Dmc Pse445tm01 User manual

Pro Controller Manual

This user manual details the features of the complete Pro Controller range:

1. Pro-AC range 24-120V, 125-650A

2. Pro-SEM range 24-120V, 125-650A

3. Pro-PM4 range 24-120V, 125-650A

4. Pro-Series range 24-120V, 125-650A

5. Pro-Pump range 24-120V, 125-650A

6. Pro-BPM range 24-120V, 125-650A T.B.A.

Modification History:

Revision Issue Date Author Changes

1.04.00 27-08-2003 R.P. Dual Motor proportional added

1.05.00 10-10-2003 R.P. Updates: Series traction & pump + general updates

1.06.00 30-01-2004 R.P. Several updates & fixes

2.00.00 23-06-2004 R.P. Support for the updated hardware and fixes + I-max increased

2.01.00 15-07-2004 R.P. Plugging setting added in motor setup PSR (series)

2.02.00 01-12-2004 R.P. Dual Pump Controller added & Improved regen adjustments (series)

2.03.00 04-02-2005 R.P. Safety improvements. SR field weakening & Speed indication.

3.01.00 19-08-2005 R.P. Modified CAN communications for display and calibrator & bugfixes

CONTENTS

1DMC PHILOSOPHY – INTRODUCTION .................................................................................................... 3

2PRO CONTROLLER VARIANTS ................................................................................................................ 4

3CONTROLLER FEATURES......................................................................................................................... 5

4TECHNICAL SPECIFICATIONS................................................................................................................. 6

4.1 ELECTRICAL ............................................................................................................................................... 6

4.2 ENVIRONMENTAL ....................................................................................................................................... 6

4.3 MECHANICAL ............................................................................................................................................. 6

5CALIBRATOR AND ADJUSTMENTS ........................................................................................................ 7

5.1 THE CALIBRATOR....................................................................................................................................... 7

5.2 CALIBRATOR MAP....................................................................................................................................... 7

5.3 TRACTION CONTROLLER:“1 ADJUSTMENTS”............................................................................................. 8

5.4 PUMP CONTROLLER:“1 ADJUSTMENTS”..................................................................................................... 9

5.5 STATUS MENU FOR ALL CONTROLLERS:“2 STATUS”................................................................................. 10

5.6 SETUP MENU FOR ALL CONTROLLERS:“3 CONTROLLER SETUP”.............................................................. 11

5.7 AC CONTROLLER:“4 MOTOR SETUP”...................................................................................................... 12

5.8 SEM CONTROLLER:“4 MOTOR SETUP”.................................................................................................... 13

5.9 SERIES CONTROLLER:“4 MOTOR SETUP”................................................................................................. 13

5.10 PM CONTROLLER:“4 MOTOR SETUP”...................................................................................................... 13

5.11 FAULT LOG............................................................................................................................................... 13

5.12 TEST MENU FOR ALL CONTROLLERS:“5 TEST”......................................................................................... 14

5.13 ABOUT MENU FOR ALL CONTROLLERS:“6 ABOUT”.................................................................................. 14

6DIAGNOSTICS ............................................................................................................................................. 15

7DASHBOARD DISPLAY ............................................................................................................................. 16

7.1 GENERAL INFORMATION........................................................................................................................... 16

7.2 DISPLAY SETUP MENU............................................................................................................................... 16

7.3 DISPLAY FEATURES SETUP ....................................................................................................................... 16

8INSTALLATION........................................................................................................................................... 17

9SAFETY.......................................................................................................................................................... 17

10 EMC GUIDELINES .................................................................................................................................. 18

11 GRAPHICS ................................................................................................................................................ 19

FIGURE 1ACCELERATOR CHARACTERISTICS.................................................................................................... 19

FIGURE 2THERMAL CUTBACK CHARACTERISTIC............................................................................................. 19

FIGURE 3LIGHT WIRING (ALL VARIANTS)........................................................................................................ 20

FIGURE 4POWER WIRING –AC ....................................................................................................................... 21

FIGURE 5POWER WIRING –SEM..................................................................................................................... 21

FIGURE 6POWER WIRING –PM4..................................................................................................................... 21

FIGURE 7POWER WIRING –SERIES.................................................................................................................. 22

FIGURE 8POWER WIRING -SERIES PUMP......................................................................................................... 22

FIGURE 9POWER WIRING -DUAL PUMP .......................................................................................................... 22

12 MECHANICAL DRAWINGS .................................................................................................................. 23

1DMC PHILOSOPHY – INTRODUCTION

DMC (Digital Motor Control) GmbH, is a new company created by a dedicated team of individuals with many

years previous experience in the design, manufacture, sales and after market support of controllers predominately

utilised in the electric vehicle industry. DMC has invested in a purpose built state of the art production facility. The

Company has been formed with enthusiasm and professionalism to create and develop a unique new product range

in this particular "niche" industry where specialist knowledge and experience are essential for success.

