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HBC - SERIES V7

18063-3 / 25063-3 / 100120-3 / 140120-3

oltage (63V) +

edium

oltage (120V)

Programmable brushless controllers for industry using

Operating Manual

– firmware version 3.8 or higher

Development, manufacture,

service:

Tel.: +420 577

001

350

MGM

COMPRO

, Ing. G. Dvorský

E-mail: mgm

mgm-compro.cz

Sv. Čecha 593, 760 01 Zlín, Czech Republic

Info: www.mgm-compro.com

Summary of Contents for 100120-3

Page 1: ...Medium Voltage 120V Programmable brushless controllers for industry using Operating Manual firmware version 3 8 or higher Development manufacture service Tel 420 577 001 350 MGM COMPRO Ing G Dvorsk E...

Page 2: ...eeks Very clear indication of controller states and error codes using 4 LED Synchronous rectification very high efficiency 98 99 Motor PWM in range 8 32 kHz Suitable for inrunners as well as outrunner...

Page 3: ...c throttle limits 60 Start with programmed throttle limits 61 Maximal revolution of the output shaft Settings 62 Maximal revolution of the motor Settings 62 Update SW inside the controller firmware 63...

Page 4: ...ring e g using heat shrinking sleeve Never connect more cells higher voltage than is specified in technical data you can damage controller We always recommend first connect the traction battery via th...

Page 5: ...yp 2 0 8 m 2 0 53 m Basic dimensions mm see picture see picture Weight without power cables 250 g 390 g Power cables cross section 6 6 or 10 10 mm2 10 16 or 35 mm2 Note alternative also 16 16 mm2 to b...

Page 6: ...puts outputs and other ports Value Controller version 18063 3 100120 3 connector 25063 3 140120 3 connector Auxiliary feeding for control electronics 14V 35V K1 14V 35V K8 2 3 Supported types of therm...

Page 7: ...controllers may be ordered suitable for sensor motors These controllers may be connected to sensorless motors as well as sensor motors In this version is automatically available to the motor temperatu...

Page 8: ...nger Guards 5 mm with Finger Guards of the fan HBC series TMM 18063 V7 TMM 100120 V7 with a fan enclosed version view from the side with a fan default dimensions for enclosed version this dimension 23...

Page 9: ...e an insulating pad If you use holes in the cooler it does not matter which material is used as the coolers are insulated they are not connected to any po tential If the system in which the controller...

Page 10: ...HBC 18063 HBC 100120 view from the cooler side without fan enclosed version power conductors through MP JET 5 0 connectors HBC 25063 V7 HBC 140120 view from side of cooler with fans open version powe...

Page 11: ...mounted with ring terminals 6 35 for cables 35mm 2 filtering capacitors axially HBC 25063 140120 V7 view from the water cooler side power cables is mounted with ring terminals 6 16 for cables 16mm 2...

Page 12: ...V Basic description of the controllers Controller HBC series TMM 25063 V7 140120 V7 view from the uncovered control board BATT BATT Phase A Phase C Phase B Antispark Control board Power board PWR 250A...

Page 13: ...A Motor sensors Alternative connectors 1 K19 K20 K21 K10 K9 K8 1 IN OUT_2 GND IN OUT_1 General inputs outputs Control of ex ternal drivers FET IGBT Jumper or soldered jumper J1 SBC compatible 1 K6 GND...

Page 14: ...Pin 7 cell 4 pole Pin 7 cell 14 pole Pin 8 cell 5 pole Pin 8 cell 15 pole Pin 9 cell 6 pole Pin 9 cell 16 pole Pin 10 cell 7 pole Pin 10 cell 17 pole Connector K6 Temperature sensor for Lipol cells K...

Page 15: ...put 3 3V Pin 5 SDA Pin 5 GND Pin 6 BL 1 signal Pin 6 output 5V Connector K19 current probe only for external FET IGBT modules Pin 1 GND Pin 2 SENSE input from current probe HALL 400 B 600B or compatib...

Page 16: ...ower board PWR 180A 4x mounting hole 3 5 mm SWITCH GND K1 1 1 1 1 1 1 Alternative connectors K4 K3 K2B K7A K6 K5A SWITCH 12V INP PWR GND GND TEMP BAT GND INP_2 OUT_2 3 3V output DC DC GND DC DC 3 3V I...

Page 17: ...of RS 485 bus or input INP_3 logical Connector K4 communication port general I O RS232 TTL can be also optically coupled Pin 1 RX or input INP_4 logical or optocoupler input Pin 2 GND or minus pole of...

Page 18: ...modules communication with PC USBCOM 4 parameters settings update firmware feeding of ext modules Note 2 Not every type of controller has all the inputs outputs and options Note 3 Some inputs outputs...

Page 19: ...ons Recommend connecting for HBC 25063 140120 The possibility of emergency disconnectio with using BMS 2 system output PO 1 of the BMS 2 unit In this case it is necessary to cancel the jumper K20 2 to...

