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Gen4 

 

Applications 

Reference 

Manual 

Document no: 

177/52701 

 

Rev. 3.3  

Summary of Contents for Gen4

Page 1: ...Gen4 Applications Reference Manual Document no 177 52701 Rev 3 3 ...

Page 2: ...en l Aumône 95041 Cergy Pontoise Cedex France Tel 33 0 1 34 30 35 00 Fax 33 0 1 34 21 77 02 sales fr sevcon com Sevcon Japan K K Kansai Office 51 26 Ohyabu Hikone Shiga Japan 522 0053 Tel 81 0 7 49465766 jp info sevcon com Sevcon Asia Ltd Room No 202 Dong Ah Heights Bldg 449 1 Sang Dong Wonmi Gu Bucheon City Gyeounggi Do 420 816 Korea Tel 82 32 215 5070 sales kr sevcon com Sevcon Germany Hintere S...

Page 3: ...cal support 1 4 Product warranty 1 4 Chapter 2 About the Gen4 2 1 Introduction 2 2 Standard features and capabilities 2 2 Available options 2 2 Intended use of the Gen4 2 3 Available accessories 2 3 Overview of a truck drive system 2 4 Principles of operation 2 5 Functional description 2 5 Interfaces 2 6 Master slave operation 2 6 Torque mode 2 7 Speed mode 2 7 Safety and protective functions 2 8 ...

Page 4: ... measures 3 6 Measures required for specific signals 3 7 Additional measures 3 7 Problems to avoid 3 8 Connecting power cables 3 9 Battery and motor connections 3 9 Cable sizes 3 10 On board fuse mounting 3 11 Fuse rating and selection 3 12 Signal wiring 3 13 Signal wire sizes 3 13 CANbus termination 3 13 Signal connections 3 14 Chapter 4 Specification 4 1 Electrical 4 2 Input voltage 4 2 Output p...

Page 5: ...tween zero and base speed 5 2 Torque required at maximum speed 5 3 Continuous power rating 5 3 Peak power rating 5 4 Selecting the correct Gen4 model 5 4 Current and power ratings considerations 5 4 Power output restrictions at motor and drive operating temperature limits 5 4 Circuit configuration 5 5 Single traction wiring diagram 5 6 Single pump wiring diagram 5 7 Twin motor systems 5 8 Auxiliar...

Page 6: ...Object Dictionary 6 4 Communication objects 6 4 Network Configuration 6 5 Configuration process overview 6 7 Access authorization 6 7 How NMT state affects access to parameters 6 7 Motor characterization 6 8 Determining motor parameters 6 8 Self characterization 6 9 Additional Motor Configuration 6 10 I O configuration 6 11 Object mapping 6 11 Encoder 6 14 Digital inputs 6 14 Analogue inputs 6 14 ...

Page 7: ... select switches 6 31 Economy 6 31 Pump configuration 6 31 Power steer configuration 6 33 Vehicle features and functions 6 34 Contactors 6 34 Line contactor 6 34 Electro mechanical brake 6 34 External LED 6 35 Alarm buzzer 6 35 Brake Lights 6 35 Horn 6 35 Vehicle Speed Calculation 6 35 Distance Calculation 6 36 Service Indication 6 36 Traction motor cooling fan 6 36 Controller heatsink motor cooli...

Page 8: ...ture 7 2 Identification and version 7 2 Battery monitoring 7 2 Hours counters 7 3 Logging 7 3 FIFO event logs 7 3 Event counters 7 4 Operational monitoring 7 4 CANopen abort code 7 4 Faults and warnings 7 6 Introduction 7 6 Fault identification 7 6 Fault list 7 10 Upgrading the controller software 7 10 ...

Page 9: ...Chapter 1 Introduction ...

Page 10: ...the express written permission of 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 a...

Page 11: ...hazard with a high level of risk which if not avoided will result in death or serious injury A WARNING indicates a hazard with a medium level of risk which if not avoided could result in death or serious injury A CAUTION indicates a hazard with a low level of risk which if not avoided could result in a minor or moderate injury A NOTE indicates a risk of damage to the process product or surrounding...

Page 12: ...duct 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 centre through the Sevcon website www sevcon com Product warranty Please refer to t...

Page 13: ...Chapter 2 About the Gen4 ...

