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1. 9 reverse foot switch seat handbrake driveability select 1 32 2 driveability select 2 power steer trigger System design SINGLE PUMP WIRING DIAGRAM EI 13 CAN connection CAN High ES 24 XXXX for configuration f CAN Low H and service i Linkto CAN term 2 terminate the 2 CANbus 23 cS c 16 CAN connection fe CAN High 2 Cont1 Supply 3 27 XXXYX to other CAN SAN Lew devices 8 Cont2 Supply 12 Cont3 Supply Alternative use a voltage Source in place of the pot 10 db NN T i pump a key switch i gene DC control switch Ame fuse 6 B To Alternative use a voltage O10 Gen4 ee pps line contactor 34 5 E traction 9 Stand alone pem i 22 y fuse b Pump TENIS DCI 1 Ein A IS i numbering 26 B may vary 10V i Giaa encoder A Alternative encoder 48 isol 3 iso a 4 KC 35 encoderB type U V W pump 1 switch 9v 5 EncU WS x 17 Enc V ump 2 switch L gt o i m M2 pump 3 switch NN n ge pump 4 switch thermistor 20 B pump 5 switch 9 o o pump 6 switch 32 ES as pump inhibit 21 pump driveability select 1 Figure 15 Stand alone pump wiring diagram Doc 177 52701 Rev 3 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 th
2. YA Dir Chg Accel Rate E Ntrl Brake Decel Rate TorqueTarget Throttle Doc 177 52701 6 25 Rev 3 SEVCON I Figure 33 Torque mode acceleration deceleration In Torque mode the acceleration and deceleration rates control the rate of change of torque In Speed mode the acceleration and deceleration rates control the rate of change of speed 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 29201 e Drivability select 1 profile invoked when drivability select 1 switch is active 29211 or an alternative trigger is active see below e Drivability select 2 profile invoked when drivability select 2 switch is active 29221 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 applie
3. 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 Y Sevcon SCWiz Control Panel E Engage Pulse duration ma 2 Magntude V DC 5 a Inductance apottioning Us olle wth the software necessary to complete you have the abity gammng ware once the charactersation process a Pulses per revolution Progam E Sonal pul up down Peak torque factor Peak speed factor Peak cower factor a Live Measurements C DSP parameters received C Badge overvotage C Powedrame idertfied C Powerrame taut C Curent sensors autozemed C Encoder pulup active C Sreto pulse C Encoder detected C Bidge enabled O SP link active 1 0 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 twin traction For manual configuration it is necessary to use PDOs and VPDOs to map application objects on the master node 2000 to 24FF1 to the hardware
4. 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 50001 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 50011 The password key allows passwords to be made unique for different customers The user ID also allows passwords to be made unique for individuals How NMT STATE AFFECTS ACCESS TO PARAMETERS Some important objects can only be written to when the controller is in the pre operational state Drive Wizard 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 2800n on the master node To restore the CANopen network to operational write 0 to 2800p The controller may refuse to enter pre operational if part of the system is active for example if the vehicle is being driven The reques
5. motor 1 3 Re Program Device ES AC 48V 450A NodelD 4 8 AC 48V 450A NodelD 2 je Comms Objects setup wizard CAN Bus Configuration tht DCF store empty ABE Monitoring store empty Submit changes on this screen to device Key Miresdony Miwrteony Bills BBReadwriteinPre op Mwrite oniy in Pre op nil Y 250 kHz baud real a Sevcon Engineer Figure 26 DriveWizard screen showing automatic object mapping Doc 177 52701 6 13 Rev 3 SEVCON I 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 1 Enter the resolution pulses rev at 6090 2 Check whether the encoder requires controller pull ups enabled e g open collector type and enable pull ups if needed at 46301 The default setting is no pull ups which is suitable for current source encoder types 3 Select the required encoder supply voltage 10V or 5V at 46305 To change the encoder polarity if required change the setting at 607 En reverses the forward and reverse speed measurements DIGITAL INPUTS The state of the digital inputs can be read at object 68001 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
6. A surroundings Y A NOTE indicates important information that helps you make better use of your Sevcon product Doc 177 52701 1 3 Rev 3 SEVCON 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 80V 350A OE an 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 1 4 Chapter 2 SEVCON EM About the Gen4 Y SEVCON Il 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 cond
7. e The most appropriate thickness will look white but with a greyish colour still showing through from the controller base or vehicle mounting face material It should be noted that too little thermal compound will not fill all gaps left the flatness mismatch of the contact surfaces but too much thermal compound may prevent the gap from closing up when tightening e It is recommended that thermal compound is applied to both the Controller base and the vehicle panel boost plate surfaces e The controller should then be placed onto the vehicle panel heatsink e Itis important that the two surfaces are then rubbed together in order to help transfer the thermal compound between the two surface e The entire assembly is then bolted together at all mounting holes An example of a good thermal compound spreading can be seen in the photo below e e e e How effective the spreading technique is can be checked by removing the controller and inspecting the paste residue left on the mounting faces On a well applied paste application the controller will be difficult to remove and a rippled surface will be left on the paste surface as shown magnified below Doc 177 52701 3 3 Rev 3 SEVCON 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 Opera
8. however this can be increased decreased for different battery technologies Setting the warning and cut out levels to 0 disables the warning and cut out functionality Read the percentage remaining charge value from 27901 sub index 1 in the Object Dictionary BATTERY CURRENT LIMIT Battery current can be limited by the controller for the purposes of efficiency or to protect batteried that are sensitive to high levels of current flow Charge and discharge currents can be limited independently If limiting the discharge current flow this can extend the time taken for the vehicle to reach top speed Note that limiting the charge current flow back to the battery can impede the performance of regenerative braking Object 2870 controls how the battery current limit is calculated Sub index 1 of this object can be set to one of the following values to specify how the current limit behaves Value Mode Ox00 Master control of battery current limit disabled To completely disable battery current limit object 4623 sub index 3 must also be set to 0x0000 OxOI1 Battery current limit set by object 4623 sub index 2 and 3 Ox02 Battery current limit controlled by compatible BMS 0x03 Battery current limit set by object 4623 sub index 2 and 3 but the drive current limit is multiplied down by factors set in sub index 4 and 5 when driveability profiles are activated Ox04 Battery current limit is calculated to maintain a p
9. output 100mA Size 4 amp 6 Power From dead side of key 7A This input supplies power models switch via suitable fuse Total of all from the battery for all the 10 Key switch contactor logic circuits input 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 voltage or current control to DO NOT USE WITH CAPACITIVE LOADS subject toa limit of 6A for the total of all the outputs V Vb the load depending on configuration The output goes low or is chopped to activate the load It goes high to Vb to de activate the load Installation 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 encoder A I 25 mA Check the speed encoder Input pulse channel internally signals have the correct limited number of pulses per V 8 V for revolution current Check Gen4 is configure
10. 5 10 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 rated 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 5 2 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 T max Org ted In the high speed region T max 2 Os ted This is shown in Figure 12 Select a motor with a torque rating greater than the peak torque required Torque speed curve for a typical induction motor 35 high speed region constant power region 25 Torque pu 0 5 0 0 5 1 1 5 2 25 3 3 5 4 45 Speed pu breakdown torque rated torque Figure 12 Torque speed curve 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 continu
11. 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 e Enable minimum pump speed Enable this to force the pump to run at minimum speed 2A011 2 even when there is no trigger Can be used to maintain minimum pump pressure e Pump to stop on Low Battery Enable to force pump to stop immediately on low battery condition e Use power steer demand to minimum pump speed Enable this to force the pump to use power steer demand as a minimum speed Can be used to maintain minimum pump pressure for power steering Set the pump minimum and maximum speed maximum torque acceleration and deceleration at 2401 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 additive 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 Configure priority additive levels in 2A10 and 2A 11 and 2A20 to 2A26p Doc 177 52701 6 29 Rev 3 SEVCON PUMP THROTTLES There
12. 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 harnesses short and route wiring close to vehicle metalwork Keep all
13. axis currents are used as part of a closed loop control system to calculate the necessary voltage demands for each 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 either 16 kHz or 24kHz the PWM frequency is set using 58301 Excellent electrical and thermal efficiency is achieved by e Minimization of thermal resistances e Use of the latest MOSFET technology e Internal thermal protection if temperatures are excessive output torque is reduced e Overcurrent protection using device characteristics e Internal measurement of output current e Overvoltage trip in the event of regenerative braking raising battery voltage to unsafe levels Doc 177 52701 9 5 Rev 3 SEVCON DUAL TRACTION MOTOR In the case of dual traction motors there is additional processing of the associated steering 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
14. e FS1 switch activating e Direction selected e Seat switch activating e Footbrake activating The power steering function will always attempt to execute even if the line contactor is open due to a fault condition This is to ensure power steering continues to operate at all times 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 6 30 Configuration VARIABLE ASSIST POWER STEERING Gen4 supports a variable assist power steering algorithm which can be used to reduce the power steering speed as vehicle traction speed increases to a user configurable level Set the reduction factor and traction speed in 2B02 This allows power steering effort to be reduced as vehicle speed increases to prevent steering becoming too light Doc 177 52701 6 31 Rev 3 SEVCON Vehicle features and functions 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 15 To configure any contactor e Set pull in voltage pull in time and hold in voltage at 2D00n e Enable each output to operate at the pull in voltage or at the maximum voltage at 2DO11 e Ifrequired enable each output to reduce to the hold voltage level at 2D02 LINE CONTAC
15. format To do this the following equation can be used e Set the divisor object 2915 sub index 2 to a known speed point of the motor e Set the multiplier object 2915 sub index 1 to the corresponding scaled vehicle speed for the known motor speed Doc 177 52701 6 33 Rev 3 SEVCON For example if it is known that 1000rpm on the motor results in a vehicle speed of 5kph then the divisor should be set to 1000 and the multiplier should be set to 0x0050 which is 5kph in 12 4 format The same process should be repeated for the user speed ratio setting the multiplier for the user speed in the desired custom format Both the vehicle and user speeds objects 0x2921 and 0x2922 can be mapped to TPDO for transmission to other devices via CAN if required DISTANCE CALCULATION Total vehicle distance and trip distance counters are available at objects 0x99 A0 and 0x29A 1 Counters will operate and will be accurate provided that the vehicle speed calculated at object 0x2721 is in kph in 12 4 format Counters are available in the following formats e Distance travelled in km in 24 8 format e Distance travelled in km in 0 1km bit increments e Distance travelled in miles in 0 1mile bit increments Both distance counters objects can be mapped to TPDOs for monitoring over the CANbus or for use by a dashboard display The trip distance counter can be reset by holding the reset switch object 0x217D closed for 1 second The total vehicle di
