue movements
immediately
●Reduce use until
Ultracaps have the
chance to charge more
To ensure that the UPC is outputting 48V
to power ULTRA, the ultra-capacitor bank
must be within a certain window of
voltages (21-29V). The percentage gauge
on the ULTRA controller shows this
voltage window mapped from 0 to 100%.
If the percentage goes below 10%, an
error will be triggered.
157
Power
Accessory COM
Warning
●Disarm system and
power cycle PSU and
UPC
Within the UPC, several communication
channels exist. This warning indicates
that the communication has been
intermittent between the main UPC
processor and the current-limiting
charging circuitry. If a power cycle does
not solve the issue, or the issue persists,
contact Customer Support, as the
electronics may be malfunctioning and
require replacement.
158
Power
Accessory COM
Error
●Disarm system and
power cycle PSU
and UPC
Within the UPC, several communication
channels exist. This error indicates that
the communication has been lost
between the main UPC processor and the
current-limiting charging circuitry. If a
power cycle does not solve the issue, or
the issue persists, contact Customer
Support, as the electronics may be
malfunctioning and require replacement.
162
Power
Accessory Temp
Warning
●Use caution and watch
temperature in the
Diagnostics page of the
Controller GUI
The charging circuit used to safely
manage the ultra-capacitors generates
significant heat while actively managing
charging current. A certain amount of
heat is normal. If the temperature
exceeds a safe range, this warning will be
triggered. If the warning is consistently
triggered, contact Customer Support, as
there may be an issue with your UPC.
163
Power
●Disarm and discontinue
The charging circuit used to safely
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Accessory Temp
Error
use until temp is
reduced
manage the ultra-capacitors generates
significant heat while actively managing
charging current. A certain amount of
heat is normal. If the temperature
exceeds a maximum value, this error will
be triggered. If the error is consistently
triggered, contact Customer Support, as
there may be an issue with your UPC.
164
Power
Accessory Temp
Sensor Failure
●Use caution - contact
Customer Support
The charging circuit used to safely
manage the ultra-capacitors generates
significant heat while actively managing
charging current. A temperature sensor
monitors this to ensure safe operation. If
the sensor fails or becomes disconnected
internally, this warning will trigger.
Contact Customer Support for next
steps.
173
Power
Accessory
Ultracap Temp
Error
●Discontinue use -
contact Customer
Support
The Ultracap modules themselves should
not generate significant heat during
normal operation. Under certain rare
situations (such as a problem with the
internal balancing circuit), an
ultra-capacitor module could become
damaged and produce heat. This
situation is detected via internal
temperature sensors. If this error persists
after power cycling and allowing the
temperatures to cool, please contact
Customer Support for next steps.
174
Power
Accessory -
Ultracap Temp
Sensor Failure
●Use caution - contact
Customer Support
An internal temperature sensor for the
Ultracap modules has failed or become
disconnected. The UPC should continue
operating normally, but the temp sensor
should be repaired as soon as
convenient, to ensure the safe operation
of the UPC. Contact Customer Support
for next steps.
175
Power
Accessory -
Ultracap Sensor
COM Failure
●Use caution - contact
Customer Support
The communication channel between the
temperature sensing processor and the
main UPC processor has been
compromised. The UPC should continue
operating normally, but the fault should
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be repaired as soon as possible. If power
cycling does not fix this warning, please
contact Customer Support for next steps.
181
Power
Accessory
Heartbeat
Failure
●Disarm system and
power cycle PSU and
UPC
The heartbeat message is detected by
the ULTRA Controller and is an indication
that the UPC is functioning and
communicating correctly. If this heartbeat
signal is lost, error and warning reporting
could be compromised. If power cycling
does not solve the issue, please contact
Customer Support for next steps.
If these steps don’t fix your problem, please contact us at [email protected].
We can help troubleshoot and diagnose the issue. If we determine that a
manufacturing defect exists in a part and it is covered under the Limited Warranty, we
will repair the unit at no cost to you. If your system is experiencing general wear and
tear, we can advise on your options to get your system back to 100%. This includes
potential upgrades, component replacement, or sending your unit back to MotoCrane
Headquarters for a tune up.
Maintenance
None required - contact Customer Support if you believe the unit requires service or
maintenance.
Weather & Water
The UPC is NOT WATER RESISTANT and should be kept out of direct sunlight to avoid
unnecessary heat buildup within the unit.
Specifications
Mechanical
Module Weight
UPC: 15lbs
Electrical
UPC Output: 48V 50A peak, CAN-BUS Signal
UPC Input: 4x V-Mount Battery or 48V 8A supply (12VA)
Certifications: CE, RoHS
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Mounting/Dimensions of UPC
The UPC is equipped with a mounting flange that can be used for more permanent
installation of the module. Make sure adequate room is given for cable and wire
routing to the UPC, and for the easy install/removal of V-Mount batteries.
The UPC and be mounted in any orientation, but must be protected from water and
direct sunlight.
The 6x mounting flange clearance slots are designed for M6 or ¼” bolts/screws.
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UPC Connection Diagram
The UPC is used in conjunction with the 48V Power Supply (PSU) included with every
ULTRA, and can also be used with the available 12VA accessory to use the 12V car
battery/alternator as a charge input.
Use the diagram below to better understand how these various components are
connected together:
12V Battery 12VA UPC PSU
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