Page 20: ...perature Sensors feeding 14V 35V Control electronics feeding GND Traction battery PSW1 Auxiliary battery for electronics feeding Fuse relay Emergency button ED PWROFF_INP K20 1 K20 2 OPT_INP K3 3 K20...

Page 21: ...switches and after filtration capacitors charge is automatically connected traction voltage closing the main contactor as in the case a But here unlike the case of a you can at any time deactivate th...

Page 22: ...nal or disconnecting existing inputs outputs sensors etc the controller must be correctly turned off and disconnected from all power supplies Please follow the instructions for connection to the power...

Page 23: ...rary switching the controller by switch use the connection C D Controller HBC series Closed contact Turn off controller Motor cut off Internal electronics cut off outputs cut off GND GND By switch rea...

Page 24: ...rs of P6 P7 and P8 main channel resp P9 P10 and P11 auxiliary channel That each position corresponds with behavior by set driving type type of model car boat etc Both end points as well as middle posi...

Page 25: ...he first and last device connected to the bus must have this resistor The controller is obtained by connecting the jumper J1 Other devices on the bus excluding terminal equipment should not contain th...

Page 26: ...converter 5V Possible supply for generator receiver system the order of mA Controller HSBC series signal generator Receiving of input PWM driving PWM for controller 3 3V or 5V 3 3V or 5 0V logic 0V GN...

Page 27: ...r the PWM Both of these functions i e throttle and brake are configured in unidirecdtional mode from the neutral position back if not set to the same value with neutral ignored If you need the engine...

Page 28: ...le only for controllers with driving board CN_B15 Another possibility is to use the management of the port K20 1 PWROFF_INP input for emergency disconnection of course only if it is not used just for...

Page 29: ...om an external generator voltage source DAC of superior system etc con nected between the terminal GND and terminal control signal An error condition occurring during control voltage drop during cutti...

Page 30: ...signal data shorting together or to GND activate emergency stop of the motor Data frame control data GND HBC series Controller Transmitted data Control data from master system TxD RxD Receive control...

Page 31: ...sets of MZK seris company or HOTT systems of Graupner Display unit that displays data transmitted from the controller plug in the appropriate module used 2 4 GHz kit When connecting and setting up th...

Page 32: ...port of the controller Data transferred from the controller to the display unit You can transfer all the measured data i e the same as the data stored in the BlackBox Which data is actually displayed...

Page 33: ...n for gear In this procedure you may not also have limited speed or current The procedure can also be made at reduced power supply voltage than the nominal operating voltage of course in the range of...

Page 34: ...differences of sensors position are more than 25 30 electric include magnet dimension tolerances and its positions con troller cannot eliminate these differences and signalize error sensors error mot...

Page 35: ...or ro tates forward If the joystick moves to the other side to P8 and the motor still ro tates forward begins to brake The braking intensity depends on the braking control signal If you move the joyst...

Page 36: ...4 model 4 aircraft one way const rpm From the production is pre set select of memory 1 Nevertheless you can any time change set tings of parameters in these memory banks by your own request and needs...

Page 37: ...ull throttle Backward Full Brake 0 7 ms 0 15 V 1 4 ms 3 15 V 1 s 1mV 1 0 ms 0 15 V 1 0 ms 0 15 V 1 0 ms 0 15 V 1 0 ms 0 15 V P12 Neutral throttle range STOP area 5 25 1 15 15 5 5 P13 Throttle terminal...

Page 38: ...time from 100 to 0 0 sec 60 sec 0 1 0 5 sec 0 5 sec 0 5 sec 0 5 sec P22 Brake intensity 0 100 1 30 P23 Brake intensity in Neutral position in STOP position 0 100 1 0 30 30 P25 Brake Ramp time to reach...

Page 39: ...start up in the opposite direction Therefore if you are braking and wish to move in the opposite direction it is necessary after stopping to first move the throttle stick to neutral and then towards t...

Page 40: ...ou have to show the controller the throttle limits after each turn on of the controller by moving the throttle forwards and backwards respectively minimal and maximal throttle In most cases is better...

Page 41: ...is is an area which the controller evaluates as STOP or neutral i e the position of the joystick po tentiometer level control voltage in which the motor is not rotating stopped Too narrow zone may not...

Page 42: ...he model by back data transfer via Telemetry as fuel tank indicator It is also important to specify when using parameter P87 Capacity countdown P44 Switch off voltage cell For P42 UNI value in Volts S...

Page 43: ...for both direction of motor rotation P20 50 i e power backward resp motor PWM backward will be reduced to 50 of PWM if previously does not apply current limita tion P19 P20 100 i e current backward wi...

Page 44: ...revolution direction is possible change by logic signal on inputs standard is used port RxD This parameters sets the desired direction of motor revolutions without having to swap two motor cables whe...