16. if specified in h w build Table 2 Connector A pin out and wiring information Doc 177 52701 Rev 3 SEVCON Ii Controller Digital Impedance to B Impedance to B voltage Input Type 24V 36V A 9k 9k B 13k 9k 36V 48V A 16k 16k B 24k 16k 79V 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 i e they are all active high or all active low See section Digital inputs page 6 14 for more details 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 Installation Calibrator connections Size 2 models only Calibrator connections are made to Gen4 via a 6 way Minifit Junior connector accessed by lifting rubber cover Ensure cover is fully engaged after use to maintain IP rating Figure 10 Calibrator Connector Pin 1 and pin 3 6 are protected against short circuits to the battery positive or negative terminals Pin Name Type What to connect Maximum Comment rating 1 CAN Comms Normally no connection This pin V 5V Internally connected to CANH Term can be connected to pin 3 ifthe via 1200hm controller wi
17. in wiper in wiper Zin 82 kQ the range 500 Q to 10 kQ or 24V 36V and voltage output device e g 36V 48V Sevcon linear accelerator models 0 to 5 VorO to 10 V Zin 100kQ Ensure that at least 0 5V 24V 36V and Margin exists between the 36V 48V maximum valid throttle and models the wire off threshold 23 Pot 2 Analog From potentiometer 2 V 9 5V Suitable for potentiometers in wiper in wiper Zin 82 kQ the range 500 Q to 10 kQ or 24V 36V and voltage output device e g 36V 48V Sevcon linear accelerator models O to 5 V or O to 10 V Zin 100 kQ Ensure that at least 0 5V 24V 36V and margin exists between the 36V 48V maximum valid throttle and models the wire off threshold 24 CAN Low Comms CANbus Low signal V 5V Maximum bus speed 1 Mbits s Alternative connection to pin 27 25 Encoder B Digital From the speed encoder B I 25 mA Input pulse channel internally limited V 8 V for current source encoders V 2 5V or 5V for open collector encoders 26 Encoder Power To the positive supply I 100 mA Check the speed encoder you power input of the speed encoder V 5V or use is compatible with Gen4 supply 10V software See page 6 12 for selectable configuration details Installation Pin Name Type What to connect Maximum Comment rating 27 CAN Low Comms CANbus Low signal V 5V Maximum bus speed 1 Mbits s Alternative connectio
18. not possible The default setting is active low To configure digital inputs e Set active high low logic at 46801 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 15 pins 14 and 15 for more details e Set digital input polarity at 6802 This is used to configure normally closed open switches ANALOG INPUTS The analog input voltages can be read at object 6CO1n 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 accept a variable voltage or a potentiometer Analog inputs can also be used as additional digital inputs The following table summarises the analog inputs and any special features Name Object Pin Usage Input from external voltage so or 3 wire pot Wiper Input 1 6c011 1 d nput from external voltage source or 3 wire p wiper Use pin 34 as supply for 3 wire pot Wiper Input 2 6c01 2 m Input from external voltage source or 3 wire pot wiper Use pin 35 as supply for 3 wire pot Analog Input 1 or Supply for Wiper Input 6c01 8 xs Use for 2 wire pot input or as a supply for wiper 1 input 1 Has internal pull up Analog Input 2 or Supply for Wiper Input 6c01 4 as Use for 2 wire pot input or as a supply for wiper 2 input 2 Has internal pull up Motor th
19. occur Table 1 Fault categories Doc 177 52701 Rev 3 SEVCON eae 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 T 305 173 B e I 156 75 l 1 i amp 1 3 158 n N Tq o7 ALL SIZE 6 MODELS Q A g o ALL SIZE 4 MODELS n A N El 2 ALL SIZE 2 MODELS 1 l6 j Y E 170 165 170 Fe ke Flatness of mounting surfaces 0 2mm Failure to comply with this flatness specification can 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 or 20 mm of Gen4 baseplate depending on controller type and your mounting surface thickness e T hand socket wrench or Allen key e Thermal grease Recommended torque setting 10 Nm 2 Nm Installation THERMAL GREASE APPLICATION Spread a layer of thermal grease such as Dow Corning 340 as described below before bolting to your mounting surface e Thermal compound should be applied with a small soft paint roller to ensures an even spread of thermal compound
20. read back the fault description from sub index 2 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 3 SEVCON Monitoring 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 12 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 IO Selection 0 1 2 3 4 5 6 7 8 9 10 Key switch 2100h Horn switch 2101h Drive enable switch 2120h MX20 MX31 Forward Switch 2121h MX18 MX18 MX18 MX18 MX18 MX18 MX18 MX18 MX18 MX18 Reverse Switch 2122h MX30 MX30 MX30 MX30 MX30 MX30 MX30 MX30 MX30 MX30 FS1 switch 2123h MX19 MX19 MX19 MX19 MX19 MX19 MX19 MX19 MX19 Seat switch 2124h MX31
21. 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 5 Rev 3 SEVCON I Connecting power cables See also EMC guidelines on page 3 5 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 for size 4 or 6 models 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 Equipment required for size 2 models e Cables sized to suit the controller and application see table below e M6 crimp ring lugs e Crimp tool e M6 wrench Torq
22. 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 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 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
23. to control Check motor load and currents on PMAC motor wiring Check motor parameters are correct 12 Communication error S Unrecoverable network Check CANbus wiring communication error has been and CANopen detected configuration 13 Internal software fault RTB Software run time error captured 13 Current sensor auto RTB Current sensor voltage out of zero fault range with no current 7 8 Monitoring LED Fault Level Set conditions Operator action flashes 13 DSP parameter error RTB Motor parameter written to while Recycle keyswitch to motor control is operational allow parameters to be reloaded correctly 14 3 d Party Anonymous I 3 d party node has transmitted an Check CANbus wiring Node EMCY received DS EMCY message and 3 party node RTB status 15 Vehicle service required I Vehicle service interval has Service vehicle and expired reset service hours Table 8 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 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 3 Object 56101 can be used to read a text description of the fault Write the fault ID to sub index 1 and
24. type of slave it is e g Pump Wy DriveWizard Se Luce loa e Tools Help Exit aa X A HIS el 219 Er system E 9g AC 48V 450A NodelD 1 EB Traction System AC 48V 450A NodelD 1 CANopen General Set up Automatic Configuration Set Up M Pump Ui t Mie Power steering Parameter name Value Units Default Automatic Configuration Set Up E W Auxiliary i Battery CANopen Auto Configuration Enabled Disabled BM Logs Digital Input Auto Configuration Both PDO and VPDO Disabled jr Comms objects setup wizar Digital Input Configuration 2 o JM CANopen Digital Output Auto Configuration Both PDO and VPDO Disabled MP NMT Error Control Analogue Input Configuration 2 o E gt General Analogue Output Configuration ol ol H Status Valid confi ns DOMAIN 0x00 E H Control Analougue Input Auto Configuration Both PDO and VPDO Disabled E H Set up Analougue Output Auto Configuration Both PDO and VPDO Disabled Force system tq Motor Auto Configuration Both PDO and VPDO Disabled This nodeis a Master local is righttraction Slavel Node indication 9 j M Assumed faut 3 Len Traction Yes No 4 Master roni Right Traction Nol Nol Automatic Con Pumi Yes No Automatic Conf Power Steer No No Physical layer aa D m CANbus faut dd FOOSE 2 2 3 H identity Sevcon PST Module No No Me Store E W Supported profiles fl Unassigned EDS Section 4i Self Char
25. 1 2 Used to configure the loops during normal operation e Low speed proportional and integral gains 46511 3 5 Used to configure the loops at low speeds lt 50 RPM and during hill hold These are normally set lower than the standard gains to dampen oscillation as the vehicle comes to a stop e Roll back integral gain 46511 4 Used to boost the integral term to prevent vehicle roll off down inclines particularly when Hill Hold is enabled Normally this gain is higher than the standard integral gain e dw dt gain 46512 6 For speed mode this is used to boost the torque output when a large increase in speed demand occurs For torque mode this is used to apply compensatory torque to damped oscillations induced from the vehicle drivetrain e Integral initialization factor 4651n 7 Used to initialize the integral term on entry to speed limit in torque mode This factor is multiplied by the actual torque to set the integral term Not used in speed mode These settings affect 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 the vehicle is driven uphill the vehicle speed will decr
26. 28 Reserved for future use 5 Not in operational 17 Invalid store command 29 Reserved for future use 6 Cannot go to 18 Bootloader failure 30 Reserved for future use pre operational 7 Cannot go to operational 19 DSP update failed 31 Reserved for future use 8 Access level too low 20 GIO module error failed 32 Checksum calculation failed 9 Login failed 21 Backdoor write failed 33 PDO not copied 10 Range underflow 22 Reserved for future use 11 Range overflow 23 Cannot write to DSP Faults and warnings INTRODUCTION In the event of a fault Gen4 takes the following action 1 Protects the operator and vehicle where possible e g inhibits drive 2 Sends out an EMCY message on the CANbus 3 Flashes the LED in a pattern determined by the fault type and severity 4 Logs the fault for later retrieval FAULT IDENTIFICATION You can identify a fault as follows Monitoring e Check the number of LED flashes and use 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 below to determine the type of fault from the number of LED flashes The LED flashes a preset numb
27. 2913p 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 31 Doc 177 52701 6 23 Rev 3 SEVCON 3 2 T c c E uv a Steer angle pu Outer Wheel Inner Wheel Figure 31 Graph of speed vs steering angle The speed and steering angle are normalized Speed is normalized to maximum vehicle speed and the steering angle to 90 In speed mode outer wheel speed target and maximum torque is scaled according the outer wheel map Inner wheel speed target and maximum torque is scaled to the outer wheel demands according to the inner wheel map In torque mode both inner and outer wheel maximum speeds are scaled according the outer wheel map The outer wheel target torque comes from the throttle The inner wheel target torque is scaled to the outer wheel actual torque according the inner wheel map In object 29131 O to 1 is represented by values in the range 0 to 32767 The inner wheel is scaled according to the outer wheel Where a demand pu of 1 is shown at 90 for the inner wheel this means the inner wheel demand will be equal and opposite to the outer wheel The calculated st
28. 4 4 Isolation ap e i NO 4 4 Io 4 5 Regulatory compliance eT 4 5 SCA NTE nr nna a a a 4 6 Operating environment in 4 6 Shock and VICO pana m oleebebo aee E a nette 4 6 bp 4 6 il Dimension al 4 7 Size DO ANA A AAA ia 4 7 SI ad 4 7 Chapter 5 System design 5 1 SUVA NA A MOTOT eise DN DUNEDIN M MEIN RM US 5 2 Information required about the application 5 2 Motor maximum speed snes ise aer esr anal ette data 5 2 Torque required between zero and base speed ie 5 2 Torquerequired at maximum speed diia 5 3 Continuous power rating ninia th nct ise sei anakaa aksa isaks iere ta acie eee eei i 5 3 leri Tecum T P eee 5 4 Selecting the Gen4 model Lucius sio ineo ie 5 4 Current and power ratings Considerations ici ii tens tlle eer dde eel ee eee Rd ke bela 5 4 Power output restrictions at motor and drive operating temperature limits 5 4 OSTIO uration aA E 5 5 Single traction wiring diagram tente te ttntetenttentetentententente tentent tentent 5 6 Single pump wiring aa 5 7 Twin TOU Sy A 5 8 Auxiliary COMPO RLS Nd 5 8 MA COM CAG COE RS M Ge 5 8 5 Way AMP Seal Connector Kit umi iia idiota 5 8 Emergency SCOP WI id ESERSE EEEE ERE EESE 5 8 On board US it tii 5 8 Key swatch os 5 10 Motor speed sensor encoder sa 5 10 Motor commutation sensor U V W and sin cos ie 5 11 Initial po
29. AA RAE donnent to is 2 9 Int nd duse Or tlie Geld soiree ePi sens 2 2 Available ACCES MUA 2 3 Overview of a truck drive SYS TO non 2 4 Principles of Opa 2 4 Functional description rere ines nantes its 2 5 Interfaces t 2 6 Mast r slaye operation o eerte eer ERE RETIRER ND ROTEN ENG nn A A REE E 2 6 EU NG DIDI M M ees 2 7 AA ee E EEEE nt 2 7 Safety and protective functions pi a 2 8 CNE ON 2 8 One Highway oi RRP 2 9 Fault detectiom and handling ss nine none 2 11 Chapter 3 Installation 3 1 Mounting ent eet E 3 2 OMEN tation A A nent 3 2 Clearance for LED access anita cda laa 3 2 Mounting hole pattern a 3 2 Equ ta 3 2 Thermal grease application Ede e Reuse akt 3 3 Cooling FE QU CPCI uta 3 4 META Ida 3 5 Connecting power cables absorto 3 6 Battery and motor connections inician id 3 6 CADE SIZES 3 6 On board fuse MONA 3 8 Fuse rating and selection alii 3 9 Soma MI stan acannon 3 10 Sonal WireSIZES AA cep E ee Se eM ta tei LIAE 3 10 CAND us ter Mati acc 3 10 Signal conteo ero 3 11 Chapter 4 Specification 4 1 Electrical A 4 2 Input Voltage iii A a aa RRA N la 4 2 Output protect A A a 4 2 Output FANS inn ia SEaa ERSE SASAS ASERS SAS RES SRE ar SS San ESS rSar SSSR E EEKEREN 4 3 CAN ITIGE AEA EAE E EAL EE E E E E E EA 4 4 Control mputs and outputs arine terit etre a E it S