Page 14: ... mapped to Gen4 s software functions to suit a wide range of traction and pump applications NOTE Given Gen4 s mapping versatility it is important to ensure you map your application signals to the correct software functions see Object mapping on page 6 11 A common configuration is supplied by default which may suit your needs or act as a starting point for further configuration Configuration and co...

Page 15: ...round support AGS including tow tractors Utility vehicles Burden carriers Sweepers and scrubbers Golf buggies carts Neighbourhood electric vehicles NEV Scooters Marine Available accessories The following accessories are available from Sevcon Loose equipment kit connectors and pins for Gen4 CANopen Calibrator Handset SmartView display ClearView display Hourmeters Contactors Fuses Drive Wizard PC ba...

Page 16: ...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 5820h of battery voltage via the key switch signal line 2 Clo...

Page 17: ... 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 NOTE 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 tor...

Page 18: ...ssion 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 Sev...

Page 19: ...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 ca...

Page 20: ...ler may be damaged if the back emf exceeds this level WARNING Do not tow vehicles that have PMAC motors the motors act as generators and may cause high currents to flow in the motor controller or battery system If towed at a speed in excess of the vehicle rated speed the voltage generated by the motor may damage the controller or battery WARNING When a PMAC motor is acting as a generator for examp...

Page 21: ...on for advice Use of inappropriate fasteners or torques could damage the controller NOTE Where appropriate use of a suitable line contactor should be considered CAUTION 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 it s ...

Page 22: ...rly the throttle 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 Analogue inputs page 6 14 and Vehicle performance configuration page 6 18 for more information Notes on Features The Gen4 is a generic motor controller intended for use in both highw...

Page 23: ...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 incorrectly configured In addition the following features must be configured correctly Steering map if used to reduce maximum outer wheel speed with steering angle ...

Page 24: ...he 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 reselecting Neutral brakes or coasts the traction motor s to a ...

Page 25: ...Chapter 3 Installation ...

Page 26: ...tion and or debris Take note of the thermal and EMC considerations as explained later in this section of the manual Protection from chemical contamination The Polycarbonate cover of Gen4 controllers are designed for good all round protection of the electronics However the controller should be sited so it cannot come into contact with significant quanties of industrial chemicals The following have ...

Page 27: ...erial or thermal paste is used between controller and mounting face Spread a layer of thermal grease such as Dow Corning 340 as described below before bolting to your mounting surface Thermal compound should be applied with a small soft paint roller to ensures an even spread of thermal compound The most appropriate thickness will look white but with a greyish colour still showing through from the ...

Page 28: ... is then bolted together at all mounting holes An example of a good thermal compound spreading can be seen in the photo below 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 surf...

Page 29: ... mm will give approximately the same thermal performance 0 3 C W Ratings achievable with conductive heatsinking are shown in Figure 10 on page 4 4 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 mus...

Page 30: ...gh 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 Keep power cables at least 300...

Page 31: ...node must be connected to the Gen4 controller B The cable screen should be connected to the B terminal at the Gen4 controller Keyswitch The keywire should be as short as possible Minimise the loop area of the loop formed by the traction battery keyswitch keyswitch supply on the Gen4 and the B return wire to the battery Do not connect additional battery loads to the keyswitch wire Contactor drivers...

Page 32: ...a typical vehicle there are many potential radiators and receivers Measures taken on a vehicle to improve EMC can unintentionally make the situation worse Beware of devices that are connected to the small signal wiring which have a significant 10nF capacitance to vehicle chassis The capacitance to vehicle chassis can cause currents to flow out of the Gen4 controller along the signal wiring to the ...

Page 33: ...g 7 Nm 1 Nm Consider cable routing before making connections Keep cable runs short Minimize current loops by keeping positive and negative cables as close together as possible 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 USE THE CORRECT TORQUE They are sized to clamp one ring lug thickness Use...

Page 34: ...emperature rating of the chosen cable 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 current Cable sizes metric US approx equivalent 180 A 25 mm 2 4 AWG 225 A 35 mm 2 2 AWG 280 A 50 mm 2 1 AWG 350 A 70 mm 2 2 0 AWG ...

Page 35: ...able 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 5 On board fuse mounting size 2 models Figure 6 On board fuse mounting size 4 models ...

