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DMC PSE445TM01 Manual Download Page 6

6     

P

ro-

C

ontroller Manual - revision 3.01.00   09/2005          

                                                       © 2005 DMC GmbH Herten 

 

4

 

TECHNICAL SPECIFICATIONS 

4.1

 

Electrical 

 

4.1.1

 

Voltage specifications: 

Model 

Voltage 

Nominal battery voltage 

Absolute operating voltage range 

PXX3xxXX 

36V Units 

24-36V 

14.5 - 50.0V 

PXX4xxXX 

48V Units 

24-48V 

14.5 - 63.0V 

PXX8xxXX 

80V Units 

72-80V        

43.0 - 97.5V 

PXX9xxXX  

96V Units 

96-120V 

60.0 - xx.0V (tbd) 

4.1.2

 

Current specifications:  

Model 

Power 

Current 
limit 
(1 min) 

 

Continuous current 1 hour rating. Unit 
mounted on an sufficient heatsink, at 20

°

C 

ambient. 

PXX410XX 48V 

100A 

100A 

 

45A 

PXX412XX 48V 

125A 

125A 

 

55A 

PXX425XX 48V 

250A 

250A 

 

80A 

PXX445XX 

48V 450A  

450A  

 

180A 

PXX465XX 

48V 650A  

650A  

 

260A 

PXX835XX 80V 

350A 

350A 

 

120A 

PXX845XX 80V 

450A 

450A 

 

160A 

PXX850XX 80V 

500A 

500A 

 

180A 

PXX865XX 80V 

650A 

 

650A 

 

240A 

PXX950XX 96V 

500A 

500A 

 

200A 

 

Switching Frequency: 

SR, PM, SEM: 14.5 KHz Traction/Regen/Pump Drive and 8KHz Plug Braking. 

 

 

 

AC, BPM: Controller frequentie is 8KHz, motor frequentie is 16KHz. 

Electrical Isolation: 

Enclosure to any live part = 1KV. Controller internal insulation specified at > 
10M

Ω 

@500V DC. Dielectric strength 6000V. 

Reverse Battery Polarity:  Not protected. 
I/O details: 

See light wiring diagram. 

 

4.2

 

Environmental 

Impact Protection (IP): 

The enclosure is protected to IP55 (varnished PCB) 

Vibration: 

 

6G, 40-200Hz for 1 hour, in x, y and z planes. 

Operating Temperature:  -30oC to +40oC ambient around controller. 

Storage Temperature: 

-40oC to +70oC. 

Humidity: 

 

95% maximum, non-condensing. 

Humidity Resistance: 

Varnished PCB stops water damaging the controller. 

 

4.3

 

Mechanical 

Details:   

 

See mechanical drawings. 

Enclosure: 

 

Aluminium heat sink with ABS plastic cover. 

Power connections: 

Vertical Copper studs. 

 

Hexagonal: 

Recommended fixing torque 9.5Nm (Slot screws are recommended!) 

Slot screw: 

Recommended, fixing torque 9.5Nm (Brass) 

 

 

Bolt length: 

Max 16mm incl. washer and spring washer 

Weight:  

 

Small: 1.2Kg; Medium: 4.1Kg; Large: 6.1Kg 

 
 

 

 

•

 

Always use a torque wrench when fixing the power terminals. 

•

 

Exceeding the maximum specified torque can cause serious damage to the 
controller and warranty might be void.  

•

 

To long bolts damage the controller. 

Summary of Contents for PSE445TM01

Page 1: ...sion Issue Date Author Changes 1 04 00 27 08 2003 R P Dual Motor proportional added 1 05 00 10 10 2003 R P Updates Series traction pump general updates 1 06 00 30 01 2004 R P Several updates fixes 2 0...

Page 2: ...M CONTROLLER 4 MOTOR SETUP 13 5 9 SERIES CONTROLLER 4 MOTOR SETUP 13 5 10 PM CONTROLLER 4 MOTOR SETUP 13 5 11 FAULT LOG 13 5 12 TEST MENU FOR ALL CONTROLLERS 5 TEST 14 5 13 ABOUT MENU FOR ALL CONTROLL...

Page 3: ...continuous power delivery 1 hour current rating as a ratio to peak power with the controllers continuous rating normally being one of the most important aspects in determining the vehicles performanc...

Page 4: ...x 200 x 56mm PAC425PS 24 48V 250A AC Pump 177 x 155 x 38mm PSE865TL 72 80V 650A SEM Traction 320 x 200 x 56mm PSE835TM 72 80V 350A SEM Traction 225 x 200 x 56mm PSE445TM 24 48V 450A SEM Traction 225...