30. An nee 6 35 Display C M M M 6 37 Chapter 7 Monitoring Gen4 7 1 Reading status Vana OS ra 7 2 Motor measurements Lina caderet ette eene eroe i I RERO HR RENE D ertet E 7 2 Heatsink temper ature assistent diia 7 2 Identification and version sssssssssesseeeeeertetnte trennt tette tetti tette tite teretes e tete tern tette nnt 7 2 Battery MOmitOr ing sinistres dt iia 7 2 LOU COUTE SE nr ee E ee ene ee ee ee eU 7 3 TOC CIS nn indien nano en dae elas 7 3 FIFO vent lon DIM 7 3 Event counters oerien i aE EAEAN EERTE EES ESER EA EESE SE EEE E EEEa EERS 7 4 Operational monitorin Presses nine EEA EE EAE RAER 7 4 CANopen abort Code La nu ia 7 4 Faults and NAO LR AS 7 5 Doc 177 52701 v Rev 3 Tra tO AU CEO cid 7 5 Fault identification ia aia 7 5 Fault Et cere mene nt ns 7 9 Upgrading the controller software ae 7 9 Appendices 1 Automatic Configuration Fables 1 Digital Inputs EA Analogue BoTP C 2 Analo pue Opus ainia vi Eg vA Introduction SEVCON About Gen4 documentation THIS VERSION OF THE MANUAL 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 p
31. DO 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 NETWORK CONFIGURATION The easiest way to configure a CANopen network is to use the auto configuration feature See section Automatic Configuration Mapping page 6 12 for more information GENERAL If auto configuration cannot be used or if additional non Sevcon nodes need to be added use the following procedure to setup the network 1 Set node ID and baudrate in 5900 to the required values Node IDs must be unique and the baudrate must be the same for each node 2 Set SYNC COB ID in 1005 to 0x40000080 for the master node or to 0x00000080 for all slave nodes Bit 30 is set to indicate to a node if it is the SYNC producer Only one node in the network should be configured as the SYNC producer This should normally be the master On the SYNC producer set the SYNC rate in 10061 3 Set the EMCY message COB ID to 0x80 node ID in 10144 EMCY COB IDs must be configured correctly to ensure the master handles EMCYs from slaves correctly 4 Configure the heartbeat producer rate in 10171 This is the rate at which this node will transmit heartbeat messages 5 Configure the heartbeat consumer rate in 10161 A consumer should be configured for each node to be monitored Heartbeats must be configured correctly for correct network error handlin
32. Gen4 Applications Reference Manual DOCUMENT NO 177 52701 TECH OPS SEVCON Il Partner with Performance Sevcon Ltd Kingsway South Gateshead NE11 00A England Tel 44 0 191 497 9000 Fax 44 0 191 482 4993 sales uk sevcon com Sevcon Inc 155 Northboro Road Southborough MA 01772 USA Tel 508 281 5500 Fax 508 281 5341 sales us sevcon 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 Gen4 docutnentatlOEL scene 1 2 This versi n of the manual ete eene de e tees estere iie lest ec dede 1 2 Copyrig Essen nn a 1 2 Scope of this it 1 2 Related documents 1 2 joe ser and Wits ae a eet Seated A Po ate eda tate tn 1 2 Warnings CAUTIONS and NOTES 1 3 Product identification Abel nie ame 1 4 Technical Support icici nm nana eau 1 4 POUCES PP nine 1 4 Chapter 2 About the Gen4 2 1 DOME OM na OO diner minuit 2 9 Standard features and capabilite8 ose nter dance 2 9 Available OPUS ta A
33. I O objects on all other nodes 6800 to 6F FF 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 Doc 177 52701 6 9 Rev 3 SEVCON Ii 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 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 t
34. MX31 MX31 MX31 MX31 MX31 MX31 Handbrake Tiller switch 2125h MX32 MX21 MX20 MX19 MX9 MX20 MX20 MX21 MX20 Driveability Select 1 switch 2126h MX20 MX9 MX31 MX20 MX9 MX9 MX9 Driveability Select 2 switch 2127h MX32 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 Outer left Steer switch 212Ch SR31 Inner right Steer switch 212Dh SR20 Outer right Steer switch 212Eh SR9 High speed switch 212Fh Doc 177 5201 A 1 Rev 3 SEVCON J IO Selection 0 1 2 3 4 5 6 7 8 9 10 Footbrake switch 2130h MX32 MX32 MX32 Traction Inhibit 2137h Belly 2139h MX32 Pump 1 switch 2140h SP18 SP18 SP18 MX18 SP18 Pump 2 switch 2141h SP30 SP30 SP30 MX30 SP30 Pump 3 switch 2142h SP31 SP19 SP19 MX19 SP19 Pump 4 switch 2143h SP31 MX31 Pump 5 switch 2144h SP20 MX20 Pump 6 switch 2145h SP9 MX9 Pump 7 switch 2146h SP32 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 IO Selection 0 1 2 3 4 5 6 Throttle Input Voltage 2220h MX22 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 Pu
35. OLING FAN An external fan to cool the controller heatsink or a motor may be connected to one of the analogue outputs The fan will be turned on by the controller when either the heatsink temperature or the motor temperature exceed a specified temperature The fan turns off when the nominated temperature is cold The temperatures at which the fans should turn on and off the analogue output to use for the fan the fan voltage and the temperature source heatsink or motor can be programmed using the heatsink fan 6 34 Configuration object 5A011 Note that the contactor driver outputs may be damaged if connected to capacitive loads It is quite common for fans to incorporate capacitive elements in which case a relay should be used to isolate the fan from the contactor driver output The temperature set point to turn on the fans should be higher than the set point to turn off the fans The fans will not operate 1f another function is configured to run on the specified analogue 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 46211 The estimate is always applied since it can detect increa
36. TOR The line contactor object 24001 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 2820p 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 Gen is configured as the vehicle master it controls the pre charge of all slave nodes automatically Pre charge the capacitors once only before closing the line contactor Repeated pre charging can damage the circuit The pre charge level is configurable between 50 and 90 The level can be adjusted by object 5820 ELECTRO MECHANICAL BRAKE Electro mechanical brakes are not recommended for on highway vehicles as they can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking Also electro mechanical brak
37. URATION 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 6 4 Configuration PDO PROCESS DATA OBJECT PDOs are used by connected nodes for example in a twin motor 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 VP
38. Wire off detection on analogue inputs particularly the throttle e A valid analogue input voltage which is more than 0 5V from wire off limits Appropriate safety interlocks to ensure a single point of failure cannot cause an unsafe driving condition Refer to sections Analog inputs page 6 14 and Vehicle performance configuration page 6 17 for more information NOTES ON FEATURES The Gen4 is a generic motor controller intended for use in both highway AND non highway industrial applications Not all of the controller features are suitable for an on highway vehicle Some features if activated could lead to the controller forcing a motor condition that is not directly requested by the throttle such as undesired drive or harsher than expected braking Sevcon recommends that the following features are DISABLED for any on highway applications Proportional Speed Limit e Hill Hold e Controlled Roll Off e Speed mode or speed control Electromechanical Brake output e Inching Belly switch e Unused Driveability Profiles NOTES 1 These features can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking 2 These features can cause unexpected drive if accidentally activated 3 This feature can cause a sudden reduction in maximum speed if a driveability profile is accidentally activated and is i
39. above diagram was connected to digital input 4 bit 3 in 68001 1 sub index 4 of 33001 would be set to 21244 Some further examples are e Map FSI to read the value of digital input 8 connector A pin 11 at 33001 sub index 8 enter the value 2123 e Map the electromechanical brake signal to be applied to analog output 2 customer connector pin 7 at 3200n sub index 2 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 5 RPDOs receive PDOs and 5 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 configuration tool the relevant Object Dictionary indices are listed in Table 6 Doc 177 52701 6 11 Rev 3 SEVCON Ii Feature Object Note
40. ain input protection fuse directly onto the controller body as shown below Select the appropriate fuse from the table below Connect the battery positive cable to the B terminal Connecting to the end marked or un named in the case of size 2 will leave your installation without a fuse unless located elsewhere in the system The B terminal is a dummy terminal to allow fuse connection only and has no internal connection Figure 6 On board fuse mounting size 4 models 3 8 Installation Figure 7 On board fuse mounting size 6 models FUSE RATING AND SELECTION On board fuse dimensions are in accordance with DIN43560 1 Gen4 input voltage Gen4 peak output current Fuse rating Sevcon part number 300 A 325 A 858 32044 24V 36 V 450 425 A 858 81990 650 750 858 33021 275 250 858 29043 36V 48 V 450 A 425 A 858 81990 650 A 750 A 858 33021 180 A 200 A 858 83339 72V 80 V 350 A 355 A 858 32045 550 A 500 A 858 32043 Doc 177 52701 3 9 Rev 3 SEVCON I 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 in some cases twisted 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 Co
41. ake 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 SEQUENCE FAULT MASKING If an application does not require it sequence fault checking can be disabled on selected drive inputs This is set at 2918 Similarly drive inputs can be masked when clearing drive inhibit faults This is set at 291An These masks must only be applied if the application has other adequate means of protection It is the responsibility of the installer to ensure this TORQUE MODE SPEED MODE Speed mode or speed control is not recommended for on highway vehicles as it can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking Doc 177 52701 6 17 Rev 3 SEVCON I The Gen4 controller provides both torque and speed control modes Objects 2900 and 60601 are used to set which mode to use The default setting is torque mode Always ensure 2900 on the master node and 6060 on all the traction nodes master and slaves match otherwise motor signals between the master and slaves may be misinterpreted The speed control speed mode or speed limit torque mode is controlled using PI loops These loops are configured at 46511 The following parameters can be configured e Standard proportional and integral gains 465115
42. alog inputs converted to digital states 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 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 46A 11 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 46A3y You can have only one low frequency setting per controller Low frequencies are normally used with current controlled outputs e Set the analog output values at object 6C1 1p The value is either a voltage or current depending on whether the output is voltage controlled or current controlled Values are 16 bit integers with a resolution of 1 256 V bit or A bit Doc 177 52701 6 15 Rev 3 SEVCON I ERROR CONTROL It is important that analog outputs on nodes other than the master must have appropriate error configuration to protect against CANbus faults This section explains how to configure the outputs to go to a safe state in the event of a CANbus fault It is the installers responsibility to define what a safe state is for each output In a CANopen network the slave node o
43. 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 perform 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
44. are 2 pump throttle inputs which can be configured independently at 2A 10 and 2A11 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 at 2A20 to 2A26 The pump switches must be mapped to digital inputs PUMP DRIVEABILITY PROFILES Pumps have configurable driveability profiles Profiles are triggered by pump driveability select switches 21521 and 21531 One or more of these switches must be mapped to enable pump profiles Each profile allows the installer to reduce acceleration and deceleration rates throttle and switch values and maximum torque Set pump driveability profiles at 2A80 and 2A31 POWER STEER CONFIGURATION GENERAL Power steering can be provided using e Contactor Map the power steer contactor drive object to an analog output e Pump motor controller Configure pump to provide power steering Power steer demand is added to pump demand e Dedicated motor controller Map power steer application motor object to motor control slave Power steer motors always run in speed mode Ensure the motor slave is also configured for speed mode in 6060 e The power steer can be triggered by a number of events e Vehicle moving
45. ate 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 21011 and an analog output is mapped to the horn object 24031 VEHICLE SPEED CALCULATION The controller can be configured to calculate vehicle speed from motor speed by setting a configurable ratio between these values in object 2915p Calculated vehicle speed can then be transmitted to the CANbus for use with compatible displays or used to keep a log of total distance travelled by the vehicle The convention is to calculate vehicle speed as a signed number in 12 4 format in kph This is required for compatibility with ClearView displays and the odometer In case a custom display is used whose units are different a user speed calculation is also provided whose units are independent from all other features Two sets of ratios are provided for calculation of a vehicle and user speeds located in object 0x2915 While vehicle speed is a signed value the option to have unsigned user speeds is also provided an absolute value will be calculated The ratio between motor speed and vehicle speed will be dependent on vehicle drivetrain parameters such as gearbox ratio and wheel size However the ratio should be calculated such than when it is multiplied by motor speed which is in rpm the result is vehicle speed in kph 12 4