Page 45: ...This acceleration is valid only for start from STOP position to achieve value of the control signal When reaching the stabilization RPM acceleration ramp switches to value defined in parameter P16 whi...

Page 46: ...tivation of braking speed of actuate brake pedal P26 Brake Ramp in Neutral time to reach full braking force value in milliseconds Define speed of activation of automatic braking in Neutral position in...

Page 47: ...in Nedutral control type Car bidirectional freewheel active 100 Engine speed matches the new settings of the control signal throttle 70 Braking with 70 intensity Braking in Neutral position with 40 i...

Page 48: ...connected set off P30 Controller temperature limit value in C If for any reason you need to reduce the maximum temperature limit of the controller enter demand value to this parameter P31 Motor temper...

Page 49: ...00 for the standard rate of 38 400 baud or 9600 for 9600 baud etc For optically isolated RS 232 TTL speed limit applies to a maximum of 2400 baud If the line is not optically isolated restrictions don...

Page 50: ...meters etc Don t forget select memory bank first change parameters after this Before switch off write parameters by button Write setting Important If the controller is feed from the battery module USB...

Page 51: ...ks parameters If the window Settings click on Lock settings you open the window where you can choose which parameter remains open and which not Mark all the parameters you want locked against overwrit...

Page 52: ...MV Unlocked parameter you can change its value Locked parameters are displayed but they can not be changed up to unlock using the correct code Locked parameters have gray box before the number paramet...

Page 53: ...u want read recorded data necessary connect Controller to PC and start program Controller 2 Choice button History and push Read history The data reading from the controller are displayed simultaneousl...

Page 54: ...The left vertical axis scale Read History Export to Excel file A new area selected to zoom Setting the properties of curves assigning to the left or right scale appearance chart Time axis Switch on a...

Page 55: ...ing on settings battery current is zero 6 partial brake input command is 55 output power goes into negative numbers the brake is about 18 7 neutral output power is zero 8 ride backward partial throttl...

Page 56: ...D10 Internal main bus voltage V The internal voltage of the controller information for service D11 Input power of the controller W Input power the controller the value calculated from the input volta...

Page 57: ...correctly programmed input signal limits OR 4b Make sequence to Start with automatic throttle limits in case P4 is set to Automatic limits and wait to the initial melody 5 connect USBCOM 4 i to the co...

Page 58: ...ng from transmitter must be set to Enabled Parameter P4 Control signal is set to Automat Subsequently is necessary set by transmitter signal generator setting position of the Neutral and max deflectio...

Page 59: ...ithout NEUTRAL without lock of STOP position position STOP is identical with the position Min throttle 1 Turn on control signal source with joystick potentiometer control signal in position full throt...

Page 60: ...t red LED and yellow LED challenge to moving throttle stick from full throttle backward position to neutral position After finishing of motion light yellow LED 2 short beep play melody 6 You can start...

Page 61: ...ghts melody 3 You can start now controller is ready to run b Type of controller s start parameter P5 is set to Immediate start In the parameter P4 Control signal is set Programmed or some possibility...

Page 62: ...rpm Result therefore this value 60 000 250 000 controller is suitable for this system In next step necessary check motor if requested output revolution is correct with available voltage Requested mech...

Page 63: ...t Starting sequence for firmware updating follows 0 Connect USBCOM 4 i module to PC and Start program Controller 2 first Connect controller but no turn on yet 1 Choice button SYSTEM 2 Choice Firmware...

Page 64: ...ot be broken down by failed update but you have to finish the update procedure without errors 8a if you want to use it with motor or parameter settings etc When procedure don t finished correctly poin...

Page 65: ...W version of your program Controller 2 is possible make by two ways 1 After start program automatically advice to new version in left up per corner start update by this way Choice Download updates and...

Page 66: ...er When happen some of next states problems correct states are not indicated These not correct states indicated some problem in the sys tem These states last until switch off also its combination b li...

Page 67: ...stor How to connect the positive leg or wire shown here without insulation Connectors as well as the resistor are insulated by heat shrink tubing How to connect the battery 1 connect the leg of the ba...

Page 68: ...Very quality hard battery voltage drop is low under load not start current reduce process b Not so hard battery worse quality or too high load or too short acceleration time current is reducing during...

Page 69: ...insignificant amount of energy the motor power would decrease very fast anyway Switching off voltage Thanks to the above described mechanisms the switching off voltage always meant as switching off vo...

Page 70: ...etail Super brightness LED with wide viewing angle Extended cable EC_2 to ICS 2 connector Y type Accessories The controllers can be directly connected LEDs drive not included Light up when you drop in...

Page 71: ...e CC_11 Additional capacitors for HBC 18063 25063 10x1G0 63 for 63V versions Additional capacitors for HBC 100120 140120 8x0G33 160 for 120V versions External antispark rezistor need when additional c...

Page 72: ...or switch off while the motor is still turning overloading with a higher number of cells than specified feeding from unspecified source e g mains source instead of the specified cells shortcut on the...

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