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1. LED Fault Level Set conditions Operator action flashes 2 Sequence fault DI Any drive switch active at power Reset drive switches up 2 SRO fault DI FS1 active for user configurable Deselect FS1 and select delay without a direction selected drive 2 FS1 recycle DI FS1 active after a direction change Reset FS1 2 Seat fault DI Valid direction selected with Must be seated with Operator not seated or operator is switches inactive not seated for a user configurable time in drive 2 Belly fault DI Set after belly function has activated 2 Inch sequence fault DI Inch switch active along with any drive switch active excluding inch switches seat switch indicating operator present or handbrake switch active 2 Invalid inch switches DI Inch forward and inch reverse Both inch switches switches active simultaneously inactive 2 Two direction fault DI Both the forward and reverse Reset switches switches have been active simultaneously for greater than 200 ms 3 Fault in electronic power VS Fault in electronic power switching switching circuit circuit e g MOSFET s c 3 Short circuits on power VS Short circuit detected on power outputs outputs 4 Line contactor welded S Line contactor closed at power up or after coil is de energized 4 Line contactor did not S Line contactor did not close when close coil is energized 6 Steering pot wire off VS Steering pot wire off is detected Check pot wiring 6 Steering switch wire off VS Stee
2. e Set wire off protection at 4681 Any two digital inputs can be configured with wire off protection See Table 2 Connector A pin out and wiring information on page 3 14 pins 14 and 15 for more details e Set digital input polarity at 68024 This is used to configure normally closed open switches ANALOG INPUTS The analog input voltages can be read at object 6C01 Voltages are 16 bit integer values with a resolution of 1 256 V bit Although each input is usually assigned a specific task by default any of the inputs can be configured to accept a variable voltage or a potentiometer Analog inputs can also be used as additional digital inputs 3 WIRE INPUTS To setup a 3 wire input e Enable wire off protection if required at 4691 e If the wiper connector A pin 26 or 27 is connected to a voltage source configure as a 2 wire input at 4692 2 WIRE INPUTS There is no configuration for 2 wire inputs Doc 177 52701 6 16 Rev2 Configuration MOTOR THERMISTOR INPUT You can connect a thermistor sensor to the Motor thermistor input or a switch to any digital input Type Specification PTC Silistor Philips KTY84 or equivalent Switch Connected to a general purpose digital input To setup go to object 4620 e Configure as none switch or PTC thermistor e If you are using a PTC thermistor set the high and low temperature voltages e If you are using a switch select the digital input source Read
3. SP22 Doc 177 52701 Rev2 IO Selection gt 0 T 2 3 4 5 Pump Throttle 2 Input Voltage 2241h MX34 ANALOGUE OUTPUTS IO Selection gt 0 1 2 3 4 5 6 7 8 9 10 Line contactor 2400h MX3 MX11 MX3 MX3 MX3 MX3 MX3 MX3 SL3 MX3 MX3 Line contactor 2400h SP3 SP3 External LED 2401h SL7 MX7 MX7 Alarm buzzer 2402h SP3 Horn 2403h SR3 SR3 Lights 2404h MX7 SR3 SP7 Service Due 2405h MX7 SR7 SR7 Electro mechanical brake 2420h MX7 MX7 MX7 MX7 MX11 MX11 MX11 Traction Motor Cooling Fan 2421h SP7 Motor Isolation Contactor 2422h High Low Speed Indication 2423h SP11 Pump contactor 2440h MX11 SR7 Power Steer contactor 2460h MX11 MX3 MX11 MX11 MX11 SR11 SR11 Doc 177 52701 3 Rev 2
4. Ensure you have completed the CANopen network setup Motor Characterization I O Configuration and Vehicle Performance Configuration processes described above CONTACTORS Ensure voltage control has been selected see Analog contactor outputs on page 6 17 To configure any contactor e Set pull in voltage pull in time and hold in voltage at 2D00 e Enable each output to operate at the pull in voltage or at the maximum voltage at 2D01 e If required enable each output to reduce to the hold voltage level at 2D02 LINE CONTACTOR DROPOUT The line contactor object 2400 must be mapped to an analog output The line contactor is used to isolate controllers and motors from the battery during power down or in case of a serious fault It is normally closed all the time the vehicle is powered but it can be configured to open when the vehicle has been stationary for a period of time Configure line contactor dropout at object 28204 See also Contactors above The controller has a capacitor pre charge feature used to protect line contactor tips from damage due to in rush currents when the contactor closes Writing to 5180 starts a pre charge cycle The pre charge circuit can only supply enough current to charge the capacitors of one controller Where more than one controller is present the pre charge circuit on each must be used If an Gen4 is configured as the vehicle master it controls the pre charge of all slave nodes aut
5. controller will invalidate the warranty Use cables of the appropriate rating and fuse them according to the applicable national vehicle and electrical codes Doc 177 52701 2 10 Rev2 About the Gen4 D Where appropriate use of a suitable line contactor should be considered A Electric vehicles are subject to national and international standards of construction and operation which must be observed It is the responsibility of the vehicle manufacturer to identify the correct standards and ensure that their vehicle meets these standards As a major electrical control component the role of the Gen4 motor controller should be carefully considered and relevant safety precautions taken The Gen4 has several features which can be configured to help the system integrator to meet vehicle safety standards Sevcon accepts no responsibility for incorrect application of their products Doc 177 52701 Rev 2 2 11 SEVCON FAULT DETECTION AND HANDLING There are five categories of faults as described in Table 1 For a detailed list of faults see Fault identification on page 6 Fault severity Controller latched off Consequences until Return to base Cleared by Sevcon Immediate shut down of the system with the exception RTB personnel of the power steering if needed Power is removed to nearly all external components Very severe VS Cleared by authorized Immediate shut down of the system with
6. 5 9 Emergency stop SWICB uie Re RR ORE SUG Sinead elias as ne I RR ONES 5 9 UE DC RBRUM 5 9 Key switch fuse Flint 5 11 Motor speed sensor encoder rererere sE e irie EE Er E SEES Renedo Dee onte sooo ee ede suene EE en 5 11 Motor commutation sensor U V Wi 5 12 Initial power Up E E 5 13 Checks prior to power Up erret tet reir P re FERRE nS ERE EE e beo td oae EE 5 13 Checks after power 1s applied terme temi dg 5 13 Chapter 6 Configuration 6 1 iniur e SORTIE CNN NR NINE 6 2 Drive Wizard configuration Dolores rad cbc 6 2 Doc st 177 52701 Rev 2 d DriveWizard functionality with lowest access level ooooonnncnnncniccnoniconoconcconocanonnnonononn conc nonononoconoss 6 3 Status b rS ci ee EUREN UU EEE a ee ee ee as ieee 6 3 Saving duplicating and restoring a node s configuration eese 6 3 Data monitorihg noon tu dpi ii 6 4 CANOPOR M 6 4 CANopen protocol cscs oerte n EENEG to uou above EEN 6 4 Communication models dominaban 6 4 Object Diction aty err RE Pe DR e ri RES ore t RE CE sites 6 4 Communication Objects eee dite ii 6 5 Configuration process OVerviewW cccessceceesteceesteeeceeeeeceeaeeeeeeneeceeaaees 6 7 Access authorlz tiotk EE 6 7 How NMT state affects access to parameters coooonoccnonconnnononononannnnnco nono nonn nooo nono nonn ccoo cra nnnn nan ncnecnnes 6 8 Motor characterization 6 8 Determining motor parameters p enenoheneeene peter be
7. Doc 177 52701 Rev 2 6 11 SEVCON VPDO MAPPING VPDO mapping is defined by objects in the range 3000 to 3FFF as shown in the table below Use DriveWizard or any other configuration tool to access these objects Feature Object Notes indices Motor 3000h Used to map the master to the type of local motor 3300h Used to map digital input signals to application inputs Input mapping 3400h Used to map analog input signals to application inputs 3100h Used to map application outputs to digital output signals Output mapping 3200h Used to map application outputs to analog output signals To help understand how to map internal objects an example VPDO mapping is shown in Figure 17 A digital switch input is mapped to the seat switch function to control the traction application ie with no seat switch input the vehicle is prevented from moving Master seat traction Switch 2124h application switch m m mapping Cbject Dictionary man Bes er digital inputs 6800h 1 digital AP 1 8 Figure 17 Example of a digital input mapped to the seat switch via VPDO The number of sub indices of each VPDO object depends on the amount of I O on the device For example 3300 has 9 sub indices on a device with 8 digital inputs Sub index 0 gives the number of 1 O channels in use Sub indices 1 to 8 correspond to the inputs To map the local I O to an application signal object set the
8. Drivability profiles can also be invoked by alternative internal software signals Such as BDI low service required or low speed These can be selected to suit specific application requirements in object 2931 each of the triggers operates in parallel with the other and the drivability select switches Where more than one profile is active the lowest value s are used by the software Speed in the Object Dictionary is measured in RPM However the vehicle gear ratio 2915 can be used to change this unit to any other preferred unit such as KPH or MPH A gear ratio of 1 is RPM Torque is measured in Nm and is converted to a value in 1 1000ths of motor rated torque at object 2916 The converted value is used by the application motor objects 2000 to 20FF and the DSP402 motor control profile 6000 to 67FF Doc 177 52701 6 26 Rev2 Configuration CONTROLLED ROLL OFF Controlled roll off limits a vehicle to a slow safe speed if it starts to move without any operator input Primarily it is to prevent uncontrolled movement if a vehicle s brakes fail on an incline Controlled roll off operates whether the operator is present or not Configure the following at object 2930 e Enable disable controlled roll off e Set a roll off maximum speed e Set a roll off maximum torque Alternatively Gen4 can apply an electromagnetic brake if one is mapped and roll off is detected Refer to Electro mechanical brake on page 6 3
9. Introduction Sevcon Gen4 controllers are designed to control 3 phase AC induction motors and Permanent Magnet AC PMAC motors in battery powered traction and pump applications A range of models is available to suit a wide number of applications and cooling regimes The controller adapts its output current to suit the loading conditions and the ambient in which it is operating temporarily shutting down if necessary It will also protect itself if incorrectly wired Signal wiring and power connections have been designed to be as simple and straight forward as possible Analog and digital signal inputs and outputs are provided for switches sensors contactors hydraulic valves and CAN communications These electrical signals can be mapped to Gen4 s software functions to suit a wide range of traction and pump applications Given Gen4 s mapping versatility it is important to ensure you map your application signals to the correct software functions see Manual object mapping on page 6 11 A common configuration is supplied by default which may suit your needs or act as a starting point for further contiguration Configuration and control of Gen4 is fully customizable using Sevcon s Calibrator handset or DriveWizard an intuitive Windows based configuration software tool A single green LED is provided to give a visual indication of the state of the controller This signal can be replicated on a dashboard mounted light for
10. TEE A ect ve E eO OE a EEE EAEE E 6 31 Alari DUZE NS 6 31 Brake Lights ica ada 6 31 Ile 6 31 SETVICE a 6 31 Traction motor cooling fan ccseeccesedsnsessssensscnessnsessaseesceeebeesndedsondedonsensstscsessuneodensessssessednesenseisasys 6 32 Motor over temperature protection eee cece cee cseecseeeseeeeeeseeeeeeeseceseceaecsaecsaecsaecaeeeaeseaeeeeeeeeees 6 32 Battery Pr e ies 6 32 Vehicle CG 6 34 Chapter 7 Monitoring Gen4 1 Reading status Vaca DIES tas 2 Motor measurements EE 2 Heatsink tempetdat re oorr er ee eR venere O 2 Identification and Ver o tereti in i eevee cause eda tee epe v tee bee Eres en Eve pe ESR 2 Battery MOm tonnes P 2 Hours COUNTS o Se aed eee iets 3 IESU PUTET 3 EIEO eyent logs cnica 3 EVENT COUMUETS yi sexsecessecsviecosahvels 4 Operational MOnitoring init 4 CANOpen abort code EE 4 Faults and warnings o epica 6 dee o e 6 Fault identification aser etr eee et ere ig ee PE EE EHE A ERE YR ERR ER Se PEL ET 6 EU C M 8 Clearing faults ME eEEE 9 Doc 177 52701 Rev 2 Upgrading the controller software ia 9 Appendices 1 Automatic Configuration Tables sir ica 1 Dista CTT 1 Analogue PU aci ed 2 EE ER oe DC 3 vi Doc 177 52701 Rev2 Chapter 1 SEVCON E Introduction SEVCON Il About Gen4 documentation THIS VERSION OF THE MANUAL
11. The controller measures actual battery voltage at two points e Battery voltage measured at keyswitch input and read at 5100 sub index 1 e Capacitor voltage measured at the B terminal and read at 5100 sub index 2 The controller also has a battery discharge indicator BDI which can be read at 2790 2 Doc 177 52701 Rev2 HOURS COUNTERS The controller supports many different hours counters for various functions Some counters run on all units and some only run on the Gen4 configured as the vehicle master Hours counters which run on all units are e Controller key hours increments while the keyswitch is in the ON position 5200 e Controller pulsing hours increments when the controller is powering its connected motor 4601 Hours counters which run only on the Gen4 configured as the vehicle master are e Vehicle key hours increments as controller key hours 2781 e Vehicle traction hours increments when the vehicle is driving or braking 2782 e Vehicle pump hours increments when the pump motor is running 2783 e Vehicle power steer hours increments when the power steer motor is running 2784 e Vehicle work hours increments when the traction pump or power steer motors are running 2785 Hours counters are preserved with a minimum resolution of 15 seconds when the system is powered down Logging The controller can log events in the system along with additional event related information
