Nellis Engineering Logic Genesis User manual

Genesis Manual Rev1.6 Copyright 2018, Nellis Engineering, Inc.
Genesis
GenesisGenesis
Genesis
Diver Propulsion Vehicle (DPV)
Owner's manual

Genesis Manual Rev1.6 Copyright 2018, Nellis Engineering, Inc.
2
Preface:
IT IS IMPERATIVE TO READ AND UNDERSTAND THIS MANUAL so that you know the
capabi ities, imitations and hazards of the Genesis DPV. Reread it occasiona y to
refresh yourse f with the operationa and maintenance requirements and refresh
yourse f on the proper responses shou d you experience difficu ties with the DPV
underwater or on and. By not fu y reading and understanding this manua , you
wou d be eaving essentia safety information out of the water, which is no different
than eaving essentia dive safety equipment on the shore, where it wi do you no
good when you need it most. If you have any question, contact the factory for
guidance.
Table of contents Page
Warnings & Cautions 3
Assemb y 5
Batteries and charging 7
Tow Cord 9
Trimming 10
Operation 10
Post Dive 13
Care & Maintenance 14
Vacuum & Pressure Testing 15
Data Logger Connection 16
Specifications 17
Power charts (P anning) 17
Warranty 19
Changes to the manual
Changes to the manua from the previous revision can be identified by a vertica b ack bar in the
right margin where the change occurs.

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Warnings & Cautions
WARNING
A warning means that injury or death is possib e
if the instructions are not obeyed.
CAUTION
A caution means that damage
to equipment is possib e.
Note
A note is added to give more
information, usua y in a procedure.
WARNING: Keep hands, ong hair and equipment away from prope er. The prope er spinning at
high power settings creates significant suction within 16 inches (40 cm) of the nozz e in et and can
draw in hands, hair or anything within range. The DPV is equipped with safety features that wi
stop the prope er rotation when enough resistance is present, but injury is sti possib e.
WARNING: A ways rotate the trigger ock tab to b ock trigger operation AND adjust the speed
contro ever to OFF when not in use to avoid accidenta operation.
WARNING: Never a ow the batteries to charge unattended or attempt to charge damaged
batteries. The Lithium Ion po ymer batteries have a high energy density and can catch fire or
exp ode if abused or damaged. On y recharge in a safe ocation, free of f ammab e materia s,
under direct supervision and on y using the supp ied charger. Do not attempt to charge the
batteries immediate y after fu y discharging them at hi power. The batteries heat up the most
during the end of a deep discharge and shou d be a owed to coo for one hour before
recharging. For the best battery ife, avoid deep y discharging the batteries if possib e.
WARNING: Do not eave the DPV batteries (a one or insta ed in DPV) in direct sun ight or a hot
car. Temperatures of 160°F (70°C) or above can damage the batteries resu ting in fire or exp osion.
WARNING: Do not attempt to charge the batteries when they are at or be ow freezing
(32°F/0°C). Permanent damage to the batteries wi resu t, decreasing both battery safety and
capacity. Whi e the outside of the batteries may be above freezing, the centers may not. Ensure
amp e time is spent in a warm environment for therma equi ibrium across the pack before
charging, fo owing exposure to freezing temperatures.
WARNING: Do not use the DPV to ascend from depth. Having the scooter tow you towards the
surface from depth can resu t in a rapid ascent which can resu t in ear drum rupture, ung over
expansion, decompression i ness or death. Do not operate any DPV without proper training.