46. available from Tyco if a contact is inserted and then subsequently removed Pin Name Type What to connect Maximum Comment rating 1 Key switch Power From dead side of key 7A This input supplies power in switch via suitable fuse Total of all from the battery for all the contactor logic circuits output The unit cannot operate currents plus without Key switch in 1 0A supply Pins 1 and 6 and 10 on Size 4 amp 6 models 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 termination to pin 24 This connects a 120Q the Gen4 is physically at the termination resistor mounted inside the end of the CANbus network controller across the CANbus see CANbus termination on page 3 10 3 Contactor Out To the switched low side 2 0A per This output provides low side out 1 of contactor or valve coil output voltage or current control to Contactor out 1 usually subject to a the load depending on drives the line contactor limit of 6A for configuration DO NOT USE WITH e total OE all The output goes low or is CAPACITIVE LOADS the outputs chopped to activate the load It NED 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
47. bus isolator L B B signals B B signals battery Gen4 controller 1 Gen4 controller 2 M1 M2 M3 M1 M2 M3 38 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 a user definable percentage using 58201 of battery voltage via the key switch signal line 2 Close line contactor 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 see On board fuse mounting section Principles of operation 2 4 About the Gen4 FUNCTIONAL DESCRIPTION The main function of Gen4 is to control 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
48. 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 IP54 when 35 way connector unmated size 2 models only SHOCK AND VIBRATION Thermal shock EN60068 2 14 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 Srms WEIGHT Controller weight Case size 2 1 3kg Case size 4 2 7kg Case size 6 4 6kg Specification DIMENSIONS SIZE 2 MODELS Doc 177 52701 4 7 Rev 3 SEVCON SIZE 6 MODELS 290 Chapter 5 System design SEVCON Sizing a motor INFORMATION REQUIRED ABOUT THE APPLICATION To select an appropriate induction motor for an
49. circuit S Unable to establish current in Check motor motor condition wiring 6 Throttle pressed at DI Throttle demand is greater than Reduce demand power up 20 at power up 6 Analog input wire off VS Analog input voltage is outside Check analog input allowable range wiring 7 6 Monitoring LED Fault Level Set conditions Operator action flashes 6 Analog output fault VS Analog output fault caused by over Check analog output over under current current gt 4A under current if wiring failsafe short circuit actual current lt 50 target driver current mode only failsafe circuit fault short circuit driver MOSFET 7 BDI warning or cutout I BDI remaining charge is less than Charge battery warning or cutout levels 7 Battery low voltage I Battery voltage or capacitor Increase battery protection voltage is below a user definable voltage above user minimum battery level for a user defined level definable time 7 Controller low voltage I Battery voltage or capacitor Increase battery protection voltage is below the minimum level voltage above allowed for the controller minimum level 7 Controller high voltage I Battery voltage or capacitor Investigate and reduce protection with line voltage is above the maximum battery voltage below contactor closed level allowed for the controller maximum level with line contactor closed 7 Battery high voltage I Battery vo
50. ction CAN Low 27 to other CAN Cont3 Supply devices key switch traction i Gen4 fuse Dual Traction Left Motor oo o 460 Slave encoder A encoder B OV Alternative use a voltage source in place of the pot Alternative use a voltage source in place of the pot 18 inch forward Pp ho 30 inch reverse thermistor 9 AG power steer trigger B Doc 177 52701 5 9 Rev 3 SEVCON I Figure 16 Dual traction wiring diagram 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 2 A Pump contactor 2A Gen4 control circuits 1A B Pre charge circuit 7A Fuse choice 7A MOTOR SPEED SENSOR ENCODER A 4 wire connection is provided for open collector or current source quadrature pulse encoder devices software configurable These types of encoder are optimized for accurate speed measurement required for efficient control of induction motors AB Quadrature Pulse Encoder pin numbering may vary Gen4 Controller 26 5 10V Supply encoder A encoder B oV Figure 17 Sample wiring for an AB quadrature speed encoder You can use the following types of encoder or equivalents Type Output Supply Specification Beari
51. d Refer to Electro mechanical brake on page 6 32 for more information HILL HOLD Hill Hold is not recommended for on highway vehicles as it can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking Doc 177 52701 6 27 Rev 3 SEVCON I 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 and the vehicle can start to move if parked on an incline If enabled the system will enter controlled roll off after hill hold You can set the hill hold delay at object 2901p Set the hill hold delay to O to disable this feature In speed mode drive torque is disabled whilst neutral braking to stop However drive torque must be re enabled when entering Hill Hold to allow torque to be applied to hold on the incline Set the speed to re enable drive torque at 2908n INCHING Ensure inch switches are only mapped to digital inputs when required Activation of these inputs can cause a drive condition to occur 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 c
52. d 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 Drivability profiles can also be invoked by internal software triggers such as BDI low service required or low speed These can be selected to suit specific application requirements Set the profile triggers in 2931p Where more than one profile is active the lowest value s are used by the software Speeds in driveability profiles are scaled according to the vehicle gear ratio 29151 This is used to convert speed in RPM to any other preferred unit such as KPH or MPH To remove this scaling and leave driveability profile speeds in RPM set 29151 3 to 1 Torques in driveability profiles are in 0 1 bit resolution These are converted to Nm using the motor rated torque value at object 60761 Ramp rates in driveability profiles are in either RPM s for speed mode or s for torque mode In speed mode RPM s becomes User Defined Units s if the gear ratio is used to rescale the driveability profile speeds Speed limit ramp rates are only used in torque mode and are in RPM s or user defined units s In addition to the speed limit ramp rates in the profiles 291E can be used to configure safety limits on speed limit ramping The installer should set these ramp rates t
53. d for SOUICE 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 in conjunction with U y pulse 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 Doc 177 52701 Rev 3 SEVCON Ii Pin Name Type What to connect Maximum Comment rating 21 Digital Digital From digital switch Type B See note to Table 3 Input 8 input 8 V Vb Alternative Sin input from See Table 3 Sin Cos analogue encoder only if specified in h w build 22 Pot 1 Analog From potentiometer 1 V 9 5V Suitable for potentiometers
54. e CANbus Motors may be operated independently in a combined traction pump application or operated in tandem where each motor drives a separate wheel In 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 16 Auxiliary components MAIN CONTACTOR Select the appropriate contactor line contactor from Table 5 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 Manufacturer Notes current P N Up to 450 A 24V 8928 37094 Albright SW200 29 See paragraph below 48V 828 57096 Albright SW200 20 80V 8928 67010 Albright SW200 460 Up to 650 A 24 V 828 39001 Albright SW200 Chop at 17 V intermittent coil Table 5 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
55. e 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 2 Invalid steer switch VS Steering switches are in an invalid Check steer switches states state for example both outer switches are active 3 Fault in electronic VS Fault in electronic power switching power switching circuit circuit e g MOSFET s c 3 Hardware over voltage VS Hardware over voltage circuit Investigate and reduce activated activated battery voltage below user defined maximum level Ensure suitable over voltage is configured in 2C011 and 46121 3 Hardware over current VS Hardware over current circuit Check motor load and trip activated activated wiring Check motor parameters are correct 4 Line contactor welded S Line contactor closed at power up Check line contactor or after coil is de energized condition wiring 4 Line contactor did not S Line contactor did not close when Check line contactor close coil is energized condition wiring 5 PST fault DI Fault detected on PST power steer Check PST condition module 5 Motor open
56. e Op write only in Pre Op 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 Drive Wizard to 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 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 Doc 177 52701 6 3 Rev 3 SEVCON 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 adhere to this standard To provide greater
57. e 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 2C03h Doc 177 52701 6 35 Rev 3 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 10096 e Discharge voltage V set this to the cell voltage when the battery is discharged e Cutout level 96 this is the level at which the vehicle adopts the low battery drivability profile e Discharge rate s this is the rate at which the BDI remaining charge value discharges Set to 0 to use default value of 16 8s to reduce by 1 This default should suit most lead acid battery types
58. e traction size 4 450 180 Single traction size 6 650 260 Single traction size 2 180 75 72 80 Single traction size 4 350 140 Single traction size 6 550 210 2 minute rating lower ratings are possible for longer periods see example in Figure 11 1 hour minimum without forced air cooling Size 2 long term rating achievable with finned heatsink approx 250mm x 180mm 0 5 C W Size 4 long term rating achievable with finned heatsink approx 330mm x 200mm 0 3 C W Size 6 long term rating achievable with finned heatsink approx 330mm x 280mm 0 2 C W Normalised Current Time mins og scale Normalised Current Figure 11 Output current available for various durations of sustained current demand Doc 177 52701 Rev 3 SEVCON I CAN INTERFACE CAN protocol CANopen profiles DS301 DS401 and DSP402 are supported Physical layer uses ISO1 1898 2 Baud rates supported 1 Mbits s default 500 kbits s 250 kbits s 125 kbits s 100 kbits s 50 kbits s and 20 kbits s CONTROL INPUTS A ND OUTPUTS Digital inputs 8 digital switch inputs software configurable polarity 24 36V controllers Active low inputs lt 2 6V active high inputs gt Vb 2 6 V 36 48V controllers Active low inputs lt 2 9V active high inputs gt Vb 2 9 V 72 80V controllers Active low inputs lt 4 4V active high inputs gt Vb 4 4 V Analog inputs 2 general purpose in
59. ease 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 GENERAL The controller can use 2 or 3 wire throttle inputs of the following types e Linear potentiometer in the range 470 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 14 The throttle voltage 22201 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 See section Analog inputs page 6 14 for more information Configuration Setup the characteristics of the throttle at 29101 sub indices 2 to 20 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 27 and Figure 28 respectively Value end voltage value 1 startvoltage value 1 Voltage startvoltage value 2 end
60. eering angle can be read at 26231 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 7 Value Description 2913n 9 Outer wheel speed during inner wheel cutback 2913n 11 Outer wheel speed during inner wheel reversal 2913n 17 Inner wheel cutback speed 2913n 19 Inner wheel reverse speed Table 7 Objects to set when using steering switches 6 24 Configuration 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 DRIVEABILITY PROFILES Ensure driveability profiles are disabled when not required Activation of a driveability profile can cause driving parameters to change Driveability profiles allow you to set maximum values for speed torque acceleration and deceleration for use in a range of operational situations In addition in torque mode there are ramp rates for speed limits as well and Figure 33 show the change in speed and torque target under various driving conditions over a period of time Dir Chg Accel Rate Ntrl Brake Decel Rate Speed Target Throttle Figure 32 Speed mode acceleration deceleration A Decel Rate Accel Rate Dir Chg Decel Rate Ntrl Brake Accel Rate