12. Write in Pre Op write only in Pre Op EJ CAN bus 1 node 1M baud a Sevcon Engineer Data uploaded successfully The bottom left status bar in the above example shows how many CAN nodes are connected and the access level of the person using DriveWizard When viewing the Object Dictionary in DriveWizard parameters are color coded and the key is shown in the lower portion of the screen SAVING DUPLICATING AND RESTORING A NODE S CONFIGURATION You can use DriveWizard to Doc 177 52701 Rev 2 6 3 SEVCON e Save a node s configuration This can be used at some later date to clone the node s configuration e Duplicate a node s configuration in real time to another node on the CANbus e Restore a configuration to a node DATA MONITORING You can use DriveWizard to monitor data or parameters of a Sevcon or 3 party node in real time and graph the data CANopen This section assumes you have an understanding of CAN and are familiar with its use If you are new to CAN or CANopen please refer to the CiA CAN in Automation website www can cia org for further information The following information provides an introduction to the important CANopen terminology used in this manual and how it relates to the configuration of your Gen4 controller CANOPEN PROTOCOL CANopen is a CAN higher layer protocol and is defined in the DS301 Application Layer and Communication Profile specification All CANopen devices must
13. adhere to this standard To provide greater standardization and interoperability with 3 party devices Gen4 is designed to use the CANopen protocol for communication on its CANbus and meets V4 02 of DS301 CANopen also supports standardized profiles which extend the functionality of a device The controller supports the following CANopen standardized profiles e DS401 V2 1 Device Profile for Generic I O Modules e DSPA402 V2 X Device Profile for Drives and Motion Control COMMUNICATION MODELS In any CANopen system there are three communication models in use These are Master Slave Client Server and Producer Consumer The function of each is explained below OBJECT DICTIONARY Any device connected to the CANopen network is entirely described by its Object Dictionary The Object Dictionary defines the interface to a device You setup configure and monitor Doc 177 52701 6 4 Rev2 Configuration your Gen4 controller by reading and writing values in its Object Dictionary using a configuration tool such as Sevcon s DriveWizard see page 6 2 There are two important text files associated with the Object Dictionary These are EDS ELECTRONIC DATA SHEET An EDS is a text file representation of the Object Dictionary structure only It contains no data values The EDS is used by configuration software such as Sevcon s DriveWizard to describe the structure of a node s Object Dictionary An EDS for each Gen4 model and software
14. and minimum and maximum levels of important parameters You need different levels of access to clear the contents of the logs Logs are normally reset individually However to reset all logs at once write to 4000 FIFO EVENT LOGS Events are recorded by these two separate FIFOs first in first out logs which operate identically e System this FIFO is 20 elements deep and is used for events such as software upgrades user logins and some hardware upgrades 4100 to 4102 e Faults this FIFO is 40 elements deep and is used for detected faults 4110 to 4112 At object 41X0 e Reset the FIFO Doc 177 52701 3 Rev 2 SEVCON e Read its length e Apply a configurable filter The filter allows you to exclude some events from the FIFO event log You can access the FIFO using objects 41X1 and 41X2 The FIFO index is entered at 41X1 and the data is read from 41X2 EVENT COUNTERS The controller provides 10 event counters at 4200 to 420A Each event counter can record information about occurrences of one event The allocation of event counters to events is user configurable however Gen4 will automatically count important events in unused counters The information recorded in each event counter is e The time of the first occurrence e The time of the most recent occurrence e The number of occurrences OPERATIONAL MONITORING At objects 4300 and 4301 Gen4 monitors and records the minimum and maximum va
15. be applied when a vehicle needs servicing 2925 See Drivability profiles on page 6 25 TRACTION MOTOR COOLING FAN This object can be used to drive a motor cooling fan when the operator is present on the vehicle as indicated by the seat switch The cooling fan object 2421 must be mapped to an analog output MOTOR OVER TEMPERATURE PROTECTION The controller protects motors from over temperature It maintains a motor temperature estimate and can also accept a direct temperature measurement via an analog input for a thermistor or a digital input for an over temperature switch The temperature estimate is calculated by monitoring current to the motor over time The estimate is configured at 4621 The estimate is always applied since it can detect increases in motor temperature more quickly then the direct measurement Direct measurement is normally done on the motor casing which lags behind the internal temperature BATTERY PROTECTION The nominal battery voltage must be set at 2C00 OVER VOLTAGE Doc 177 52701 6 32 Rev2 Configuration Battery over voltage usually occurs during regenerative braking To provide protection set values for these parameters at 2C01 e Over voltage start cutback the value at which the braking effort is linearly reduced to limit voltage increase e Over voltage limit the value at which the controller cutouts out A fault is set if the voltage exceeds the cutout voltage U
16. characterise most induction motors and hence simplify the process of putting a new motor into service For simple visual diagnosis of system faults and to monitor system status a green LED is provided on the body of the controller It is continuously lit when there is no fault but flashes a different number of times in a repeated pattern when there is a fault The number of flashes indicates the type of fault see LED flashes on page 6 MASTER SLAVE OPERATION The Gen4 controller contains both master and slave functions as shown in Figure 4 They operate as follows Doc 177 52701 2 8 Rev2 About the Gen4 e Slave function implements the CANopen Generic I O Profile DS402 and the Drives and Motion Control Profile DSP401 e Master function implements vehicle functionality traction and pump control and CANopen network management to motors switches pedals etc Figure 4 Single controller TORQUE MODE In this mode Gen4 maintains the motor torque output at a constant value for a given throttle position This is similar to DC motors in particular series wound DC motors and provides a driving experience like a car To prevent excessive speed when the load torque is low for example when driving down hill a maximum vehicle speed can be set SPEED MODE In this mode Gen4 maintains the motor at a constant speed for a given throttle position as long as sufficient torque is available Speed mode differ
17. encoder A 25 mA Check the speed encoder Input pulse channel internally signals have the correct number limited of pulses per revolution V 8 V for Check Gen4 is configured for current source the type of encoder you are encoders using open collector or V 2 5V or current source 5V for open collector encoders 15 Encoder Power To the negative supply I 100 mA We recommend the use of power input 0 V of the speed V 05V screened cable for the encoder supply encoder wiring Connect the screen to this pin only along with the negative supply 16 CAN High Comms CANbus High signal V 5V Maximum bus speed 1 Mbits s Alternative connection to pin 13 17 Encoder Digital Position encoder 10V Use this in conjunction with ey pulse U and W for PMAC motors 18 Digital Digital From digital switch Type A See note to Table 3 Input 1 input 1 V Vb In a basic configuration See Table 3 this is usually the forward switch 19 Digital Digital From digital switch Type A See note to Table 3 Input 3 input 3 V Vb In a basic configuration See Table 3 this is usually the foot switch FS1 20 Digital Digital From digital switch Type B See note to Table 3 Input 5 input 5 V Vb See Table 3 3 12 Doc 177 52701 Rev2 Installation Pin Name Type What to connect Maximum rating Comment 2 Digital Input 8 Digital From digital switch input 8 Type B V Vb See Table 3 See
18. example Standard features and capabilities AVAILABLE OPTIONS There are two mechanical package options Figure 2 for the Gen4 controller at each voltage and current rating Doc 177 52701 2 2 Rev2 About the Gen4 Frame size 4 Frame size 6 Figure 2 Mechanical package options INTENDED USE OF THE GEN4 The Gen4 motor controller can be used in any of these main applications for both pump and traction control e Counterbalanced warehouse and pedestrian fork lift trucks Classes 1 to 3 FLT1 2 amp 3 e Airport ground support AGS including tow tractors e Utility vehicles e Burden carriers e Sweepers and scrubbers e Golf buggies carts e Neighborhood electric vehicles NEV e Scooters e Marine AVAILABLE ACCESSORIES The following accessories are available from Sevcon e Loose equipment kit connectors and pins for Gen4 e Gen4 cooling kit e CANopen Calibrator Handset Doc 177 52701 Rev 2 2 3 SEVCON 2 4 SmartView display ClearView display Hourmeters Contactors Fuses Drive Wizard PC based configuration tool SCWiz PC based motor characterisation tool Doc 177 52701 Rev2 About the Gen4 Overview of a truck drive system Each traction or pump application requires a number of system components The main components excluding control inputs such as throttle and seat switch are shown in Figure 3 In this example there are two controllers a traction motor and a hydraulic
19. feeds power to the Supply a contactor to be contactors The output is at controlled by Contactor battery voltage out 2 9 Digital Digital From digital switch Type B See note to Table 3 Input 6 input 6 V Vb See Table 3 10 Key switch Power From dead side of key TA This input supplies power from in switch via suitable fuse Total of all the battery for all the logic contactor circuits output The unit cannot operate currents plus without Key switch in 1 0A supply Pins 1 6 and 10 are connected together internally and can be used individually or in parallel 11 Contactor Out To the switched low side 2 0A per This output provides low side out 3 of contactor or valve coil output subject voltage or current control to the to a limit of load depending on 6A for the configuration total of all the The output goes low or is outputs chopped to activate the load It V Vb goes high to Vb to de activate the load Doc 177 52701 Rev 2 3 11 SEVCON Pin Name Type What to connect Maximum Comment rating 12 Output 3 Power To one end high side of 2A This output feeds power to the Supply a contactor to be contactors The output is at controlled by Contactor battery voltage out 3 13 CAN High Comms CANbus High signal V 5V Maximum bus speed 1 Mbits sec Alternative connection to pin 16 14 Encoder A Digital From the speed
20. note to Table 3 22 Pot 1 wiper in Analog From potentiometer 1 wiper V 10V Zin 82 KQ 24V 36V and 36V 48V models Zin 100 kQ 24V 36V and 36V 48V models Suitable for potentiometers in the range 500 to 10 kQ or Voltage output device e g Sevcon linear accelerator 0 to 5 V orO to 10 V 23 Pot 2 wiper in Analog From potentiometer 2 wiper V 10V Zin 82 KQ 24V 36V and 36V 48V models Zin 100 kQ 24V 36V and 36V 48V models 24 CAN Low Comms CANbus Low signal V 5V Maximum bus speed 1 Mbits s Alternative connection to pin 27 25 Encoder B Input Digital pulse From the speed encoder B channel T 25 mA internally limited V 8 V for current source encoders V 2 5V or SV for open collector encoders 26 Encoder power supply Power To the positive supply input of the speed encoder I 100 mA V 5V or 10V software selectable Check the speed encoder you use is compatible with Gen4 See page 6 14 for configuration details 27 CAN Low Comms CANbus Low signal V 5V Maximum bus speed 1 Mbits s Alternative connection to pin 24 Doc 177 52701 Rev 2 3 13 SEVCON Pin Name Type What to connect Maximum Comment rating 28 CAN Power To CAN device requiring V 24V Check that the CAN device power external supply I 100 mA
21. power supply requirement is supply suitable for Gen4 29 Encoder Digital Position encoder 10V Use this in conjunction with ew pulse U and V for PMAC motors 30 Digital Digital From digital switch Type A See note to Table 3 Input 2 input 2 V Vb In a basic configuration See Table 3 this is usually the reverse switch 31 Digital Digital From digital switch Type A See note to Table 3 Input 4 input 4 V Vb In a basic configuration See Table 3 this is usually the seat switch 32 Digital Digital From digital switch Type B See note to Table 3 Input 7 input 7 V Vb See Table 3 33 Motor Analog From a thermistor device V 5V A NTC thermistor having a thermistor mounted inside the motor via 2 2 kQ resistance of approximately in internal pull 2 2 kQ at 100 C will give best up resistor sensitivity Connect the other lead of the thermistor to the B terminal of the Gen4 controller Can also be used as an additional analog input 34 Pot 1 Power Supply feed to V 10V Suitable for potentiometers in power potentiometer 1 Ina basic I2 15 mA the range 500 Q to 10 KQ supply configuration this is the throttle 35 Pot 2 Power Supply feed to V 10V Suitable for potentiometers in power potentiometer 2 I215mA the range 500 to 10 kQ supply Table 2 Connector A pin out and wiring information Doc 177 52701 Rev2 Installation Controller Digital Impedance to B Impedance to B voltage Inpu
22. switch 2124h MX31 MX31 MX31 MX31 MX31 MX31 Handbrake Tiller switch 2125h MX32 MX21 MX20 MX19 MX9 MX20 MX20 Driveability Select 1 switch 2126h MX20 MX9 MX31 MX20 MX9 MX9 Driveability Select 2 switch 2127h MX32 MX32 MX32 Inch forward switch 2129h MX32 MX20 SR18 SR18 Inch reverse switch 212Ah MX21 MX9 SR30 SR30 Inner left Steer switch 212Bh SR19 SEVCON IO Selection gt 1 4 5 6 7 8 Outer left Steer switch 212Ch SR31 Inner right Steer switch 212Dh SR20 Outer right Steer switch 212Eh SR9 High speed switch 212Fh Footbrake switch 2130h MX32 MX32 Traction Inhibit 2137h Belly 2139h MX32 Pump 1 switch 2140h SP18 SP18 SP18 MX18 Pump 2 switch 2141h SP30 SP30 SP30 MX30 Pump 3 switch 2142h SP31 SP19 SP19 MX19 Pump 4 switch 2143h SP31 MX31 Pump 5 switch 2144h SP20 MX20 Pump 6 switch 2145h SP9 MX9 Pump Inhibit switch 2150h MX32 Pump Drivability 1 switch 2152h MX21 Pump Drivability 2 switch 2153h Power Steer trigger switch 2160h MX21 MX21 MX35 SR32 SR9 ANALOGUE INPUTS lO Selection 0 1 2 3 4 5 Throttle Input Voltage 2220h MX22 MX22 MX22 MX22 MX22 Footbrake Pot Input Voltage 2221h MX34 MX34 SR34 Economy Input Voltage 2222h SR22 SR22 SR23 Steer Pot Input Voltage 2223h SL22 SR34 MX34 Motor temp thermister 2224h Pump Throttle 1 Input Voltage 2240h MX22
23. the measured motor temperature PTC or switch operation at object 4600 ANALOG INPUTS CONFIGURED AS DIGITAL INPUTS Each analog input can also be used as a digital input To configure an analog input as a digital input set the high and low trigger voltages at object 4690 The digital input status object 6800 contains enough bits for the digital and analog inputs The first n bits are the actual digital inputs where n is the number of digital inputs and the last 5 bits are from the analog inputs ANALOG CONTACTOR OUTPUTS There are 3 analog outputs which you may have mapped to one or more contactor functions such as line contactor pump power steer electro brake external LED traction motor cooling fan alarm buzzer and horn Configure each of the outputs used in your system e Choose voltage control or current control for each analog output at 46A1 At the time of writing current controlled devices can only be operated from Gen4 by mapping a signal input to the controller from an external 3 party node e Set the frequency of each output to a fixed value of 16 kHz or any value between 40 Hz and 1 kHz at 46A2 and 46A3 You can have only one low frequency setting per controller Low frequencies are normally used with current controlled outputs Doc 177 52701 Rev 2 6 17 SEVCON e Set the analog output values at object 6C11 The value is either a voltage or current depending on whether the output is voltage
