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Installation and maintenance instructions

 

GVI Product Manual: Frames C, D & E

 

48 

192-300300N1 GVI Frames C, D & E 2019-9

 

10.6.1.  Terminals with threads 

Figure 31 shows the assembly order for the terminal connection fasteners. 

 

 

NOTE 

Mount the optional on-board fuse according to chapter 10.6.2. 

 

 

Pos 

Name 

GVI Frame C 

GVI Frame D 

GVI Frame E 

1 

Screw for terminal B+ (for 
optional on-board fuse) 

[1 piece] 

M6 x L 
Screw engagement 

8-12.5 mm 
Tightening torque 

8 ± 1 Nm 

M8 x L 
Screw engagement 

12-16 mm 
Tightening torque 

15 ± 2 Nm 

M8 x L 
Screw engagement 

8-12 mm 
Tightening torque 

15 ± 2 Nm 

2 

Flat washer 
[6 pieces] 

ISO 7089 12 x 6.4 x 1.6 - 200 
HV or similar 

ISO 7089 16 x 8.4 x 1.6 
- 200 HV or similar 

ISO 7089 16 x 8.4 x 
1.6 - 200 HV or similar 

3 

Ring lug 
[5 pieces] 

6.5 mm hole diameter for 
battery and motor 

connections 

8.5 mm hole diameter 
for battery and motor 

connection 

8.5 mm hole diameter 
for battery and motor 

connection 

4 

On-board fuse (optional) 
[1 piece] 

OEM’s responsibility. See 
chapter 7.7.1 

OEM’s responsibility. 
See chapter 7.7.1 

OEM’s responsibility. 
See chapter 7.7.1 

5 

Rectangular washer (for 

optional on-board fuse) 
[3 pieces] 

Tin plated rectangular 

copper washer 

Tin plated rectangular 

copper washer 

Tin plated rectangular 

copper washer 

6 

Screw for terminals (Table 
12) 

[5 pieces] 

M6 x L 
Screw engagement 

8-12.5 mm 
Tightening torque 

8 ± 1 Nm 

M8 x L 
Screw engagement  

28-32 mm 
Tightening torque 

15 ± 2 Nm 

M8 x L 
Screw engagement 

12-19 mm 
Tightening torque 

15 ± 2 Nm 

Figure 31 Fasteners for terminal posts with threads 

Содержание GVI Series

Страница 1: ...e technical changes 25 09 19 06 47 192 300300N1 GVI Frames C D E 2019 9 The data correspond to the current status at the time of printing Product Manual GVI GVI Global Vehicle Inverter Frame C D and E...

Страница 2: ...m mailto EM Motion parker com Parker Hannifin GmbH registered office Bielefeld HRB 35489 Management Board Ellen Raahede Secher Dr Ing Hans J rgen Haas Kees Veraart Chairman of the board Hansgeorg Greu...

Страница 3: ...oduct version 11 6 1 1 GVI drives 11 6 2 Components on the GVI 12 6 3 Terminal posts 12 6 4 Product identification label 13 6 5 LED status indicator 14 6 6 Cooling method 14 7 Integration guidelines 1...

Страница 4: ...values for different functions 27 7 18 2 4 Power stage 27 7 18 3 Default parameters EEPROM considerations 28 8 I O interface description 29 8 1 Mating connector specification 29 8 1 1 Part numbers 29...

Страница 5: ...on and maintenance instructions 42 10 1 Introduction 42 10 2 Periodic inspection preventive maintenance 43 10 3 Replacement of on board fuse 44 10 4 GVI removal 44 10 5 GVI installation 45 10 5 1 Asse...

Страница 6: ...5 13 4 4 Encoder input 56 13 4 5 Open drain output 56 13 4 6 High side in and out 56 13 4 7 Motor temperature measurement input 57 13 4 8 Sensor supply 57 13 4 9 CAN 58 13 5 Physical characteristics 5...