61. en 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 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 8 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 EN 61000 4 4 Table 1 Test Levels Level 2 transient Electrostatic discharge EN 12895 2000 4 2 Electrostatic Discharge 4 kV contact discharge 8 kV air 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 4 5 Rev 3 SEVCON Ii Mechanical OPERATING ENVIRONMENT Operating temperature 30 C to 25 C no current or time derating 25 C to 80 C no current derating
62. ent early exit from neutral braking a debounce timer can be set at 290Dy Neutral braking only finishes when the vehicle has been stopped for longer than this time This can help prevent early exit of neutral braking due to motor oscillation caused by under damped suspension On vehicles with gearbox meshing issues a slower rate of torque ramp up at low speeds can be configured at 291Cy This slow rate of change of torque lessens shock due to gear meshing Used in torque mode only Brake feathering reduces neutral and foot braking torques as the vehicle speed approaches O to prevent any roll back in the opposite direction This is set at 290E Used in torque mode only 6 22 Configuration 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 21301 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 22211 must be mapped to an analog input Configure the characteristics of the footbrake at 2911 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 inpu
63. er 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 RTB Hardware circuitry not operating failure 1 Configuration item out VS At least one configuration items is Set configuration item of range outside its allowable range to be in range Use 56211 to identify out of range object 1 Corrupt configuration VS Configuration data has been data corrupted 1 Hardware incompatible VS Software version is incompatible with software or invalid with hardware Calibration data for calibration data sensors invalid 2 Handbrake fault I Direction selected with handbrake Release handbrake switch active 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 delay without a direction selected select drive 2 FS1 recycle DI FS1 active after a direction change Reset FS1 Doc 177 52701 Rev 3 SEVCON a LED Fault Level Set conditions Operator action flashes 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 configurabl
64. ermistor 6c011 5 33 Use for motor thermistor input or 2 wire pot input Configuration Has internal pull up WIRE OFF DETECTION Enable wire off detection at 46C0 to 46C4n For each input specify the allowable range of input voltages To disable set the ranges to maximum 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 KTY 84 or equivalent Switch Connected to a general purpose digital input To setup go to object 4620h e Configure as none switch or PTC thermistor e For KTY84 thermistors set the PTC type to KTY84 e For non KTY84 PTC thermistors set the PTC type to User Defined and then set the expected voltages at 100 C high temperature voltage and 0 C low temperature voltage The Gen4 will linearly interpolate temperature with voltage e Ifyou are using a switch select the digital input source Read the measured motor temperature PTC or switch operation at object 46001 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 46901 The digital input status object 6800 contains enough sub indices for the digital and analog inputs Sub index 1 is the states of the digital inputs and sub index 2 is the states of the an
65. es normally fail to the applied state meaning any loss of power or wiring fault can cause the brakes to be applied The electro mechanical brake object 24201 must be mapped to an analog output Set the conditions under which it is applied at 29031 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 6 32 Configuration 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 24011 can be mapped to an analog output to drive a lamp on a vehicle dashboard ALARM BUZZER The alarm buzzer object 24021 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 e BDIlow A different cadence for each of the above conditions can be configured BRAKE LIGHTS A brake light output object is available 24041 and can be mapped to an analog output The brake lights will illumin
66. g The master node should monitor heartbeats from all slave nodes Slave nodes should at a minimum monitor heartbeats from the master node Loss of CANbus communication from any one node must cause a heartbeat fault to occur 6 On standalone systems with non CANopen nodes attached hardware CANbus fault detection should be enabled at 59011 CANbus fault detection is automatically enabled for multi node CANopen systems 7 Configure additional SDO servers An SDO server allows another CANopen device to SDO read write from a node s object dictionary Each node has one default SDO server 12001 which is reserved for communication with configuration tools like DriveWizard or the Doc 177 52701 6 5 Rev 3 SEVCON 10 dde calibrator Another 3 SDO servers can be configured at 1201 to 12031 These should be used as follows a On slave nodes configure a server to allow the master node to communicate b If there is a display in the system configure a server to allow the display access On the master node configure SDO clients at 1280 to 1286n There must be one client for each slave node The SDO clients must be configured to match the corresponding SDO server on each slave On the master node list all slave node IDs at 2810 Configure RPDOs 1400 to 17FFn and TPDOs 1800 to 1BFF appropriately for the system See section Manual object mapping page 6 10 for more information Configure the RPDO timeout funct
67. hese 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 24 A digital switch input is mapped to the seat switch function to control the traction application i e with no seat switch input the vehicle is prevented from moving Configuration Master seat traction Switch 2124h application amd Switch En RS mapping Object Dictionary ni digital inputs 6800h 1 Imm inputs 1 8 Figure 24 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 14 sub indices on a device with 8 digital inputs and 5 analog inputs Sub index O gives the number of I O channels in use In 3300 sub indices 1 to 8 correspond to the digital inputs and sub indices 9 to 14 correspond to the digital state of analog inputs To map the local I O to an application signal object set the appropriate VPDO sub index to the application signal object index If the seat switch shown in the
68. indicates the type of fault see on page 1 gt MASTER SLAVE OPERATION The Gen4 controller contains both master and slave functions as shown in Figure 4 They operate as follows e Slave function implements the CANopen Generic I O Profile DS401 and the Drives and Motion Control Profile DSP402 e Master function implements vehicle functionality traction and pump control and CANopen network management About the Gen4 Controller 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 Speed mode or speed control is not recommended for on highway vehicles as it can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking 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 differs 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 thrott
69. ion if required See section PDO mapping page 6 11 for more information 3 PARTY CANOPEN DEVICES At power up the Gen4 master will communicate with all slave nodes to identify which nodes are Sevcon devices and which are not using the vendor ID in 1018 This instructs the Gen4 how to handle EMCY messages from each node Gen4 knows how to react to EMCYs faults from Sevcon slaves and can take appropriate action Gen4 does not know how to react to EMCYs from 3 party devices so the required fault reaction to 3 party device EMCYs must be set at 28305 A Configuration Configuration process overview 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 9 3 Vehicle performance configuration 6 17 4 Vehicle features and functions 6 32 ACCESS AUTHORIZATION
70. itions 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 Junctions see Manual object mapping on page 6 10 A common configuration is supplied by default which may suit your needs or act as a starting point for further configuration 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 example Standard features and capabilities AVAILABLE OPTIONS There are three mechanical package options Figure 2 for the Gen4 controller at various voltage and current ratings Size 2 models Size 4 models Size 6 models Figure 2 Mechanical package options INTENDED USE OF THE GEN4 The Gen4 motor controller can be used in an
71. ke fault If enabled a handbrake fault is set when a direction is selected whilst the handbrake input is active e Proportional speed limit during braking enable disable If enabled speed limit is proportional to throttle only in drive states Maximum speed limit is allowed in braking states Only used in torque mode e Driveability Consolidation Normally driveability profiles are only used to reduce vehicle performance however if this is enabled an active driveability profiles over writes the baseline This allows vehicle performance to increase when a profile is active Note that this feature is not available in all software builds e Allow step change in steering angle If enabled steering angle can change instantly with steering voltage If disabled steering angle is rate limited to 90 s which prevents sudden steering angle changes in the event of a steering sensor wire off e Virtual FS1 enable disable If enabled this sets up a virtual FS1 feature on systems with dual throttle inputs configured An s curve profile can be applied to the speed target in speed mode or maximum speed in torque mode This can be set at 290An ACCELERATION AND BRAKING See Driveability profiles for more information on page 6 25 Some vehicles can exhibit shock due to the rapid reversal of torque after a direction change 29091 can be set to force the vehicle to remain stationary for a period before driving in the new direction To prev
72. l Speed ex ex em Speed Limit Speed Vehicle wheels lock but rather than stepping down speed limit it ramps down at the maximum speed limit deceleration rate as specified in object 291E When wheels recover the motor control will allow them to rotate again Figure 34 Example of behaviour of speed limit when drive wheels are locked It is important to consider the behaviour of the vehicle under all drive conditions including when traction is lost due to locking of the drive wheels When testing a vehicle check that the vehicle behaves in a safe manner when performing harsh braking on low friction surfaces such as gravel CONTROLLED ROLL OFF Controlled Roll Off is not recommended for on highway vehicles as it can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking 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 29301 e Enable disable controlled roll off e Setaroll 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 detecte
73. le 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 2 7 Rev 3 gt Pb gt PD 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 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 controller will invalidate the warranty Use cables of the appropriate rating and fuse them according to the applicable national vehicle and electrical c
74. ltage or capacitor Investigate and reduce protection voltage is above a user definable battery voltage below maximum battery level for a user user defined maximum definable time level 7 Motor low voltage I Capacitor voltage has entered the Increase battery protection motor low voltage cutback region voltage above start of defined in 46121 motor low voltage cutback region 7 Motor high voltage I Capacitor voltage has entered the Reduce battery voltage protection motor high voltage cutback region below start of motor defined in 46121 high voltage cutback region 7 Controller high voltage S Battery voltage or capacitor Isolate controller and protection with line voltage is above the maximum investigate high contactor open level allowed for the controller battery voltage with line contactor open 7 Battery voltage below S Battery voltage is below the Increase battery critical level for absolute minimum voltage at voltage controller which the controller hardware is guaranteed to operate 7 Precharge failure VS Capacitor voltage is less than 5V Check controller after pre charge operation is wiring to ensure there complete are no short circuits between B and B Doc 177 52701 Rev 3 SEVCON LED Fault Level Set conditions Operator action flashes 8 Controller too hot I Controller has reduced power to Remove loading to motor s below maximum specified allo
75. ly powered by a 5V supply Therefore it is important to ensure that the controller is configured to supply 5V on pin 26 This should be done by setting the encoder configuration object dictionary entry at 46301 The standard Gen4 build does not provide inputs for the sin and cos signals Therefore if operation with a sin cos analogue encoder is required then this must be specified as a hardware build option Controllers built for use with sin cos encoders have the functions of pins 31 and 35 reassigned from digital and analogue inputs to sin and cos signal inputs respectively Please contact your local dealer for more information on the sin cos encoder build option Doc 177 52701 5 13 Rev 3 SEVCON I Initial power up sequence 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 f