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WARNING: Do not re y on the DPV to save your ife. The DPV is capab e of taking you p aces that
you may not be ab e to swim back from if the DPV fai s. It is not and was never intended to be ife
support equipment, so do not re y on it as such.
WARNING: Be prepared to separate yourse f from the DPV shou d it become uncontro ab e, a
dangerous restriction to movement or extreme y negative y buoyant from f ooding.
WARNING: The DPV is capab e of compensating for diver buoyancy trim changes with itt e
indication of the change in buoyancy detectab e by the diver unti they stop. Operating the DPV
over varying depths can resu t in the diver becoming very positive y or negative y buoyant when
they stop, resu ting in an out of contro ascent or descent. Ensure proper trim adjustments are
made when changing depths whi e scootering and be prepared for this when stopping.
WARNING: Powerfu magnets are used in the magnetic coup ing for the prope er. When the
prope er assemb y is removed from the tai section, it can be attracted to magnetic surfaces with
great force. Treat the prope er assemb y with extreme caution when removed to avoid pinching
hands and fingers and a so damaging the coup ing.
CAUTION: Avoid running the DPV unti battery cutout. Deep y discharging the battery shortens
the battery ife and can ead to over-discharge of the batteries. Shou d the DPV be run unti cutout,
remove the recharge p ug cover on the nose of the DPV after exiting the water and recharge the
batteries at your ear iest opportunity.
CAUTION: Ensure the DPV recharge connector cover is insta ed prior to entering the
water. Corrosion of the connector can occur if eft off for extended periods in the water.
CAUTION: The prope er is capab e of ingesting rocks off the bottom, sea ife and other objects at
high power settings, which can damage the prope er. Use caution when operating near oose
objects and dive responsib y near sea ife.
CAUTION: A ways inspect the o-ring grooves and sea ing surfaces for dirt, sand or debris and
remove if present to ensure a good sea . Check that the o-rings between the body and tai section
are c ean, undamaged and ubricated when assemb ing the DPV. Ensure the body/tai connection
is proper y a igned before engaging the sea s and do not force the connection together if abnorma
resistance is fe t. Poor attention to assemb y can resu t in damage to the sea ing surfaces and
f ooding of the DPV.
A ways remember to remove the recharge p ug cover when not
in use or the batteries may be permanent y damaged by over
discharge. Over discharge is not covered by the warranty!

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Assembly
Before charging the DPV for the first time,
the batteries must be connected to the tai
section interna y. The DPV can be opened
by s iding the arge rubber band forward to
expose the orange p astic ocking strips
(2ea) at the 3 & 9 O'c ock positions (Fig. 1).
Remove the two ocking strips by pu ing on
the c ear tab to ift the strip out of the
groove and then grasp the tab and strip
before pu ing it free of the housing. It may
be necessary to compress the tai section
into the body to free the ocking strip, as a
s ight pressure inside the DPV can cause
them to bind. With the ocking strips
removed, stand the DPV on its nose and ift
the tai section off of the body.
Note
It is possib e to have a s ight vacuum or
pressure inside the DPV body that prevents
the tai section from being removed. A test
port p ug (Fig. 2) on the nose of the DPV can
be removed with an 11/16" socket to equa ize
the pressure. This is the pressure/vacuum
test port that wi be discussed ater.
Figure 1
Lock strip slot view
Figure 2
Nose cone view

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Next, ensure the battery ocks are engaged
and the batteries cannot move inside the
body. If the battery assemb y was removed,
it wi need to be reinsta ed in the proper
orientation. The battery packs are s ight y
heavier on the side opposite from where the
wires exit. This side shou d be insta ed on
the right hand side of the scooter to he p
counteract the motor torque when running
(Fig. 3) and the wires from the front of the
scooter shou d run a ong the bottom.
There are three connections inside the DPV
that need to be mated (Fig. 4). First, ensure
the trigger is ocked OFF (sma tab rotated
underneath trigger to prevent it from being
depressed) and the speed ever set to the OFF
position (pointing towards the nozz e - Fig. 5)
and then connect the two battery p ug sets to
the tai section. You shou d expect a spark
when the second battery is connected; it is
due to the capacitors in the motor contro er
charging. It does not matter which battery is
connected to which p ug set on the tai . The
batteries are connected in series, once they
are p ugged into the tai section. After the
batteries are connected, p ug in the circu ar
connector, paying attention to the key, which
is towards the center of the tai section and
turn the ocking ring c ockwise to secure it.
Ensure the o-rings and sea ing surfaces are c ean and generous y greased with Mo ykote 111
si icone ubricant. Insufficient grease or debris on the sea ing surfaces can resu t in f ooding of the
scooter. Insta the tai section into the body carefu y, ensuring an even gap a the way around
before engaging the o-ring sea s. The s ot openings for the orange p astic ocking strips shou d be
at 3 and 9 o'c ock with the pins of the recharge connector on the nose, pointing up. The s ots ine
up with the nozz e struts at 3 and 9 o'c ock for reference. Insta the orange p astic ock strips and
s ide the rubber band over the joint. Never grease the grooves used by the ock strips.
Figure 4
Tail section inside view
Figure 3
Battery orientation