24. vehicle adopts the low battery drivability profile Setting the warning and cut out levels to 0 disables the warning and cut out functionality Read the percentage remaining charge value from 2790 sub index 1 in the Object Dictionary VEHICLE HOURS COUNTERS All vehicle hours counters have user configurable offsets This allows vehicle hours counters to be maintained if the master controller is replaced Apply offsets at 2780 Vehicle hours counters can be read at 2781 to 2785 Doc 177 52701 6 34 Rev2 Monitoring Gen4 SEVCON Reading status variables All status variables are in Gen4 s object dictionary They can be accessed using SDOs Some can be mapped to PDOs for continuous transmission to remote nodes such as displays and logging devices MOTOR MEASUREMENTS The following status objects can be read e Motor slip frequency power and temperature at object 4600 e Motor torque speed etc at objects 6000 to 67FF HEATSINK TEMPERATURE Read the heatsink temperature at object 5100 sub index 3 IDENTIFICATION AND VERSION Read identification and version information at e 1008 Controller name e 1009 Hardware version e 100A Software version e 1018 Identity object Contains CANopen vendor ID product code CANopen protocol revision and controller serial number e 5500 NVM EEPROM format e 5501 Internal ROM checksum e 5502 External ROM checksum BATTERY MONITORING
25. version is available from Sevcon The EDS file format is described in the DSP306 Electronic Data Sheet Specification Each Object Dictionary matches a particular Gen4 software revision and its structure is hard coded into the controller software DCF DEVICE CONFIGURATION FILE This is a text file similar to an EDS except that it contains data values as well as the Object Dictionary structure DCFs are used to e Download a complete pre defined configuration to a node s Object Dictionary e Save the current configuration of a node s Object Dictionary for future use COMMUNICATION OBJECTS These are SDO service data object and PDO process data object as described below There is a third object VPDO virtual PDO used by Gen4 which is not a CANopen object It is described here because its function is important and similar to that of a PDO SDO SERVICE DATA OBJECT SDOs allow access to a single entry in the Object Dictionary specified by index and sub index They use the client server communication model where the client accesses the data and the server owns the target Object Dictionary SDOs are typically used for device configuration e g via DriveWizard or for accessing data at a very low rate They can be used to transmit large amounts of data using one of these methods PDO PROCESS DATA OBJECT Doc 177 52701 Rev 2 6 5 SEVCON PDOs are used by connected nodes for example in a twin m
26. 0 for more information HILL HOLD A vehicle on a hill can be held at a standstill for a configurable time when the operator selects neutral At the end of this time or if the seat switch indicates the operator is not present hill hold terminates You can set the hill hold delay at object 2901 Set the hill hold delay to 0 to disable this feature INCHING Inching allows an operator to maneuver a vehicle at low speeds towards a load Inching can be initiated with one switch A time out is used to prevent the vehicle from continuing to drive indefinitely if the switch gets stuck or goes short circuit To configure inching e Ensure forward and reverse inching switches have been mapped to two digital inputs e Specify an inching speed 0 to 25 of the full speed of the vehicle at 2905 sub index 1 e Specify a time out 0 1 s to 5 0 s at 2905 sub index 2 DRIVABILITY SELECT SWITCHES There are two drivability select switches 2126 and 2127 To enable either of these they must be mapped to digital inputs When they are active the corresponding drivability profiles 2921 and 2922 are applied Doc 177 52701 Rev 2 6 27 SEVCON ECONOMY The economy input is an analog input which can be used to increase vehicle efficiency and extend battery life It is normally controlled using a potentiometer mounted on the vehicle s dashboard The economy voltage 2222 must be mapped to an analog input Efficiency is imp
27. 0x5810 0x00A Disabled Ik Node indication This nodeis a Master local is right traction 0x5810 0x00B Slave he Assumed faut 3 eft Traction Yes 0x5810 oxooc No Master Slave RightTraction No 0x5810 OxOOD No e Pump Yes OxS810 0x00E No M Semer Power Steer No 0x5810 oxooF No CANDus faut ad 2otused No 0x5810 0x010 No CR entity Sevcon PST Module No 0x5810 0x011 No mW Store Figure 19 DriveWizard screen showing automatic object mapping ENCODER It is important that the number of encoder pulses per revolution is entered correctly If this information is not correct the controller may not be able to brake the motor effectively To configure the encoder 3 Enter the resolution pulses rev at 6090 Doc 177 52701 Rev 2 6 15 SEVCON 4 Check the encoder pull up and change to voltage driver if needed at 4630 The default setting is current source To change the encoder polarity if required change the setting at 607E reverses the forward and reverse speed measurements DIGITAL INPUTS The state of the digital inputs can be read at object 6800 Digital inputs are either all active low switch return to battery negative or all active high switch return to battery positive A mixture of active low and active high inputs is not possible The default setting is active low To configure digital inputs e Set active high low logic at 4680
28. 1 switch whereby it inhibits drive until it is active However the deadman switch applies the electro mechanical brake immediately on deactivation whereas FS1 waits for the vehicle to stop before applying the brake SEAT The seat switch indicates operator presence on the vehicle Drive is not allowed if this switch is open If the seat switch opens during drive for a period longer than the seat switch delay a fault is set disabling drive To clear a seat fault close the seat switch open FS1 and deselect the forward reverse switch Set the seat switch delay at object 2902 HANDBRAKE If mapped to a digital input the handbrake switch inhibits drive if the vehicle handbrake is applied Controlled roll off detection is still active when the handbrake is applied in case the brake fails Doc 177 52701 Rev 2 6 19 SEVCON TORQUE MODE SPEED MODE The Gen4 controller provides both torque and speed control modes Object 2900 is used to set which mode to use The default setting is torque mode This setting affects how driver demands are interpreted by the controller In torque mode the throttle push translates into a torque demand which is applied to the traction motor In speed mode the throttle push translates to a speed demand The controller then calculates the torque required to maintain this speed The difference between these control methods is most apparent when driving on an incline In torque mode when th
29. CAN Bus Configuration e DCF store empty WR Monitoring store empty dd G 250 kHz baud real Submit changes on this screen to device NU key Mireadony Mlwriteony Wanze MresarvriteinPre op Brite only inPre op iveWizare e DriveWizard ru an Lo L tze Tools Help Exit aa x A 2 el 210 7 EN system E 2 AC 48V 450A NodelD 1 L Tracttin System AC 48V 450A NodelD 1 CANopen General Set up Automatic Configuration Set Up ca ean Parameter name Value Units Index Sub Default JW Power steering SR Auxiary Automatic Configuration Set Up Bi Battery CANopen Auto Configuration Enabled Oxs810 0x001 Disabled D We Loos Digital Input Auto Configuration Both PDO and VPDO Oxs810 oxo02 Disabled 6 2 Comms objects setup wizar Digital Input Configuration 2 0x5810 0x003 ol Ei CANopen Digital Output Auto Configuration Both PDO and VPDO Oxs810 oxo04 Disabled E B NMT Error Control Analogue Input Configuration 2 0x5810 0x005 H EMP General Analogue Output Configuration H 0x5810 0x008 H IW Status alid configurations DOMAIN 0x5810 0x007 Me Control Analougue Input Auto Configuration Both PDO and VPDO 0x5810 oxoo8 Disabled EM Set up Analougue Output Auto Configuration Both PDO and VPDO Ox5810 0x009 Disabled Force system tq Motor Auto Configuration Both PDO and VPDO
30. Contactor out 1 usually to a limit of load depending on drives the line contactor 6A for the configuration total of all the The output goes low or is outputs chopped to activate the load It V Vb goes high to Vb to de activate the load 4 Output 1 Power To one end high side of 2A This output feeds power to the Supply a contactor to be contactors The output is at controlled by Contactor battery voltage out Doc 177 52701 Rev2 Installation Pin Name Type What to connect Maximum Comment rating 5 Encoder Digital Position encoder 10V Use this in conjunction with U pulse VI and W for PMAC motors 6 Key switch Power From dead side of key TA This input supplies power from in switch via suitable fuse Total of all the battery for all the logic contactor circuits output The unit cannot operate currents plus without Key switch in 1 0A supply Pins 1 6 and 10 are connected together internally and can be used individually or in parallel 7 Contactor Out To the switched low side 2 0A per This output provides low side out 2 of contactor or valve coil output subject voltage or current control to the to a limit of load depending on 6A for the configuration total of all the The output goes low or is outputs chopped to activate the load It V Vb goes high to Vb to de activate the load 8 Output 2 Power To one end high side of 2A This output
31. ECTION On board fuse dimensions are in accordance with DIN43560 1 Gend input voltage Gen4 peak output current Fuse rating Sevcon part number 24V 36 V 450 A 425A 858 81990 650 A 750 A 858 33021 36V 48 V 450 A 425A 858 81990 650 A 750 A 858 33021 72V 80 V 350 A 355 A 858 32045 550 A 500 A 858 32043 Doc 177 52701 3 8 Rev2 Installation Signal wiring Assemble your wiring harness using wire of the sizes recommended below and the Sevcon loose connector kit P N 661 27091 The use of twisted pair and or screened cables is recommended for the speed sensor and CANbus wiring To make a connection gently push the connector housing onto the appropriate mating half on the Gen4 Never force a connector Connectors are keyed to prevent incorrect insertion Shielded or twisted wire is recommended Keep signals away from power cables to avoid interference See also EMC guidelines on page 3 4 SIGNAL WIRE SIZES Use wire between 0 5 mm 20 AWG and 1 5 mm 16 AWG for all signal wiring Single twisted pair cable is readily available in 0 5 mm 20 AWG CANBUS TERMINATION See also EMC guidelines on page 3 4 If your system has more than one CAN node connect the nodes in a daisy chain arrangement Figure 7 and terminate the connections of the two end nodes with a 120 O resistor If the end node is a Gen4 link pins 2 and 24 on the customer connector a 120 Q resistor is built in
32. Gen4 Applications Reference Manual DOCUMENT NO 177 52701 TECH OPS SEVCON Il Partner with Performance Sevcon Ltd Kingsway South Gateshead NE11 0QA England Tel 44 0 191 497 9000 Fax 44 0 191 482 4223 sales uk sevcon com Sevcon Inc 155 Northboro Road Southborough MA 01772 USA Tel 508 281 5500 Fax 508 281 5341 sales us Osevcon com Sevcon SA 12 Rue Jean Poulmarch 95100 Argenteuil France Tel 33 0 1 34 10 95 45 Fax 33 0 1 34 10 61 38 sales fr sevcon com Sevcon Japan 4 12 1 Shinbashi Minato Ku Tokyo 105 0004 Japan Tel 81 0 3 5408 5670 Fax 81 0 3 5408 5677 sales jp sevcon com Sevcon Asia Ltd 4th Floor Eun Hyae Building 463 1 Sang dong Wonmee gu Bucheon City Kyunggi do 420 030 Korea Tel 82 0 32 215 5070 Fax 82 0 32 215 8027 sales kr sevcon com www sevcon com Table of Contents Chapter 1 Introduction 1 1 About Gend documentation dali 1 2 This version of the inanual iie terere tenere a aei e eot ee SER Pe er eee ee eres 1 2 VT E E 1 2 Scope OL this manual eerte tirer tee Toe ERR eee ebore eee e e ER ok eel eoe eie RE 1 2 Related documents asar adidas 1 2 Drawings Lt CN 1 2 Warnings cautions and notes 1 3 Product identification label asnos 1 4 Ree E E 1 4 Product WAS 1 4 Chapter 2 About the Gen4 2 1 MTL A EE 2 2 Standard features and capabilities csi iii iaa 2 2 Available options ninia oa Seve eed hele Wises scutes ia
33. NDER VOLTAGE To prevent excessive battery discharge set values for these parameters at 2C02 e Under voltage start cutback the value at which the current drawn from the battery is reduced to limit voltage decrease e Under voltage limit the value at which the controller cutouts out A fault is set if the voltage drops below the cutout voltage for longer than the protection delay e Protection delay the time it takes for the controller to cutout after the under voltage limit has been reached 2C03 Doc 177 52701 Rev 2 6 33 SEVCON BATTERY DISCHARGE INDICATOR BDI Monitor battery voltage using Gen4 s Battery Discharge Indicator BDI The BDI presents the driver with a percentage remaining charge figure and has become an industry standard in recent years The BDI is not a measure of the absolute battery charge remaining and therefore we recommend you regularly check the absolute value in accordance with the battery manufacturer s instructions To use the BDI configure the following parameters at 2C30 in the Object Dictionary e Cell count this is the number of battery cells and is normally half the battery voltage as cells are usually 2 volts each e Reset voltage V set this to the cell voltage when the batteries have just been charged This resets the BDI back to 100 e Discharge voltage V set this to the cell voltage when the battery is discharged e Cutout level this is the level at which the
34. Notes when they appear in this manual Examples of the style and purpose of each are shown below A WARNING is an instruction that draws attention to the risk of injury or death and tells you how to avoid the problem A CAUTION is an instruction that draws attention to the risk of damage to the product process or surroundings A NOTE indicates important information that helps you make better use of your Sevcon product Doc 177 52701 Rev 2 1 3 SEVCON J Product identification label If you have a customized product your unique identifier will appear at the end of the Type number When discussing technical issues with Sevcon always have your product s Type number Part number and Serial number available Figure 1 shows a typical product identification label SEVCON X MERE Figure 1 Product identification label Technical support For technical queries and application engineering support on this or any other Sevcon product please contact your nearest Sevcon sales office listed on the inside front cover of this manual Alternatively you can submit enquiries and find the details of the nearest support center through the Sevcon website www sevcon com Product warranty Please refer to the terms and conditions of sale or contract under which the Gen4 was purchased for full details of the applicable warranty Doc 177 52701 1 4 Rev2 SEVCON J SE About the Gen4 SEVCON