76. mp Throttle 1 Input Voltage 2240h MX22 SP22 SP22 Pump Throttle 2 Input Voltage 2241h MX34 Doc 177 52701 Rev3 Monitoring ANALOGUE OUTPUTS IO Selection 0 1 2 3 4 5 6 7 8 9 10 11 12 Line contactor 2400h MX3 MX11 MX3 MX3 MX3 MX3 MX3 MX3 SL3 MX3 MX3 MX3 MX3 Line contactor 2400h SP3 SP3 External LED 2401h SL7 MX7 MX7 Alarm buzzer 2402h SP3 MX7 MX7 Horn 2403h SR3 SR3 Lights 2404h MX7 SR3 SP7 Service Due 2405h MX7 SR7 SR7 Electro mechanical 2420h MX7 MX7 MX7 MX7 MX11 MX11 MX11 MX11 brake Traction Motor Cooling Fan 2421h SP7 Motor Isolation Contactor Seon High Low Speed Indication 2423h SP11 Pump contactor 2440h MX11 SR7 Power Steer contactor 2460h MX11 MX3 MX11 MX11 MX11 SR11 SR11 SUGGESTED SAMPLE CONFIGURATIONS This table lists suggested digital input analogue input and analogue output configuration schemes for common vehicle configurations Vehicle Type Suggested Configuration Scheme Digital Inputs Analogue Inputs Analogue Ouptuts Doc 177 52701 Rev 3 SEVCON Golf car or light urban vehicle 0 0 0 Generic standalone traction system 3 0 0 Walkie or palette truck 4 0 6 Generic standalone pump 6 1 1 Dual traction with digital steer switches 7 3 0 Dual traction with analogue steer angle sensor 8 4 0 A 4 Doc 177 52701 Rev3
77. n and 21271 To enable either of these they must be mapped to digital inputs When they are active the corresponding drivability profiles 29211 and 29221 are applied 6 28 Configuration See Driveability profiles page 6 25 for more information 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 improved by reducing the acceleration rate or the maximum torque Configure the economy input at object 29121 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 18 The economy value calculated from the voltage can be read at 26221 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 Pump motors always run in speed mode Ensure the motor slave is also configured for speed mode in 6060 GENERAL SETUP Configure the pump features at 2A001 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
78. n to pin 24 28 CAN Power To CAN device requiring V 24V Check that the CAN device power external supply I 100 mA power supply requirement is supply suitable for Gen4 29 Encoder Digital Position encoder 10V Use in conjunction with U Ww pulse 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 5 V 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 In a I 15 mA the range 500 Q to 10 kQ supply basic configuration this is the throttle 35 Pot 2 Power Supply feed to V 10V Suitable for potentiometers in power potentiometer 2 I 15 mA the range 500 Q to 10 kQ supply Alternative Cos input from Sin Cos analogue encoder only
79. n 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 6C431 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 but the the bottom 16 bits are ignored The top 16 bits give the error value in 1 256 V bit or A bit for current controlled outputs Some examples of typical configurations may be e Electro mechanical brake on slave node If CANbus communication is lost it may be desirable to apply the electro mechanical brake on the slave device In this case enable error control in 6C431 and set the error value in 6C44 to O e Power steer contactor on slave node If CANbus communication is lost it may be desirable to leave the power steer output in its previous state In this case disable error control in 6C431 e CANbus communication error lamp on slave node If CANbus communication is lost it may be desirable to activate an output on the slave device In this case enable error control in 6C431 and set the error value in 6C44 to an appropriate voltage for the lamp The above examples are for illustration purposes only It is the respon
80. ncorrectly configured Doc 177 52701 9 9 Rev 3 SEVCON In addition the following features must be configured correctly e Steering map if used to reduce maximum outer wheel speed with steering angle FAULT DETECTION AND HANDLING About the Gen4 There are five categories of faults as described in Table 1 For a detailed list of faults see Table 8 on page 7 9 Fault severity Controller latched off until Consequences Return to base RTB Cleared by Sevcon personnel Immediate shut down of the system with the exception of the power steering if needed Power is removed to nearly all external components Very severe VS Cleared by authorized service personnel Immediate shut down of the system with the exception of the power steering if needed Power is removed to nearly all external components Severe S Keyswitch recycled turned off then on Immediate shut down of the system with the exception 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 reselecting but 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
81. ng 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 the maximum motor speed for a given encoder on a 4 pole motor Encoder Maximum motor ppr speed rpm 128 6000 80 10000 5 10 System design 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 fmax HZ and _ 20000 rpm N max pm 012 Encoder PPR is set at 60901 Additional encoder configuration pull up supply etc is set at 4630 MOTOR COMMUTATION SENSOR UVW COMMUTATION SENSORS Commutation sensors are designed to measure the position of the rotor shaft within the motor rather than its rotational speed Rotor position information is used for control of permanent magnet motors as it allows the controller to energise the motor phases appropriately based on the measured position of the magnets on the rotor The Gen4 controller provides inputs for both digital UVW style position sensors and analogue sin cos sensors Either
82. nnectors are keyed to prevent incorrect insertion Twisted shielded wire is recommended Keep signals away from power cables to avoid interference See also EMC guidelines on page 3 5 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 5 If your system has more than one CAN node connect the nodes in a daisy chain arrangement Figure 8 and terminate the connections of the two end nodes with a 120 Q resistor If the end node is a Gen4 link pins 2 and 24 on the customer connector a 120 Q resistor is built into 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 link p ARE ENS E Y Other CAN node Gen4 Figure 8 CAN node termination Signal connections Signal connections are made to Gen4 via a 35 way AMPSeal connector U Toop 0000000000 1000000000002 2440900000000005 Figure 9 Customer Connector Installation Pins are protected against short circuits to the battery positive or negative terminals Inserting contacts into connector housing pierces the sealing diaphragm to make the seal to the wire To maintain IP rating unused positions must be sealed with appropriate hardware
83. ntroller 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 Configuration multi node systems providing they match one of a selection of pre defined setups refer to page 1 for details 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 e fitis Master or Slave in the CANBus system 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
84. o suitable levels to ensure speed limits can not ramp faster than could actually happen on a vehicle This can protect against harsh braking if traction wheels are momentarily locked PREVENTING WHEEL LOCK SCENARIOS For certain vehicle types particularly on highway vehicles or electric motorcycles the possibility of wheel locking during drive must be considered During braking the controller will maintain a speed limit to ensure the vehicle does not overspeed if entering braking whilst travelling downhill If proportional speed limit is set then the speed limit will follow actual speed toward zero whenever actual speed is dropping rapidly usually due to some external influence such as application of mechanical brakes 6 26 Configuration If the brakes are applied too harshly then there is possibility to lock the drive wheels In these circumstances the normal reaction of the driver is to release the brake to allow the wheels to rotate again The correct operation of the controller in this scenario is to allow the wheels to continue to rotate and not impose a speed limit The maximum rate at which the speed limit can increase or decrease is specified in object 291E y By limiting the rate at which the speed limit can decrease we can ensure that if the brakes are released after they had locked the drive wheels the controller s speed limit will allow them to rotate again The operation of this is shown in Figure 34 below Actua
85. 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 43001 and 43011 Gen4 monitors and records the minimum and maximum values 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 Service engineers 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 080000001 when the object dictionary is accessed This can occur for many reasons Object 53101 gives the exact abort reason These are O None 12 Invalid value 24 Cannot read from DSP 1 General 13 EEPROM write failed 25 Peek time out 2 Nothing to transmit 14 Unable to reset service time 26 Reserved for future use 3 Invalid service 15 Cannot reset log 27 Reserved for future use 4 Not in pre operational 16 Cannot read log
86. odes Where appropriate use of a suitable line contactor should be considered 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 2 8 About the Gen4 ON HIGHWAY VEHICLES GENERAL This applies to all on highway vehicles such as motorcycles and cars The installer must ensure an appropriate controller configuration is set to ensure that the vehicle remains in a safe condition even in the event of a fault INPUTS Always ensure drive inputs have adequate protection Inputs such as the throttle should have appropriate wire off detection configured Single point failures should never cause an unsafe condition Gen4 supports wire off detection on all analogue inputs and it contains various safety interlocks to prevent unexpected drive due to a wiring fault e g FS1 switch dual throttle inputs Sevcon recommends that the following features are enabled for all applications e
87. 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 11 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 Drive Wizard tool In addition Sevcon s SC Wiz PC based tool provides the function to self 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 T he number of flashes
88. of these can be used for control of permanent magnet motors UVW Position Encoder pin Gen4 Controller numbering may vary 5 10V Supply channel U channel V channel W 0v Figure 18 Sample wiring for a UVW commutation sensor 3 digital inputs are provided for UVW encoders The encoder should provide one pulse on each channel per electrical cycle of the motor and each pulse should be 120 out of phase with the others and have a 5096 duty cycle Doc 177 52701 5 11 Rev 3 SEVCON Tek Stop E Chi 10 0V Ch 10 0V M4 00ms Ch2 Y 4 00 V 10 0 V 24 Sep 2009 B 118 800ms 19 23 48 Figure 19 Example pulse train from a UVW commutation sensor SIN Cos COMMUTATION SENSOR Analogue sin cos encoders should provide one sine wave and one cosine wave per mechanical rotation of the motor Peak and trough signal voltages must have a minimum of 1V difference Tek Stop gt 119ms TA triader 98 4ms 0 E ul Chi 1 00 V SE 1 00 V 17 M20 0ms A Chi F 3 12 V 0 00000 s i Mode Source Coupling Slope Level Type Auto Edge chi DC FA 3 12V amp Holdoff Figure 20 Example of signals from a sin cos position sensor Sin cos Position Encoder pin numbering may vary Gen4 Controller 26 5V Supply Sin input Cos input 0v Figure 21 Sample wiring for a sin cos commutation sensor System design Sin cos encoders are typical
89. on of battery protection Note 1 Conventionally the controller may be set to operate without cutback in the range 70 to 120 of the nominal battery voltage although cutback parameters may be used to set cutbacks higher or lower than this range Cutbacks are set by the user for various reasons including e Battery protection against high current in deep discharge condition e Providing smoothly reducing performance at extremes of working voltage range rather than a sudden loss of function Note 2 Working voltage range outside which the controller will be non operational OUTPUT PROTECTION Output current Reduced automatically from peak to continuous rating depending on the time a peak load is applied to the controller see Figure 11 on page4 3 Reduced automatically if operated outside normal temperature range Short circuit Protected against any motor phase to B or B at power up Protected against any motor phase to another motor phase at any time during operation At switch on Gen4 detects valid output loads are present before applying drive current i Repetitive short circuits may damage the controller OUTPUT RATINGS Specification Input Function Short term Continuous Vdc rating Arms rating A rms 24 Single traction size 2 300 120 24 36 Single traction size 4 450 180 Single traction size 6 650 260 Single traction size 2 275 110 36 48 Singl
90. 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 Contactor coils must not be wired to the supply side of the key switch Use the Output 1 Supply Output 2 Supply Output 3 Supply pins provided see Table 2 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 8 5 8 System design 11 Gants CAN High 13 CAN connection Cont2 24 for configuration CAN Low H and service o a Cont1 CAN term 2 i m Link to terminate the CANbus Q E 16 CAN j E ae ein E to oe e 9 CAN Low Cont2 Supply devices Cont3 Supply Alternative use a voltage source in place of the pot 1 6 10 key switch LO control key fuse switch Gen4 Dual Traction Right Motor Master Alternative use a voltage source in place of the pot B 18 forward 10 V encoder A 30 reverse encoder B 19 o 0v foot switch 31 E rd M1 seat 20 M2 handbrake y driveability select 1 thermistor 32 B driveability select 2 21 B eee CAN High H ry CaN comecton Cont2 CAN Low H and service 5 Cont1 _ Sa 25 i Linkto 28 38 CANterm 2 terminate the of 8 PF CANbus 39 Cont1 Supply oo 1 amp Cont2 Supply CAN High 16 CAN conne
