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MillipaK 4QPM Controller User Manual

1. 300A 4QPM controller with Soft Start 633T43901 MillipaK 4QPM Controller Manual 15 06 05
2. 0 7 1 0 See also contactor drive output configuration System Digital IO MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features High Speed Switch High Speed Switch and Anti Tie Down Vehicles with a High Speed Switch configured will normally drive at the Cutback 1 Speed but will allow the maximum speed of the vehicle to increase to 100 in Reverse or the Cutback 2 Speed in Forward when the High Speed Switch is active This is usually used for a Walkie type vehicle with a ride on platform where Reverse Power unit forward Forks trailing is the normal driving direction This function has two modes Normal and Momentary Normal mode only activates this feature so long as the switch is active Momentary mode activates this feature when the switch is active and keeps the High Speed Operation active after the switch is released High Speed Mode is configurable via the Calibrator High Speed Mode Power On Calibrator Menu Reference 12 12 Typical Value Normal NOR Latched LAT Normal NOR There are two separate options for High Speed Operation Normal Unlatched High Speed Operation is only active when the switch is active Momentary Latched High Speed Operation is active as soon as the switch is made active and remains active after the switch is released until any of the Anti Tie Down conditions become true High Speed Operation will be activated when the following conditions are
3. The MillipaK controller has several features designed to offer the user maximum flexibility safety and performance whilst ensuring the controller is protected against adverse or harsh driving conditions These features can be split into three categories standard controller features safety features and controller protection features Standard Controller Features The following section details the standard features found on a MillipaK controller MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features Power Steer Power Steer A contactor drive is available to control a separate Power Steer motor An adjustable delay allows the motor to operate for a set time after the power steer trigger or power steer demand has been removed The following triggers are available and configurable for power steer Power Steer Trigger Triggers Configuration Item FS1 switch Fwd or Rev switch Seat switch 0 No No No 1 Yes No No 2 No Yes No 3 Yes Yes No 4 No No Yes 5 Yes No Yes 6 No Yes Yes 7 Yes Yes Yes Table 7 Internal Power Steer Triggers The software also monitors the motor for movement if the Anti Roll Off feature is enabled and activates the power steer driver accordingly Power Steer Personalities Power Steer Timer Immediate Calibrator Menu Reference 9 01 os 60S 1S 2S Power Steer Trigger Power On Calibrator Menu Reference 12 14 Liha
4. Drive will be allowed after the Quick Pick switch is released only if all Drive Switches are deselected For example if the Forward switch is activated during the Quick Pick operation Drive is inhibited when the Quick Pick switch is released until the Forward switch is deactivated MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features Seat Switch Seat Switch If the seat switch is opened and the seat switch timer has timed out during drive the controller will stop pulsing and a seat fault will be indicated Before drive can be restarted the seat switch must be closed and FS1 and the direction switch must be recycled through neutral Note the start sequence for drive requires that the seat switch is closed and both the direction and FS1 switches are in the neutral position simultaneously before drive can be initiated The time period is programmed by means of the Calibrator Seat Switch Delay As a setup menu option the seat switch can also inhibit pump operation if required Seat Delay Immediate Calibrator Menu Reference 10 01 O 0 18 5 08 0 18 5 08 Seat Cuts Pump Power On Calibrator Menu Reference 12 04 Typical Value OFF ON OFF MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features Handbrake Switch Handbrake Switch An input is provided for the connection of a handbrake switch which 1f operated will disable armature pulsing MillipaK 4QPM C
5. MillipaK 4QPM Controller Manual 15 06 05 Fault Reporting Form Fault Reporting Sevcon is committed to improving the quality if all of its products Please help us by using this form to report faults to Sevcon Please give as much detail as possible Use extra sheets if required Fax this form to 44 191 482 4223 Your Name Your Company Vehicle Manufacturer Controller Type Serial Number Date Time that fault first occurred Exact Fault Message calibrator or display When did the fault message appear How did the fault occur Please describe The vehicle speed The approximate gradient up or down hill Pedal and switch changes by the driver What happened to the vehicle when the fault occurred Telephone Number email address Vehicle Type Part number Software Version during drive when the vehicle stopped in neutral after a keyswitch off on delete as applicable What is the status of the vehicle now Is there a fault message at key switch on Can it be driven Table 12 Fault Reporting Form MillipaK 4QPM Controller Manual 15 06 05 Software Version Software Version and Serial Number indication For identification purposes and to assist in queries the software version and the controller serial number are indicated in the calibrator Test Menu The software version and revision are shown in the Test menu When giving the software version and revision the ent
6. 0 8 01 I Cubed Lower Limit AAA Y A 8 02 I Cubed Upper Limit He i o 255 9 01 Power Steer Timer re O 60s 10 01 Seat Delay E Ode 350 11 01 Roll Off Enable C ROFRION 2 5 52 5 i 11 02 Walk Speed Eo 0 11 03 Belly Delay E 0d 5 5 2508 1 11 04 PSS Ramp Up Delay Es 0M amp d s 11 05 PSS Timer po 05 co 11 06 Line Contactor Dropout Timer 1s 60s 11 07 SRO Delay 11 08 Low Voltage Start _ Low V Cutout System Voltage 11 09 Low Voltage Cutout o po o l sv LowVStart 11 10 High Voltage Start System Voltage HighVCutout 11 11 High Voltage Cutout HighVSart 500Vor620V 1112 Battery Warning Level uw 8y 11 13 Battery Warning Timer Os ee 11 14 Temp Armature I Limit 50a 300A 11 15 Temp Armature ILimit Timer Os Ts 11 16 Stall Motor Voltage ES AE AN 24V 11 17 Stall Motor Current a 10A 11 18 Stall Timer cs 60 11 19 Idle Timer 0 os 11 20 Foot Brake Zero Volts 0 00V 4 50V 11 21 Foot Brake Full Volts E EA 0 00V 4 50V 12 01 Chop Select Me OFF ON 24V 12 02 SRO Enable EE OFF ON MillipaK 4QPM Controller Manual 15 06 05 Commissioning Personalities Record Personality New Range Setting Minimum 12 03 Control Mode n TOROUE SPEED 12 04 Seat Cuts Pump E gt OO _ 12 05 Roll Off Electro brake oooO OWON O 12 06 Reverse Speed Limit _ O OWON 12 07 FS1 recycle on Dir Ch
7. Seucon PC paK on MillipaK 40 gt TTL Min max pefaut information Node 0 504 330 A 330 4 J Traction 35 5 100 96 5 Personalities Neutral Brake Level 70 1 100 1 E Status Reduction Braking Level 0 0 100 0 El Test Acceleration Dela 28s D1s 50s 15s Drive Deceleration Dela 15s O1s 100s 01s Direction Deceleration Dela D1s D1s 100s O1s Neutral Deceleration Dela 80s O1s 10 0s 01s Creep Speed fo 0 25 0 Maximum Speed 100 96 0 100 100 Maximum Reverse Speed 100 96 09 100 96 100 96 Cutback 1 Speed hos 0 100 96 100 96 Cutback 2 Speed 100 0 100 100 96 Seat Dela 20s D1s 50s 50s English z Online Node 0 Ready Figure 8 PCpaK Window PCpaK provides many advantages over using the standard calibrator including the following features Easy to use Windows Explorer style GUI Personalities can be easily modified by typing new values in directly Configuration personality setups can be saved and loaded to and from file Previously saved configurations can be quickly downloaded using the Rapid Download wizard Service log analysis Controller status checking Quick viewing of entire controller menu structure Offline viewing of previously stored configurations A controller does not need to be connected to view a saved configuration Flash program capability PCpaK can reprogram the software in the
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9. ynomp saaow xoyeredo an 2 i i mamo ZVI 9 uonebIAeN i i i 7 ere C i i i E i son E Mu AC Wy i i H l i i amaraj 007 FUME 60 TO OSZA WOSIA UI9 S S I9 IO DUO OF 103 deN y y i D OPTED L 9 10c oop 6DE Dz I den soyeuques Commissioning Checklist Commissioning Checklist Controller Mounted on suitable flat heatsink with appropriate heatsink compound Power wiring checked shortest routes taken where possible Light wiring checked use calibrator to verify controller correct switch operation Accelerator set up and checked 0 100 Personalities are all set checked and record filled out MillipaK 4QPM Controller Manual 15 06 05 Commissioning Personalities Record Personality Record Personality Setting 0 01 Armature Current Limit 50A ABR 1 01 Direction Change Braking Level 5 doe 1 02 Neutral Braking Level po d w 1 03 Reduction Braking Level 0 100 1 04 Foot brake BrakingLevel cw 100 2 01 Acceleration Delay gt e 7 0082 e 2 02 Drive DecelerationDelay Ols bo gos 203 Direction Change Decel Delay Olis 1008 2 04 Neutral Deceleration Delay os 100s 2 05 Accelerator Zero Voltage OV 4s0ow 2 06 Accelerator Full Voltage 00V 4s0ow 3 01 Creep Speed A Pd Do 5 01 Maximum Speed o o o ee ee 5 02 Maximum Reverse Speed o 100 6 01 Cutback Speed I A HT 100 7 01 Cutback Speed 2