Page 36: ...60 1 Gen4 input voltage Gen4 peak output current Fuse rating Sevcon part number 24V 36 V 300 A 325 A 858 32044 450 A 425 A 858 81990 650 A 750 A 858 33021 36V 48 V 275 A 250 A 858 29043 450 A 425 A 858 81990 650 A 750 A 858 33021 72V 80 V 180 A 200 A 858 83339 350 A 355 A 858 32045 550 A 500 A 858 32043 96V 110V 300A 355A 858 32045 ...

Page 37: ...ce See also EMC guidelines on page 3 6 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 6 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...

Page 38: ...riate hardware available from Tyco if a contact is inserted and then subsequently removed It is recommended that Tyco strain relief 776463 1 is used especially for applications where the connector is less than fully populated to reduce change of ingress through connector body Pin Name Type What to connect Maximum rating Comment 1 Key switch in Power From dead side of key switch via suitable fuse 7...

Page 39: ...tch in Power From dead side of key switch via suitable fuse 7A Total of all contactor output currents plus 1 0A This input supplies power from the battery for all the logic circuits The unit cannot operate without Key switch in supply Pins 1 and 6 and 10 on Size 4 6 models are connected together internally and can be used individually or in parallel 7 Contactor out 2 Out To the switched low side o...

Page 40: ...0A per output subject to a limit of 6A for the total of all the outputs V Vb This output provides low side voltage or current control to 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 12 Output 3 Supply Power To one end high side of a contactor to be controlled by Contactor out 3 2A This output feeds power to th...

Page 41: ...Vb See Table 3 See note to Table 3 19 Digital Input 3 Digital From digital switch input 3 In a basic configuration this is usually the foot switch FS1 Type A V Vb See Table 3 See note to Table 3 20 Digital Input 5 Digital From digital switch input 5 Type B V Vb See Table 3 See note to Table 3 21 Digital Input 8 Digital From digital switch input 8 Type B V Vb See Table 3 See note to Table 3 Alterna...

Page 42: ...ally limited V 8 V for current source encoders V 2 5V or 5V for open collector encoders 26 Encoder power supply Power To the positive supply input of the speed encoder I 100 mA V 5V or 10V software selectable Check the speed encoder you use is compatible with Gen4 See page 6 14 for configuration details 27 CAN Low Comms CANbus Low signal V 5 V Maximum bus speed 1 Mbits s Alternative connection to ...

Page 43: ...sensitivity Connect the other lead of the thermistor to the B terminal of the Gen4 controller Can also be used as an additional analogue input 34 Pot 1 power supply Power Supply feed to potentiometer 1 In a basic configuration this is the throttle V 10 V I 15 mA Suitable for potentiometers in the range 500 Ω to 10 kΩ 35 Pot 2 power supply Power Supply feed to potentiometer 2 V 10 V I 15 mA Suitabl...

Page 44: ...tive 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 approximately 0 5 x Vb type A or 0 4 x Vb type B The input sinks current in active high configurations and sources current in active low configurations ...

Page 45: ...Chapter 4 Specification ...

Page 46: ...y the user for various reasons including Battery protection against high current in deep discharge condition 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 Upper working voltage limits for 72V 80V Gen4 is being increased to 120V and will be rolled ou...

Page 47: ...Specification Doc 177 52701 Rev 3 3 4 3 CAUTION Repetitive short circuits may damage the controller ...

Page 48: ... 350 140 Single traction size 6 550 210 96 110 Single traction size 4 300 120 2 minute rating lower ratings are possible for longer periods see example in Figure 10 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...

Page 49: ...potentiometers or as supplies for the 3 wire potentiometer wiper inputs Motor thermistor input All analogue 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 2 ...

Page 50: ...4 6 Isolation Any terminal to the case Meets EN1175 1 1998 and ISO3691 Complies with IEC 60664 ...

Page 51: ...truck affect the performance of safety related parts of the truck or system produce any incorrect signal that may cause the driver to perform hazardous operations cause speed changes outside limits specified in the standard cause a change of operating state cause a change of stored data Radiated RF field EN 61000 4 3 5 1 Test Level user defined test level of 12 V m EN 12895 2000 4 2 Immunity EN 61...

Page 52: ... IP66 rated all sizes Signal connector un mated IP66 rated size 4 6 models Signal connector un mated IP42 rated 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 r...

Page 53: ...Specification Doc 177 52701 Rev 3 3 4 9 Dimensions Size 2 models Size 4 models ...