91. onfigure 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 29051 sub index 1 This is either a speed target in speed mode or maximum speed in torque mode e Specify an inching throttle O to 100 at 2905 sub index 3 This gives a torque target in torque mode This is not used in speed mode e Specify a time out 0 1 s to 5 0 s at 29051 sub index 2 BELLY SWITCH Ensure the belly switch is only mapped to a digital input when required Activation of this input can cause a drive condition to occur The belly switch is normally connected to the end of the tiller arm on class 3 vehicles When activated it forces a drive condition in forward at a user specified throttle value and maximum speed for a specified time To configure belly e Ensure the belly switch is mapped to a digital input e Specify the maximum belly speed at 290C sub index 2 e Specify a belly throttle at 290C sub index 1 This will determine the torque demand in torque mode or speed demand in speed mode e Specify a belly time out at 290C sub index 3 The belly function will cease after this time has expired DRIVABILITY SELECT SWITCHES Ensure the driveability switches are only mapped to digital inputs when required Activation of these inputs can cause driving parameters to change There are two drivability select switches 2126
92. or the fan cooled version Check the routing of cables 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 12 It should now be safe to lower the vehicle to the ground and test drive Proceed with caution Chapter 6 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 22 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 con
93. ottle input 2 If the throttle values differ by more than 5 a throttle fault is set and the system will not drive To enable dual throttle functionality map a second analog input to 22244 The throttle value for the second throttle input can be read at 2626p Dual throttle systems allow a virtual FS1 feature which can be used instead of an actual FS1 switch This feature can be enabled on dual throttle systems using 2910 1 The voltage input characteristics of the two analogue throttle inputs must be different CREEP TORQUE Creep torque allows a small amount of torque to be applied as soon as the throttle is closed This can be used on some vehicles to overcome the friction required to achieve initial vehicle movement o Max torque Torque Demand EN Creep torque Throttle value Figure 30 Illustration showing behaviour of creep torque Increasing the creep torque level can improve how the vehicle feels when drive is first selected and the vehicle starts to move However too much creep torque can make the vehicle uncontrollable at low speeds Creep torque will be applied as soon as drive is selected and the throttle is closed Do not increase the creep torque value to a level that would cause unexpected high levels of torque output for comparatively low levels of throttle push If in doubt set the creep torque level to 0 DRIVEABILITY FEATURES These features are used to configure how the system use
94. ous rating Select a motor whose ratings are equal to or greater than your calculated load over 1 hour Doc 177 52701 5 3 Rev 3 SEVCON PEAK POWER RATING The peak power rating required for the application is actually determined by the peak torque required as this determines the motor current required Motor manufacturers will provide S1 S2 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 13 Gen4 Cutback Curve 120 100 E 80 E x s E 60 o x 2 40 wT 20 o 0 70 75 80 85 90 95 100 Base temperature C Figure 13 Current allo
95. ower limit as set in sub index 6 and 7 Object 46231 shows the current limits that are in effect Sub index 3 of this object allows you to specify the cutback aggressiveness and a measurement correction factor Setting this to zero Battery current flow can be monitored at object 5100 Note that regen currents flowing back to the battery are specified as negative numbers 6 36 Configuration DISPLAYS Gen4 is compatible with Smartview and Clearview displays Clearview displays use the CANopen protocol To use set up TPDOs to transmit the required data for the display Smartview displays use Sevcon s proprietary CAN protocol To use set the CAN baudrate to 100kHz at 59001 enable Smartview and select hours counter at 2E00 Doc 177 52701 6 37 Rev 3 SEVCON Chapter 7 Monitoring Gen4 SEVCON Il 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 currents voltages and temperature at object 4600p e Additional motor debug information is available at 46021 e Motor torque speed etc at objects 6000 to 67FF HEATSINK TEMPERATURE Read the heatsink temperature at object 51001 sub index 3 IDENTIFICATION AND VERSION Read identification and ve
96. puts which can be used for 2 wire potentiometers or as supplies for the 3 wire potentiometer wiper inputs Motor thermistor input All analog inputs can also be used as digital inputs Potentiometer wiper inputs Two 3 wire protected inputs Inductive drive outputs DO NOT USE WITH CAPACITIVE LOADS 3 configurable PWM outputs Use in voltage or current control mode Voltage controlled Continuous sink current 2A Peak current limited to lt 2 5A Open circuit detection Iout lt 0 1 A is a configurable option Short circuit detection lout gt 0 2 A when drive is in off state 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 Motor speed sensor inputs Quadrature AB encoder signal inputs provided for control of induction motors UWYV digital position sensor or sin cos analogue position sensor inputs provided for control of permanent magnet motors ISOLATION Any terminal to the case Withstands 2 kV d c Meets EN1175 1 1998 and ISO3691 Complies with IEC 60664 4 4 Specification EMC Radiated emissions EN 12895 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 giv
97. r braking 27821 e Vehicle pump hours increments when the pump motor is running 27831 e Vehicle power steer hours increments when the power steer motor is running 27844 e Vehicle work hours increments when the traction pump or power steer motors are running 2785n Since these hours are specific to the vehicle they are writeable so that they can be reset to known good values if the master controller is replaced Logging The controller can log events in the system along with additional event related information 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 41001 to 4102 e Faults this FIFO is 40 elements deep and is used for fault logging 41101 to 41121 At object 41XO e Reset the FIFO e Read its length You can access the FIFO using objects 41 X1 and 41X2 The FIFO index is entered at 41X 1 and the data is read from 41X2 Doc 177 52701 7 3 Rev 3 SEVCON J EVENT COUNTERS The controller provides 10 event counters at 4200 to 420A Each event counter can record information about
98. ring does not terminate the bus on the 35 way connector and the equipment being connected via the calibrator port does require termination 2 OV OV Connects the controller OV to the Internally connected to the B OV of the calibrator terminal 3 CAN Comms Normally no connection This pin V 5V Maximum bus speed 1 Low can be connected to pin 1 if the Mbits s controller wiring does not terminate the bus on the 35 way connector and the equipment being connected via the calibrator port does require termination 4 CAN Power To CAN device requiring 24V V 24V Check that the CAN device power supply I 100 mA power supply requirement is supply suitable for Gen4 5 CAN Comms CANbus High signal V 5V Maximum bus speed 1 High Mbits s 6 CAN Comms CANbus Low signal V 5V Maximum bus speed 1 Low Mbits s Table 4 Connector B pin out and wiring information Doc 177 52701 Rev 3 EX ded Specification SEVCON Ii Electrical INPUT VOLTAGE 24V only 24 36V 36 48V 72 80V Size 2 24V controllers controllers controllers Conventional 16 8V to 28 8V 16 8V to 43 2V 25 2V to 57 6V 50 4V to 96V working voltage range Note 1 Working 12 7V to 34 8V 12 7V to 52 2V 19 3 V to 69 6 V 39 1 V to 116 V voltage limits Note 2 Non operational 39 6V 59 4V 79 2 V 132 V overvoltage limits Battery voltage Vnom to 0 5 x Vnom for 100 ms droop Input Input protected against reverse connecti
99. rior notice COPYRIGHT This manual is copyrighted 2009 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 1 2 Introduction WARNINGS CAUTIONS AND NOTES Special attention must be paid to the information presented in Warnings Cautions and 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 A how to avoid the problem A CAUTION is an instruction that draws attention to the risk of damage to the product process or
100. rsion information at e 10085 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 5501j Internal ROM checksum BATTERY MONITORING The controller measures actual battery voltage at two points e Battery voltage measured at keyswitch input and read at 51001 sub index 1 e Capacitor voltage measured at the B terminal and read at 51001 sub index 2 The controller also has a battery discharge indicator BDI which can be read at 27901 7 2 Monitoring 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 are preserved with a minimum resolution of 15 seconds when the system 1s powered down LOCAL HOURS COUNTERS Local hours counters which run on all units are e Controller key hours increments while the keyswitch is in the ON position 52001 e Controller pulsing hours increments when the controller is powering its connected motor 46011 VEHICLE HOURS COUNTERS Vehicle hours counters which run only on the Gen4 configured as the vehicle master are e Vehicle key hours increments as controller key hours 27811 e Vehicle traction hours increments when the vehicle is driving o
101. s 1400h 15FFh RPDO communication parameters Input mapping 1600h 17FFh RPDO mapping 1800h 19FFh TPDO communication parameters Output mappin pom 1A00h 1BFFh TPDO mapping Table 6 Objects associated with mapping An example mapping Figure 25 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 Master Slave o EE 1600 8h 1A00 8h RPDO mapping TPDO mapping traction Switch 2124h application seat switch 5 PDO PDO amp Cbject Dictionary 2 2 Cbject Dictionary 3 digital 6800h 1 inputs local digital inputs 1 8 1 0 consumer roducer CANbus o Figure 25 Example of a digital input mapped to the seat switch object via PDO and the CANbus Gen4 supports RPDO timeout fault detection This can set a warning drive inhibit or severe fault depending on the configuration in 59021 RPDO timeout can be used for non CANopen systems which do not support heartbeating By default RPDO timeout is disabled and normal CANopen heartbeating protocol see section Network Configuration page 6 5 is assumed to be used 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 co
102. s throttle information and how it handles speed limits in torque mode The installer must ensure these features are configured appropriately Doc 177 52701 6 21 Rev 3 SEVCON I Set the following driveability features at 2910h 1 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 If enabled speed limit is proportional to the throttle otherwise speed limit is fixed at the forward or reverse maximum speed Only used in torque mode A Proportional Speed Limit is not recommended for on highway vehicles as it can cause the traction motor wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and or mechanical braking e Braking directional throttle enable disable If enabled a directional throttle can be used to demand a drive or braking torque in conjunction with the direction switches Only used in torque mode e Reverse speed limit encoding Controls how reverse speed limits are handled in torque mode Must always be enabled on Slip control systems and must always be disabled on flux vector and PMAC systems e Handbra
103. ses in motor temperature more quickly then the direct measurement Direct measurement is normally done on the motor casing which lags behind the internal temperature MOTOR OVER SPEED PROTECTION A facility to protect the motor or vehicle powertrain due to damage by overspeeding is available on the controller A maximum speed can be configured at object 46944 Under normal operation the controller should output braking torque to prevent the overspeeding initially if the measured speed exceeds this limit then the controller will shut down and a fault will be set The trip speed offers a final level of protection for the vehicle mechanics and should be set to a level that would not be expected to be reached under normal operation BATTERY PROTECTION The nominal battery voltage must be set at 2C001 OVER VOLTAGE Battery over voltage usually occurs during regenerative braking To provide protection set values for these parameters at 2CO11 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 UNDER VOLTAGE To prevent excessive battery discharge set values for these parameters at 2C021 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 valu
104. silbity of the installer to decide on the required state for each output in the event of a CANbus failure 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 29144 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 FS1 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 29021 HANDBRAKE If mapped to a digital input the handbr