10. 14 15 16 Forward B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 Reverse B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 Belly B4 B4 B4 B4 B4 B4 Tiller B5 B5 B5 B5 B5 B5 FS1 B4 B4 B4 B4 B4 B4 B4 B4 B4 B4 Seat B5 B5 B5 B5 B5 B5 B5 B5 B5 B5 Speed Cutback 1 B6 B6 B6 B6 B6 B6 B6 Speed Cutback 2 B7 B7 Handbrake B7 B7 B7 B7 P Steer Trigger B6 B7 B6 B7 Pump Trigger B7 B7 B7 B7 B7 B6 B7 B7 High Mast B6 B6 Motor Over Temp B6 High Speed B6 Ouick Pick B7 Brk Override Sw B6 Footbrake Sw B6 Line Contactor B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 P Steer Contactor B9 B9 B9 B9 Pump Contactor B9 B9 B9 B9 Electro Brake B9 B9 B9 External LED B9 B9 B9 Hours Counter B9 Buzzer B9 Electric Board Drive Table 5 Digital Functions Notes 1 Bx refers to Socket B pin numbers All vehicles have Forward and Reverse Switches and a Line Contactor All Walkie vehicles have Belly and Tiller Switches All Ride On vehicles have FS1 and Seat Switches Pump Trigger will trigger Pump Soft Start function as well as the Pump Contactor This is why some configurations have a Pump Trigger but no corresponding Pump Contactor DAA ND MillipaK 4QPM Controller Manual 15 06 05 Configuration System I O Configuration Analogue Functions Analogue Value of Analogu
11. Fed E edn yda Fr 80 MillipaK 4QPM Controller Manual 15 06 05 Introduction Introduction The MillipaK 4QPM Four Quadrant Permanent Magnet range of controllers provides a new range of power frames for 24V 48V 300A in small highly efficient packages This is achieved using a Sevcon patented power switching scheme and radical new construction techniques which enable large powers to be incorporated into very small packages The MillipaK provides a completely sealed IP66 unit containing power and logic circuitry as well as all suppression components and an optional integrated pump soft start stop chopper MillipaK supports Sevcon s existing MOS90 calibrator for adjustment of vehicle performance characteristics MillipaK is ideally suited to applications reguiring a single traction controller for example walkies golf cars and basic ride on trucks Controllers are FLASH microprocessor based enabling field re programming for new features and have numerous user set up options The MillipaK uses high freguency silent MOSFET power switching technology to control a 4O power frame bridge Armature current is monitored Motor feedback should not be necessary Controllers have been designed to satisfy the reguirements of the relevant UL and EC standards MillipaK 4OPM Controller Manual 15 06 05 Safety Safety The MillipaK controller contains a triple fail safe system to give a high level of safety If the diagnostic LED is not illuminat
12. MillipaK controller MillipaK 4QPM Controller Manual 15 06 05 PCpaK Functionality PCpaK is a powerful tool Some of the typical uses are Analyzing controllers in the field and recording information such as personalities to a file Reprogramming the MillipaK controller software The MillipaK Controller does not need to be removed from the vehicle for the software to be upgraded Asa tool in a production line to program controller software and or personalities this allows customers to stock one part number for the Controller hardware and simply reconfigure it when the controller is installed onto the vehicle For information about PCpaK please contact Sevcon Inc Program Mode The MillipaK 4QPM controller must be configured into program mode to allow the down load of application software only into the flash memory when using PcpaK Pin 16 of the 16 way Molex connector B connector must be connected to pin 1 key switch input The controller will automatically enter program mode when it is keyed on and the system status LED shall remain off MillipaK 4QPM Controller Manual 15 06 05 aor E J bald i H H wma amines amunt SC E i oon mt fama Bae aa el JA i i semo Gy aoLoM a t H i 20401 i H i ON i f h 4 seine G NOLOW 91 i U i SHOA llyg SI H i i urays s apung
13. On vehicle with Handbrake switch Power Steer Trigger switch and Power Steer Contactor 10 Ride On vehicle with Speed Cutback 1 switch Power Steer Trigger switch and Power Steer Contactor 11 Ride On vehicle with Handbrake switch Pump Trigger switch and Pump Contactor 12 Ride On vehicle with Handbrake switch Pump Trigger switch and Pump Contactor 13 Ride On vehicle with Power Steer Trigger switch Pump Trigger switch and Power Steer Contactor Pump Trigger activates Pump Soft Start function 14 Ride On vehicle with Traction Motor Overtemperature switch Handbrake switch and external LED drive 15 Ride On vehicle with Power Steer Trigger switch Footbrake switch and Power Steer Contactor 16 Ride On vehicle with Speed Cutback 1 and 2 switches and Alarm Buzzer drive 17 Ride On vehicle with Speed Cutback 1 and 2 switches Electric Board drive and Virtual FS1 Table 4 Description of each Digital I O configuration MillipaK 4QPM Controller Manual 15 06 05 Configuration System l O Configuration WARNING _ Incorrect configuration could cause a vehicle to move unexpectedly for example if FS1 was inadvertently configured as a belly switch If your application doesn t fit any of the above please contact Sevcon with details of your reguirements Each of the above configurations allocates the controller I O as shown below Digital Value of Digital I O Configuration Item Function 1 2 3 4 5 6 7 8 9 10 11 12 13
14. Protection Cutback Power Up Calibrator Menu Reference 12 09 OFF ON OFF Current Cubed Lower Limit Immediate Calibrator Menu Reference 8 01 Minima Maximum SS Tica Vac 0 254 1 25 Current Cubed Upper Limit Immediate Calibrator Menu Reference 8 02 inima Maximum SS Tica Vale 1 255 1 40 MillipaK 4QPM Controller Manual 15 06 05 Controller Protection Idle Fault Idle Fault Briggs amp Stratton specific This feature is intended to prevent accidents caused by unintentional movement The system will exhibit a severe fault cannot be cleared without a key recycle and a 2 flash fault will be displayed by the Diagnostic LED mounted on the controller if the following is true system is powered up FSI is open The above conditions are both true continuously for the time specified by the Idle Timer personality Setting the Idle Timer personality at zero disables the feature Idle Timer Immediate Calibrator Menu Reference 11 19 Typical Value Os 255s Is 240s MillipaK 4QPM Controller Manual 15 06 05 Controller Protection Motor Stall Protection Motor Stall Protection Briggs amp Stratton specific By monitoring the motor current and voltage over a period of time the controller is able to detect if a motor stall condition has occurred If the armature current rises above the level specified by the Stall Motor Current personality while the motor voltage drops below the level specified by
15. TRUE Normal mode The High Speed Switch is active and Anti Tie Down is not inhibiting the feature Anti Tie Down is used to prevent High Speed operation under conditions where the operator may not be expecting it Momentary mode The High Speed Switch has been active at least once to initiate the function and Anti Tie Down is not inhibiting the feature The speed demand in the Reverse direction Power Unit Forward is limited to the Cutback Speed 1 configuration item if High Speed Operation is not active The speed demand in the Forward direction Forks Forward is limited to one of the following The lower of the Cutback Speed 1 configuration item or the Cutback Speed 2 configuration item if High Speed Operation is not active The Cutback Speed 2 configuration item if High Speed Operation is active Other speed demand limits may be applied whether High Speed Operation is active or not MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features High Speed Switch Anti Tie Down inhibiting to the High Speed Switch Feature will be applied if any of the following conditions are TRUE The system has just powered up A change in direction has just occurred i e The reverse direction is selected after the forward direction and vice versa The Tiller Switch is inactive Anti Tie Down inhibiting will be kept active until the High Speed Switch is cycled through its inactive state Anti Tie Down is u
16. be displayed for 1s indicating the password was accepted If the password was incorrect or no password was entered the system defaults to Service mode After the Security Level has been displayed the system enters the normal menu structure shown in the Calibrator Map To change the password level the Key switch needs to be recycled MillipaK 4QPM Controller Manual 15 06 05 Calibrator Calibrator Navigation Navigation The Calibrator uses all three buttons for navigating through the menu structure Use the SELECT button to move through the menu structure When the SELECT button is pressed the next menu item is displayed The default direction is from left to right top to bottom If the and buttons are held down together the ID of the currently displayed menu item is shown For example if the Armature Current Limit personality was selected then the ID would be 0 01 menu O item 1 This allows for the exact Calibrator Map position to be identified If the and buttons are held down together for more than 3 seconds the direction through the menu structure is reversed As a result when the SELECT button is pressed the direction is from right to left bottom to top In this mode the LED on the Calibrator will flash If the and buttons are held down together for more than 3 seconds again the direction reverts back to the initial direction and the Calibrator LED stops flashing The SELECT button is used to naviga