Utilising revolutionary power heat sinking technology called IMS (Insulated Metal Substrate) a new generation of

highly efficient controllers for all popular motor types can now be offered from a single core design, in the 24V -

120V, 1KW - 24KW power range. Using 'flash memory' in the control electronics coupled with a unique design

architecture, all powers and motor types including AC, Separately Excited, Permanent Magnet and Series (BLDC

in future), can be accommodated within 3 standard power frames. Particular attention has been placed on

providing high-resolution control circuitry and software, to provide fully optimised, highly efficient motor control.

The principle advantage of IMS technology (which can be visualised as a metal PCB) is that cost effective SMD

Mosfet power devices can be mounted and soldered directly onto the IMS PCB, which provides immediate and

excellent 'integral' heat sinking. Consequently, reliability and efficiency are significantly enhanced due to the

power switching devices running cooler and therefore inherently more efficiently. This approach also leads to

significantly improved continuous power delivery (1 hour current rating), as a ratio to peak power, with the

controllers continuous rating normally being one of the most important aspects in determining the vehicles

performance.

By using an innovative patented technique, DMC has fully exploited IMS technology to realise a unique controller

design. The construction provides manufacturing simplicity and reliability by removing the need for any

interconnections and using a minimal number of mechanical and electronic components. This gives a totally robust

and environmentally sealed, space efficient controller.

An additional feature, a ground breaking concept which epitomises DMC’s innovative spirit, is the Directly

Integrated Current Control module. This module is at the heart of all DMC controllers and provides continuous,

real time control, of motor power delivery, whilst at the same time providing full, instantaneous hardware

protection, against any over current fault condition.

DMC’s AC controller utilises a powerful dedicated motor control microprocessor together with rapid look up table

based pre-calculations, to perform it’s Sequential Phase Control (SPC) strategy. SPC uses it’s Directly Integrated

Current Control technology to independently measure all 3 phase currents every PWM cycle to provide totally

balanced smooth and efficient vehicle control. SPC provides enhanced performance over standard slip control

especially with dynamic loads, offering improved cost effective performance in between that of slip and more

complex, costly flux vector systems.

A full range of associated accessories and support infrastructure completes the DMC service.

To conclude, in our specialised purpose built facility, a fusion of creative thinking, collective experience and latest

state of the art technology, has produced what we believe to be the most flexible and thermally advanced

controller range available in the market place to date.

David Miller - Technical Director

DMC GmbH

2PRO CONTROLLER VARIANTS

PAC950TL01 Model number description

Use for motor type: AC= 3 phase AC Induction Motors

SE = Separately Exited Motors (SEM)

PM= Permanent Magnet Motors

SR=SeriesMotors

BP = Brushless Permanent Magnet (BPM)

st Digit voltage range: 3 = 24/36V 2nd and 3rd Digit I.max.: 10 = 100A

4 = 24/48V 12 = 125A

8 = 72/80V 17 = 175A

9 = 96/120V 20 = 200A

25 = 250A

st Suffix controller type: T = Traction 30 = 300A

P = Pump 35 = 350A

E = Electric Power Steer (EPS) 40 = 400A

D = Dual Pump 45 = 450A

50 = 500A

nd Suffix Controller size: L = Large 60 = 600A

M= Medium 65 = 650A

S = Small 70 = 700A

80 = 800A

rd and 4th Suffix Software Version

Model Power Configuration Unit size (L*W*H)

