© 2005 DMC GmbH Herten
P
ro-
C
ontroller manual – Revision 3.01.00 09/2005
17
8
INSTALLATION
The controller should be bolted down to a flat (0.2mm max. deviation) paint free surface that has been lightly
coated with a thermal transfer compound, such as GE G641 or Dow Corning heat sink compound, by the 4 fixing
holes provided. Care should be taken not to trap any wires, etc., under the controller. The mounting surface MUST
be a substantial metal section of the truck for the full controller ratings to be achieved.
Power connections should be made with flexible heat resisting cables of suitable cross-sectional area for the
current to be carried. These should be terminated in soldered or crimped lugs attached to controller and the
contactors. Note that bolts and washers are supplied for the connections on the controller. Be careful not to use to
long bolts, as they can damage the PCB. A battery-disconnect switch should be used (EC Directive).
The contactor mounting plane can affect performance, contactors should never be mounted with their terminal
studs vertically down. For further applications information on contactors, please consult
DMC
GmbH in Herten.
The controller may be supplied as a stand-alone unit or pre-wired onto a base-plate with contactors etc.
Control wiring connections should be made using 0.56mm² (AWG#20) or equivalent stranded wire. The correct
pressure release crimping tools MUST be used for long term connection reliability.
The main battery cable should be fused with a suitable air-break fuse. The key switch line must also be fused at a
level not exceeding 10 A when using the specified Ametek contactors.
The return wiring for the accelerators should be connected to the B- terminal on the controller to prevent large
currents altering accelerator signals.
Fixing torque for power connectors M8 terminals is 11NM, for M6 power connectors 9NM
9
SAFETY
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 OR ATTEMPTING ANY REPAIRS OF
THE CONTROLS.
Before working on the controls disconnect the battery and connect the B+ and B- controller terminals via a 10 ohm
25 watt resistor to discharge the internal capacitors.
Never connect the controller to a battery with its 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 moulding.
The
P
ro
C
ontroller must NOT be used with permanently-connected on-board chargers or damage to the system
may result. Using a change-over contactor as line contactor is a good solution to fit both the charger and the
controller in the truck.