17. the Roll Off Enable option Roll Off Enable Immediate Calibrator Menu Reference 11 01 OFF ON ON Roll Off E Brake Power On Calibrator Menu Reference 12 05 OFF ON OFF MillipaK 4OPM Controller Manual 15 06 05 Safety Features Fail safe Fail safe The controller s safety system includes a microprocessor watchdog which can detect software failure and a hardware fail safe system which can prevent dangerous runaway conditions in the event of certain hardware failures Every time the controller is powered up the software checks that the fail safe circuit is able to switch off the MOSFETs and open the contactors MillipaK 4OPM Controller Manual 15 06 05 Controller Protection Temperature Monitoring Controller Protection Features There are several in built features which are designed to protect the MillipaK controller from damage due to excessive load currents voltages and prolonged periods of high demand Temperature Monitoring If the temperature of either power frame exceeds 759C its maximum available current will be reduced Note however that if the set current limit is less than the maximum available current limit actual cutback will occur at progressively higher temperatures than 759C The thermal cutback ensures that the maximum heatsink temperature is limited to 909C See Figure 6 When cutback occurs the diagnostic LED will flash 8 times Inspection of the calibrator fault messages
18. 06 05 Configuration Performance Braking Regen Braking All braking types are implemented using regenerative braking in the 4QPM MillipaK Braking can be initiated in one of 3 ways 1 Direction Braking Initiated when the direction switch inputs are reversed during drive i e Reverse is selected when driving in Forward or Forward is selected when driving in Reverse 11 Footbrake Braking Initiated when the operator depresses the Footbrake pedal and a footbrake input is configured See section below for more information about setting up and configuring the system for Footbraking iii Neutral braking Initiated when the vehicle is put into neutral during drive and neutral braking level is greater than 0 Braking Levels Each Braking Type has its own personality for setting the required braking level These are shown below Direction braking level Immediate Calibrator Menu Reference 1 01 5 100 1 15 Neutral braking level Immediate Calibrator Menu Reference 1 02 Miniman Marim ET Sie Tical vale 0 100 1 10 Reduction braking level Immediate Calibrator Menu Reference 1 03 ee SYRTH 0 100 1 10 Footbrake braking level Immediate Calibrator Menu Reference 1 04 Minima Maximum ET 0 100 1 0 The four braking levels for direction neutral reduction when reducing accelerator demand without opening FS1 and footbraking are used to determine the strength of the brak
19. 1 14 A YTT HI 5A 300A 10A 100A Temporary Armature I Limit Timer Immediate Calibrator Menu Reference 11 15 Minimum Maximum EE Typical Vale OS 10S 1S 4S MillipaK 4QPM Controller Manual 15 06 05 Safety Features Safety Features Start Up Sequence Safety Features The features listed in this section are designed with the safety of the operator in mind Start Up Sequence At keyswitch on the Direction and FS1 switches must be in the neutral condition simultaneously at least once before drive can be selected This is a safety feature to help prevent unexpected movement immediately after power up Alternatively the system may be programmed only to check FS1 at power on This option is programmable Direction Switch Checking Power Up Calibrator Menu Reference 12 08 OFF ON OFF MillipaK 4QPM Controller Manual 15 06 05 Safety Features Safety Features FS1 Recycle FS1 Recycle On some vehicles such as Golf Cars it is desirable to force the driver to remove accelerator demand before allowing the vehicle to drive in the opposite direction than it has been traveling in This feature is implemented as an option and is selected in the PERS setup FS1 Recycle Power Up Calibrator Menu Reference 12 07 OFF ON OFF MillipaK 4QPM Controller Manual 15 06 05 Safety Features Safety Features SRO SRO Static return to off This feature is optional in the setup menu and when spec
20. All items except those in the Setup menu can be Engineering Eng 1645 displayed Contact 5 All Adjust All SEVCON All items are displayed regardless of configuration Table 1 Calibrator Security Levels Note that only items appropriate to the current system configuration are displayed For example if none of the switch inputs is configured as a Cutback 1 Speed Switch then the Cutback 1 Speed personality will not be displayed The All Adjust security level allows access to all personalities including those not required by the current configuration The items in the Setup menu can only be accessed at this security level The password can only be entered just after power up while the Traction Drive Hours Counter is displayed The and buttons are used to enter the password The first digit is entered by pressing the button the appropriate number of times i e once to enter 1 The second digit is entered by pressing the button the appropriate number of times i e 6 times to enter 6 The third digit is entered using the button again and the final digit is entered using the button again Note that when the or buttons are pressed the display still changes to show hours or 1000 x hours After entering the password press either the button or the SELECT button to initiate verification If the password has been entered correctly the text shown in Table 1 appropriate to the required level will
21. Calibrator Menu Reference 5 02 Minima Maximum icp Sz ERTH 0 100 1 100 Reverse Speed Limit Enable Power Up Calibrator Menu Reference 12 06 OFF ON OFF MillipaK 4QPM Controller Manual 15 06 05 Features Optional Features Pump Soft Start Pump Soft Start The MillipaK units may be fitted with a Pump Soft Start feature This allows a pump motor up to 120A to be connected directly to the controller and eliminates the need for a contactor It also has the added benefit of providing a soft start to the pump motor by gently ramping up the voltage over a pre determined period After triggering the pump will remain active for as long as the trigger input remains active or the pre set timer expires whichever is shorter Pump Soft Start Ramp Up Delay Immediate Calibrator Menu Reference 11 04 inim Marim e ID 0 18 1 08 0 18 0 18 Pump Soft Start Timer Immediate Calibrator Menu Reference 11 05 0 58 10 08 0 18 2 08 WARNING The pump soft start option when fitted is NOT current limited and care should be taken not to exceed the maximum current specified by the controller rating MillipaK 4QPM Controller Manual 15 06 05 Features Optional Features Alarm Buzzer Alarm Buzzer The Alarm Buzzer function is used to drive a warning buzzer when the vehicle moving in different conditions The function works by activating the Buzzer output when Mode OFF 1 The buzzer will not sou
22. Direction or FS1 switch closed at power up 14 Low Battery Fault Battery voltage is too low 15 High Battery Fault Battery voltage is too high 16 High Battery Fault with Battery voltage is too high before the line Line Contactor Open contactor is closed Configuration Range PEN 17 Fault A personality is out of range 18 eee oe The personality CRC is incorrect 19 Pee OH OE Mad Line contactor is welded Fault Line Contactor did not as 20 Close Fault Line contactor is open circuit 21 Lower MOSFETs Short Short circuit on Q2 Q4 Armature MOSFETs Circuit detected 22 Reserved for future use MOSFETs did not pulse during power on 23 MOSER OH failsafe checks failsafe circuit enabled MOSFETs pulsed during power on failsafe a MOS PET OR checks failsafe circuit disabled 25 Upper MOSFETs Short Short circuit Q1 Q3 Armature MOSFETs Circuit detected Contactor 2 did not pulse during power on EDD OU failsafe checks failsafe circuit enabled a Contactor 2 pulsed during power on failsafe 21 DRWS On checks failsafe circuit disabled a Contactor 1 did not pulse during power on NE HON failsafe checks failsafe circuit enabled 29 Drive 1 On Contactor 1 pulsed during power on failsafe Table 11 Fault Numbers and Descriptions MillipaK 4QPM Controller Manual 15 06 05 Fault Clearance Fault Clearance Any fault indication will be cleared by re initiating the start sequence after the cause of the fault has been removed
23. Flash Fault Descriptions In addition to the LED indication a more detailed description of any faults detected may be found by using the calibrator Menu item number 13 01 gives a code which corresponds to the following detected faults ID Fault Description Flash Fault O System OK On Maximum power available to the motor has 1 Thermal Cutback been reduced due to excessive Heatsink 8 temperature a noe Maximum power available to the motor has 2 Tee EL Hm been reduced by the Timed Current Limit 8 Cutback i Cutback function 3 Accelerator Wire Off Input wire from accelerator has been 6 disconnected 4 ACC rator eased at Accelerator pedal pressed at power u 6 Power Up P P P P 5 Belly Fault The Belly switch function has occurred 2 6 Seat Fault Drive selected and no seat switch closed 2 7 System Idle Fault Idle timer expired 2 8 System Stall Fault System stall condition occured 9 9 Autozero Not Taken No drive allowed until power up autozero has 10 been taken 10 FSI Recycle FS1 switch remained closed during a direction 2 change MillipaK 4QPM Controller Manual 15 06 05 Fault Finding checks failsafe circuit disabled ID Fault Description Flash Fault 11 SRO Fault FSI switch selected for greater the SRO delay with Direction switches open 12 Two Direction Fault Two directions selected together 13 Sequence Fault
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25. S When set to NORMAL the vehicle will activate belly operation for the duration set by the personality Belly Delay Calibrator Menu Item 11 03 When set to continuous the belly action will operate for as long as the Belly switch input is active Belly Delay Immediate Calibrator Menu Reference 11 03 Minimu ena Sip Sizo TeV 0 18 5 0S 0 18 1 08 Belly Style Power Up Calibrator Menu Reference 12 13 Normal Continuous Normal MillipaK 4QPM Controller Manual 15 06 05 Safety Features Safety Features Anti Rollback Anti Rollback This is a standard SEVCON feature and is used to help prevent roll back conditions on ramps If the driver reselects the previous direction after a neutral condition braking is not attempted and full drive power is available to restart on a hill MillipaK 4QPM Controller Manual 15 06 05 Safety Features Safety Features Anti Rolloff Anti Rolloff This feature is designed so that if a vehicle is powered up without its handbrake applied any non drive condition on a gradient results in the vehicle braking slowly in a controlled way down a ramp without running away The vehicle has to be stationary at least once after power up before the feature is applied The Roll Off Electro brake option may be set so that the Electro brake if fitted amp configured is applied brakes on when Roll Off is detected The Roll Off strength is not adjustable but can be enabled and disabled using