Page 54: ...4 10 Size 6 models ...

Page 55: ...Chapter 5 System design ...

Page 56: ... 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 th...

Page 57: ...ue required Figure 11 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 continuous rating Select a motor whose ratings are equal to or greater than you...

Page 58: ...nsider the following when choosing the appropriate Gen4 controller Ensure the controller chosen matches or exceeds the peak current and average current requirements of the motor s in the application 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 ...

Page 59: ...n Once motor size is determined the application circuit configuration can be defined A basic single traction configuration Figure 13 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 14 to see what each I O signal is capable of doing as you design your system For pump applicatio...

Page 60: ...5 6 Single traction wiring diagram Figure 13 Single traction wiring diagram ...

Page 61: ...System design Doc 177 52701 Rev 3 3 5 7 Single pump wiring diagram Figure 14 Stand alone pump wiring diagram ...

Page 62: ...ntactor 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 current Coil Sevcon P N Manufacturer Notes Up to 450 A 24 V 828 37024 Albright SW200 29 See paragraph below 48 V 828 57026 Albright SW200 20 80 V 828 67010 Albright SW200 460 Up to 650 A 24 V 828 3...

Page 63: ...System design Doc 177 52701 Rev 3 3 5 9 On board fuse See On board fuse mounting on page 3 11 ...

Page 64: ...5 10 Figure 15 Dual traction wiring diagram ...

Page 65: ...oder B Figure 16 Sample wiring for an AB quadrature speed encoder You can use the following types of encoder or equivalents Type Output Supply Specification Bearing Type SKF and FAG Open collector 5 to 24 V DC 64 and 80 pulses per revolution Dual quadrature outputs Output low 0 V nominal HED Type Thalheim Constant current 10 V nominal 80 pulses per revolution Dual quadrature outputs Output low 7 m...

Page 66: ...ather 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 of these can be used for control of permanent ma...

Page 67: ...y voltage For 10V supply the low to high transition threshold is 5 3V and for 5V supply it is 2 7V 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 Figure 19 Example of signals from a sin cos position sensor ...

Page 68: ...vide 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 co...

Page 69: ...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 for any fan cooling system 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 Sevcon DVT see page 6 2 the Sevco...

Page 70: ......

Page 71: ...Chapter 6 Configuration ...

Page 72: ...overview only Contact Sevcon for more information about DVT and the functions it provides DVT functionality DVT provides the following facilities Configuration of controller IO CANBus motor parameters vehicle drive performance parameters Loading DCF configuration file into the Sevcon controller Saving of DCF configuration file from controller to file on computer Controller status and fault diagnos...

Page 73: ...lates to the configuration of your Gen4 controller 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 standardization and interoperability with 3 rd party devices Gen4 is designed to use the CANopen protocol for communication on its CANbus a...

Page 74: ... the Object Dictionary structure DCFs are used to Download a complete pre defined configuration to a node s Object Dictionary 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 descr...

Page 75: ...each node to be monitored WARNING Heartbeats must be configured correctly for correct network error handling The master node should monitor heartbeats from all slave nodes Slave nodes should at a minimum monitor heartbeats from the master node 6 On standalone systems with non CANopen nodes attached hardware CANbus fault detection should be enabled at 5901h CANbus fault detection is automatically e...

Page 76: ...nodes to identify which nodes are Sevcon devices and which are not using the vendor ID in 1018h 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 rd party devices so the required fault reaction to 3 rd party device EMCYs must be set at 2830h ...

Page 77: ...ccessibility 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 DVT select User ID and password when prompted To login with other configuration tools write your password and optionally a user ID to object 5000h sub indices 2 and 3 The ac...

Page 78: ...tor in the constant power and high speed regions Current and speed control gains Figure 21 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 4640h and 4641h Also enter encoder data at 4630h and 6090h and motor maps at 4610h to 4615h The motor maps are depe...

Page 79: ...ne provided by Gen4 and DVT described below The flux vector variant of software includes motor temperature compensation which can be used to adjust rotor resistance 4641h 8 with motor temperature This is set at 4621h 4 to 7 Self characterization WARNING The self characterization function will cause the motor to operate Always ensure the vehicle is jacked up with the driving wheels off the ground a...