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Figure 5 - Trigger locked off
Note
The rubber band is not needed to retain the ocking strips or sea the DPV. It is
there so e y to keep sand, si t or other debris out of the joint, which may get
into the o-ring groove when the DPV is opened. At the end of the diving day,
the rubber band shou d be s id forward so fresh water can f ow around the
joint when it is rinsed and eft c ear of the joint unti the next dive.
The recharge p ug cover shou d on y be insta ed when you are ready to dive. It contains a circuit
that enab es the motor contro er and shou d be thought of as an ignition key for an automobi e.
When the cover is insta ed the batteries wi begin discharging s ow y, so do not eave the cover
insta ed when storing the scooter, or the batteries may be damaged by over discharge. Remove
the cover at the end of the diving day or after exiting the water if the DPV is run unti battery
cutout. The recharge p ug cover is rather expensive, so do not ose it.
Before entering the water, insta the recharge p ug cover and test that the DPV operates norma y
by depressing the trigger and operating the variab e speed up and down with the prope er speed
tracking the commanded speed. A ways ock the trigger OFF and adjust the speed ever to OFF
whi e entering and exiting the water.
TAB BEHIND T
RI ER
SPEED LEVER
DOWN (OFF)

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atteries and charging
On y recharge the batteries in a safe ocation where they can be monitored. Do not charge them
unattended. The ithium ion po ymer batteries do not off gas whi e charging ike ead acid or NiMH,
so the DPV body can remain sea ed during charging. It is recommended to remove the orange
p astic ock strips from the DPV prior to charging in the un ike y event the batteries fai and vent.
By standing the DPV on its tai to recharge, the weight of the body with the batteries inside wi
maintain the sea un ess interna pressure bui ds up inside. Obey a warning and cautions
previous y isted on pages 3 & 4.
When the batteries and circu ar connector are p ugged into the tai section, they can then be
recharged via the supp ied charger. P ug the charger into the DPV first, then p ug the charger into
the wa out et. The power ight shou d be on and charging ights shou d change from green to red
within one minute, indicating that the batteries are charging. At the end of charging, the
CHARGING LEDs wi turn green, but most ike y not at the same exact time. The batteries are
connected in series inside the DPV, so both batteries need to be charged together, whenever it
needs charging.
If one or both ights turn green after p ugging the cord into the out et and the batteries have not
been previous y charged, it is an indication of ow battery vo tage and a possib e over discharge.
Reseat a the connectors and try charging again. If they sti do not begin charging, disconnect the
batteries from the tai section and contact the factory.
CAUTION
The batteries shou d never be charged direct y from the supp ied charger
with any kind of adapter. There is a protection circuit in the DPV tai section
that prevents power from being present at the recharge p ug on the nose,
shou d the cover not be insta ed in the water. This circuit decreases the
charger vo tage and bypassing it wou d resu t in excessive vo tage app ied to
the batteries.
The Genesis batteries shou d on y be charged when you intend to use the DPV. Charge them 12 to
24 hours before you p an to dive. When storing the DPV for more than a few days, the batteries
shou d receive a partia charge to bring the vo tage into the storage range of 29.0 to 30.0V. Under
norma operation, it is recommended to p an your dives so that the batteries are on y discharged
about 80% of the avai ab e capacity to avoid deep cyc ing the ce s, which decreases their service
ife. If you suspect that ess than 80% the capacity was used, a storage charge is not necessary.
Whi e the battery vo tages cannot be checked at the recharge connector pins, it is possib e to
insta power meters such as the "Watts-Up", "Doc Wattson" or simi ar meters in the recharge
cab e to read the vo tage and power during recharge. Contact the factory for instructions on how
to insta these, shou d you choose to. The Sentry DPV Dashboard wi read the battery vo tages
whi e charging, if insta ed.