Page 5: ...yes Seat switch timer yes yes yes Power steer timer yes yes yes Electro brake timer yes yes yes Belly switch operation yes yes yes Regenerative and plug braking yes yes yes Braking proportional to ac...

Page 6: ...quentie is 16KHz Electrical Isolation Enclosure to any live part 1KV Controller internal insulation specified at 10M 500V DC Dielectric strength 6000V Reverse Battery Polarity Not protected I O detail...

Page 7: ...ff course a copy of the new DMC software release For detailed information on updating software please contact your DMC supplier CAN Node Setup When connecting the Calibrator to a controller it will sc...

Page 8: ...ug SR 0 off 100 1 25 Direction brake End delay DBrkEnd EPS 0 1 S 10 S 0 1 S 0 1 S S 14 Neutral brake ramp time NBrkRamp AC SE PM 0 1 S 10 S 0 1 S 3 S S Footbrake Plugging FPlug SR 0 100 1 50 Neutral b...

Page 9: ...ty 1 additive 1 0 15 Compensation speed 6 Pcomp 6 AC SR 0 off 100 1 0 16 Accel deceleration Speed 6 Paccel 6 All 0 1 S 10 0 S 0 1 S 0 3 S S 17 Max Current MaxCurr All 10 A Unit max 10 A Unit max A Mai...

Page 10: ...speed RPM Speed PM SR RPM Secondary pump motor on SPMot Dual Pump 1 on As 10 15 Slip Slip AC 10 RPM Drive slip Brake slip Motor field voltage MotFld SE 0 5 V Secondary pump motor voltage SPMot Dual P...

Page 11: ...h 1 Pot switch 0 1 7 Power steer trigger PsF FR S 0 FS1 1 Fwd Rev 2 Seat switch 0 2 8 Truck type select Ride Wlk 0 Ride on 1 Walkie 0 1 9 Display hours counter Key Drv 0 Key 1 Drive hours 0 1 10 Displ...

Page 12: ...imum D Smin 0 Hz 15 93 Hz 0 0625 Hz Hz 15 Drive slip boost D Sboost 0 Hz 15 93 Hz 0 0625 Hz Hz 16 Drive slip base D Sbase 0 Hz 15 93 Hz 0 0625 Hz Hz 17 Drive slip max D Smax 0 Hz 15 93 Hz 0 0625 Hz Hz...

Page 13: ...PlugEnd 0 100 1 71 6 Neutral Plugging start level NPlugSta 0 100 1 71 7 Neutral Plugging end level NPlugEnd 0 100 1 71 8 Neutral Plug on at start NPlug on 1 50 1 15 9 Reverse plug Compensation RPlugCm...

Page 14: ...5 Pin A12 Line contactor Output Line contactor Output 0 1 Forward contactor Series Output 16 Pin A13 Electric brake Output Power steer contactor Output 0 1 Reverse contactor Series Output 17 Pin A14 P...

Page 15: ...up 13F Accelerator voltage 50 at key on EPS Steering wheel outside deadband Check controller settings and accelerator mechanics EPS Adjust 14 Inching or belly fault 14F Forbidden input selected with i...

Page 16: ...x9 character field to show a text The text can be edited with the display buttons 7 Hours counter Here either Work or Key hours are displayed selectable with the display buttons The hours counter valu...

Page 17: ...y 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 acceler...

Page 18: ...cient 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...

Page 19: ...2005 DMC GmbH Herten Pro Controller manual Revision 3 01 00 09 2005 19 11 GRAPHICS Figure 1 Accelerator Characteristics Figure 2 Thermal Cutback Characteristic...

Page 20: ...As Traction Select program 4 Monitor i o line As Traction Flash memory 5 CAN L As Traction 6 CAN H As Traction CAN Communications 7 12V o p As Traction Max 20mA 8 0V o p As Traction Connector C Motor...

Page 21: ...01 00 09 2005 21 Figure 4 Power Wiring AC B Optional protection diode M3 M2 M1 AC L1 L3 L2 B Figure 5 Power Wiring SEM M1 Field B Optional protection diode M2 B M3 Armature Figure 6 Power Wiring PM4 B...

Page 22: ...ure 8 Power Wiring Series Pump Link M1 and M2 for high power variants M3 B B M2 M1 N C Figure 9 Power Wiring Dual Pump B Main Pump Motor M2 B M1 M3 Optional protection diode Secundairy pump hydraulic...

Page 23: ...M1 Pro Controller large size DMC M3 A B C B B M2 M1 1 1 1 16 8 4 8 3 6 5 9 4 150mm 303mm 30mm 200mm 320mm Overall height incl Terminals 56mm Power terminals M8 5x Fixings M8 4x Connector A 16 way Mole...

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