Azure Dynamics DMOC445 Manual/Operating Instructions Download Page 24

 

 

  Proprietary 

 

24 

DMOC445 Manual and Operating Instructions

 

8. Installation 

Requirements 

1. Mounting 

The DMOC is recommended for mounting with cooling fans face-up on a flat rigid surface and located in a 
compartment that provides easy access for servicing and replacement.  

The DMOC should be kept dry at all times, however, it is understood that some water splash to the 
underside of a vehicle is unavoidable. The DMOC is factory sealed to withstand small amounts of 
moisture.  

 

Avoid locations where the DMOC will be routinely exposed to water.  

 

Do not wash the DMOC with a pressure sprayer. Large amounts of water will cause a 
malfunction. 

 

If you have reason to believe water has entered the DMOC, do not open the case. Disconnect the 
DMOC and return it for service as soon as possible. 

 

When not in use, keep the protective plastic cap over the unit’s serial data port or connector. 

 

Vibration damping mount should have ¼ inch nominal diameter threaded stud on each end of the 
mount.  A minimum of four (4) mounts are required to secure the DMOC on a stationary surface. 

 

Position vibration damping mounts, DMOC, washers and fasteners as depicted on figure 7.   

 

Torque all ¼ inch fasteners on the vibration damping mounts to 10-11 ft-lb.   

 

If non-factory supplied vibration damping mounts are used, please consult with the new vibration 
damping mount manufacturer for the proper fastener torque. 

 

All power wires, cables and cooling hoses should be strain relieved thru the use of cable or hose 
clamps that are attached to solid surface. 

 

42.9mm [1.69 inched] diameter thru hole is provided to accept grommet or similar cable retention 
device for the AC wires (see figure 4).  Grommet should meet IP57. 

 

26.7mm [1.05 inched] diameter thru hole is provided to accept grommet or similar cable retention 
device for the battery positive and negative wires (see figure 6).  Grommet should meet IP57. 

 

DMOCs with extensive water damage may not be repairable. DMOCs returned to Azure Dynamics with 
the factory seal broken will be ineligible for warranty service 

All electronic systems must be isolated from vehicle vibration. This is done through the use of vibration 
mounts. 

All DMOCs are shipped from the factory with vibration mounts in the accessory kit.  Attaching the DMOC 
directly onto the solid surface or rigid vehicle frame without vibration damping mounts is not 
recommended.  This method of mounting of the DMOC will greatly reduce the life expectance of the unit 
and void the unit warranty.   

Vibration mounts must be operated in compression, with the weight of the DMOC on them. For improved 
vibration protection, or when the DMOC is not mounted face-up, heavy-duty mounts must be used. 
Heavy-duty mounts are available through Azure Dynamics. 

Summary of Contents for DMOC445

Page 1: ...Or Fax 781 932 9219 Customer Service only customersupport azuredynamics com APPROVALS Rev XX Project Engineer _____________________ Date XX XX XXXX Date _____________________ Customer Service_________...

Page 2: ...4 2 High Voltage Connections 14 3 Low Voltage Power Connections 15 4 Signal Connections 15 7 MODES OF OPERATION 18 1 Motor Control 18 2 Variables and Calibration 19 3 Error Codes 19 4 Status Code 20 5...

Page 3: ...3 DMOC445 Manual and Operating Instructions Figure 5 29 7 Connecting the High Voltage Battery Pack 34 8 Water Ingress Prevention 34 9 Grounding and Shielding 35...

Page 4: ...e the error s appear Serial number of your unit Please feel free to call with any suggestions that you may have regarding the content of your manual If additional service information is needed or to o...

Page 5: ...ing appropriate precautions Labels include 2 3 Safety Symbols Always use caution when working on or around any electrical equipment Wear eye protection at all times The following symbols will be locat...

Page 6: ...and offers several layers of protections to prevent safety critical conditions Figure with application module and control core Typical applications for the DMOC include the following Traction drive f...

Page 7: ...s document Since the DMOC is part of a high voltage system it is extremely important the directions of the document are followed and that only personnel trained to work with high voltage install and m...

Page 8: ...DC Max Nominal Battery Voltage 312VDC Min Operational Voltage 100VDC Max Operational Voltage 400VDC Unit Peak Efficiency 97 Min Max Operating Ambient Temperature 40 C to 75 C Max Motor Current 280A rm...

Page 9: ...Proprietary 9 DMOC445 Manual and Operating Instructions Battery Voltage vs Peak Power DMOC445 30 40 50 60 70 80 90 120 170 220 270 320 370 Battery Voltage V 5 Dimensions...

Page 10: ...Proprietary 10 DMOC445 Manual and Operating Instructions 1 FIGURE 2 FIGURE...

Page 11: ...Proprietary 11 DMOC445 Manual and Operating Instructions 3 FIGURE 4 FIGURE...