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The charger output is approximate y 3A, which equates to a 0.3C charge rate on the Genesis 600
and a 0.15C charge rate on the Genesis 1200. This means that during the bu k charge period (first
90% of capacity), the 600 batteries wi increase about 30% of the tota capacity per hour up to
approximate y 90% and the 1200 batteries wi increase about 15% per hour, up to approximate y
90%. During the ast 10% of the charge, the current decreases as it approaches fu charge and the
fina 10% of charge takes approximate y 1.5 and 3.0 hours to finish, respective y. As an examp e
for the Genesis 600, if during a dive, you used 50% of the battery capacity and then recharged it
for one hour during your surface interva , the battery capacity wou d be at approximate y 80% for
the next dive.
Genesis DPV battery capacity based on resting voltage
(i.e. motor not running)
attery Reset Instructions
The Battery Management System (BMS) in the Genesis DPV batteries can go into “s eep” mode,
when the nose p ug that enab es the motor is accidenta y eft insta ed for days or weeks or the
scooter is stored for ong periods (months) without use. The proper operation of the batteries
can be identified easiest by ensuring that the green LEDs on the charger both turn red when the
batteries begin charging. If one or both LEDs remain green for more than 60 seconds after
connecting the charger, it is an indication that one or both of the batteries may be in “s eep” mode.
The fo owing instructions detai how to reset the BMS to “wake” the battery up. If a battery goes
into s eep mode frequent y or not for one of the reasons stated above, contact the factory.
First, it is recommended that you check the vo tage of each battery with a qua ity Digita Vo tage
Meter (DVM). Low qua ity meters may not read the vo tage correct y when a battery is shut off.
Fu y charged vo tage wi be 33.2 – 33.6VDC. The shutdown vo tage is approximate y 24.5VDC. A
vo tage be ow 20.0VDC shou d be returned to the factory for an eva uation of the ce s and a ow
current recovery charge.
To reset the BMS:
1. Remove the prope er from the tai . The magnets on the prope er coup ing wi be used to
activate the reed switch in the battery.
100% 33.6V 50% 30.5V
90% 32.7V 40% 30.2V
80% 32.0V 30% 30.0V
70% 31.4V 20% 29.6V
60% 30.9V 10% 29.0V

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2. Open the scooter, if not a ready open, and check the battery vo tage between the Red and
B ack connectors on each battery pack to verify at east 20.0VDC.
3. Remove the batteries from the body and wave the magnetic end of the prope er coup ing over
the ocation of the reed switch inside the battery pack shown be ow (b ue rectang e). The ocation
is the same distance from the wire sea ing g and on a batteries, regard ess of size. It is
approximate y 3.5” (90mm) from the end of the battery housing, direct y behind the sea ing g and.
4. Whi e not necessary, you may visua y confirm a battery reset by p ugging the batteries into the
tai a ong with the circu ar p astic connector from the nose and the charger p ugged into the
outside nose of the scooter, but not p ugged into the wa yet. This is done with the DPV open and
the batteries removed for the body.
5. Once everything is connected, p ug in the wa socket and wave the magnetic end of the
prope er coup ing over the b ue rectangu ar area show above. A battery that is charging wi stop
charging when a magnet is passed over the reed switch and resume charging when it is removed.
A battery that is NOT charging shou d begin charging when a magnet is passed over the reed
switch AND removed.
It is not necessary to connect the charger to a battery to reset the BMS. A magnet simp y needs to
pass over the reed switch at any time to reset the BMS. A so note, that the charger has a “time-
out” that shuts off power output after approximate y 2 minutes of no output. Shou d one of the
charger’s LEDs remain green for more than 2 minutes, that charger wi turn off a output to the
DPV. The charger wi need to be unp ugged from the wa for 10-15 seconds and then p ugged in
again to restart the output. (Note: there are actua y two independent chargers inside the charger
case)