26. SEVCON MillipaK 4QPM Controller User Manual For System Version V2 50 01 Document History Document History MillipaK 4QPM Controller Manual Init _Author _ ON Version Reason for Modification PB 06 03 01 0 01 Original Gn DM Fl Document updated for V1 01 software PG 19 11 01 1 50 00 Document updated for V1 50 00 software PG 07 03 02 1 50 01 Document updated for V1 50 01 software PMR 20 03 02 1 50 01 Document updated to reference PCpaK PS 24 05 02 1 50 03 Modified over temp cutback characteristics SRO Delay personality TSN 06 11 03 1 51 01 Added Briggs amp Stratton specific features and optimized software v1 50 04 1 Electric Board Drive 2 Virtual FS1 3 Low Battery Warning 4 Stall Motor Fault 5 Idle Fault 6 Reduction Braking 7 Temporary Current Boost AJK 13 08 03 2 50 01 Calibrator map updated DC 06 08 04 2 50 01 Updated for Current limit reduction and Hi V Cut increase 15 06 05 Contents CONTENTS Introduction AA 5 MN A FT AT Di so 6 Installation RR 7 A O O de Goe 7 Millipak 4 OPM Power WITE 0 aa 8 MillipaK Light Wiring example oooocoonnnncoccnonocccnonnonccnnononnncnnnonononnonnncnnnnnnnaconnnnnncnnnn na ncnnnnnnccninnss 9 SS O O 11 Traction Drive Hours Counte seieun aia AAEE EEEE E EE EEIE 12 Calibrator Security Levels ee cd e Y Y DG Y E seme sae 13 N VigatlOl edyn du EEE YT FY E E A I EENE ERE 14 ACJUSUMENS O RO 15 Status and Test Information oooonnooc
27. The accelerator push refers to how much the operator has the accelerator depressed This is the value which is displayed on item 19 01 in the Test menu on the Calibrator The Accelerator Demand refers to how much accelerator demand is reguested after the Characteristic function is applied This accelerator demand is then used along with the Creep Speed and Maximum Speed personalities to determine the speed demand for the vehicle If a valid direction is selected and the accelerator demand is at 0 the speed demand will be set to the Creep Speed personality As the accelerator demand is increased to 10090 the speed demand increases linearly to the Maximum Speed personality MillipaK 4OPM Controller Manual 15 06 05 Features Performance Accelerator Characteristics Examples 1 The Accelerator Characteristic is set to Dual Slope the Creep Speed personality is set to 0 and the Maximum Speed personality is set to 100 If the accelerator push was at 70 then the accelerator demand and the vehicle speed demand would be 35 2 Same conditions as 1 but the Creep Speed personality is set to 10 and the Maximum Speed 1s set to 75 The accelerator push is still 70 and the accelerator demand is still 35 but now the vehicle speed demand is 32 75 i e Accelerator a 100 Speed Demand Creep Speed Maximan Speed Creep Speed x 104 95 10 100 32 75 MillipaK 4QPM Controller Manual 15 06 05 Features Features Features
28. ange OWON 12 08 Dir Sw Seq Checking PS E O SI 12 09 Motor Thermal Protection OFHON 12 10 Line Contactor Dropout OFWON 12 11 Accelerator Characteristics LINEAR CURVED 2 SLOPE CRAWL 12 12 High Speed Mode NORMAL MOMENTAR Y 12 13 Belly Style NORMAL CONTINUOUS 12 14 Power Steer Trigger FS1 SEAT DIRECTION 12 15 Foot brake Priority DRIVE FOOTBRAKE 12 16 Buzzer Alarm Off REVERSE ROLLOFF ALL 12 17 Digital I O 1 16 12 18 Analogue I P 1 3 12 19 System Voltage 24V 48V Table 9 Personality Record MillipaK 4QPM Controller Manual 15 06 05 Fault Finding Fault Finding The MillipaK controller includes a number of features designed to help the user track down operational faults wiring faults or internal controller faults The Diagnostic LED mounted next to the calibrator connectors on the front of the controller serves as a simple diagnostic tool as explained below ON No fault normal condition OFF Internal controller fault 1 flash Personality out of range 2 flashes Illegal start condition Traction or Idle Fault 3 flashes MOSFET Short Circuit 4 flashes Contactor fault or Motor Open Circuit 5 flashes Not used 6 flashes Accelerator wire off fault 7 flashes Low or High battery voltage or BDI cutout operating 8 flashes Over temperature or timed cutback 9 flashes System stalled 10 flashes Power Up Autozero has not yet been completed Table 10
29. cncnooocnconononnnnnnnnnnnnnnnonononnnnncnnnnnnncncnnnn nn conan R a iE 16 Coniisuration se eu A A A did es 17 NACI A AS 17 NACIO ET 18 System I O Configuration cc eceeecceessssceceesnsceecessecececesneceesesaeecceseaceccesscaeeesesaeceesesaeeeeeseaees 19 System Motor Set up iii A ae ees 22 Coritactor Choppin y 22 ereas Ore Enan E EEEE EAEE EEEE TE EEO E EE 24 Accelerator Full Zero Setn sessione en eaa ea O ESEE Y ONE aio spas 25 Performancen pein eean RG HR HYR ESF Ea EY ANF 26 Acceleration Delay saelat don YN o a Y GAN 26 Drive Deceleration Delay Donori pr iE og YSGO canoa ren Cn FL linia d dg ydd 26 Direction Change Deceleration Delay ooooonnnnncccnnonccncononcnnononnanccnonanaconnnnnncn cnn nnncnnnnnccnannnnos 26 Neutral Deceleration Delay escri RA Tn FF Fd NY YF dodd YNGL Yd pey 26 Control Mode td a eels YU Ay Y OD RF RT YOU wo FY FYN 27 R gen Bra id do aaa 28 Braking Et A ddd CD 28 Footbrakimg 5 es GA yg yn YY HAD dy Y YY lagna RY Y gd NY FF 29 Creep Speed in cosas pai ss IU es 32 Maximum Speed obey a Daiana 33 Accelerator Characteristics cesccccesssceccessseeceessaceeceseceeecsceceesenaeecesscaeeecesaeceesesaeeeeeseaees 34 A E A cist tvs Ye y sea vce venues vata Y od odes Gada A NN dydy 36 Standard Controller Features 0 0 0 0 ceeessccccessececeeesececessseececeseaeeccesaceecesececessnaecessssaeecessaeeeeesas 36 POWET eri ias 37 High Speed Switch and Anti Tie DOWN ooccnooocccononcnncnnoncnnonononncnnnnnonon
30. d high voltage settings are within an appropriate range System Voltage Power Up Calibrator Menu Reference 12 19 24v 48v 2v 24vy MillipaK 4QPM Controller Manual 15 06 05 Configuration System l O Configuration System I O Configuration The digital inputs analogue inputs and contactor drive outputs available on socket B can be configured in a number of ways to suit various applications Table 4 shows a range of pre determined settings which are available to the user and should cover the majority of applications see below Digital VO Description Value 1 Walkie vehicle with Speed Cutback 1 switch Pump Trigger switch and Electromagnetic Brake Pump Trigger activates Pump Soft Start function 2 Walkie vehicle with High Mast switch Pump Trigger switch and Pump Contactor 3 Walkie vehicle with High Mast switch Pump Trigger switch and Electromagnetic Brake Pump Trigger activates Pump Soft Start function 4 Walkie vehicle with Speed Cutback 1 switch Pump Trigger switch and Pump Contactor 5 Walkie vehicle with Quick Pick switch High Speed switch Electromagnetic Brake and Hours Counter Drive 6 Walkie vehicle with Pump Trigger switch Brake Override switch and Electromagnetic Brake 7 Ride On vehicle with Speed Cutback 1 and 2 switches and external LED drive 8 Ride On vehicle with Speed Cutback 1 switch Handbrake switch and external LED drive 9 Ride
31. e Input Configuration Item Function 1 Accelerator 2 3 Footbrake Table 6 Analogue Functions Notes 1 Bx refers to Socket B pin numbers 2 All vehicles have an Accelerator input Table 6 details which analogue functions are configured for each value of the Analogue Input Configuration Item Digital Configuration Power Up Calibrator Menu Reference 12 17 ERE 1 16 1 As Required Analogue Configuration Power Up Calibrator Menu Reference 12 18 Miniman TEEN Defn 1 3 1 As Required MillipaK 4QPM Controller Manual 15 06 05 Configuration System Motor Set up System Motor Set up There are various settings available to the user to tailor the MillipaK controller to specific motors and applications MillipaK 4QPM Controller Manual 15 06 05 Configuration System Armature Current Limit Armature Current Limit The armature current limit personality is provided to allow the user to limit the maximum current supplied to the motor to a value lower than the peak rating of the controller Armature Current Limit Immediate Calibrator Menu Reference 0 01 Typical Value 50A ABR 10A ABR ABR Armature Block Rating refers to the controller maximum peak current MillipaK 4OPM Controller Manual 15 06 05 Configuration System Contactor Chopping Contactor chopping This feature allows 24 V contactors to be used at all bat
32. e current limit is reduced by 1 of the ABR If the temperature is below 80 C then the current limit is increased by 1 of the ABR The current limit can be reduced to a minimum of 60 of the ABR The system will limit the current through the armature to the calculated limit during drive and braking MillipaK 4QPM Controller Manual 15 06 05 Controller Protection Motor Protection Cutback Motor Protection Cutback By monitoring the motor current over a period of time the controller then calculates the total power dissipation within a typical motor and so estimates the motor temperature rise After setting Motor Protection Cutback to ON the estimated motor temperature can then be used to set the maximum allowed motor current and thus prevents excessively high motor temperatures being reached The maximum allowed motor current will reduce down to a minimum of 30 of the Armature Block rating if the estimated Motor Temperature rises to a dangerous level If Motor Protection Cutback is set to OFF then there will be no reduction in allowed maximum motor current due to estimated motor temperature although any other forms of maximum current reduction such as thermal cutback will still be applied The Upper and Lower Limits set the cutback levels The maximum allowed current is linearly cutback between the two levels As the levels are reduced the maximum allowed current will be cutback earlier Motor