Страница 7: ...e or correction without prior notice 1 1 4 Scope This product manual presents instructions guidelines diagrams and other information relevant to integration installation and maintenance of the motor c...

Страница 8: ...ensure that all persons responsible for the design and use of equipment employing the GVI have the proper professional skills and knowledge about the equipment WARNING High voltage high torque risk o...

Страница 9: ...cturer responsibility The Parker inverter products are intended for controlling motors in electric powered vehicles These inverters are supplied to original equipment manufacturers OEMs for incorporat...

Страница 10: ...eturn of authorization RMA number for returns and a form RMA request which describes how to proceed Contact addresses for return requests China service tzm evs Parker com USA service blb evs Parker co...

Страница 11: ...9 9 6 1 Product version The motor controller product range consists of three single drives frames C D and E each with its own size and current and power output rating characteristics 6 1 1 GVI drives...

Страница 12: ...O connector see chapter 8 I O interface description 4 U1 V1 and W1 connections 5 On board fuse optional see section 7 7 6 Heat sink see chapter 6 6 Cooling method Figure 5 Components on the GVI 6 3 T...

Страница 13: ...ttached to the motor controller cover The product label fields relevant to product identification are described in Figure 7 and Table 2 Figure 7 Example of product identification label Pos Description...

Страница 14: ...dicator see chapter 11 1 provides useful diagnostic information when troubleshooting vehicle problems see chapter 11 6 6 Cooling method The motor controller is mounted upon a cold plate heat sink whic...

Страница 15: ...nsfers heat from the power conversion components to the surroundings In order to cool the power conversion components efficiently it is important to consider the thermal resistance between the heat si...

Страница 16: ...10 5 Motor controller model Thermal resistance GVI C024 0350 GVI C024 0550 GVI C048 0280 0 17 C W GVI C024 0550 GVI D048 0450 GVI D048 0550 GVI 080 D0230 GVI D080 0350 GVI D080 0400 0 12 C W GVI E048...

Страница 17: ...eric wiring configurations to fit their individual requirements or conventions It is the responsibility of the OEM to develop vehicle specific wiring schematics and instructions for each vehicle mode...

Страница 18: ...taken to minimize length of the stub lines If the motor controller is placed at one end of the CAN bus the built in 120 termination resistor can be utilized by placing a jumper between pin 15 and pin...

Страница 19: ...e at a central fuse panel In this configuration battery power is connected directly to the motor controller terminal NOTE The fuse is not intended to protect the motor controller or motor against ove...

Страница 20: ...nt of fuse No current goes through this washer 4 Washer 2 serves to distribute pressure between on board fuse 1 and washer 3 No current flows through this washer 2 The washers 2 3 and 4 are used as re...

Страница 21: ...de energized if motion is not permitted as a result of some error fault condition Selection and sizing of the main contactor circuit is the OEMs responsibility The following power output vs DC input...

Страница 22: ...on in the motor Contact the motor manufacturer to get the correct wiring and relationship between rotational direction and feedback sensor signals Swapping the channels from feedback sensor will lead...

Страница 23: ...justments individual for each channel are done in software to compensate for minor changes in sensor characteristics For a new motor sensor it is necessary to setup correct default values for amplitud...

Страница 24: ...n the same stable surface so that movements and vibrations from the vehicle cannot twist the busbar between them If other components are connected to the motor controllers on a separate mounting surfa...

Страница 25: ...are responsible for ensuring that the motor controllers are used for their intended purpose only safe function of the system and for compliance with all applicable regulations See chapter 0 for a cor...

Страница 26: ...I Frames C D E 2019 9 7 18 2 2 Travel and brake control Performance according to EN 1175 1 1998 A1 2010 chapter 5 9 4 Pulse control travel systems and 5 9 5 Prevention of travel i e according to ISO 1...

