Azure Dynamics DMOC445 User manual

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DMOC445 Manual
&
Operating Instructions

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DMOC445 Manual and Operating Instructions
Table of Contents
1. FOREWORD..........................................................................................................4
How to Report Errors .................................................................................................................................................4
2. SAFETY.................................................................................................................5
1. Warning Labels..................................................................................................................................................5
2.................................................................................................................................................................................5
3. Safety Symbols..................................................................................................................................................5
3. OVERVIEW............................................................................................................6
4. SPECIFICATION....................................................................................................8
5. DIMENSIONS.........................................................................................................9
1. FIGURE...........................................................................................................................................................10
2. FIGURE...........................................................................................................................................................10
3. FIGURE...........................................................................................................................................................11
4. FIGURE...........................................................................................................................................................11
5. FIGURE...........................................................................................................................................................12
6. FIGURE...........................................................................................................................................................12
7. FIGURE...........................................................................................................................................................13
6. GENERAL INFORMATION .................................................................................14
1. Mechanical.......................................................................................................................................................14
Electrical.....................................................................................................................................................................14
2. High-Voltage Connections ..............................................................................................................................14
3. Low Voltage Power Connections....................................................................................................................15
4. Signal Connections..........................................................................................................................................15
7. MODES OF OPERATION....................................................................................18
1. Motor Control..................................................................................................................................................18
2. Variables and Calibration ................................................................................................................................19
3. Error Codes......................................................................................................................................................19
4. Status Code......................................................................................................................................................20
5. Finite State Machines (FSM)...........................................................................................................................21
6. Principal Variables...........................................................................................................................................22
7. Main Parameters..............................................................................................................................................23
8. INSTALLATION REQUIREMENTS.....................................................................24
1. Mounting .........................................................................................................................................................24
2. Electrical Connections.....................................................................................................................................25
3. Connecting the 14-pin, AMP, Motor Sensor ...................................................................................................25
4. Connecting the 35-Pin AMP, Vehicle Interface Cable....................................................................................25
5. Connecting the 8-pin AMP Connector, Communications ...............................................................................25
6. Connecting the Motor Cable............................................................................................................................26

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DMOC445 Manual and Operating Instructions
Figure 5....................................................................................................................................................................29
7. Connecting the High Voltage Battery Pack.....................................................................................................34
8. Water Ingress Prevention.................................................................................................................................34
9. Grounding and Shielding.................................................................................................................................35

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DMOC445 Manual and Operating Instructions
1. Foreword
The information provided in this manual is intended for use by persons with appropriate technical skills.
Any effort to perform repairs to, or service your unit without the proper tools or knowledge required for the
work can result personal injury and product damage.
How to Report Errors
If, while reading through this manual, you discover an error in the technical information provided, Azure
Dynamics asks that you notify its Customer Service Department at the phone number provided. Please
be prepared to provide the following information:
Your name
Name and edition of your manual
Page number(s) where the error(s) appear
Serial number of your unit
Please feel free to call with any suggestions that you may have regarding the content of your manual. If
additional service information is needed or to order replacement parts, please call Monday-Friday 8AM to
5:30PM USA Eastern Time:
Phone: [phone]
Or Fax: [phone]
Information contained in this manual is based on the latest product information available at the time of
publication. The right is reserved to make changes at any time without notice
Copyright 2006 Azure Dynamics Inc. All rights reserved.
No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by
any means (including but not limited to electronic, mechanical, photocopying, and recording) without the
prior written permission of Azure Dynamics Inc. This applies to all text, illustrations, tables, and charts.

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DMOC445 Manual and Operating Instructions
2. Safety
For your safety and the safety of others, please read and understand this entire manual before installing.
If you have any questions regarding the contents of this manual, please call the Azure Dynamics
Customer Service Department before proceeding.
1. Warning Labels
Labels will be located on the right–hand side of the page to indicate areas in a procedure where you
should be taking appropriate precautions. Labels include:
2.
3. Safety Symbols
Always use caution when working on or around any electrical equipment. Wear eye protection at all
times. The following symbols will be located in the right-hand margin of your manual to indicate sections
in a procedure where extra caution and/or safety equipment is required.
Hearing Protection
Required Eye Protection Required
Always follow any safety instructions that are given at the beginning of a procedure. If you are uncertain
as to the safe and proper handling of your equipment, contact the Azure Dynamics Customer Service
Department.
WARNING and DANGER RISK OF
ELECTRIC
SHOCK

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DMOC445 Manual and Operating Instructions
3. Overview
The Azure Dynamics Digital Motor Controller (DMOC) is a rugged traction inverter for
controlling 3-phase AC motors and generators. A flexible control-software architecture
allows for application-specific customization by loading software application modules.
These application modules communicate with the motor-control core and implement the
interface to the higher level controls or directly to the driver inputs and outputs. The
application module can be as simple as a CAN communication layer or as complex as to
provide a complete electric vehicle control. The DMOC is based on state-of-the-art
control techniques and electronic devices, and offers several layers of protections to
prevent safety critical conditions.
Figure with application module and control core
Typical applications for the DMOC include the following:
• Traction drive for EVs, HEVs, and FCEVs
• Generator controller for Hybrid APUs
• Generator controller for Distributed Generation
• 3-phase motor controller for industrial applications
Note that this document only addresses the generic DMOC features. Application specific
details can be found in the following manuals which are revised and distributed
separately:
•CAN Controlled DMOC
•Pedal Controlled DMOC
The DMOC is designed to operate in a system as illustrated in the figure below.
On the DC-side, it is connected to an energy storage system (ESS) such as a battery
pack or super capacitor bank. In general, the ESS needs to be able to sink and source
power. The DMOC can be used with sources that can only source power, such as fuel-

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DMOC445 Manual and Operating Instructions
cells, but special protections are needed in such cases in order to ensure the safety of
the DMOC and ESS.
On the AC-side, the DMOC connects to a Azure Dynamics supported three-phase motor,
such as an AC Induction Motor or Permanent Magnet Motor. Specific instructions on how
to safely install the DMOC and make the necessary electrical connections are given in
this document. Since the DMOC is part of a high-voltage system it is extremely important
the directions of the document are followed and that only personnel trained to work with
high voltage install and maintain this product.
Figure with typical DMOC connections
Azure’s PC based diagnostics/calibration tool ccShell allows to access and modify DMOC
calibrations and to visualize and capture signals in real-time. While the meaning of the
most important calibrations and signals of the DMOC core is described in this document,
the reader is referred to the ccShell manual for information on how to install and use this
tool.

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DMOC445 Manual and Operating Instructions
4. Specification
Dimensions 450.1mm x 237.3mm x
231.1mm
(mating plugs not
connected)
Weight 14.7kg
Min. Nominal Battery Voltage 120VDC
Max. Nominal Battery Voltage 312VDC
Min. Operational Voltage 100VDC
Max. Operational Voltage 400VDC
Unit Peak Efficiency 97%
Min. /Max. Operating Ambient Temperature -40°C to 75°C
Max. Motor Current 280A rms
Peak Power 78kW @ 312V
Continuous Power 38kW @ 312V
Max. Voltage “On Charge” 450VDC
Minimal Auxiliary Supply Input Voltage 11 VDC 12 VDC
Maximal Auxiliary Supply Input Voltage 15 VDC 30 VDC

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DMOC445 Manual and Operating Instructions
Battery Voltage vs. Peak Power
DMOC445
30
40
50
60
70
80
90
120 170 220 270 320 370
Battery Voltage (V)
5. Dimensions

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DMOC445 Manual and Operating Instructions
1. FIGURE
2. FIGURE