33. e taken not to exceed the maximum current specified by the controller rating EMC standards All MillipaK variants are tested to and conform to EN12895 Socket B protection All user connections on socket B are protected against indefinite short circuit to battery minus and battery positive Contactor drive ratings All contactor drives are rated at 3A peak 10s and 1 5A continuous All the drives have reverse battery connection protection inbuilt freewheel diode and are internally protected against short circuit Analogue Input Impedance The two analogue inputs are internally pulled up to 12v via a 12k resistor This is primarily designed for use with 5k potentiometers but may also be used with suitable voltage sources Digital Input Impedance The digital inputs are internally pulled up and are active LOW They therefore must be connected to battery minus to operate a function Maximum resistance to battery minus to operate is 500ohms MillipaK 4QPM Controller Manual 15 06 05 EMC Guidelines 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 act
34. ed or flashes the safety circuit may have tripped and the truck may not drive The controller must be used with a line contactor as indicated in the wiring diagrams 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 The MillipaK controller may be used with suitable onboard chargers as supplied by Sevcon There are several software features which are intended to prevent inadvertent or unexpected vehicle movement SRO Accelerator power up fault and seguence checking Some of these features cannot be disabled and the appropriate signals must be supplied to the controller before drive will be allowed MillipaK 4OPM Controller Manual 15 06 05 Installation Mounting Installation The small footprint of the MillipaK controller gives maximum flexibility to the user for mounting options The following section gives details of certain criteria that should be considered when situating the controller on a vehicle Mounting The MillipaK HP unit provides 4 x M6 clearance holes for mounting The controller should be mounted onto a metal base plate as large as possible to provide heat sinking The surface finish should be flat clean and burr free and thermal compound should be applied to the controller base before fitti
35. ed to setup the speed for Cutback Speed 2 8 Motor Setup Used to setup motor protection levels 9 Power Steer Timer Used to setup the Power Steer timer 10 Seat Delay Used to setup the Seat Switch debounce delay Used to setup additional personalities These are personalities 11 Additional which do not belong in any of the menus shown above or they Personalities are deemed to be unsuitable for modification by service engineers or end users Used to configure the system at a high level Items to configure the system I O and performance are located in here It is recommended that items in this menu are configured first before 12 System Setup any of the other personalities Unlike the personalities in the other menus changes to items in this menu do not take affect until the Keyswitch is recycled 15 06 05 Calibrator Calibrator Status and Test Information Status and Test Information Menus 13 to 19 are primarily used for providing information about the system Every parameter which the system measures in located in one of these menus A brief description of the purpose of each menu is listed below Menu Name Purpose Tf there is a fault active in the system this menu provides 13 System Status information about what the fault is Refer to the Diagnostics section for more information 14 Reserved for future use Used to display Battery and Capacitor Voltage measurements The Battery Voltage measurement shows the voltage mea
36. ght Wiring MillipaK 4QPM Controller Manual Horn 15 06 05 Installation Wiring Light NOTES The line and auxiliary contactors are wired to B on the switched side of the key switch Pin 12 is available for 100mA supply typically used for but not limited to accelerator modules Pins 13 14 amp 15 are general purpose suppression connections and may be used to suppress spikes generated by contactors opening closing The internal configuration is shown below Pin 16 is used to select FLASH memory program update mode and should normally be left unconnected MillipaK 4OPM Controller Manual 15 06 05 Calibrator Calibrator General Calibrator The Calibrator is a hand held adjustment unit which can be used to configure and test the system The MillipaK is designed to work with the Calibrator currently in use with Sevcon s MOS90 system See diagram below The menu structure is shown in the Calibrator Map located near the end of this manual SELECT CALIBRATOR Sevcontrol Figure 4 MillipaK Calibrator MillipaK 4OPM Controller Manual 15 06 05 Calibrator Calibrator Traction Drive Hours Counter Traction Drive Hours Counter When the Calibrator is first plugged into the unit after power up the Calibrator shows the Traction Drive Hours Counter Refer to the Traction Drive Hours Counter section for more information on this function With no buttons pressed the number displayed shows the number of minutes accurate
37. ified forces the following sequences of switch inputs to be followed before drive is allowed Keyswitch Direction FS1 or Keyswitch FS1 Direction within SRO delay of FS1 Any other sequence will not allow drive Drive will be inhibited if FS1 is active for more than the SRO Delay with no direction selected In this case the FS1 will need to be recycled Static Return to Off Power Up Calibrator Menu Reference 12 02 OFF ON OFF SRO Delay Immediate Calibrator Menu Reference 11 07 EEE AN os 5S 1S 2S MillipaK 4OPM Controller Manual 15 06 05 Safety Features Safety Features Belly Switch Belly Switch A Belly Switch function is available when the controller is used on a Walkie type truck The feature can be enabled in the setup menu See this section and wiring diagrams for additional information Basic operation is as follows Truck moving in Reverse and activating the Belly Switch accelerator in reverse position a The controller applies 100 braking b The vehicle will accelerate in the Forward direction Forks Forward at full speed along the accelerator curve when the vehicle has stopped c All drive will cease after driving for the time given by the Belly Delay personality See below d The controller will wait for neutral to be selected before drive will operate If the Belly Switch is pressed again however action starts at b above The Belly operation may be set to NORMAL or CONTINUOU
38. ing Setting the level to 0 disables braking Note Direction Braking cannot be disabled 1 sets the braking strength to minimum weakest braking and 100 sets the braking strength to maximum strongest braking MillipaK 4QPM Controller Manual 15 06 05 Configuration Performance Braking Footbraking Footbraking can be initiated in one of two ways Via an analogue input configured as a Footbrake Pot Using a potentiometer allows the operator to vary the amount of braking they want See below Via a digital input configured as a Footbrake switch When the switch is active the system will brake at the footbrake level Footbrake Pot If the system is configured to use a Footbrake Pot then the system will allow the operator to vary the amount of footbraking depending on the position of the footbrake pedal Similar to the Accelerator input there are 2 personalities which can be used to setup the input voltage range of the Footbrake Pot MillipaK 4QPM Controller Manual 15 06 05 Configuration Performance Braking Footbrake Zero Volts Immediate Calibrator Menu Reference 11 12 ee Typical valne a 0 00V 4 50V 0 02V 0 10V Footbrake Full Volts Immediate Calibrator Menu Reference 11 13 inim Maxim scp Se lypi ale 0 00V 4 50V 0 02V 3 50V As the input voltage varies from the Zero level to the Full level the footbrake demand varies from 0 to 100 When the footbrake demand is at 0 there is no fo
39. ing as a receiving or transmitting antenna Wiring should be arranged to take maximum advantage of the structural metal work inherent in most vehicles Vehicle metalwork should be electrically linked with conductive braids Power Cables All cables should be routed within the vehicle framework and kept as low in the structure as 1s 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 Power cables should be kept 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 All wiring harnesses should be kept short Wiring should be routed close to vehicle metalwork All signal wires should be kept clear of power cables or made from screened cable Control wiring should be kept clear of power cables when it carries analogue information for example accelerator wiring Tie all wiring securely and ensure wiring always follows the same layout Controller Thermal and EMC emissive requirements tend t