35. Test Na Repetitive shock 50 g peak 3 orthogonal axes 3 and 3 in each axis 11 ms pulse width Drop test BS EN 60068 2 32 1993 Test Ed Free fall appendix B Table 1 Bump 40 g peak 6 ms 1000 bumps in each direction repetition rate 1 to 3 Hz Vibration 3 g 5 Hz to 500 Hz Random vibration 20 Hz to 500 Hz acceleration spectral density 0 05 g Hz equivalent to 4 9 gins WEIGHT Controller weight Case size 4 2 7kg Case size 6 3 8kg 4 6 Doc 177 52701 Rev2 Specification DIMENSIONS SIZE 4 MODELS 24 76 170 61 150 Doc 177 52701 Rev 2 4 7 SEVCON SIZE 6 MODELS Doc 177 52701 4 8 Rev2 SEVCON J SE System design SEVCON Sizing a motor INFORMATION REQUIRED ABOUT THE APPLICATION To select an appropriate induction motor for an application find or estimate the following information e Minimum battery voltage e Maximum motor speed required e Peak torque required at base speed e Peak torque required at maximum motor speed e Continuous average motor power output required to pe
36. This version of the Gen4 manual replaces all previous versions Sevcon has made every effort to ensure this document is complete and accurate at the time of printing In accordance with our policy of continuing product improvement all data in this document is subject to change or correction without prior notice COPYRIGHT This manual is copyrighted 2008 by Tech Ops Sevcon All rights are reserved This manual may not be copied in whole or in part nor transferred to any other media or language without the express written permission of Tech Ops Sevcon SCOPE OF THIS MANUAL The Application Reference Manual provides important information on configuring lift and traction drive systems using Gen4 controllers as well as details on sizing and selecting system components options and accessories The manual also presents important information about the Gen4 product range RELATED DOCUMENTS The following documents are available from Sevcon e The Object Dictionary providing important information about CANopen communication with Gen4 e Device Configuration Files DCF and Electronic Data Sheets EDS for each Gen4 model and revision DRAWINGS AND UNITS Orthographic illustrations in this manual are drawn in Third Angle Projection SI units are used throughout this manual Doc 177 52701 1 2 Rev2 Introduction WARNINGS CAUTIONS AND NOTES Special attention must be paid to the information presented in Warnings Cautions and
37. a 2 2 Intended use OF the Gen eene eee t renes oa GEERT EPa EE eege 2 3 Avallable accessorle s eege EE 2 3 Overview of a truck drive SM 2 5 Punciples of OPAL taa 2 6 Functional description uenit erectae Dee ENEE rn eL bc EE dE 2 6 lusit pp E M 2 8 AER des CINE 2 8 jEeouciu t 2 9 Speed MOE e 2 9 Safety and protective functions oooccnoocccnoncccnoonccnnnonanonnnnnccnonnncnnanonoss 2 10 cM LOR 2 10 Fault detection and handling ooooocconoccconcconocononcnonnncconononnncnononnnnnncnnn nter enter ennr enne 2 12 Chapter 3 Installation 3 1 Mounting E EE 3 2 Bn E isc eh 3 2 Clearance for LED access AAA ouscasesasced sepsacnebesabbincesnsvarssansbienbaass 3 2 Mounting hole pattern EE 3 2 Equipment tequila ias 3 3 Cooling TE UEM id 3 3 EMC El BINS geet 3 4 Connecting power cables eessen dEr PS IR APR EUER E sad Viae Id 3 5 Battery and motor connections oooooocnccnoonconnconnconoconoconocononnnonnnonn nono cnn tenent tren nest nest en rennen enne 3 5 AAA rearen er E E EE E r EEEE Ere E EA EEE OEA EEEE Ae EEEN EEE S 3 6 On board fuse mounting naa 3 7 Fuse rating and selec viii iio 3 8 Siena WINNS ii 3 9 Signal Wife SIZE m 3 9 CANDus termina idad 3 9 Signal Connecti ONS seis 3 10 Chapter 4 Specification 4 1 Elec
38. and the steering angle to 90 In object 2913 O to 1 is represented by values in the range 0 to 32767 The calculated steering angle can be read at 2623 An angle value of 32767 indicates full steering to the left 32767 full steering to the right and 0 is straight ahead If steering switches are used instead of a steering potentiometer only part of the steering map is used as shown in Table 6 Doc 177 52701 6 24 Rev2 Configuration Value Description 2913 5 Outer wheel speed during inner wheel cutback 2013 7 Outer wheel speed during inner wheel reversal 2913 13 Inner wheel cutback speed 2913 15 Inner wheel reverse speed Table 6 Objects to set when using steering switches During a turn the inner wheel speed is slowed by power reduction instead of braking to prevent the outer wheel motor working against the inner wheel motor DRIVABILITY PROFILES Drivability profiles allow you to set maximum values for speed torque acceleration and deceleration for use in a range of operational situations Figure 24 shows the change in speed under various driving conditions over a period of time direction change deceleration rate Time neutral braking deceleration rate direction c acceleration Figure 24 Example acceleration deceleration parameter settings In Torque Speed mode the acceleration and deceleration rates control the rate of change of torque In Speed Control
39. appropriate VPDO sub index to the application signal object index If the seat switch shown in the above diagram was connected to digital input 4 bit 3 in 6800 1 sub index 4 of 3300 would be set to 2124 Doc 177 52701 6 12 Rev2 Configuration Some further examples are e Map FSI to read the value of digital input 8 connector A pin 11 at 3300 sub index 8 enter the value 2123 e Map the electromechanical brake signal to be applied to analog output 4 connector C pin 6 at 3200 sub index 4 enter the value 2420 The data flow direction between the application signal objects and the local I O objects depends on whether they are inputs or outputs For inputs the flow is from the local I O to application objects and vice versa for outputs Motor VPDOs are slightly different There are six parameters for each motor some of which flow from application to local I O controlword target torque and target velocity and some of which flow from local I O to application statusword actual torque and actual velocity PDO MAPPING The controller supports 9 RPDOs receive PDOs and 9 TPDOs transmit PDOs Up to 8 Object Dictionary entries can be mapped to each PDO Every PDO must have a unique identifier COB ID Setup RPDOs and TPDOs to transmit and receive events between nodes and map I O from one node to applications in another node The easiest way to do this is using DriveWizard If you are using a 3 party configu
40. arnesses short and route wiring close to vehicle metalwork Keep all signal wires clear of power cables and consider the use of screened cable Keep control wiring clear of power cables when it carries analogue information for example accelerator wiring Tie all wiring securely and ensure it always follows the same layout CONTROLLER Thermal and EMC requirements tend to be in opposition Additional insulation between the controller assembly and the vehicle frame work reduces capacitive coupling and hence emissions but tends to reduce thermal ratings Establish a working balance by experiment Document the complete installation in detail and faithfully reproduce on it all production vehicles Before making changes consider the effect on EMC compliance A simple cost reduction change could have a significant negative effect on the EMC compliance of a vehicle Doc 177 52701 3 4 Rev2 Installation Connecting power cables See also EMC guidelines on page 3 4 BATTERY AND MOTOR CONNECTIONS Cables carrying high AC currents are subject to alternating forces and may require support in the cable harness to avoid long term fatigue Equipment required e Cables sized to suit the controller and application see table below e M8 crimp ring lugs e Crimp tool e M8 wrench Torque setting 11 Nm 2 Nm Consider cable routing before making connections e Keep cable runs short e Minimize current loops by keeping positive an
41. can also be used to monitor and configure the parameters of any 3 party CANopen node The information presented here is an overview only For more information see DriveWizard s on screen help system Computer PDA USB CAN interface espAC Figure 15 DriveWizard and hardware Doc 177 52701 6 2 Rev2 Configuration DRIVEWIZARD FUNCTIONALITY WITH LOWEST ACCESS LEVEL The lowest access level allows you to review or monitor e DCF files on disk e the contents of the Object Dictionary applies also to 3rd party nodes e the mapping of CANopen PDO communication objects e system logs e fault logs e counters e operational logs e real time data applies also to 3rd party nodes You can also change the baud rate and Node ID of a connected node To write information to a Sevcon CANopen node you will need a higher level of access STATUS BARS User controls are invisible when DriveWizard is busy reading writing User prompts are displayed in the top left of the screen as shown below Drive Wizard File Help Enter new values then Submit to UNKNOWN Node ID 14 The bottom right area of the status bar shows what DriveWizard is doing if busy and sometimes the result of DriveWizard s action if this is not clear from the main display area 1Uzo Ud rrompr 1026 1 Stdln yes 255 1200 Server SDO 1 Default parameters Key Header row Bl Read only Write only lil Read Write Pl Read
42. cation is actually determined by the peak torque required as this determines the motor current required Motor manufacturers will provide S1 2 or S3 duty cycle ratings for the motors Selecting the Gen4 model Matching motor and controller ratings is not an exact exercise and therefore you may need to perform iterative calculations The main considerations when choosing an appropriate Gen4 controller are described below CURRENT AND POWER RATINGS CONSIDERATIONS Consider the following when choosing the appropriate Gen4 controller e Ensure the controller chosen matches or exceeds the peak current and average current requirements of the motor s in the application e Ensure the application can dissipate the waste heat generated by the controller If the controller gets too hot it reduces its output limiting vehicle performance POWER OUTPUT RESTRICTIONS AT MOTOR AND DRIVE OPERATING TEMPERATURE LIMITS A controller protects itself by reducing the current and hence torque available when its temperature limit is reached Figure 11 Doc 177 52701 5 4 Rev2 System design Gen4 Cutback Curve 120 100 E 80 E x s E 60 o ES 2 40 9 o 20 5 o 0 70 75 80 85 90 95 100 Base temperature C Figure 11 Current allowed vs controller base temperature CIRCUIT CONFIGURATION Once motor size is determined the application circuit configuration can be defined A basic single t
43. controlled or current controlled Values are 16 bit integers with a resolution of 1 256 V bit or A bit ERROR CONTROL In a CANopen network the slave node on which the analog contactor outputs reside can be different to the master node which calculates the output value If the CANbus fails the master node is no longer able to control the slave outputs In this situation the outputs may need to change to a safe value This is achieved with error control To configure error control e Set each output at object 6C43 to use its last set value or the value at 6C44 if the CANbus fails e Set values if needed at 6C44 for each output These values are 32 bit integers in which the bottom 16 bits are ignored Doc 177 52701 6 18 Rev2 Configuration Vehicle performance configuration Ensure you have completed the CANopen network setup Motor Characterization and I O Configuration processes described above SAFETY INTERLOCKS FS1 The FS1 switch is normally part of the throttle assembly It closes when the throttle is pressed The throttle voltage is ignored until FS1 is closed FS1 features are configured at 2914 e SRO static return to off inhibits drive if FS1 is closed for the SRO delay without any direction forward or reverse being selected e FS1 recycle forces the operator to lift their foot off the throttle before allowing drive after a direction change DEADMAN The deadman switch operates similar to the FS
44. d negative cables as close together as possible e Route cables away from the LED if you intend to make this visible under normal operating conditions Connect your power cables using the bolts supplied They are sized to clamp one ring lug thickness Use a longer bolt if you are fastening more than one ring lug You need thread engagement of at least 10 mm and the maximum penetration is 15 mm If you use a bolt which is too long damage to the terminal and overheating of the connection may occur If you use a bolt which is too short and there isn t enough thread engagement you may damage the threads Doc 177 52701 Rev 2 3 5 SEVCON CABLE SIZES When deciding on power cable diameter consideration must be given to cable length and temperature rating of the chosen cable Gen4 average rms Cable sizes current metric US 150 A 35 mm 1 AWG 250 A 50 mm 1 0 AWG 3 6 Doc 177 52701 Rev2 Installation On board fuse mounting You can mount your main input protection fuse directly onto the controller body as shown in Figure 6 Select the appropriate fuse from the table below Connect the battery positive cable to the B terminal The B terminal is a dummy terminal only and has no internal connection Figure 5 On board fuse mounting size 4 models 3 7 Doc 177 52701 Rev 2 SEVCON Figure 6 On board fuse mounting size 6 models FUSE RATING AND SEL
45. d up with the driving wheels off the ground and free to turn before starting the test The motor self characterisation process allows a user to determine the electrical parameters required for efficient control of AC induction motors using a Gen4 controller connected to a PC or laptop running characterisation software For further information please contact your local Sevcon representative EN Sevcon SCWiz Control Panel E F Oupavotago 17 5 En Pulte duration fra 2 E Inductance aporioning Us Rated ine vokege Vena 32 Rated frequency Hz 2 e Rated phase curent A ms Rated power W Rated speed pm Pole pars AY important Motor ID This option wil flash pr the ch Pulses per revolution Sgnel pul up down Peak torque factor Peak speed factor Peak power factor Live Measurements C Bottom MOSFETs OK O Gesten charged O Top MOSFETs OK C DSP parameters received C Powerrame identified C Gast sensors autozemed O Safe to puse C Encoder detected C Bidge enabled 7 SPl irk active T O configuration Ensure you have completed the CANopen network setup and Motor Characterization processes described above The individual characteristics and mapping of the I O in your application need to be setup This can be done manually or one of a selection of predefined setups can be selected Predefines setups exist for many of the common vehicle functions such as standalone traction standalone pump and tw