Page 80: ...to 200 RPM X X Current control gain scheduling enable If enabled current control proportional gains increase with frequency Can reduce audible noise at low motor speeds X Drive Braking torque inhibit to 0 RPM enable If enabled allows motor torque to be disabled to 0 RPM X X Motor open circuit detection enable X Disable automatic discharge function for line contactor checks at power up X Salient mo...

Page 81: ...o 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 Standalone controllers setup VPDOs only Networked controllers setup VPDOs and PDOs NOTE Before starti...

Page 82: ...300h would be set to 2124h Some further examples are Map FS1 to read the value of digital input 8 connector A pin 11 at 3300h sub index 8 enter the value 2123h Map the electromechanical brake signal to be applied to analogue output 2 customer connector pin 7 at 3200h sub index 2 enter the value 2420h The data flow direction between the application signal objects and the local I O objects depends o...

Page 83: ...r slave configuration in which a digital input to the slave has been mapped to the seat switch object in the master Figure 23 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 5902h NOTE RPDO timeout can be used for non CANopen systems w...

Page 84: ...le internal pull up is only available with inputs dedicated to AB encoder UVW inputs always have internal pull up present Digital inputs The state of the digital inputs can be read at object 6800h NOTE 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 not possible The def...

Page 85: ... input You can connect a thermistor sensor to the Motor thermistor input or a switch to any digital input Type Specification PTC Silistor Philips KTY84 KTY83 or equivalent Switch Connected to a general purpose digital input To setup go to object 4620h Configure as none switch PTC or CAN based thermistor For KTY84 thermistors set the PTC type to KTY84 For KTY83 thermistors set the PTC type to KTY83...

Page 86: ... controlled or current controlled Values are 16 bit integers with a resolution of 1 256 V bit or A bit Error control WARNING It is important that analogue 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 respon...

Page 87: ... to activate an output on the slave device In this case enable error control in 6C43h and set the error value in 6C44h to an appropriate voltage for the lamp NOTE The above examples are for illustration purposes only It is the responsibility of the installer to decide on the required state for each output in the event of a CANbus failure ...

Page 88: ...S1 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 dela...

Page 89: ... than the standard integral gain dw dt gain 4651h 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 drive train Integral initialization factor 4651h 7 Used to initialize the integral term on entry to speed limit in torque mode This factor is ...

Page 90: ...See section Analogue inputs page 6 14 for more information Configure throttle wire off detection threshold at 2910h 21 Setup the characteristics of the throttle at 2910h sub indices 2 to 21 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 ...

Page 91: ...characteristic this is a profile to the throttle value and can be linear curved crawl or user defined as shown in Figure 26 The curved and crawl characteristics give greater throttle control at low speeds Figure 26 Input characteristics The throttle value calculated from the voltage can be read at 2620h ...

Page 92: ...nputs must be different Creep Torque Set creep torque at 291fh 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 Torque Demand Throttle value Creep torque Max torque Figure 27 Illustration showing behaviour of creep torque Increasing the creep torque le...

Page 93: ...portional 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 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 vehi...

Page 94: ...n analogue voltage configure the voltage levels in the same way as the throttle The footbrake voltage 2221h must be mapped to an analogue input Configure the characteristics of the footbrake at 2911h 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 Minimum speed for braking Foot braking stop...

Page 95: ...eering angle to 90º 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 ...

Page 96: ...motor working against the inner wheel motor Driveability profiles WARNING 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 ra...

Page 97: ...rivability select 2 profile invoked when drivability select 2 switch is active 2922h 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 applied by the software under preset conditions For example y...

Page 98: ...than could actually happen on a vehicle This can protect against harsh braking if traction wheels are momentarily locked Smoothing Output Torque Torque Demand from throttle Applied torque demand limited by ramp rate from driveability profile Curve applied to torque demand in this range Size of this range defined by s curve parameter Figure 31 Illustration of s curve on torque demand The controller...

Page 99: ...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 h By limiting the rate at which the speed limit can decrease we can ensure that if the brakes are released ...

Page 100: ...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 2901h Set the hill hold delay to 0 to disable this feature In speed mode drive torque is disabled whilst neutral braking to stop Howe...

Page 101: ...switches 2126h and 2127h To enable either of these they must be mapped to digital inputs When they are active the corresponding drivability profiles 2921h and 2922h are applied See Driveability profiles page 6 26 for more information Economy The economy input is an analogue input which can be used to increase vehicle efficiency and extend battery life It is normally controlled using a potentiomete...