40. ire number should be quoted i e MM mm rr The Serial Number is shown across three items in the Test menu The first item is the date code and the next two are the identifier All these items need to be used to get the complete serial number The format is Test Item Ser No Date Ser No ID 1 Ser No ID2 Serial Number MMYY AA BB Table 13 Serial Number Format MMY Y gives the month and year when the controller was manufactured e g 0701 will indicate July 2001 AABB are combined to give a 4 digit identifier which is simply a number from 0001 to 9999 When giving the Serial Number the entire number should be guoted i e MMYYAABB The MillipaK range of controllers uses the latest FLASH technology to allow In System Reprogramming This is achieved without having to remove the controller from its installation all that is needed is connection to the 6 way calibrator socket MillipaK 4QPM Controller Manual 15 06 05 Specifications Specifications The following specifications apply to all MillipaK controllers Power Configurations At present the MillipaK 4O controller is available in the following power configurations Housing Armature Soft Start Option HP Large 180A 100A Soft Start HP Large 300A 100A Soft Start Table 14 Power Configurations All the MillipaK 4Q range of controllers operate from 24 48v batteries WARNING The pump soft start option when fitted is NOT current limited and care should b
41. mmediate Calibrator Menu Reference 2 01 Typical Value 0 15 5 08 0 15 1 58 Drive Deceleration Delay This is an adjustable delay to ramp down the pulsing from 100 on to 0 on when a Drive direction is selected and can be used to provide a smooth reduction of power to the motor Drive Deceleration Delay Immediate Calibrator Menu Reference 2 02 0 18 10 08 0 18 0 18 Direction Change Deceleration Delay This is an adjustable delay to ramp down the pulsing from 100 on to 0 on when a new Drive direction is selected and can be used to provide a smooth reduction of power to the motor Direction Change Deceleration Delay Immediate Calibrator Menu Reference 2 03 Typical Value 0 15 10 08 0 15 0 15 Neutral Deceleration Delay This is an adjustable delay to ramp down the pulsing from 100 on to 0 on when Neutral is selected and can be used to provide a smooth reduction of power to the motor Neutral Deceleration Delay Immediate Calibrator Menu Reference 2 04 0 18 10 08 0 18 0 18 MillipaK 4QPM Controller Manual 15 06 05 Configuration Performance Control Mode Control Mode The method of motor control may be switched between Torque and Speed control Control Mode Calibrator Menu Reference Torque Speed Power Up 12 03 Torque Currently only torque control mode is available MillipaK 4QPM Controller Manual 15
42. nd at any time if the Buzzer contactor drive output is configured Mode Rol 1 The Reverse Switch is active or vehicle is traveling in reverse continuous output 2 The vehicle is moving without a direction selected pulsed output Mode Al 1 The Forward Switch is active or vehicle is traveling in forward continuous output 2 The Reverse Switch is active or vehicle is traveling in reverse continuous output 3 The vehicle is moving without a direction selected pulsed output Alarm Buzzer Power Up Calibrator Menu Reference 12 16 Options Default Off Rol AM Rol MillipaK 4QPM Controller Manual 15 06 05 Features Optional Features Electric Board Drive Electric Board Drive and Low Battery Warning Briggs amp Stratton specific The Electric Board Drive is used to drive a solenoid which in turn activates a hook that holds the propeller in place when the REVERSE direction is selected It is also used to drive an alarm buzzer when the FORWARD direction is selected in conjunction with the Low Battery Warning feature When the REVERSE direction is selected the solenoid engages the hook which holds the propeller in place by outputting battery voltage for 100ms after which the output is chopped at 16V When the FORWARD direction is selected the buzzer alarm will sound if the following is true The average battery voltage drops below the Battery Warning Level personality setting contin
43. ng SEYCON ii MILLIPAK CONTR UT M CLEARNCE UNLLE 176 50 190 Figure 1 MillipaK HP Dimensions Maximum terminal torque M8 terminals 10NM M6 terminals 7NM MillipaK 4QPM Controller Manual 15 06 05 Installation Wiring Power MillipaK 4QPM Power Wiring To Keyswitch main line Contactor Fuse E Battery ve a Traction Mosfet Bridge Battery ve Figure 2 MillipaK 4QPM Power Wiring NOTE The Pump MOSFET s are optional soft start versions only MillipaK 4QPM Controller Manual 15 06 05 Installation Wiring Light MillipaK Light Wiring example CALIBRATOR Sevcontrol Battery QDO O NAA Fuse Key switch Battery ve NOTES Contactor Coil Suppression fitted internally Connector A FS1 Belly Dig 3 Seat Tiller Dig Digital Input 5 e g Accel Digital Input 6 Line Contactor TTY Auxiliary Contactor Analogue Input 1 Module Analogue Input 2 can also be configured as a digital input Extra Suppression and Horn Suppression inputs to be used as shown below Battery ve Y cc Analogue Input 2 12V Output Extra Suppression 1 Extra Suppression 2 Horn Suppression Connector B 13 14 15 16 Extra Suppression 1 or 2 or Horn Suppression External Contactor Battery ve lt Figure 3 MillipaK Li
44. o be in opposition Additional insulation between the controller assembly and the vehicle framework reduce capacitive coupling and hence emissions but tend to reduce thermal ratings A working balance needs to be established by experiment The complete installation should be documented in detail and faithfully reproduced on all production vehicles When making any changes consider their effect on compliance ahead of any consideration of cost reduction or other improvement MillipaK 4QPM Controller Manual 15 06 05 Ordering Information Part Numbers Ordering Information The controllers and contactor panels are allocated 633 numbers as shown The lettering section gives the full listing of item types Item description voltage current logic Customer Code A 2 24 1 100 199 1 SEM plug XX B 3 36 2 200 299 2 SEM plug s start C Controller only 4 48 3 300 399 3 SEM regen D Traction panel 1 72 4 400 499 4 SEM regen s start E Traction Pump Panel 8 80 5 500 599 5 Series Pump F Twin Traction Panel 9 96 6 600 699 6 BPM Twin Traction Pump Panel 7 700 799 7 BPM s start 8 800 899 8 4QPM 9 900 9 4QPM s start S T HP Controller only W HP Traction panel X HP Traction Pump Panel Y HP Twin Traction Panel Z HP Twin Traction Pump Panel HP High Power For panels then the voltage current and logic numbers should be used to describe the traction controller Examples 300A 4QPM controller 633T43801
45. ociated with it to allow the input voltage range to be determined For the Traction Accelerator for example the 2 adjustments are called the Accelerator Zero Level and the Accelerator Full Level If these were set to 0 20V and 4 80V then 0 pulsing would start at 0 20V at the input increasing to 100 pulsing at 4 80V For accelerators with decreasing voltage outputs the Zero adjustment might be set to 3 5V and the Full adjustment to 0 0V The Calibrator test menu shows the instantaneous voltage reading and the equivalent push for each input Accelerator Zero Volts Immediate Calibrator Menu Reference 2 05 I a 0 00V 4 50V 0 02V 0 10V Accelerator Full Volts Immediate Calibrator Menu Reference 2 06 Miniman Maximum icp Size pc Va 0 00V 4 50V 0 02V 3 50V Note that a 6 flash fault will occur 1f the full and zero levels are set within 0 50V of each other The PWM demand will vary between the Creep level and Maximum Speed level as the accelerator voltage varies between Accelerator Zero and Accelerator Full MillipaK 4OPM Controller Manual 15 06 05 Configuration Performance Acceleration Performance Various parameters may be adjusted to tailor the performance of the vehicle to customer requirements Acceleration Delay This is an adjustable delay to ramp up the pulsing from 0 on to 100 on and can be used to ensure smooth acceleration Acceleration Delay I
46. oltage Cutback Levels Over voltage Start adjustable System V up to Over Voltage Cut out The following calibrator menu items are used to set these values Low Voltage Start Calibrator Menu Reference Immediate 11 08 Typical Value Low V System 0 5V 18 0V Cutout Voltage Low Voltage Cutout Immediate Calibrator Menu Reference 11 09 Typical Value 0 5V System Voltage High V Cutout 14 5V Low V Start 0 5V 16 0V High Voltage Start Immediate Calibrator Menu Reference 11 10 Typical Value High V Cutout MillipaK 4OPM Controller Manual Over voltage Cut out 30 0V 45 0V 62 0 V 15 06 05 Controller Protection Under Over Voltage Protection High Voltage Cutout Immediate Calibrator Menu Reference 11 11 High V 50 0V or 0 5V 50 0V or 62 0V Start 62 0V The maximum High Voltage Cutout depends on the level of the System Voltage item If the System Voltage is set to 36V or lower then the maximum is 50 0V If the System Voltage is set greater than 36V then the maximum is 62 0V MillipaK 4OPM Controller Manual 15 06 05 PCpaK Functionality PCpaK allows a PC to communicate with an individual MillipaK controller PCpaK can perform all the functions provided via the Calibrator along with a number of additional features y Sevcon PCpaK laj x File View Connection Log Tools Help Fs oh e peset E
47. oncnncnnnnnnncnnnnoncncnnonnncncannnncnnannnncnns 62 Motor Stall Protection Briggs amp Stratton specific oooooooccnnnnnccccnonoconanonnaccnonnnnnccnonrnnncnnnnnnnanns 63 Safe Operating Area SOA 0cccoconoccononoonancnnoncnnnonononannonncnnnnnnonancnnonnnnnnnonnnnnnnn nan nnnonencnnancnnnnnnnss 64 Under voltage and over voltage protectiOM ooococonnoncccnonococcnnnononncnnnonnnononnnncncnnnnnncnonnnncnnannnncnns 65 PCPA uu GG dd Fu WW DW FF TYN UY A WG GW 67 NAAA SA I FD Y NN Couns OEREN SE EOE STE 68 Commissioning Checklisten i i A E a aE aiea Ea 70 Personality RECO ennenen riera iaa radio 71 Fault Biman ei Tu GAN ud dy WAR YDAN TD IA DD Fyd RYD ED WR CY 73 Fault Clearanc uw Y YY RYN RY Y YN Fy 75 Fault Reporting A i A DDd YR TRAC dbs TYDY even Fn dnd FD EE Et 76 Software Version and Serial Number indicatiON ocoononcccnnnooncccnnononncnonnnnnnnnnnnnancnnonnnccnanannanonnes 77 Specifications nin iio 78 Power Configurations ossen eeen ers Un FD Y unced Go Idd dnd YNA ad YO ddd sey Ee 78 EMC standards y y AA 78 SocketBuprotection o uni Gy Yd Y ed so 78 Contactor drive Patines comision ygyd YY Yy dd Yd shes EEEE E sudaud deni OAE EEEE YY 78 Analogue Input Impedance eienenn etaa eaea dd FY dg Y FY Fd ddd tren caia EAE conti tees 78 Digital Input Impedance cooooncccnnnnocccnonocnnnnnnnonnccnnonananonnnnnonnnnnnnncnnnn aE E E aA Ee 78 EMC Guid eines x Aii ud Gyd te cds oe da Dl ek 79 Ordering Information socia tren Ras IRA FF nn