46. e maximum motor speed for a given encoder on a 4 pole motor Encoder Maximum motor ppr speed rpm 128 6000 80 10000 64 10000 For other types of encoder and motor use the formulae n per revolution x N rpm 60 with fmax limited to 13 3 kHz Je Hz Doc 177 52701 Rev 2 5 11 SEVCON and 20000 rpm p 2 N max rpm MOTOR COMMUTATION SENSOR U V W A 3 wire connection is provided for open collector phase commutation sensors The sensor must provide one cycle per electrical cycle The signals may be used for angle and speed information Doc 177 52701 5 12 Rev2 System design Initial power up sequence A Incorrectly wired or configured vehicles may behave in unexpected ways At the end of the following procedure only lower the drive wheels to the ground after correct operation of the motor and encoder has been confirmed CHECKS PRIOR TO POWER UP Follow this checklist prior to applying power to your system Jack up the vehicle so that the drive wheels are clear of the ground Confirm all connections are tightened to specified level Ensure all plugs are fully inserted Confirm power wiring connections are made to the correct terminals B B M1 M2 and M3 Ensure the controller is securely mounted from a mechanical and thermal perspective Ensure there is adequate and correctly ducted airflow for the fan cooled version Check the routing of cabl
47. e vehicle is driven uphill the vehicle speed will decrease due to the increased load The operator must apply more throttle demand in order to maintain speed In speed mode the controller will apply additional torque in order to maintain the operator s speed demand without the operator having to increase throttle demand THROTTLE The controller can use 2 or 3 wire throttle inputs of the following types e Linear potentiometer in the range 470 Q to 10 kQ e Voltage source in the range OV to 10V compliant with the standard 0 5 V 0 10 V or 3 5 0 V ranges To setup throttle inputs see Analog inputs on page 6 16 The throttle voltage 2220 must be mapped to an analog input It is recommended that inputs with wire off detection are used for the throttle input to detect wiring faults This is especially important if a wire off sets maximum throttle Setup the characteristics of the throttle at 2910 e Enable disable proportional braking If enabled the braking torque during direction braking is proportional to the throttle e Enable disable directional throttle If configured as a directional throttle the throttle voltage indicates the direction as well as the speed demand This removes the need for forward and reverse direction switches e Proportional speed limit enable disable Only used in torque mode If enabled speed limit is proportional to the throttle otherwise speed limit is fixed at the forward or r
48. er defined linear curved Doc 177 52701 Rev2 Configuration Figure 22 Input characteristics The throttle value calculated from the voltage can be read at 2620 ACCELERATION AND BRAKING See Drivability profiles on page 6 25 FOOTBRAKE The controller can use a switch or analog voltage as the footbrake input If a footbrake switch is mapped it applies maximum foot braking when the switch is closed The footbrake switch object 2130 must be mapped to a digital input If the footbrake input is an analog voltage configure the voltage levels in the same way as the throttle The footbrake voltage 2221 must be mapped to an analog input Configure the characteristics of the footbrake at 2911y e Drive foot braking priority If the throttle and footbrake are pressed at the same time this setting determines whether the system attempts to drive or brake e Minimum speed for braking Foot braking stops when the vehicle speed drops below this level e Footbrake voltage input and Input characteristic These settings are similar to those for the throttle Refer to the Throttle section above for more information The footbrake value calculated from the voltage can be read at 2621 STEERING INPUTS TWIN DRIVING MOTOR SYSTEMS Loss of steering information can make a vehicle operate erratically We recommend the use of steering inputs with wire off protection Twin motor systems which use the drive motors for tu
49. es is safe with no risk of short circuit overheating or cable insulation wear due to rubbing CHECKS AFTER POWER IS APPLIED Apply power and do the following Use DriveWizard see page 6 2 or any configuration tool to complete the configuration process which starts on page 6 7 Using the drive controls ensure the wheels rotate in the expected direction If they do not check the motor wiring encoder wiring and encoder configuration page 6 14 It should now be safe to lower the vehicle to the ground and test drive Proceed with caution Doc 177 52701 Rev 2 5 13 EA ECH Configuration SEVCON Introduction This section covers what you need to do to configure Gen4 s software once you have designed and installed your hardware All of Gen4 s parameters have a default value and the amount of configuration needed is dependent on your particular system The main topics are e DriveWizard configuration tool installation and use e CANopen an introduction to the protocol and its use in Sevcon products e An overview of the configuration process outlining what needs to be done and the order in which it must be done e The configuration steps DriveWizard configuration tool DriveWizard Figure 15 is Sevcon s proprietary configuration tool It allows the user subject to a secure login process to monitor configure and duplicate the parameters of any Sevcon CANopen node such as the Gen4 controller DriveWizard
50. etails on the available configurations To enable auto configuration on all nodes set 5810 sub index 1 to OCFF This corresponds to Enabled Both VPDO and PDO for all IO auto configuration options in Drive Wizard This enables the auto configuration of local and remote via CANopen analogue IO digital IO and motor control This is the default state for automatic configuration It is possible to disable individual parts of the configuration to allow for user customization via the methods described above Digital input analogue input and analogue output configurations can be selected from the predefined tables and their numbers entered into sub indices 3 5 and 6 This need only be set on the master controller if a multimode system is being configured CAN node function and configuration can also be defined via the auto configure feature For each node the following should be specified Doc 177 52701 6 14 Rev2 e If it is Master or Slave in the CANBus system Configuration e On the Master node specify it s function e g Traction right side controller and also which other nodes are present as slaves e g Pump Power steer e On the Slave node simply specify that it is a slave and which type of slave it is e g Pump i Supported profiles W Unassigned EDS Section 18 Self Char motor 1 ai Re Program Device BJ AC 48V 450A NodelD 4 E SI AC 48V 450A NodelD 2 jg Comms Objects setup wizard
51. everse maximum speed Doc 177 52701 6 20 Rev2 Configuration e Braking directional throttle enable disable Only used in torque mode If enabled a directional throttle can be used to demand a drive or braking torque in conjunction with the direction switches e Define the throttle voltage input this is the relationship between the throttle voltage and the throttle value Separate relationships can be specified for forward and reverse Each relationship has two points a start and an end The points are configured differently for standard and directional throttles as shown in Figure 20 and Figure 21 respectively o e gt end voltage value 1 startvoltage value 1 0 Voltage startvoltage value 2 end voltage value 2 forward valie s reverse valie Figure 20 Standard throttle configuration Doc 177 52701 6 21 Rev 2 SEVCON Value start voltage end voltage value 2 start voltage value 2 end voltage value 1 forward value 9 reverse value Figure 21 Directional throttle configuration e Define the input characteristic this is a profile to the throttle value and can be linear curved crawl or user defined as shown in Figure 22 The curved and crawl characteristics give greater throttle control at low speeds Vehicle speed voltage 3 value 3 voltage 2 value 2 voltage 1 value 1 Throttle value crawl e s
52. fault Write the fault ID to sub index 1 and read back the fault description from sub index 2 CLEARING FAULTS 5301 and 5302 allow faults to be cleared Upgrading the controller software It is possible to field update the firmware of the Gen4 controller typically using Sevcon s DriveWizard configuration tool Please contact Sevcon for assistance with this process Doc 177 52701 Rev 2 SEVCON Appendices SEVCON Automatic Configuration Tables This section lists the pre defined digital and analogue input and output configurations that can be used with the CANopen automatic object mapping see page 6 14 The entries in the tables refer to the pin a particular function is connected to MX refers to a pin on the master node SR refers to a pin on the slave node driving the right traction motor and SP refers to a pin on the slave node driving the pump motor For example analogue input configuration number 3 has throttle and footbrake inputs going to pins 22 and 34 on the master node and an economy input going to pin 22 on the right traction slave node DIGITAL INPUTS lO Selection gt 0 1 2 3 4 5 6 7 8 Key switch 2100h Horn switch 2101h Drive enable switch 2120h MX20 Forward Switch 2121h MX18 MX18 MX18 MX18 MX18 MX18 MX18 MX18 Reverse Switch 2122h MX30 MX30 MX30 MX30 MX30 MX30 MX30 MX30 FS1 switch 2123h MX19 MX19 MX19 MX19 MX19 MX19 MX19 Seat
53. h can be used for 2 wire potentiometers software configurable They can also be configured as digital inputs Motor thermistor input Potentiometer inputs Two 3 wire protected inputs software configurable Inductive drive outputs 3 configurable PWM outputs Use in voltage or current control mode Voltage controlled Continuous sink current 2A Peak current limited to 2 5A Open circuit detection Iout 0 1 A is a configurable option Voltage controlled PWM mode allows contactors with a rating less than Vnom to be used range 24 V to Vnom Current controlled Current output configurable between 0 and 2A ISOLATION Any terminal to the Withstands 2 kV d c case Meets EN1175 1 1998 and ISO3691 Complies with IEC 60664 4 4 Doc 177 52701 Rev2 Specification EMC Radiated emissions EN12895 Industrial Trucks Electromagnetic Compatibility EN 55022 1998 6 class B EN 12895 2000 4 1 Emissions When part of a system with a motor operating FCC Part 15 Radiated Emissions Meets the standards given in FCC Part 15 Section 15 109 Conducted emissions No mains port therefore not required Susceptibility Performance level A no degradation of performance or level B degradation of performance which is self recoverable subject to the additional requirement that the disturbances produced do not e affect the driver s direct control of the truck e affect the
54. in traction Doc 177 52701 6 10 Rev2 Y Configuration For manual configuration it is necessary to use PDOs and VPDOs to map application objects on the master node 2000 to 25FF to the hardware I O objects on all other nodes 6000 to 6FFF Auto configurations will create the required PDO and VPDO mappings depending on which pre defined I O configuration has been selected but additional PDO mappings can be added if desired To configure I O e Either configure PDOs and VPDOs to map application objects on the vehicle master node to hardware I O objects on other nodes or select a pre defined configuration and use auto configuration to set up PDOs and VPDOs e Setup each hardware I O object including wire off protection MANUAL OBJECT MAPPING To enable the controller to perform the functions required in your system it is necessary to map object to object e g a measured input signal mapped to a steer operation This is achieved by setting up PDOs node to node mapping and VPDOs internal mapping on each controller as described below Apply mapping to Gen4 as follows e Standalone controllers setup VPDOs only e Networked controllers setup VPDOs and PDOs Before starting the mapping process it is a good idea to draw out a map of what you want to do The amount of mapping required depends on the electrical wiring of your vehicle Check to see if the default settings satisfy your needs before making changes
55. is ready to drive but no torque is being demanded by the driver the d axis or magnetizing current will be present in the motor so that the vehicle will respond immediately to a torque demand To save energy the magnetizing current is removed if the vehicle is stationary and no torque has been demanded after a set period Measured phase currents and current demands ig and ig the d q axis currents are used as part of a closed loop control system to calculate the necessary voltage demands for each Doc 177 52701 2 6 Rev2 About the Gen4 phase of the motor Voltage demands are then turned into PWM demands for each phase using the Space Vector Modulation SVM technique SVM ensures optimum use of the power semiconductors POWER CONVERSION SECTION The power conversion section of Gen4 employs a 6 switch MOSFET bridge operating at an effective frequency of 16 kHz Excellent electrical and thermal efficiency is achieved by Minimization of thermal resistances Use of the latest MOSFET technology Internal thermal protection if temperatures are excessive output torque is reduced Overcurrent protection using device characteristics Internal measurement of output current Overvoltage trip in the event of regenerative braking raising battery voltage to unsafe levels Doc 177 52701 Rev 2 2 7 SEVCON DUAL TRACTION MOTOR In the case of dual traction motors there is additional processing of the associated steeri
56. lues of these quantities e Battery voltage e Capacitor voltage e Motor current e Motor speed e Controller temperature Two instances of the operational monitoring log are maintained You can access and clear the first log the second is accessible and clearable only by Sevcon engineers The Customer copy is normally recorded and reset each time the vehicle is serviced The Sevcon copy records data over the controller s entire working life CANopen abort code The controller will sometimes respond with a CANopen General Abort Error 08000000 when the object dictionary is accessed This can occur for many reasons Object 5310 gives the exact abort reason These are 4 Doc 177 52701 Rev2 0 None 7 Cannot go to operational 14 Unable to reset service time 1 General 8 Access level too low 15 Cannot reset log 2 Nothing to transmit 9 Login failed 16 Cannot read log 3 Invalid service 10 Range underflow 17 Invalid store command 4 Not in pre operational 11 Range overflow 18 Bootloader failure 5 Not in operational 12 Invalid value 19 DSP update failed 6 Cannot go to 13 EEPROM write failed 20 GIO module error failed pre operational Doc 177 52701 Rev 2 SEVCON Faults and warnings INTRODUCTION In the event of a fault Gen4 takes the following action Protects the operator and vehicle where possible e g inhibits drive Sends