Page 102: ...2A01h 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...

Page 103: ...ctivating Direction selected Seat switch activating Footbrake activating CAUTION 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 2B01h This is not required if the power steer motor is operated by a...

Page 104: ...TE Writing to 5180h 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 Gen4 is configured as the vehicle master it controls the pre charge of all slave nodes automatically The pre charge level is configurable between 50 and 90 The level...

Page 105: ...switch object 2101h and an analogue output is mapped to the horn object 2403h 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 2915h 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 t...

Page 106: ...closed for 1 second The total vehicle distance 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 2850h Service indication via an analogue contactor output e g to drive a dashboard lamp and or Gen4 s L...

Page 107: ...is calculated by monitoring current to the motor over time The estimate is configured at 4621h The estimate is always applied since it can detect increases in motor temperature more quickly than the direct measurement Direct measurement is normally done on the motor casing which lags behind the internal temperature Additional protection is provided for thermistor wire off conditions If the tempera...

Page 108: ...ructions To use the BDI configure the following parameters at 2C30h in the Object Dictionary Cell count this is the number of battery cells and is normally half the battery voltage as cells are usually 2 volts each Reset voltage V set this to the cell voltage when the batteries have just been charged This resets the BDI back to 100 Discharge voltage V set this to the cell voltage when the battery ...

Page 109: ...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 0x04 Battery current limit is calculated to maintain a power limit as set in sub index 6 and 7 Object 2871h provides a means to have TracApp cut back the torque demand in situations where the battery current limit is reduced This is useful for configurations where an ...

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Page 111: ...Chapter 7 Monitoring Gen4 ...

Page 112: ...Read the heatsink temperature at object 5100h sub index 3 Identification and version Read identification and version information at 1008h Controller name 1009h Hardware version 100Ah Software version 1018h Identity object Contains CANopen vendor ID product code CANopen protocol revision and controller serial number 5500h NVM EEPROM format 5501h Internal ROM checksum Battery monitoring The controll...

Page 113: ... the pump motor is running 2783h Vehicle power steer hours increments when the power steer motor is running 2784h Vehicle work hours increments when the traction pump or power steer motors are running 2785h 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...

Page 114: ...rvice 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 08000000h when the object dictionary is...

Page 115: ... 3 7 5 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 ...

Page 116: ...e of fault from the number of LED flashes The LED flashes a preset number 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 flashe s Fault Leve l Set conditions Operator action 0 off Internal hardware failure RTB Hardware circuitry not ope...

Page 117: ...switches active simultaneously Both inch switches inactive 2 Two direction fault DI Both the forward and reverse switches have been active simultaneously for greater than 200 ms Reset switches 2 Invalid steer switch states VS Steering switches are in an invalid state for example both outer switches are active Check steer switches 3 Fault in electronic power switching circuit VS Fault in electronic...

Page 118: ...age or capacitor voltage is below a user definable minimum battery level for a user definable time Increase battery voltage above user defined level 7 Controller low voltage protection I Battery voltage or capacitor voltage is below the minimum level allowed for the controller Increase battery voltage above minimum level 7 Controller high voltage protection with line contactor closed I Battery vol...

Page 119: ...own 8 Controller too cold I Controller has reduced power to motor s below maximum specified by user settings due to controller under temperature Allow controller to warm up to normal operating temperature 8 Motor over temperature I Controller has reduced power to motor s below maximum specified by user settings due to motor over temperature Reduce load to motor to allow it to cool down 8 Motor too...

Page 120: ...ltage out of range with no current 13 DSP parameter error RTB Motor parameter written to while motor control is operational Recycle keyswitch to allow parameters to be reloaded correctly 14 3 rd Party Anonymous Node EMCY received I DS RTB 3 rd party node has transmitted an EMCY message Check CANbus wiring and 3 rd party node status 15 Vehicle service required I Vehicle service interval has expired...

Page 121: ...itoring Doc 177 52701 Rev 3 3 7 11 It is possible to field update the firmware of the Gen4 controller typically using Sevcon s DVT configuration tool Please contact Sevcon for assistance with this process ...

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Page 123: ...Monitoring Doc 177 52701 Rev 3 3 A 1 ...

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