Page 12: ...Proprietary 12 DMOC445 Manual and Operating Instructions 5 FIGURE 6 FIGURE...

Page 13: ...Proprietary 13 DMOC445 Manual and Operating Instructions 7 FIGURE...

Page 14: ...flow rate is 7 5 to 10 LPM 1 4 and 2 5 psi respectively The cooling chamber cover plate has been tapped to accept 1 4NPT fittings see figure 5 Electrical 2 High Voltage Connections All high voltage co...

Page 15: ...d inverters need to be configured specifically for one nominal voltage Units without fans can operate from either voltage The 12 24 V auxiliary supply needs to be able to source 10 5 A of current and...

Page 16: ...ET collector or LED 13 KEYED_12V_SINK Keyed 12V and relay power 14 BRAKE_LT_SRC Isolated MOSFET drain 15 POWER_SAVER Power saver potentiometer 16 GND_A Top Board Gnd 17 ANAIN1 Analog input 0 5V 18 REV...

Page 17: ...nd 6 ENC_I1 Motor position encoder input 7 ENC_I2 Motor position encoder input 8 FUSED_ 5V Fused digital 5V 9 MTR_TEMP Motor temp input 10 GND_A Top Board Gnd 11 5Ref Analog 5V reference 12 GND_D Top...

Page 18: ...ore the DMOC is a voltage source inverter VSI with high bandwidth synchronous frame current regulation Synchronous Frame Current Regulator Torque Flux Controller Id Iq Torque Command Speed DC Voltage...

Page 19: ...tile variables 3 Error Codes The DMOC stores error conditions in non volatile variables and maintains an error history by means of five variables EE3LastError Most recent error EE3LastError1 EE3LastEr...

Page 20: ...nt sensor calibration error 4 Status Code The status of the DMOC is displayed by the variable ISR2StatusCode Similar to the error code the information is coded in a bit wise fashion Bit 0 0 contactor...

Page 21: ...lay open 1 RELAY_CLOSING Relay closing and debouncing 2 RELAY_ON Relay is closed 3 RELAY_FAULT Low 12 24V supply or mechanical problem The Power stage FSM handles the enabling and disabling of the pow...

Page 22: ...t torque ISR2IqF Quadrature current ISR2IqSet Set point for quadrature torque ISR2MotorLimit Limiting due to motor temperature 100 no limit ISR2MotorPTCVoltage Motor temperature sensor output non line...

Page 23: ...bration factor for voltage reading EE2AccelBatRamp Under voltage ramp EE2FanOffTemp Temperature below which the fans turn off EE2FanOnTemp Temperature above which the fans turn on EE2IsMax Maximal mot...

Page 24: ...damping mounts are used please consult with the new vibration damping mount manufacturer for the proper fastener torque All power wires cables and cooling hoses should be strain relieved thru the use...

Page 25: ...DMOC to monitor the speed direction and temperature of your motor Push the 14 pin AMP Motor Sensor Connector into the 14 pin connector port located to the right of the 35 pin connector port 4 Connecti...

Page 26: ...ree DMOC connectors in the position 6 Connecting the Motor Cable Do not connect or disconnect while high voltage is present It is important that all cables be properly crimped Shock Hazard Extreme cau...

Page 27: ...445 Manual and Operating Instructions Improper crimping can lead to failures and fires Use a Thomas Betts TBM5 Crimper or equivalent Use two opposing wrenches so that you will not apply torque to the...

Page 28: ...nated using a 360 degree connection to the DMOC terminal box cable entrance fitting See Figure 5 below The rubber seal which is a removable part of the entrance fitting should be slid underneath the c...

Page 29: ...nd Operating Instructions underneath the fitting cap The flange washer Fig 10 makes contact with the shield and rubber seal Figure 5 Shielded AC motor cable connection at DMOC terminal box RUBBER SEAL...

Page 30: ...and Operating Instructions Figure 6 Shows fitting rubber seal slid underneath cable shield Figure 7 Shows AC motor cable inserted into entrance fitting with 360 degree connection of the cable shield...

Page 31: ...tions Figure 8 Trim off excess cable shielding inside terminal box If excess cable shielding makes contact with DMOC AC terminals then a shock hazard will be created Make sure that no shielding enters...

Page 32: ...Proprietary 32 DMOC445 Manual and Operating Instructions Figure 9 Screw on entrance fitting cap nut with black plastic flange washer underneath cap...

Page 33: ...Proprietary 33 DMOC445 Manual and Operating Instructions Figure 10 Shows black plastic flange washer PLASTIC FLANGE WASHER...

Page 34: ...ng all high voltage connections junction box cover has to be reinstalled using proper gasket Cable fittings for the HV battery cables and motor cable need to be tightened up to ensure liquid tight sea...

Page 35: ...unding can lead to unreliable operation of systems such as EMI electrostatic discharge damage to sensitive electronics and personnel shock hazard Perform all grounding and shielding connections as sho...

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