57. mode the acceleration and deceleration rates control the rate of change of speed Doc 177 52701 Rev 2 6 25 SEVCON You can select reverse while driving in the forward direction with your foot still on the throttle In this situation the controller applies braking in the form of a direction change deceleration rate down to zero speed It then applies a direction change acceleration rate to increase the vehicle s speed in the reverse direction up to the set maximum speed as shown above Configure the following drivability profiles to suit your application each containing the same set of parameters e Traction baseline profile the default and highest set of values 2920 e Drivability select 1 profile invoked when drivability select 1 switch is active 2921 or an alternative trigger is active see below e Drivability select 2 profile invoked when drivability select 2 switch is active 2922 or an alternative trigger is active see below The traction baseline profile contains the default maximum values All of the remaining profiles apply lower modifying values to the baseline profile BDI and service profiles when configured are automatically applied by the software under preset conditions For example you may want to limit the acceleration and maximum speed of a vehicle when the battery gets low to maximize the operating time before recharge The remaining profiles are applied by the driver with a switch
58. n T Left Motor in numbering B Alternative use a voltage may very 10V Slave source in place of the pot encoder A encoder B 0v M1 M2 18 inch forward M3 30 inch reverse thermistor 9 deeg e power steer trigger Figure 14 Dual traction wiring diagram 5 10 B Doc 177 52701 Rev2 System design KEY SWITCH FUSE F2 Use a fuse rated for the larger of A the sum of the drive currents plus 1A for internal circuits and B the capacitor pre charge circuit In the following example there are two contactors each drawing 2 A Device Current Line contactor 2A A Pump contactor 2A Gen4 control circuits 1A B Pre charge circuit TA Fuse choice 7A MOTOR SPEED SENSOR ENCODER A 4 wire connection is provided for open collector or current source encoder devices software configurable You can use the following types of encoder or equivalents Type Output Supply Specification Bearing Type Open collector 5 to 24 V DC 64 and 80 pulses per revolution SKF and FAG Dual quadrature outputs Output low 0 V nominal HED Type Constant current 10 V nominal 80 pulses per revolution Thalheim Dual quadrature outputs Output low 7 mA Output high 14 mA The number of encoder pulses per revolutions n and the maximum motor speed N are related to and limited by the maximum frequency of the encoder signal fmax The following table shows th
59. n cause deformation of the frame and damage to the product EQUIPMENT REQUIRED e 4x M6 socket cap head bolts nuts and spring washers Bolts need to be long enough to pass through 12 mm of Gen4 baseplate and your mounting surface thickness e T hand socket wrench or Allen key e Thermal grease Recommended torque setting 10 Nm 2 Nm Spread a layer of thermal grease such as Dow Corning 340 on the Gen4 base plate before bolting to your mounting surface Apply the grease at the minimum thickness sufficient to fill in the gaps due to non flatness and follow the manufacturer s documentation Cooling requirements To ensure you get the maximum performance from your Gen4 controller e Keep it away from other heat generating devices on the vehicle e Maintain its ambient operating temperature below the specified maximum see Operating environment on page 4 6 To obtain maximum performance it is important to keep Gen4 s base plate within the operating temperature range To do this mount Gen4 to a surface capable of conducting away the waste heat A plate approximately 420 mm x 270 mm x 9 5 mm thermal resistance 0 30 C W will give thermal performance as shown in Figure 9 on page 4 3 Cooling performance is affected by mounting surface flatness and the thermal transfer between mounting surface and Gen4 Ensure you apply thermal grease and your mounting surface meets the flatness figures as described in the Mounting
60. ng signal from a potentiometer or switches in order to generate separate torque demands for the left and right motors of the vehicle This allows the two motors to be operated at different speeds which greatly assists in turning the vehicle and prevents wheel scrub After the torque demands have been generated the operation of each motor control system is as described in the case of a single traction motor PUMP MOTORS Pump motor control is similar to traction motor control although motion is requested using a different combination of switches INTERFACES In addition to its motor control functions Gen4 offers many other functions designed to interface with electric vehicles A variety of digital and analog input sources are supported as listed in Signal connections on page 3 10 Voltage and current control of up to three contactors or proportional valves is provided by Gen4 and includes built in freewheeling diodes for spike suppression All I O on the Gen4 controller is protected against short circuit to the battery positive and negative terminals Connectivity and interoperability with other system devices for example another Gen4 controller using a CANbus and the CANopen protocol is provided In addition to in service operation the CANopen protocol allows the controller to be commissioned using the Calibrator handset or Sevcon s DriveWizard tool In addition Sevcon s SCWiz PC based tool provides the function to self
61. ntrol the power to 3 phase squirrel cage AC induction or PMAC motors in electric vehicles Four quadrant control of motor torque and speed driving and braking torque in the forward and reverse directions is allowed without the need for directional contactors Regenerative braking is used to recover kinetic energy which is converted into electrical energy for storage in the battery In a traction application control commands are made by the driver using a combination of digital controls direction foot switch seat switch etc and analog controls throttle and foot brake The controller provides all the functions necessary to validate the driver s commands and to profile the demand for speed and torque according to stored parameters Throttle inputs can be configured as speed or torque speed demands with throttle dependent speed limits in either case a torque demand is continually calculated to take account of pre set limits on the level and rate of change of torque The torque demand is used to calculate current demands that is the controller calculates what currents will be required within the motor to generate the required torque There are two distinct components of the current known as the d q axis currents which control current flow in the motor The d axis current is responsible for producing magnetic flux but does not by itself produce torque The q axis current represents the torque producing current When a vehicle
62. oc 177 52701 5 8 Rev2 System design 35 Way AMPSEAL CONNECTOR KIT Kit consists of Gen4 mating 35 way AMPSeal connector and pins Sevcon p n 661 27901 EMERGENCY STOP SWITCH Refer to the appropriate truck standards ON BOARD FUSE See On board fuse mounting on page 3 7 Doc 177 52701 Rev 2 5 9 SEVCON electro brake control fuse isolator power steer contactor pi CAN High Cont2 CAN Low a Cont1 CAN term UI e E 2 Cont1 Supply CAN High 9 CAN Low Cont2 Supply Cont3 Supply o7 o key switch key switch Gen4 Dual Traction Right Motor 13 CAN connection 24 for configuration and service 2 Link to terminate the CANbus 16 CAN connection 27 to other CAN devices E Alternative use a voltage source in place of the pot Analog input 2 Alternative use a voltage source in place of the pot Master B 18 forward 10 V AAA o encoder A 30 reverse encoder B 19 0v foot switch 131 M1 seat 20 LEU es MZ handbrake driveability select 1 thermistor 32 B driveability select 2 21 B Cont3 CAN High 13 CAN connection Cont2 24 for configuration CAN Low H and service o Cont 25 i Linkto Ze CAN term 2 i terminate the 8 CANbus Cont1 Suppl in CAN High LS CAN connection Soe Sy 5 to other CAN CAN Low Cont3 Supply devices key switch Alternative use a voltage E source in place of the pot d B Gen4 raction fuse Dual Tractio
63. omatically Pre charge the capacitors once only before closing the line contactor Repeated pre charging can damage the circuit ELECTRO MECHANICAL BRAKE The electro mechanical brake object 2420 must be mapped to an analog output Set the conditions under which it is applied at 2903 Doc 177 52701 6 30 Rev2 Configuration The brake can be applied when the vehicle stops or when roll off is detected If the brake is configured to apply when the vehicle stops it is not applied until the vehicle has been stationary for more than the brake delay time To prevent vehicle roll away on inclines the electro mechanical brake normally does not release until the traction motor s are producing torque This feature can be disabled using 2903 3 EXTERNAL LED This mirrors the operation of the controller s on board diagnostic LED The external LED object 2401 can be mapped to an analog output to drive a lamp on a vehicle dashboard ALARM BUZZER The alarm buzzer object 2402 must be mapped to an analog output Configure the alarm buzzer output if required to be activated by one or more of these conditions at 2840 e forward motion or forward direction selected e reverse motion or reverse direction selected e faults other than information faults e controlled roll off A different cadence for each of the above conditions can be configured BRAKE LIGHTS A brake light output object is available 2404 and can be ma
64. otor configuration to exchange real time data during operation PDOs allow up to 8 bytes of data to be transmitted in one CAN message They use the producer consumer communication model where one node the producer creates and transmits the PDO for any connected nodes consumers to receive Transmitted PDOs are referred to as TPDOs and received PDOs as referred to as RPDOs VPDO VIRTUAL PROCESS DATA OBJECT VPDOs do a similar job as PDOs for data exchange but internal to a single Sevcon node They are unique to Sevcon and are not part of CANopen Doc 177 52701 6 6 Rev2 Configuration Configuration process overview A Electric vehicles can be dangerous All testing fault finding and adjustment should be carried out by competent personnel The drive wheels should be off the floor and free to rotate during the following procedures We recommend saving parameter values by creating a DCF before making any alterations so you can refer to or restore the default values if necessary Do this using DriveWizard This part of the manual assumes you have a vehicle designed and correctly wired up with a CANopen network setup Before you can safely drive your vehicle it is necessary to go through the following process in the order presented Step Stage Page 1 Motor characterization 6 8 2 I O configuration 6 10 3 Vehicle performance configuration 6 19 4 Vehicle features and function
65. out an EMCY message on the CANbus Flashes the LED in a pattern determined by the fault type and severity Pd WN p Logs the fault for later retrieval FAULT IDENTIFICATION You can identify a fault as follows e Check the number of LED flashes and use Table 7 below to determine what action can be taken A complete and comprehensive fault identification table will be available from Sevcon in due course e Pick up the EMCY on the CANbus and read the fault condition using configuration software e Interrogate the fault on the node directly using DriveWizard or other configuration software LED FLASHES Use Table 7 below to determine the type of fault from the number of LED flashes The LED flashes a preset number of times in repetitive sequence e g 3 flashes off 3 flashes off and so on Only the faulty node in a multi node system flashes its LED Possible operator action is listed in the right hand column of the table LED Fault Level Set conditions Operator action flashes O off Internal hardware failure RTB Hardware circuitry not operating 0 off Hardware failsafe checks RTB Hardware failsafe circuitry not operating 1 Configuration item out of VS At least one configuration items is range outside its allowable range 1 Corrupt configuration VS Configuration data has been data corrupted 6 Doc 177 52701 Rev2
66. performance of safety related parts of the truck or system e produce any incorrect signal that may cause the driver to perform hazardous operations e cause speed changes outside limits specified in the standard e cause a change of operating state e cause a change of stored data Radiated RF field EN 61000 4 3 5 1 Test Level user defined test level of 12 V m EN 12895 2000 4 2 Immunity EN 61000 4 6 Table 1 Test Levels Electrical fast transient EN 61000 4 4 Table 1 Test Levels Level 2 EN 12895 2000 4 2 Electrostatic Discharge 4 kV contact discharge 8 kV air discharge Electrostatic discharge Electrical surge EN 61000 4 5 1995 Table A 1 Selection of Test Levels Class 3 REGULATORY COMPLIANCE Designed to meet EN1175 1 1998 which covers EN1726 for the controller ISO 3691 UL583 ASME ANSI B56 1 1993 Doc 177 52701 Rev 2 4 5 SEVCON Mechanical OPERATING ENVIRONMENT Operating temperature 30 C to 25 C no current or time derating 25 C to 80 C no current derating but reduced time at rated operating point 80 C to 90 C and 40 C to 30 C with derating Non operation temperature 40 C to 85 C can be stored for up to 12 months in this ambient range Humidity 95 at 40 C and 3 at 40 C Ingress of dust and water IP66 rated SHOCK AND VIBRATION Thermal shock EN60068 2 14
67. phase to B or B at power up time during operation applying drive current Protected against any motor phase to another motor phase at any At switch on Gen4 detects valid output loads are present before A Repetitive short circuits may damage the controller 4 2 Doc 177 52701 Rev2 Specification OUTPUT RATINGS Input Function Short term Continuous Vdc rating A rms current A rms 24 36 Single traction 450 180 Single traction 650 260 36 48 Single traction 450 180 Single traction 650 260 72 80 Single traction 350 140 Single traction 550 220 2 minute rating lower ratings are possible for longer periods see example in Figure 9 Normalised Current Boost Normalised Current 96 Time mins og scale Figure 9 Output reduction over time with sustained peak demand Doc 177 52701 Rev 2 4 3 SEVCON CAN INTERFACE CAN protocol CANopen profiles DS301 DS401 and DS402 are supported Physical layer uses ISO11898 2 Baud rates supported 1 Mbits s default 500 kbits s 250 kbits s 125 kbits s 100 kbits s 50 kbits s 20 kbits s and 10 kbits s CONTROL INPUTS AND OUTPUTS Digital inputs 8 digital switch inputs software configurable polarity Can be wire off protected Active low inputs lt 1 8 V active high inputs gt Vb 1 8 V Analog inputs 2 general purpose inputs whic