105. stance counter cannot be reset by the user 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 28501 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 be applied when a vehicle needs servicing 29251 See Driveability 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 24211 must be mapped to an analog output CONTROLLER HEATSINK MOTOR CO
106. 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 DSP402 V2 X Device Profile for Drives and Motion Control 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 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 Drive Wizard to describe the structure of a node s Object Dictionary An EDS for each Gen4 model and software 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 CONFIG
107. t and Input characteristic These settings are similar to those for the throttle Refer to the Throttle section above for more information e Footbrake priority timeout allows the configured priority to change after a timeout period Setting zero will disable this feature The footbrake value calculated from the voltage can be read at 26211 STEERING INPUTS TWIN DRIVING MOTOR SYSTEMS Loss of steering information can make a vehicle operate erratically The analog input use for the steering sensor should have suitable wire off protection configured Twin motor systems which use the drive motors for turning require some means of determining the angle of the steering wheel To do this use one of these options e A steering potentiometer to give an analog voltage which is a linear function of the steering angle The steer potentiometer voltage 22231 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 removed The outer switches indicate the steering angle where inner wheel motor changes direction The outer switches are optional The steer switches 219Bi to 212Ex must be mapped to digital inputs e Steering angle from 3 party CAN device This can be received via RPDO on object 26244 in 0 01 bit resolution To configure steering inputs go to index
108. t 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 Doc 177 52701 6 7 Rev 3 SEVCON 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 23 e The magnetic saturation characteristics of the motor in the constant power and high speed regions e Current and speed control gains Rs Lis Lir Vs Lm Rr s Figure 23 AC motor single phase equivalent circuit To determine these parameters use one of the following methods 1 Ask the motor manufacturer to provide the data and enter it in the Object Dictionary at 4640 and 4641 Also enter encoder data at 46301 and 6090 and motor maps at 4610p to 4613p 2 Use the motor name plate data and the self characterization routine provided by Gen4 and DriveWizard described below 6 8 Configuration SELF CHARACTERIZATION The self characterization function will cause the motor to operate Ensure the vehicle is jacked up with the driving wheels off the ground and free to turn before starting the test
109. ting environment on page 4 6 To obtain maximum performance it is important to keep Gens base plate within the operating temperature range To do this mount Gen4 to a surface capable of conducting away the waste heat Finned heatsinks are considerably better at doing ths than flat plates For example a finned heatsink used at Sevcon has a footprint of 330mm x 200mm and thermal resistance of 0 3 C W whereas a plate approximately 420 mm x 270 mm x 9 5 mm will give approximately the same thermal performance 0 3 C W Ratings achievable with conductive heatsinking are shown in Figure 11 on page 4 3 In Sevcon s experience the thermal resistance of the stand alone Gen4 packages and achievable thermal resistances to ambient using conductive heatsinking are as shown in the table below These are given as a guide actual performance in an application must be verified Gen4 Size Thermal resistance Thermal resistance Dimension of finned without additional achievable with finned heatsink W x L heatsinking C W heatsink C W Size 2 0 7 0 5 250mm x 180mm Size 4 0 6 0 3 330mm x 200mm Size 6 0 5 0 2 330mm x 280mm Cooling performance is affected by mounting surface flatness and the thermal transfer between mounting surface and Gen4 Ensure your application of thermal grease is effective and your mounting surface meets the flatness figures as described in the Mounting section above Installation
110. troller DriveWizard can also be used to monitor and configure the parameters of any 3 l 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 22 DriveWizard and hardware 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 faultlogs Configuration 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 YS Frompt 1026 1 Stdln yes jl ES 1200 Server SDO 1 Default parameters Key Header row B Read only write only il ReadWrite Ro Read Write in Pr
111. ue setting 7 Nm 1 Nm Consider cable routing before making connections e Keep cable runs short e Minimize current loops by keeping positive and 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 CABLE SIZES When deciding on power cable diameter consideration must be given to cable length grouping of cables the maximum allowable temperature rise and the temperature rating of the chosen cable 3 6 Installation The following table gives guidance on the cable size needed for various currents in welding cable not grouped with other cables in 25 C ambient with 60 C temperature rise on the cable surface Gen4 average rms Cable sizes current metric US approx equivalent 180 A 25 mm 4 AWG 295 A 35 mm 2 AWG 280 50 mm 1 AWG 350 70 mm 2 0 AWG Doc H 177 52701 Rev 3 SEVCON On board fuse mounting You can mount your m
112. voltage value 2 e forward vale e reverse value Figure 27 Standard throttle configuration Y If the reverse characteristic is the same as the forward characteristic just set all the reverse throttle parameters to O gt in 2910 Doc 177 52701 6 19 Rev 3 SEVCON Value i end voltage value 2 start voltage value 2 end voltage value 1 start voltage value 1 forward value 9 reverse value Figure 28 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 29 The curved and crawl characteristics give greater throttle control at low speeds voltage 3 value 3 voltage 2 value 2 Vehicle speed voltage 1 value 1 Throttle value crawl e user defined curved linear Figure 29 Input characteristics 6 20 Configuration The throttle value calculated from the voltage can be read at 2620 DUAL THROTTLE INPUTS Single and dual throttle inputs are supported Single throttle inputs are normally used with other interlock inputs eg FS1 deadman etc and use a single input voltage to determine driver demand Dual throttle inputs use two separate input voltages each of which is converted to a throttle value using 29101 subindices 3 to 6 throttle input 1 and subindices 7 to 10 thr
113. voltage out 1 5 Encoder Digital Position encoder 10V Use in conjunction with V U pulse and W for PMAC motors Doc 177 5201 Rev 3 SEVCON Ii Pin Name Type What to connect Maximum Comment rating 6 Key switch Power From dead side of key 7A This input supplies power in switch via suitable fuse Total of all from the battery for all the contactor logic circuits output The unit cannot operate currents plus without Key switch in 1 0A supply Pins 1 and 6 and 10 on Size 4 amp 6 models 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 voltage or current control to DO NOT USE WITH subject to a the load depending on CAPACITIVE LOADS limit of 6A for configuration the total ofall The output goes low or is the 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 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 Size 2 Power 5Vsupply output I 100mA This output can be used to models V 5V power transducers or similar 5V supply devices at 5V and up to
114. w 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 8 Motor too cold I Motor thermistor reports less than Allow motor to warm 30 C up Check motor thermistor 8 Heatsink over VS Heatsink temperature Remove loading to temperature measurement has exceed absolute allow controller to cool maximum for controller and down system has powered down 10 Pre Operational I Controller is in pre operational Use DriveWizard to state put controller into operational state 10 I O initializing I Controller has not received all Check CANbus wiring configured RPDOs within 5s of and PDO power up configuration 10 RPDO Timeout I One or more RPDOs have not been Check CANbus wiring DI received within 3s at power up or and PDO S within 500ms during operation configuration 11 Encoder fault VS Speed measurement input wire off Check encoder wiring is detected 11 Over current VS Software has detected an over Check motor load and current condition wiring Check motor parameters are correct 11 Current Control fault VS Software is unable
115. wed vs controller base temperature System design CIRCUIT CONFIGURATION Once motor size is determined the application circuit configuration can be defined A basic single traction configuration Figure 14 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 11 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 15 Doc 177 52701 5 5 Rev 3 SEVCON SINGLE TRACTION WIRING DIAGRAM CAN High CAN Low o Ow x Lo E Se E s 38 8 e o Cont1 Supply Cont2 Supply 2 Cont3 Supply control 9 fuse b Gen4 Stand alone line contactor 10 V encoder A encoder B OV ma lt lt a j traction 9 Traction fuse 4 pin numbering 26 i j I Alternative encoder isolator type UNIW 5 EncU 17 Enc V 29 Enc W Dl M1 M2 M3 thermistor di Figure 14 Single traction wiring diagram 5 6 CAN High CAN Low CAN term 2 13 CAN connection 124 XXXX for configuration and service Link to terminate the CANbus 16 CAN connection 27 XXX to other CAN devices m ip Analog Alternative use a voltage source in place of the pot input 2 Alternative use a voltage source in place of the pot 18 forwa rd 30 19 31 20
116. wer up sequelibei ne bu e i t dE 5 14 Checks prior t power cis 5 14 Checks after power 1s applied iii nn nn E EERTE 5 14 Chapter 6 Configuration 6 1 ntroduction ERR TE DR RE DU RU RE RTE 6 2 Doc 177 52701 111 Rev 3 lv Drive Wizard configuration tool ic de Gestores ete 6 2 DriveWizard functionality with lowest access level ss 6 2 Status DAYS a 6 3 Saving duplicating and restoring a node s configuration ss 6 3 Data TON CO WT aa 6 3 CANOPEN ENT 6 3 CANopen proto Oli 6 4 Object DICHONANV oeste TREE ET LE ne 6 4 Communication ODE iaa 6 4 Network Confipuration zscesaccocteeadaendaantaneedton eene esaet dete 6 5 Configuration process OVerVIe W usi ione Getae rie isi ciegas dd 6 7 JAC CESS AUN cocotte ic iH e ce reU 6 7 How NMT state affects access to parameters 6 7 Motor Character b able Re nn 6 8 Determining motor parameters 6 8 Seltcharacterizatiolit eee RERUM UE RUD EMPRUNM RUE 6 9 E SR arses ibl usb tv eas bit Sedis due futt 6 9 Manual object mappllig suceeee seite RHEIN Y NEED ESDUREHERU nn ENTERA NNI THEOD AE ERE us 6 10 Automatic Configuration Mapping sin 6 12 Encoder isses MP CEU Ee ene er te eR P 6 14 Digital inputs Aie ae EEUU ERECTAE UA unes 6 14 Analog 1np ts ote tee eet ee tee ette eiie ette t e etate be a 6 14 Analog Contactor Gut puts acea et t eben bee eate even me en den rent 6 15 Vehicle performance COMM Our atoms ueteri eet pini sie pret tud 6 17 Safet
117. y InterlockS oli ne Aci 6 17 Torque mode speed Moli 6 17 TT A a e aa de ne el 6 18 Driveability Features M ne ee SON 6 21 Acceleration and braking siennes 6 22 ED aiii 6 23 Steering inputs twin driving motor systems ins 6 23 Driveability pro ls e T Re nl 6 25 Preventing Wheel Lock SeendElOSa ecce ne nie ni NENNEN ENDE DOE Re E 6 26 Controlled roll off ett nn ent ne tn nn 6 27 FAM 2 CC Ko PSE NT EP HET CREER EU EP RON ONU e eer 6 27 Inchinp a EEE E UM 6 28 Belly Witch daa dd dte E 6 28 Drivabilityselect Witches ci nets nus ententes 6 28 ECONOMY A O RO A dear BS 6 29 Pump COMM ULATION M M tia ainia sos sssisessossStebensstnsgsesits0usosai aasnssOsshasndteassssdississsduasseradbiasnsstes 6 29 Power steer COMM OUMATION eiit tette tetti te het erint tede herede aser s keen eek datu 6 30 Vehicle features and functions 6 39 A 6 32 LME COMM AC LON EE a ea on a 6 32 Electro mechanical Drake ii 6 32 External LED oia ias 6 33 Alarm buzz ri aaa 6 33 Brake Lists eee 6 33 I m COT a a 6 33 Service Indication REM 6 33 Traction motor cooling fanc 152a under entente 6 34 Controller heatsink motor cooling fan ss 6 34 Motor ov r temp ratur protection sissictscisscscectesdacassasisenctsscetssdsterecssadhesdescaseseaddsenstiscotosdstienosssadeesdtudeestas 6 35 Battery protection eret e Eee E ete
118. y of these main applications for both pump and traction control Counterbalanced warehouse and pedestrian fork lift trucks Classes 1 to 3 FLT 1 2 amp 3 Airport ground support AGS including tow tractors Utility vehicles Burden carriers Sweepers and scrubbers Golf buggies carts Neighborhood electric vehicles NEV Scooters Marine AVAILABLE ACCESSORIES The following accessories are available from Sevcon Loose equipment kit connectors and pins for Gen4 Gen4 cooling kit CANopen Calibrator Handset SmartView display Clear View display Hourmeters Contactors Fuses Drive Wizard PC based configuration tool SCWiz PC based motor characterisation tool Doc 177 52701 Rev 3 About the Gen4 SEVCON J 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 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 IO o 7 key switch line contactor CAN

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