Страница 27: ...values for different functions NOTE MTTFd for complete GVI D is calculated to 36 years and for GVI E 19years 7 18 2 4 Power stage Although the power stage is an important block in the basic functiona...

Страница 28: ...o checksums do not match it is assumed that the parameters contained in the EEPROM are not valid and default parameters are loaded from flash memory instead During run time the EEPROM is only used for...

Страница 29: ...L_IN_2 8 4 2 DIGITAL_IN_7 8 4 20 ENCODER_IN_2B 0 3 KEY_INPUT 8 3 21 CAN_Low 8 13 4 OPEN_DRAIN_OUT_1 8 8 22 ANALOG_IN_2 8 6 5 SENSOR_SUPPLY_1 12 V 8 11 23 DIGITAL_IN_3 8 4 6 SENSOR_SUPPLY_GND 8 11 24 O...

Страница 30: ...ess than 10 m The KEY_INPUT is protected against reverse polarity with a diode and has a capacitance to B for ESD protection and other filtering This capacitance may give a high current spike at KEY_I...

Страница 31: ...g jumpers in the cable harness for the different nodes The HW_ID jumper configuration controls which CAN ID and which functionality is used for each position in the system The HW_ID s are commonly use...

Страница 32: ...nnected to an analog input 8 6 2 Protection Analog inputs are B and B protected and have a capacitor to B for ESD protection 8 6 3 Circuit WARNING Risk of injury and or damage to material missing data...

Страница 33: ..._1B The internal pull up is activated by software settings Threshold level for low signal is 2V and the max usable frequency of an open drain type encoder is 20kHz ENC1 pull up is controlled from the...

Страница 34: ...4 Yes Yes No 5 6 Yes No No Table 8 Open drain functionality PWM frequencies are settable The setting will apply to all PWM outputs PWM shall only be used for inductive loads such as relays contactors...

Страница 35: ...nect any switch or fuse in series with the diode 8 8 3 Circuit CAUTION Overvoltage sensitive equipment risk of damage to equipment Internal free wheeling diodes are provided to protect the motor contr...

Страница 36: ...side switch has only ON OFF control Voltage to power the loads driven should be applied to the HIGH_SIDE_IN pin and the load should be connected between HIGH_SIDE_OUT and an open drain output as show...

Страница 37: ...surement input 8 10 1 Function Motor temperature sensor input for measurement of the motor winding temperature The input is optimized for temperature sensors KTY84 with 1 000 100 C see chapter 7 14 8...

Страница 38: ...l connection to B with a diode 8 11 3 Circuit Figure 25 Schematic of the Sensor Supply Output circuit 8 12 Sensor Supply GND 8 12 1 Function CAUTION Do not use this GND connection for units supplied f...

Страница 39: ...R_SUPPLY_GND must NOT be used as supply ground for B supplied units Figure 26 Schematic of the Sensor Supply GND circuit 8 13 CAN NOTE Error frames counter is available in the motor controller and is...

Страница 40: ...not recommended to use units with 3 3 V CAN drivers in this type of application with high current motor controllers The noise margins will be reduced and there will be high risk for CAN error frames i...

Страница 41: ...emperatures outside the normal operating temperature range as seen in Figure 28 and the motor controller will shut down completely at 110 C Figure 28 Available power as a result of power stage monitor...

Страница 42: ...oller in a specific vehicle may vary from what is presented here or include additional steps It is the responsibility of the vehicle manufacturer to develop detailed instructions for installation and...

Страница 43: ...ive s internal filter capacitors shall be discharged as described in the instruction below Do not short the to B terminal as this may cause an arc WARNING Hot surfaces risk of personnel injury After o...

Страница 44: ...ay be too hot to touch Allow it to cool before performing any maintenance work on the motor controller Replace the on board fuse according to chapter 10 6 10 4 GVI removal WARNING High voltage risk of...