68. pped to an analog output The brake lights will illuminate whenever the footbrake is pressed providing either an analog or digital footbrake input is available or the system is in direction change braking HORN Ensure a digital input switch is mapped to the horn switch object 2101 and an analog output is mapped to the horn object 2403 SERVICE INDICATION The controller can reduce vehicle performance and indicate to the operator when a vehicle service is required The interval between services is user configurable Configure the following at object 2850 Doc 177 52701 Rev 2 6 31 SEVCON e Service indication via an analog contactor output e g to drive a dashboard lamp and or Gen4 s LED e Source hours counter selects the hours counter and is used to determine when a service is required e Service interval hours between vehicle services Can be used by the reset function see below or for information only e Next service due Servicing is required when the source hours counter reaches this time This can be set manually or automatically using the reset function see below e Reset function write to the reset sub index at 2850 to automatically reset the service timer for the next service The next service due time is calculated as the source hours counter time plus the service interval SERVICE PROFILE This is a drivability profile where you can set maximum torques speeds and acceleration rates to
69. pump however all the main components would be the same if controller 2 was also powering a traction motor Communication between the controllers is achieved using the CANopen protocol This protocol also allows Gen4 to communicate with other non Sevcon CANopen compliant devices control fuse NO o S key switch line contactor CAN bus isolator L E i B B signals B B E signals battery Gen4 controller 1 Gen4 controller 2 MI M2 M3 MI M2 M3 EN 30 motor pump Figure 3 Truck system components Signal power for the internal control circuits and software is derived from the battery via the control fuse and key switch as shown No external in rush current limiting is needed as long as Gen4 is used to control the line contactor and hence the timing of its closure The software controls the start up sequence in this order 1 Charge the input capacitors to within 10V of battery voltage via the key switch signal line 2 Close line contactor Doc 177 52701 Rev 2 2 5 SEVCON 3 Generate output to the motor as demanded A line input fuse can be mounted on the body of the controller The B terminal is a dummy terminal If the fuse is mounted elsewhere connections from the battery positive are made to the controller terminal Principles of operation FUNCTIONAL DESCRIPTION The main function of Gen4 is to co
70. r ree ERR PR Dele 6 8 Self character zatton eroe oen re DR IRURE ROO GI rt re Pr RR 6 10 VOM s a eo de ene ee 6 10 Manu alobjectmapping z eoim dees depre ren pet tme uet rte DO 6 11 Automatic Configuration Mapping coccccconconnconoconccononononononnnonnnnnn non nnnn crec nennen ren een eene tnnt nenne 6 14 Encoder zen epe EE E Se a b 6 15 RICH 6 16 Prae 6 16 Analog contactor outputs essere enne ene E trente enne eterne enne emet 6 17 Vehicle performance configuration oooocoocccnononcnononcconononannnancnnnnncconannss 6 19 safety Interlocks spa oe let EE be ESSE 6 19 Torque amode speed Mode k iiis pb ee tete UE DERE IR ROSE IRE 6 20 ON ue P tionacriets e 6 20 Acceleration and braking eee EO el Ee pO HIR eue et eee reo coin 6 23 Footbr ke a DD SN est Sd EHI oed 6 23 Steering inputs twin driving motor SyStemS nennen nennen nennen ens 6 23 Ree e 6 25 Controlled roll off iii de 6 27 Hl bet gunge eege tco eerte n ec ete eee a a Seti eret i eed 6 27 Inching 5 E nb Ee D eee obe epe teehee 6 27 Drivability select Switches iier teet eie i ete Se det ete WA 6 27 Doc 177 52701 Rev2 ECONOMY eeh EENS 6 28 P urmp confipuration oie ea eee SB RR ee is aa an 6 28 POWer EU EE 6 29 Vehicle features lee 6 30 Contaclors deo eet Has dents aE oE e Ae alan 6 30 Line contactor dropout tc in kou eese ebbe EE E EEEE E E EE 6 30 El ctro mechanicall brake rte e E E REA E a aa PEE aE 6 30 External LED gees Een EEE e EEE
71. raction configuration Figure 12 is provided as a starting point for new designs Given the flexibility of the I O it is possible to configure a wide range of systems Refer to Signal connections on page 3 10 to see what each I O signal is capable of doing as you design your system For pump applications a basic single pump system is shown in Figure 13 Error Reference source not found Doc 177 52701 Rev 2 5 5 SEVCON SINGLE TRACTION WIRING DIAGRAM o Ow E Lo g no S cG oc 5 0 O 90 O Kg o Cont1 Supply CAN High CAN Low CAN term CAN High CAN Low Cont2 Supply 2 Cont3 Supply key switch control 9 fuse 6 line contactor B I I traction Y fuse i pin beri pa E EE 1 QUEM encoder A isolator EE encoder B M1 M2 M3 thermistor I Figure 12 Single traction wiring diagram 5 6 Gen4 Stand alone Traction Alternative encoder type U V W 5 EncU 17 Enc V 29 Enc W CAN connection 2 9000 for configuration and service i Linkto 2 terminate the CANbus 16 CAN connection az XXX to other CAN devices Alternative use a voltage source in place of the pot Alternative use a voltage source in place of the pot 18 forward 30 reverse 19 Eu foot switch 31 Pes seat 20 a handbrake 9 driveability select 1 32 e driveability select 2 21 power steer trigger Doc 177 52701 Rev2 S
72. ration tool the relevant Object Dictionary indices are listed in Table 5 Feature Object Notes indices 1400h 15FFh RPDO events Input mapping 1600h 17FFh RPDO mapping 1800h 19FFh TPDO events Output mapping 1A00h 1BFFh TPDO mapping Table 5 Objects associated with mapping An example mapping Figure 18 shows the movement of PDOs in a master slave configuration in which a digital input to the slave has been mapped to the seat switch object in the master Doc 177 52701 Rev 2 6 13 SEVCON Master Slave as 1600 8h 1A00 8h RPDO mapping TPDO mapping traction Switch 2124h application seat switch 5 PDO PDO 3 Cbject Dictionary 2 2 Cbject Dictionary 8 3 digital 6800h 1 inputs local digital inputs 1 8 1 0 consumer roducer CANbus o Figure 18 Example of a digital input mapped to the seat switch object via PDO and the CANbus AUTOMATIC CONFIGURATION MAPPING The auto configuration feature allows the user to select their vehicle I O from a list of pre defined configurations The principle is identical to the manual process described above but the PDO and VPDO mappings are created by each controller automatically at start up as well as CANopen network configuration settings This feature provides an easy and reliable method of setting up both single and multi node systems providing they match one of a selection of pre defined setups refer to page 1 for d
73. rform the work cycle e Peak motor power output required and duration Include inertia and friction contributed by the motor as well as any gearing in the drive chain when calculating torque and load requirements If replacing a DC motor with an AC motor in an existing application the DC motor torque vs speed curve is a good starting point to determine the required ratings MOTOR MAXIMUM SPEED Determine the maximum motor speed using the required vehicle or pump maximum speeds and the ratio of any gear box or chain between the motor and the load Most motor manufacturer rate induction motors at synchronous speed which is 1 500 and 1 800 rpm for a 4 pole motor when operated from 50 Hz and 60 Hz line frequencies respectively The maximum speed an induction motor can be used at is determined by the limit of the mechanical speed typically 4 000 to 6 000 rpm and the reduction in useful torque at higher speeds Increasing losses in the iron of the motor at higher speeds may further limit the maximum speed Always check the maximum speed with the motor manufacturer Check also any limitations imposed by the maximum frequency of the encoder input signal see Motor speed sensor encoder on page 5 11 TORQUE REQUIRED BETWEEN ZERO AND BASE SPEED Calculate the torque required by the application Use figures for the work that needs to be done against friction and gravity plus those required to accelerate the load inertia and momentum Up to ra
74. ring switch wire off is detected Check switch wiring 6 Speed measurement VS Speed measurement input wire off Check encoder wiring wire off is detected 6 Belly switch wire off VS Belly switch wire off is detected Check switch wiring 6 Throttle wire off DI Throttle wire off is detected Check throttle wiring 6 Throttle pressed at power DI Throttle demand is greater than Reduce demand up 20 at power up Doc 177 52701 Rev 2 SEVCON LED Fault Level Set conditions Operator action flashes 7 Controller high voltage S Battery voltage or capacitor voltage Isolate controller and protection with line 1s above the maximum level investigate high battery contactor open allowed for the controller with line voltage contactor open 7 Battery low voltage DI Battery voltage or capacitor voltage Increase battery voltage protection is below a user definable minimum above user defined battery level for a user definable level time 7 Controller low voltage DI Battery voltage or capacitor voltage Increase battery voltage protection 1s below the minimum level above minimum level allowed for the controller 7 Controller high voltage DI Battery voltage or capacitor voltage Investigate and reduce protection with line 1s above the maximum level battery voltage below contactor closed allowed for the controller with line maximum level contactor closed 7 Battery high voltage DI Ba
75. rning require some means of determining the angle of the steering wheel To do this use one of these options e Asteering potentiometer to give an analog voltage which is a linear function of the steering angle The steer potentiometer voltage 2223 must be mapped to an analog input e Four digital inputs representing inner left inner right outer left and outer right The inner switches indicate the steering angle where torque to the inner wheel motor is Doc 177 52701 Rev 2 6 23 SEVCON removed The outer switches indicate the steering angle where inner wheel motor changes direction The outer switches are optional The steer switches 212B to 212E must be mapped to digital inputs To configure steering inputs go to index 2913 in the Object Dictionary e Setup the voltages corresponding to fully left fully right and straight ahead Using this information Gen4 calculates the steering angle based on the voltage from a steering potentiometer e Setup the steering map This map defines the relationship between the inner and outer wheel speeds and the steering angle Each map has 4 user definable points as shown in Figure 23 1 2 0 8 2 06 Kai o amp amp o4 02 0 0 2 Steer angle outer wheel speed inner wheel speed Figure 23 Graph of speed vs steering angle The speed and steering angle are normalized Speed is normalized to maximum vehicle speed
76. roved by reducing the acceleration rate or the maximum torque Configure the economy input at object 2912 as follows e Economy function select acceleration or torque e Economy voltage input These settings are similar to those for the throttle see page 6 20 The economy value calculated from the voltage can be read at 2622 PUMP CONFIGURATION The controller can use a mixture of switch and analog voltages as the pump input In addition the power steer function can be used as an extra input to the pump if the pump motor is required to supply pump and power steering GENERAL SETUP Configure the pump features at 2A00 e Inhibit pump when BDI drops below cutout level If already operating when the cutout occurs the pump will continue to operate until all pump inputs are inactive e Drive Enable switch and or Seat switch input disables pump e Ignore Line Contactor state Allows the pump to operate if it is not connected to the battery through the line contactor Should be set if the pump also supplies power steering and the power steer is required to operate when the line contactor is open e Use Power Steer target velocity as pump input if pump also supplies power steering Set the pump maximum speed acceleration and deceleration at 2A01 The pump speed is calculated as the value from the inputs multiplied by the maximum speed PRIORITY ADDITIVE INPUTS Each pump input can be configured as a priority input or an additi
77. s 6 30 ACCESS AUTHORIZATION To prevent unauthorized changes to the controller configuration there are 5 levels of accessibility 1 User 2 Service Engineer 3 Dealer 4 OEM Engineering and 5 Sevcon Engineering The lowest level is 1 allowing read only access and the highest level is 5 allowing authorization to change any parameter To login with DriveWizard select User ID and password when prompted To login with other configuration tools write your password and optionally a user ID to object 5000 sub indices 2 and 3 The access level can be read back from sub index 1 The password is verified by an encryption algorithm which is a function of the password user ID and password key 5001 The password key allows passwords to be made unique for different customers The user ID also allows passwords to be made unique for individuals Doc 177 52701 Rev 2 6 7 SEVCON How NMT STATE AFFECTS ACCESS TO PARAMETERS Some important objects can only be written to when the controller is in the pre operational state DriveWizard takes Gen4 in and out of this state as required If you are not using DriveWizard you may need to request the CANopen network to enter pre operational before all objects can be written to To enter pre operational write 1 to 2800 on the master node To restore the CANopen network to operational write 0 to 2800 The controller may refuse to enter pre operational if part of the sy
78. s from torque mode in that the torque value applied to the motor is calculated by the controller based on the operator s requested speed determined by throttle position and the vehicle s actual speed This mode is useful where accurate speed control is required irrespective of the motor torque Doc 177 52701 Rev 2 2 9 SEVCON Safety and protective functions GENERAL Electric vehicles can be dangerous All testing fault finding and adjustment should be carried out by competent personnel The drive wheels should be off the floor and free to rotate during the following procedures The vehicle manufacturer s manual should be consulted before any operation is attempted The battery must be disconnected before replacing the controller or one of its fans After the battery has been disconnected wait 30 seconds for the internal capacitors to discharge before handling the controller Never connect the controller to a battery with vent caps removed as an arc may occur due to the controller s internal capacitance when it is first connected As blow out magnets are fitted to contactors except 24V ensure that no magnetic particles can accumulate in the contact gaps and cause malfunction Ensure that contactors are wired with the correct polarity to their power terminals as indicated by the sign on the top molding Do not attempt to open the controller as there are no serviceable components Opening the
