Azure Dynamics DMOC445 User manual

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Azure Dynamics Inc.
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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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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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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

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3. FIGURE
4. FIGURE

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5. FIGURE
6. FIGURE

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7. FIGURE

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DMOC445 Manual and Operating Instructions
6. General Information
1. Mechanical
The DMOC has a light-weight aluminum package which is rated IP 54. The component
cover and heatsink base are gold Iridited per MIL-C_5541-E-Class 1a for corrosion
protection. When installing the DMOC into a system, avoid locations in which the DMOC
is frequently exposed to water. Also, the DMOC is not designed to withstand pressure-
washing and needs to be protected accordingly.
In order to isolate the DMOC from vehicle vibrations and shock, it is very important that
the controller be vibration damping mounted. Please refer to the “Installation” section in
this document for further information.
Two DMOC versions exist: air-cooled and liquid cooled. For the air-cooled version, the
cooling fans are automatically turned on by the DMOC thermal management system.
The liquid cooled version required cooling mixture of water (43%) and ethylene glycol
(57%) by volume.
•Maximum and minimum cooling pressure to apply at the inlet side is 12-10 psig,
•Maximum and minimum cooling temperature at inlet is +55C and +40C.
•Normal cooling flow rate is 7.5 to 10 LPM @ 1.4 and 2.5 psi, respectively.
•The cooling chamber cover plate has been tapped to accept 1/4NPT fittings (see
figure 5).
Electrical
2. High-Voltage
Connections
All high-voltage connections are made in the terminal box which is attached to the
heatsink of the DMOC. It is imperative that appropriate safety steps are taken when
connecting or disconnecting high-voltage cables. This manual provides some
recommended safety practices, but they are not meant to be comprehensive and it is
important that only people with up to date high-voltage training install or uninstall the
DMOC. All high-voltage connections have to be assumed to be “hot” at all times,
independent of the state of the DMOC or signals reported by the DMOC.
For correct operation of the traction drive, the AC connections to the motor need to be
appropriately shielded and the connection to the terminal box must be made according to
the instructions in this document. Since the DMOC is only indented to be used with Azure
motors, the motor wiring will be “dressed-up” appropriately for connecting with the
DMOC. Do not shorten or lengthen the motor cables without duplicating the original
connection and shielding configuration.
Shock
Hazard:
Extreme caution should be used whenever
working on or near the high voltage system.

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The DC connection may be non-shielded. Only 4 AWG 600 V rated cables are to be
used, which need to be properly fused as close as possible to the energy storage system
(ESS). Note that the DMOC does not provide any internal fusing on the high-voltage
connections. It is also very important that ESS be galvanically isolated (i.e. no direct
electrical connection) from the chassis of the vehicle as well as from the low voltage
system of the vehicle.
Some versions of the DMOC do not provide an internal contactor with pre-charge
function. These units are clearly marked as such and require an external pre-charge
mechanism (typically provided by the ESS). If a DMOC is connected without correct pre-
charge, the unit can be damaged.
For additional safety as well as for controlling EMI, the DMOC needs to be grounded to
the frame of the vehicle by means of a braided ground strap (preferably one that is short
and wide in dimension).
3. Low Voltage Power Connections
The DMOC requires a 12 V or 24 V auxiliary supply in order to power its internal circuits
as well as the main contactor (if present) and the cooling fans (in case of an air-cooled
heatsink). Air-cooled inverters need to be configured specifically for one nominal voltage.
Units without fans can operate from either voltage.
The 12/24 V auxiliary supply needs to be able to source 10/5 A of current and must
protected by a 15/7 A fuse. The auxiliary supply also acts as an enable signal for the
internal power supply of the DMOC. In other words, even a DMOC without contactor or
cooling fan requires 12/24 V to be present in order to operate.
4. Signal Connections
Three connectors located on the side of the DMOC cover near the mounting holes
provide all signal connections. Please select mating connectors from the table below.
AMPSEAL connector contacts will accept 20 to 16 AWG wire with insulation diameter of
1.7 – 2.7 mm. Use CERTI-CRIMP Straight Action Hand Tool, AMP P/N: 58440-1.
Table 2. AMPSEAL Automotive Plugs.
No. of positions AMP Brand AMP Connector P/N AMP Terminal P/N
8 AMPSEAL 776286-1 770854-3
35 AMPSEAL 776164-1 770854-3
14 AMPSEAL 776273-1 770854-3
The smallest connector has eight pins and provides the signals for CAN communications
as well as RS-232. A second connector with 16 pins is used for connecting the motor
speed-sensor cable. The third and largest connector has 35 pins and carries general
digital and analog IO pins as well as the inputs for the auxiliary 12/24V power supply.
Application specific connections to the 35-pin connector are described in the applications
user manuals.