Страница 45: ...B B U V and W terminals 6 Remove the bolts securing the motor controller to the vehicle Figure 29 Demounting hole and slot 7 GVI frame D and E Use the M8 demounting hole to release the motor controll...

Страница 46: ...1 Assembly material for GVI mounting The depth of thread in the vehicle body should be at least 1 5 x mm For bolt lengths L and drilling pattern see chapter 13 5 2 The following sub chapters describe...

Страница 47: ...and do not activate the main contactor until the capacitors are charged up to the predefined voltage The capacitors will not charge to the proper level if polarity is reversed The following sub chapte...

Страница 48: ...8 4 x 1 6 200 HV or similar ISO 7089 16 x 8 4 x 1 6 200 HV or similar 3 Ring lug 5 pieces 6 5 mm hole diameter for battery and motor connections 8 5 mm hole diameter for battery and motor connection...

Страница 49: ...ions monitor battery voltage heat sink temperature motor temperature and other conditions Error and warning information is available to the master controller and all event information is stored in an...

Страница 50: ...controller is functional and able to communicate over CAN bus 1 Apply logic power to motor controller by applying battery power to KEY_INPUT 2 Verify that the LED status indicator see chapter 11 1 on...

Страница 51: ...a control system Therefore it is strongly recommended to connect all wires of sensors supplied by the motor controller directly to the intended GVI I O connector pins Consider an alternative path for...

Страница 52: ...cart is used connect the frame of the cart to the frame of the truck to avoid different charge levels on truck frame and battery Different levels may damage the unit or motor Depending on the units c...

Страница 53: ...C048 0280 10 880 GVI C024 0550 TBA GVI D048 0450 15 640 GVI D048 0550 17 680 GVI D080 0230 4 590 GVI D080 0350 6 210 GVI D080 0400 7 020 GVI E048 0700 21 760 GVI E080 0500 8 640 GVI E080 0700 12 420...

Страница 54: ...put ratings GVI model Nominal DC supply voltage V DC Rated current S2 2 min ARMS Rated current S2 1 h ARMS Rated power S2 2min kVA Rated power S2 1h kVA Frame C GVI C024 0350 24 350 150 10 3 4 4 GVI C...

Страница 55: ...Function Inrush current reduced by internal resistor 3 A The current ripple peaks may initially exceed 5 A Circuit Capacitor B for ESD protection Approximately 20 nF 13 4 2 Digital inputs Refer to Fi...

Страница 56: ...n 4 5 6 Open drain output peak pull current max 200ms 4 A Open drain 1 2 3 2 A Open drain 4 5 6 PWM frequency setting interval 1 16 kHz Current measurement and control Current measurement 0 5 4 A with...

Страница 57: ...to Figure 24 Description Value Circuit Internal voltage reference 3 0 V Input impedance 1 65 k Difference voltage measurement gain 2 2 Input capacitance 10nF 13 4 8 Sensor supply Refer to Figure 25 D...

Страница 58: ...ion Value Function Internal supply 5 V Data rate 125 250 or 500 kbit s CAN driver supply 5 V Circuit Capacitor B for ESD protection 1 nF Termination resistor 120 13 5 Physical characteristics 13 5 1 W...

Страница 59: ...Parker EME Physical characteristics 59 192 300300N1 GVI Frames C D E 2019 9 13 5 2 2 GVI Frame D 13 5 2 3 GVI Frame E...

Страница 60: ...latness requirement 13 6 Environmental testing standards appliance 13 6 1 General Subject Standard Protection class IP65 Test IEC 60529 with mating connector installed Standard EC declaration of incor...

Страница 61: ...ngth 6 ms for all 3 octagonal axis tested as described in EN60068 2 27 Test Ea Shock 50 G 5 positive and 5 negative half sine pulses with acceleration of 50 g pulse length 6 ms for all 3 octagonal axi...

Страница 62: ...Product Specifications GVI Product Manual Frames C D E 62 192 300300N1 GVI Frames C D E 2019 9...

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