48. onnnnncnnnnnnncnnnnnnccnannnnos 38 EN WITCH A WW e FFO ate yT DF Y NR ddyd SaR EI PP 41 Handbrake Switch un gy iT AA 42 Cutback Speeds iy Y it 43 Traction Drive Hours MeteT oooooocnnnococonocooccncnnonnncononnnncnnnnnnnannnnnncncnnnnnccnnnnnnncn nan nnncnnnnnncnnannnnos 44 IREVETSE opeed E A y UF LAM Y Y E E ydy 45 Pump Soft Start aY ashen ee GYF FYN FFY YY FYW Wd 46 Alarm BUZzGD 3 ie WY YY GN Aaa 47 Electric Board Drive and Low Battery Warning Briggs amp Stratton specific 48 Line Contactor Drop Ut sss peen neari danad EA nn alioli tos 49 Virtual FS1 Briggs amp Stratton specific oooooocccnnooccncnnoncnnononnanccnonannaconnonnncnnnnnnncnnnnnccnnnnnnos 50 MillipaK 4QPM Controller Manual 15 06 05 Contents Temporary Current Boost Briggs amp Stratton specific oocononnocccnnnooccconooannononannnananannccnannnnos 51 Safety EEx o ete 52 Stat Up EU A aos 52 ESTRES A A eens 53 SRO Static return TO ds E E DL Tr ANNEDD DYF dU y O 54 Belly switch a Ga a cule nga aguas Y OO CU FO NAT YO enat aiaa 55 A N ROlDa KB GU Y GY a EE E EEE a y ay sours 56 AQUI a ea A CAWR O CAG AAT YU CAG OS GYRU da 57 A A E E OEA 58 Controller Protection Features sseseeseseseeeeseesssressssretsstrresssresessreesstresestessssreessteeesssesssseessee 59 Temperature Monitoring s mea errre eterra eree aE eere EARTE oe T ERE ETE EATE EEOSE eE aoe 59 Idle Fault Briggs amp Stratton Speci iC oooonnonccccnoonoccnonococcnon
49. ontroller Manual 15 06 05 Configuration Performance Creep Speed Creep Speed The Creep speed is adjustable and is used to select a minimum pulsing level as soon as drive is requested to minimize delays and dead bands The motor voltage is rapidly ramped to the creep level equivalent to a 100mS acceleration delay Creep Speed Immediate Calibrator Menu Reference 3 01 Typical Value 0 25 1 0 MillipaK 4QPM Controller Manual 15 06 05 Configuration Performance Maximum Speed Maximum Speed Adjustment limits the maximum applied on to the armature Maximum Speed Immediate Calibrator Menu Reference 5 01 Typical Value 0 100 1 100 MillipaK 4QPM Controller Manual 15 06 05 Features Performance Accelerator Characteristics Accelerator Characteristics Accelerator Characteristics Accelerator Demand 0 10 20 30 40 50 60 70 80 90 100 Accelerator Push Linear Curved Dual Slope Crawl Figure 5 Accelerator Characteristics Accelerator Characteristics Power Up Calibrator Menu Reference 12 09 Options Default Linear Curved 2 Slope Crawl Linear This function is used to vary how much speed is demanded depending on the accelerator position Setting either Curved Dual Slope or Crawl gives a smaller change in speed for large changes in accelerator position and is useful for low speed maneuvering
50. ontroller Manual 15 06 05 Features Standard Features Cutback Speeds Cutback speeds There are 2 cutback switch inputs as standard Each one has an associated personality to adjust the maximum on when the switch is active When both switches are active together the lower speed is selected The cutback speed inputs are usually normally closed so that a wire off type fault or bad connection initiates a lower speed Cutback Speed 1 Immediate Calibrator Menu Reference 6 01 0 100 1 100 Cutback Speed 2 Immediate Calibrator Menu Reference 7 01 ERE A 0 100 1 100 MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features Traction Drive Hours Meter Traction Drive Hours Meter The MillipaK maintains a log of the number of hours during which the controller is providing Traction functionality The Traction Drive Hours Meter runs whenever the vehicle is driving or braking The current number of logged Traction hours can be viewed using the Calibrator Refer to the Calibrator section for more information MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features Reverse Speed Reverse Speed In some instances the maximum reverse speed of the vehicle is required to be slower than the forward speed This can be achieved by enabling the reverse speed limit and setting the Maximum Reverse Speed personality accordingly Maximum Reverse Speed Immediate
51. otbraking As the footbrake demand increases from 1 to 100 the braking level applied by the system increases from 50 of the Footbrake Level personality to 100 of the Footbrake Level personality For example assume the system is configured to have a footbrake pot and the Footbrake Level personality is set to 60 If the operator has not depressed the footbrake pedal then the voltage into the controller will be outside of the Footbrake Zero Level personality and the footbrake demand will be 0 There will be no Footbraking If the operator starts to press the footbrake pedal then the footbrake demand will increase When the demand increases above 0 the system will start braking and will set the braking effort according to the following formula footbrake demand gt 50 braking effort 100 Xfootbrake level personality So for this example at 1 demand the braking effort would be 3 50 x 60 braking effort 100 30 2 2 x 60 100 And at 75 demand the braking effort would be braking effort 52 5 MillipaK 4QPM Controller Manual 15 06 05 Configuration Performance Braking Footbrake Priority Footbrake priority can be set to drive or brake and this determines the controller action in the case of the accelerator and footbrake pedal both being active at the same time Footbrake Priority Power Up Calibrator Menu Reference 12 15 Drive Brake Drive MillipaK 4QPM C
52. r Its effect is more significant in protecting the controller against adverse loads such as damaged motors and static test rigs 24 48V Controllers of Max Current Figure 7 SOA Characteristic MillipaK 4QPM Controller Manual 15 06 05 Controller Protection Under Over Voltage Protection Under voltage and over voltage protection In order to prevent a sudden loss in power the controller will begin to linearly ramp down the current limit once the average battery voltage falls below a pre set under voltage start level The current will be ramped down to 0 and a 7 flash fault indicated if the averaged battery voltage falls below the under voltage cut out level To protect the controller from over voltage caused by prolonged regen braking regen braking will be reduced when the average battery voltage reaches the over voltage start level If the voltage exceeds the over voltage cut out level in braking then the line contactors will open and freewheeling will occur requiring the vehicles foundation brakes to be used Under any other circumstances if the battery voltage exceeds the over voltage cut out level all pulsing is stopped and a 7 flash fault is indicated This protects against incorrect battery connection Nominal Under voltage Under Battery Cutout Voltage Start Voltage adjustable 24 V 14 5V Under Voltage 36 V 14 5V Cut out up to 48V 14 5V System V Table 8 Under and Over V
53. sed to prevent High Speed operation under conditions where the operator may not be expecting it MillipaK 4QPM Controller Manual 15 06 05 Features Standard Features Quick Pick Quick Pick The Quick Pick function is used to drive a Walkie vehicle at a set speed in the Reverse direction Power Unit First when a switch is active on the Tiller arm This feature is usually set up so that the vehicle will drive at walking speed This allows the operator to drive the Walkie using one switch whilst they walk along side it Drive in the Reverse direction Power Unit First will be applied at a speed demand specified by the Walk Speed personality when all the following conditions are TRUE The Quick Pick switch is active The Tiller switch is active All Drive Switches Are Deselected No Drive Inhibit or Severe faults are active The Walk Speed personality can be adjusted via the calibrator i e Walk Speed Immediate Calibrator Menu Reference 11 02 0 100 1 As required Quick Pick speed demand will be treated exactly the same way as a normal accelerator demand where any cutbacks apply Cutback Speeds etc and the demand will be treated appropriately in both Torque and Speed Control modes The following inputs will be ignored during Quick Pick operation Forward Switch Reverse Switch FSI Switch Accelerator Demand Belly operation will still be allowed when the Quick Pick function is active
54. setting Rolloff Electrobrake to ON provides the user with access to a Virtual FS1 feature which will enable system operation without an FS1 being physically wired The software looks for acceleration demand greater than 1 17 in order to flag the virtual FS1 as CLOSED Any acceleration demand lower than the above mentioned value will cause the virtual FS1 to be flagged as OPEN User must ensure that when the accelerator pedal is depressed the acceleration demand shown in the calibrator test menu see calibrator map is equal to zero by setting the Accelerator Zero Voltage item accordingly SRO and FS1 Recycle functionality will be preserved MillipaK 4OPM Controller Manual 15 06 05 Features Optional Features Temporary Current Boost Temporary Current Boost Briggs amp Stratton specific This is a feature intended to allow the user to temporarily boost the armature current limit in an attempt to improve acceleration Immediately after FS1 closes the system will set the armature current limit to the Temporary Armature Current Limit personality not to exceed the controller s block rating for the time period specified by the Temporary Armature Current Limit personality setting After the expiration of the Temporary Armature Current Limit Timer the system will reset the armature current limit according to the Armature Current Limit personality Temporary Armature I Limit Immediate Calibrator Menu Reference 1