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Table 3. Typical Signal Connector Pin-out.
Pin # Signal: Function:
J6: Primary Control Interface Connector, 35-pin Amp seal
1 KEYED_12V_SRC Keyed-12V and relay power
2 SOC_BUF 12V open-collector gauge drive
3 ACCEL_PEDAL Accelerator pot signal
4 BRAKE_LO Brake pedal pot low
5 GND_A Top Board Gnd
6 PEDAL_LO Accelerator pot low
7 REGEN_DISABLE- Regen brake disable
8 DRIVE_DISABLE- Interlock
9 NONISO_ADIO2 Analog/digital I/O
10 AHC_DATA_- Amp-hour counter input
11 ANAIN3/LED_OVERTEMP Analog input or LED
12 BACKUP_LT_SINK/LED_EMPTY Isolated MOSFET collector or LED
13 KEYED_12V_SINK Keyed-12V and relay power
14 BRAKE_LT_SRC Isolated MOSFET drain
15 POWER_SAVER Power saver potentiometer
16 GND_A Top Board Gnd
17 ANAIN1 Analog input 0-5V
18 REVERSE- Reverse direction
19 GND_D Top Board Gnd
20 GND_D Top Board Gnd
21 GND_A Top Board Gnd
22 AHC_GND Amp-hour counter return
23 BACKUP_LT_SRC/LED_FULL Isolated MOSFET collector or LED
24 BRAKE_LT_SINK Isolated MOSFET collector
25 SPEEDO_BUF 12V open-emitter gauge drive
26 BRAKE_PEDAL Brake pedal pot signal
27 ANAIN0 Analog input 0-5V
28 PEDAL_HI Accelerator pot high
29 FORWARD- Forward direction
30 DRIVE_ENABLE- Interlock
31 NONISO_ADIO1 Analog/digital I/O
32 AHC_DATA_+ Amp-hour counter input
33 AHC_NEG Amp-hour counter input
34 ANAIN2/LED_MALFN Analog input or LED
35 GND_D Top Board Gnd

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J4: Motor Signal Connector (14-pin Amp seal)
1 ENC_A1 Motor position encoder input
2 ENC_A2 Motor position encoder input
3 ENC_B1 Motor position encoder input
4 ENC_B2 Motor position encoder input
5 GND_D Top Board Gnd
6 ENC_I1 Motor position encoder input
7 ENC_I2 Motor position encoder input
8 FUSED_+5V Fused digital +5V
9 MTR_TEMP Motor temp input
10 GND_A Top Board Gnd
11 +5Ref Analog 5V reference
12 GND_D Top Board Gnd
13 NONISO_DI1 Digital Input
14 NONISO_DO1 Digital Output
J5: Communications Connector (8-pin Amp seal)
1 RS232_TXD RS232 Tx
2 RS232_RXD RS232 Rx
3 GND_B Comm. GND (RS232 & CAN)
4 CANH CAN High
5 GND_B Comm. GND
6 CANL CAN Low
7 GND_B Comm. GND
8 Chassis GND Chassis GND

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7. Modes of Operation
1. Motor Control
At its core, the DMOC is a voltage source inverter (VSI) with high-bandwidth synchronous frame current
regulation.
Synchronous Frame Current Regulator
Torque & Flux
Controller
Id*
Iq*
Torque Command
Speed DC Voltage
Motor & IGBT
Protection Current Limit
Battery
Protection Power Limit
Torque Controller with Protections

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2. Variables and Calibration
DMOC diagnostics and configuration is achieved by means of Azure’s diagnostics tool called ccShell,
which allows access to a number of variables (signals) and parameters (a.k.a. calibrations). Variables are
read-only while parameters can be modified (depending on the access rights) in order to configure the
DMOC. Parameter changes can be made persistent by saving them to non-volatile memory (EEPROM).
There also exists a special category of non-volatile parameters which are saved to EEPROM and
maintain their values when the unit is powered down. Non volatile parameters and variables can be
identified by their prefix. The following naming convention is used:
•EE1, EE2, EEX: parameters
•EE3: non-volatile variables
3. Error Codes
The DMOC stores error conditions in non-volatile variables and maintains an error history by means of
five variables:
•EE3LastError: Most recent error
•EE3LastError1 – EE3LastError3: Error history, where Error3 is the oldest error.
•EE3ErrorCounter: Total number of errors
Only the four (4) most recent errors are retained.
Error codes are stored in a 16-bit representation where each bit is a signal for a specific error.
•Bit 0: Over-current phase A (hardware protection)
•Bit 1: Over-current phase B (hardware protection)
•Bit 2: Over-current phase C (hardware protection)
•Bit 3: Over-voltage on DC link (hardware protection)
•Bit 4: Relay error (hardware protection)
•Bits 5-6: Reserved
•Bit 7: Desat Error
•Bit 8: Relay error (software protection)
•Bit 9: Phase over-current (software protection)
•Bit 10: Over-voltage DC link (software protection)
•Bit 11: Current sensor offset calibration error (software protection)
•Bit 12: Over-speed protection (software protection)
•Bits 13-15: Reserved

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Most errors can be reset by the application software. However, a small subset of errors is considered
critical and can not be cleared without completely powering down the controller. Errors falling into the
critical category are: desat-error and current sensor calibration error.
4. Status Code
The status of the DMOC is displayed by the variable ISR2StatusCode. Similar to the error code, the
information is coded in a bit-wise fashion:
Bit 0: 0= contactor open, 1=contactor closed
Bit 1: 0=power stage not ready, 1=power stage ready
Bit 2: 0=power stage OK, 1=power stage faulted
Bit 3: 0=more torque available, 1=max torque limit reached
Bit 4: 0=more power available, 1=max power limit reached
Bit 5: 0=no thermal limit active, 1=thermal limit active
Bits 6-7: reserved