79. section above Doc 177 52701 Rev 2 3 3 SEVCON EMC guidelines The following guidelines are intended to help vehicle manufacturers to meet the requirements of the EC directive 89 336 EEC for Electromagnetic Compatibility Any high speed switch is capable of generating harmonics at frequencies that are many multiples of its basic operating frequency It is the objective of a good installation to contain or absorb the resultant emissions All wiring is capable of acting as a receiving or transmitting antenna Arrange wiring to take maximum advantage of the structural metal work inherent in most vehicles Link vehicle metalwork with conductive braids POWER CABLES Route all cable within the vehicle framework and keep as low in the structure as is practical a cable run within a main chassis member is better screened from the environment than one routed through or adjacent to an overhead guard Keep cables short to minimize emitting and receiving surfaces Shielding by the structure may not always be sufficient cables run through metal shrouds may be required to contain emissions Parallel runs of cables in common circuits can serve to cancel emissions the battery positive and negative cables following similar paths is an example Tie all cables into a fixed layout and do not deviate from the approved layout in production vehicles A re routed battery cable could negate any approvals obtained SIGNAL CABLES Keep all wiring h
80. stem is active for example if the vehicle is being driven The request is logged in the EEPROM however so if power is recycled the system won t enter operational and remains in pre operational after powering up The NMT state can be read at 5110 where 05 operational and 7F pre operational Motor characterization Ensure you have completed the CANopen network setup process DETERMINING MOTOR PARAMETERS To provide optimum motor performance Gen4 needs the basic motor information normally found on the name plate as well as the following information e A value for each of the electrical parameters of the induction motor as shown in Figure 16 e The magnetic saturation characteristics of the motor in the constant power and high speed regions e Current and speed control gains Rs Lls Ur Vs 1 Lm y Rr s Figure 16 AC motor single phase equivalent circuit To determine these parameters use one of the following methods Doc 177 52701 6 8 Rev2 Configuration Ask the motor manufacturer to provide the data and enter it in the Object Dictionary at 6410 Also enter encoder data at 4630 and 6090 and motor maps at 4610 to 4613 Use the motor name plate data and the self characterization routine provided by Gen4 and DriveWizard described below Doc 177 52701 Rev 2 6 9 SEVCON SELF CHARACTERIZATION A The self characterization function will cause the motor to operate Ensure the vehicle is jacke
81. t Type 24V 36V A 9k 9k B 13k 9k 36V 48V A 16k 16k B 24k 16k 72V 80V A 44k 44k B 66k 44k Table 3 Impedance at Digital Input Pins Note to Table 3 Configure the digital input switches as active high switched to Vb or active low switched to battery negative Configuration applies to all digital input switches 1 to 8 e they are all active high or all active low When a switch is open the digital input pin sits at 0 5 x Vb The input sinks current in active high configurations and sources current in active low configurations Wire off protection is possible by combining a type A digital input with a type B digital input Doc 177 52701 Rev 2 3 15 EA Ge Specification SEVCON Electrical INPUT VOLTAGE 24 36V controllers 36 48V controllers 72 80V controllers Working voltage 12 7V to 52 2V 25 9 V to 69 6 V 43 5 V to 116 V limits Non operational 59 4V 79 2 V 132 V overvoltage limits Battery voltage Vnom to 0 5 x Vnom for 100 ms droop Vnom to 0 V for 50 ms Input protection Input protected against reverse connection of battery OUTPUT PROTECTION Output current Reduced automatically from peak to continuous rating depending page4 3 range on the time a peak load is applied to the controller see Figure 9 on Reduced automatically if operated outside normal temperature Short circuit Protected against any motor
82. ted speed the peak torque that can be supplied when using a correctly specified Gen4 is equal to the breakdown torque Select a motor with a breakdown torque rating greater than the peak torque required Doc 177 52701 5 2 Rev2 System design TORQUE REQUIRED AT MAXIMUM SPEED Calculate the torque as above As speed increases beyond base speed the maximum torque an induction motor can supply falls as defined by the following two equations In the constant power region T max O rated In the high speed region T T 2 O ted This is shown in Figure 10 Select a motor with a torque rating greater than the peak torque required Torque speed curve for a typical induction motor 3 5 3 constant power region high speed region 25 g 2 5 15 PS 05 a au a 0 0 0 5 1 15 2 25 3 3 5 4 45 Speed pu breakdown torque rated torque Figure 10 Torque speed curve Doc 177 52701 Rev 2 5 3 SEVCON CONTINUOUS POWER RATING The required continuous power rating of the motor is governed by the application load cycle over a shift Use the maximum RMS current over a period of one hour to determine the motor rating required The motor manufacturer will typically specify a 1 hour or continuous rating Select a motor whose ratings are equal to or greater than your calculated load over 1 hour PEAK POWER RATING The peak power rating required for the appli
83. the exception service personnel of the power steering if needed Power is removed to nearly all external components Severe S Keyswitch recycled Immediate shut down of the system with the exception turned off then on of the power steering if needed Power is removed to nearly all external components Drive inhibit DI User deselects all drive switches before Neutral brakes or coasts the traction motor s to a stop The fault prevents the operator initiating drive but reselecting does not inhibit braking function in particular controlled roll off braking Information I Not latched Information faults do not require immediate action although some cutback of power or speed may occur Table 1 Fault categories Doc 177 52701 Rev2 Chapter 3 Installation SEVCON Mounting Gen4 ORIENTATION The controller can be mounted in any orientation CLEARANCE FOR LED ACCESS If you want an operator of your vehicle to be able to view the onboard LED it is advisable to consider the line of sight to the LED at this time MOUNTING HOLE PATTERN 155 7 5 al K ry amp D QT 156 11 9 e P 4 n 1 E o ALL SIZE 6 MODELS S La e N 1 amp 07 Qo ALL SIZE 4 MODELS 8 aj N La 170 xl J 170 Flatness of mounting surfaces 0 2mm Doc 177 52701 3 2 Rev2 Installation Failure to comply with this flatness specification ca
84. this latter case the controller where there are two controllers the controller configured as master e Assists in the steering of a vehicle by adjusting the torque of each motor dependent on the steering angle e Reverses the direction of the inner wheel in order to provide a smaller turning circle The speed of the outer wheel is also limited during a turn An example of possible wiring for Gen4 traction controllers operating in master slave configuration is shown in Figure 14 Auxiliary components MAIN CONTACTOR Select the appropriate contactor line contactor from Table 4 A line contactor used at its rated coil voltage must be rated continuous Contactor coil voltage chopping allows the use of coils rated intermittent provided the manufacturer s conditions are met Gen4 peak output Coil Sevcon P N Manufacturer Notes current Up to 450 A 24V 828 37024 Albright SW200 29 See paragraph below 48V 828 57026 Albright SW200 20 80V 828 67010 Albright SW200 460 Up to 650 A 24V 828 39001 Albright SW200 Chop at 17 V intermittent coil Table 4 Main contactor rating The controller can drive any contactor with coil voltages from 12 V to Vb It is worth considering the use of 24 V contactors with the contactor drive output set to voltage control mode This allows you to use one type of contactor for any battery voltage 24 V to 80 V Pull in voltage pull in time and hold in voltage values are all configurable D
85. to the controller If you have a single node system the termination resistor should be connected so that the bus operates correctly when configuration tools are used CANbus 1200 Other CAN node Figure 7 CAN node termination Doc 177 52701 Rev 2 3 9 SEVCON Signal connections Signal connections are made to Gen4 via a 35 way AMPSeal connector U loooooooooooo 10000000000 028 0000000000003 Figure 8 Customer Connector Pins are protected against short circuits to the battery positive or negative terminals Pin Name Type What to connect Maximum Comment rating 1 Key switch Power From dead side of key TA This input supplies power from in switch via suitable fuse Total of all the battery for all the logic contactor circuits output The unit cannot operate currents plus without Key switch in 1 0A supply Pins 1 6 and 10 are connected together internally and can be used individually or in parallel 2 CAN Comms To terminate a Gen4 CAN node link pin 2 Make the connection only if the termination to pin 24 This connects a 1204 termination Gen4 is physically at the end of resistor mounted inside the controller the CANbus network see across the CANbus CANbus termination on page x y 3 Contactor Out To the switched low side 2 0A per This output provides low side out 1 of contactor or valve coil output subject voltage or current control to the
86. trical EE 4 2 Input yoltape escien a ae a AA aia 4 2 Output proteCtOn sedere he ete ee eer ag E S pat AEE 4 2 A E 4 3 VO P 4 4 Control inputs and QU PU S coins E 4 4 Isolation ios 4 4 Inge EE 4 5 Regulatory compliance sta i 4 5 KEE ias 4 6 Operating COVE ii i 4 6 Shock and vibration eee REGE UBER SURGE UO OI RON OI RON 4 6 ho m Q 4 6 Doc 177 52701 Rev2 DIMEN SIONS Nooo RR tus EI euet nc ete in LR eee 4 7 Size models ici docencia 4 7 Chapter 5 System design 5 1 EES 5 2 Information required about the application sese eene 5 2 Motor maximum speed eere bo ERR eee ERE ves eges E EE eue se ERR ER aree ree Sens 5 2 Torque required between zero and base speed 5 2 Torque required at maximum speed 5 3 Continuous Power Tati gs Em 5 4 Peak power TatBg eiii frei e dr Hb dec RUE 5 4 Selecting the EE 5 4 Current and power ratings considerations nennen nennen rennen nennen 5 4 Power output restrictions at motor and drive operating temperature limits esses 5 4 Ee ue ila EE 5 5 Single traction wiring dageram ee eee eeeeeseeeeseeeeceecesecaecaecsaecsaecaeecseseaeseeeseeeeeeeeeeseeeaeeeaees 5 6 Single PUMP wiring Din 5 7 ice a TRU aaa nemus 5 8 Auxiliary COMPONEN 5 8 Main COMLAC ION vestida illa dia traida 5 8 35 Way AMPS al Connector EEN
87. ttery voltage or capacitor voltage Investigate and reduce protection is above a user definable maximum battery voltage below battery level for a user definable user defined maximum time level 8 Controller too hot I Controller has reduced power to Remove loading to motor s below maximum specified allow controller to cool by user settings due to controller down over temperature 8 Controller too cold I Controller has reduced power to Allow controller to motor s below maximum specified warm up to normal by user settings due to controller operating temperature under temperature 8 Motor over temperature I Controller has reduced power to Reduce load to motor motor s below maximum specified to allow it to cool by user settings due to motor over down temperature 12 Communication error S Unrecoverable network communication error has been detected 13 Internal software fault RTB Software run time error captured Table 7 Fault identification FAULT LIST Use DriveWizard to access the Fault list If you don t have DriveWizard you can use any configuration tool as follows Doc 177 52701 Rev2 1 Object 5300 gives information about all active faults Read sub index 1 to get the number of active faults Write to sub index 2 to select one of the active faults 0 highest priority and read back sub index 3 to read the fault ID at that index 5 Object 5610 can be used to read a text description of the
88. ve input When calculating the pump demand the controller selects the demand from the highest priority active input and then adds the demand from all the active additive inputs PUMP THROTTLES Doc 177 52701 6 28 Rev2 Configuration There are 2 pump throttle inputs which can be configured independently The pump throttles allow proportional control of the pump speed Configure inputs as priority or additive and set the voltage levels in the same way as the traction throttle The pump throttles must be mapped to analog inputs PUMP SWITCHES There are 7 pump switch inputs Configure each input as priority or additive and assign it a value The pump switches must be mapped to digital inputs POWER STEER CONFIGURATION Power steering can be provided e Contactor Map the power steer contactor drive object to an analog output e Dedicated motor controller Map power steer application motor object to motor control slave e Pump motor controller Configure pump to provide power steering Power steer demand is added to pump demand The power steer can be triggered by a number of events e Vehicle moving e FS1 switch activating e Direction selected e Seat switch activating e Footbrake activating Set the power steer motor speed acceleration and deceleration at 2B01 This is not required if the power steer motor is operated by a contactor Doc 177 52701 Rev 2 6 29 SEVCON Vehicle features and functions
89. ystem design SINGLE PUMP WIRING DIAGRAM e 13 CAN connection CAN High ha j 24 XXXX for configuration CAN Low 1 and service i Link to CAN term 2 terminate the 8 CANbus EE cas c 16 CAN connection e CAN High 2 Cont1 Supply 3 27 XXXX to other CAN CAN Low devices 8 Cont2 Supply 12 Cont3 Supply Alternative use a voltage source in place of the pot 10 db NN 1 ump Je PERT key switch i P DC control 9 swim jel oo l JR fuse gt B STO Alternative use a voltage OO i Gen4 AA t line contactor 34 F 1 traction 9 Stand alone pun i i fuse D Pump 22 3 throttle pc i pin SOLER beri E akaga Ec B 13 j AE encoder A Alternative encoder 18 isol sO 25 i e i90 0 3 SETH encoder B type U V W pump 1 switch I OV 5 EncU 30 r i 17 Enc V i 1 ump 2 switch o o i m M2 pump 3 switch e N n ts pump 4 switch thermistor 20 B pump 5 switch pump 6 switch 32 T pump inhibit 21 pump driveability select 1 Figure 13 Stand alone pump wiring diagram Doc 177 52701 Rev 2 5 7 SEVCON Twin motor systems A twin motor system may be powered by two Gen4 controllers operating in master slave configuration In this case the necessary commands are transmitted by the master node to the slave node via the CANbus Motors may be operated independently in a combined traction pump application or operated in tandem where each motor drives a separate wheel In

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