55. sured 15 System Voltages atthe Key switch pin pin 1 on connector B The Capacitor Voltage measurement shows the voltage measured at the B terminal 16 Motor Voltages Used to show the voltage measured at the Point A terminals 17 Motor Currents Used to show the Armature Current Measurement 18 Heatsink Used to access the Heatsink Temperature measurement Refer to Temperature the Temperature Monitoring section Used to access items which allow for testing of all the Analogue and Digital inputs available on connector B Also displays unit 19 Test Menu information such as the Software Version Controller Serial Number and the Personality Checksum Refer to the appropriate sections for more information on each of these items Table 3 Status and Test Information Menus MillipaK 4QPM Controller Manual 15 06 05 Configuration System Configuration Configuration of the MillipaK controller is split into two categories system and performance which will be discussed in turn System Configuration The MillipaK system configuration items relate to how the MillipaK will interface with connected hardware such as the system battery vehicle control switches accelerator and the traction motor MillipaK 4QPM Controller Manual 15 06 05 Configuration System Voltage System Voltage The system voltage usually refers to the main system supply battery voltage The controller uses this information to ensure low an
56. te through most of the menu structure however the Test menu menu 19 is slightly different To navigate the Test menu the and buttons are used The button moves up the Test menu and the button moves back down Pressing the SELECT button at any time exits the Test menu and moves to the first item in the menu structure menu item 0 01 Armature Current Limit The items which are displayed depend on the current system configuration and the Security Level MillipaK 4OPM Controller Manual 15 06 05 Calibrator Adjustments Calibrator Adjustments Menus 0 to 12 are primarily used for configuring the system All the personalities that the system uses to configure each function are in one of these menus A brief description of the purpose of each menu is listed below For more complete descriptions of each personality refer to the appropriate section in this manual Table 2 Adjustment Menus MillipaK 4OPM Controller Manual Menu Name Purpose 0 Current Limits Used to setup maximum currents for motor 1 Braking Levels Used to setup braking strength and performance Used to setup acceleration and deceleration performance and to 2 Accelerator configure the accelerator input voltage range 3 Creep Speed Used to setup creep speed 4 Bypass Not Used 5 Maximum Speed Used to setup maximum speeds 6 Cutback 1 Speed Used to setup the speed for Cutback Speed 1 i Cutback 2 Speed Us
57. tery voltages 24V 48V by continuously monitoring the battery voltage and chopping the contactor output pins accordingly to present an average voltage suitable for 24V coils Chopping is selectable by the calibrator Care must be taken to ensure that chopping is always selected 1f 24V contactors are being used on battery voltages higher than 24V In applications gt 24 volts contactors must be fitted with blow out magnets Chopping can reduce the overall dissipation in the coils and allows only one set of contactors to be stocked for all battery voltages Chopping Frequency approx 667Hz Slightly audible Typical contactor coil voltage during chopping 16 volts Typical contactor coil voltage during energisation 24 volts for 1 second There are 3 contactor chopping options available via the setup menu OFF ON and 24V The OFF setting is used for nominal battery voltage coils and the ON setting is for 24V coils on higher voltage vehicles Setting to 24V provides chopping for 24V coils and lamps without the drop to 16V after 1s Chop Select Power Up Calibrator Menu Reference 12 01 OFF ON 24V OFF MillipaK 4OPM Controller Manual 15 06 05 Configuration System Accelerator Accelerator Full Zero Setting The accelerator analogue inputs are flexible in the range of signal sources they can accommodate and can be adjusted to minimize dead bands and mechanical tolerances Each analogue input has 2 adjustments ass
58. the Stall Motor Voltage personality for a continuous period of time longer than that specified by the Stall Timer personality setting then a motor stall condition will be identified As a result the controller will exhibit a severe fault cannot be cleared without a key recycle accompanied by a 9 flash fault being displayed by the Diagnostic LED mounted on it Setting the Stall Timer personality to zero disables the feature Stall Motor Voltage Immediate Calibrator Menu Reference 11 17 1V 24V 1V 8V Stall Motor Current Immediate Calibrator Menu Reference 11 17 a 10A 300A 10A 50A Stall Timer Immediate Calibrator Menu Reference 11 18 ee Typical valee Os 60s Is 2s MillipaK 4QPM Controller Manual 15 06 05 Controller Protection Safe Operating Area Safe Operating Area SOA The controller s current may be limited at high and or low duty cycles depending on its current and voltage specification This is to reduce the thermal stress on the power components in order to increase long term reliability See Figure 7 The Safe Operating Area is a characteristic of the MOSFETs and Freewheel Diodes which make up the power frame The MOSFET SOA restricts current at high duty cycles on all configurations and the Diode SOA tends to restrict the current at lower duty cycles on lower voltage applications For most applications SOA will have little or no effect on the operation of the controlle
59. to 0 5 minutes Pressing the button displays the number of hours under 1000 and pressing the button displays the number of 1000 x hours For example if the hours counter was 12 345 hours 13 minutes and 40 seconds with no buttons pressed the display would show 13 5 Minutes are only shown to the nearest 0 5 minutes If the button was pressed the display would show 345 number of hours under 1000 and if the button was pressed the display would show 12 number of 1000 x hours This is the only time that the hours counter can be viewed Once the Select button has been pressed to enter the normal calibrator menu structure it is not possible to return to this point To view the hours counter again you must recycle the Key switch This is also the point at which you can enter a password to enable different levels of access to personalities Refer to the section below on Calibrator Security Levels for more details MillipaK 4OPM Controller Manual 15 06 05 Calibrator Calibrator Security Levels Calibrator Security Levels The personalities and status items which can be viewed on the Calibrator is restricted using passwords There are two levels of Calibrator access These are shown in Table 1 Access Level Text Password Description Default This level is selected when no password or an Service Ser invalid password is entered Only items shown in the Calibrator Map with a thick solid border are displayed
60. uously for a period of time longer than that specified by the Battery Warning Timer personality setting If the above is true the buzzer will sound intermittently and will be ON for 5s and OFF for 30s In order for the Electric Board Drive to become available digital I O 17 must be selected MillipaK 4OPM Controller Manual 15 06 05 Features Optional Features Line Contactor Drop Out Line Contactor Drop out The controller will close the line contactor once a successful power up sequence has been carried out after which drive operation can be achieved The line contactor will remain closed unless it is opened following a serious fault or power being disconnected A further configurable option is available where the line contactor is opened dropped out if no drive activity has occurred for a period exceeding the Line Contactor Dropout Timer personality If drive operation is selected once the line has been opened then it will be closed again so that drive operation can occur Line contactor dropout operation can be enabled or disabled in the setup menu Line Contactor Drop out Power Up Calibrator Menu Reference 12 10 OFF ON OFF Line Contactor Dropout Timer Immediate Calibrator Menu Reference 11 06 A ca alc 1S 60S 1S 10S MillipaK 4QPM Controller Manual 15 06 05 Features Optional Features Virtual FS1 Virtual FS1 Briggs amp Stratton specific Selection of digital I O 17 and
61. will indicate which unit is in thermal cutback Thermal Cutback Characteristic Armature Current Limit 100 90 7 80 7 70 7 60 7 50 7 40 7 30 7 207 10 7 Current Limit 70 72 74 76 78 80 82 84 86 88 90 Temperature DegC Armature Current Limit Figure 6 Armature Thermal Cutback Characteristic MillipaK 4QPM Controller Manual 15 06 05 Controller Protection Timed Current Cutback Timed Current Cutback During periods of high current usage the power components of the controller produce considerable heat Under normal circumstances the controller will cutback the maximum current supplied to the load when the heatsink temperature rises above a safe level for the controller components However when the current supplied is close to the maximum rating of the controller the temperature rise of the components leads the heatsink temperature by up to 409C If this situation was allowed to arise damage may result in the controller In order to prevent this situation a timed current cutback feature is incorporated in the MillipaK controller which works as described below The controller monitors the load current each second and estimates the junction temperature of the MOSFETs If the estimated temperature exceeds 105 C then the current limit is reduced by 1 of the Armature Block Rating ABR If the temperature is above 80 C and the temperature has exceeded 105 C without falling below 100 C then th

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