PAC950TL** 96-120V 500A AC Traction 320 x 200 x 56mm

PAC865TL** 72-80V 650A AC Traction 320 x 200 x 56mm

PAC835TM** 72-80V 350A AC Traction 225 x 200 x 56mm

PAC465TL** 24-48V 650A AC Traction 320 x 200 x 56mm

PAC445TM** 24-48V 450A AC Traction 225 x 200 x 56mm

PAC425TS** 24-48V 250A AC Traction 177 x 155 x 38mm

PAC950PL** 96-120V 500A AC Pump 320 x 200 x 56mm

PAC865PL** 72-80V 650A AC Pump 320 x 200 x 56mm

PAC835PM** 72-80V 350A AC Pump 225 x 200 x 56mm

PAC465PL** 24-48V 650A AC Pump 320 x 200 x 56mm

PAC445PM** 24-48V 450A AC Pump 225 x 200 x 56mm

PAC425PS** 24-48V 250A AC Pump 177 x 155 x 38mm

PSE865TL** 72-80V 650A SEM Traction 320 x 200 x 56mm

PSE835TM** 72-80V 350A SEM Traction 225 x 200 x 56mm

PSE445TM** 24-48V 450A SEM Traction 225 x 200 x 56mm

PSE425TS** 24-48V 250A SEM Traction 177 x 155 x 38mm

PSE465TL** 24-48V 650A SEM Traction 320 x 200 x 56mm

PPM835TM** 72-80V 350A PM Traction 225 x 200 x 56mm

PPM465TL** 24-48V 650A PM Traction 320 x 200 x 56mm

PPM445TM** 24-48V 450A PM Traction 225 x 200 x 56mm

PPM425TS** 24-48V 250A PM Traction 177 x 155 x 38mm

PSR865TL** 72-80V 650A Series Traction Regen and Plugging 320 x 200 x 56mm

PSR850TM** 72-80V 500A Series Traction Regen and Plugging 225 x 200 x 56mm

PSR465TM** 24-48V 650A Series Traction Regen and Plugging 225 x 200 x 56mm

PSR445TM** 24-48V 450A Series Traction Regen and Plugging 225 x 200 x 56mm

PSR425TS** 24-48V 250A Series Traction Regen and Plugging 177 x 155 x 38mm

PSR865PL** 72-80V 650A Series Pump 320 x 200 x 56mm

PSR865DL** 72-80V 650A+60A Series Dual Pump (Pump and Power steer) 320 x 200 x 56mm

PSR850PM** 72-80V 500A Series Pump 225 x 200 x 56mm

PSR465PM** 24-48V 650A Series Pump 225 x 200 x 56mm

PSR445PM** 24-48V 450A Series Pump 225 x 200 x 56mm

PSR445DM** 24-48V 450A+50A Series Dual Pump (Pump and Power steer) 225 x 200 x 56mm

PSR425PS** 24-48V 250A Series Pump 177 x 155 x 38mm

PPM425ES** 24-48V 250A PM Electric Power Steer (EPS) 177 x 155 x 38mm

PPM817ES** 72-80V 175A PM Electric Power Steer (EPS) 177 x 155 x 38mm

3CONTROLLER FEATURES

Feature Large Medium Small

All

variants

All

variants

All

variants

Number of Digital switch inputs. 7 7 7

Number of Analogue inputs 3 3 3

Number of Contactor drive outputs (3 Amps) 3 3 2

Number of signal only (DMC external driver module needed) 2 2 3

24V - 96V Operation yes yes yes

Single PCB design, no internal connections yes yes yes

IMS PCB for superb thermal conduction yes yes yes

Heat sinked Power terminals yes yes yes

Full automatic assembly yes yes yes

Flash memory, easy software update yes yes yes

Environmental protection IP 55 (PCB varnished) yes yes yes

Microprocessor control yes yes yes

High frequency (Silent Operation) yes yes yes

Internal watchdog monitoring microprocessor operation yes yes yes

Arc less contactor switching and built in coil suppression yes yes yes

Low impedance, active low inputs switched to B-ve yes yes yes

Thermally compensated current limit yes yes yes

Selectable accelerator characteristics yes yes yes

Adjustable creep speed yes yes yes

Seat switch timer yes yes yes

Power steer timer yes yes yes

Electro brake timer yes yes yes

Belly switch operation yes yes yes

Regenerative and plug braking yes yes yes

Braking proportional to accelerator position yes yes yes

Braking in neutral yes yes yes

Braking with brake pedal yes yes yes

Under and Over-voltage protection yes yes yes

Accelerator wire off detect yes yes yes

Inching facilities yes yes yes

Short circuit and open circuit contactor detect yes yes yes

3 traction cutback speeds yes yes yes

6 Pump speeds with Additive, Priority & Compensation yes yes yes

Input to disable pump operation yes yes yes

Independent Power steer speed and compensation settings yes yes yes

Hardware and Software fail-safe systems yes yes yes

+ 12V output pin yes yes yes

Diagnostics with LED indication yes yes yes

Remote LED on SEM and PM4, optional on Series controllers yes yes yes

Adjustments made via a calibrator yes yes yes

CAN communications yes yes no

Hours count displaying Key & Pulsing hours on calibrator yes yes yes

BDI on Calibrator yes yes yes

Dashboard display connectable yes yes no

Easy to use ‘icons’ for display information yes yes no

Reset table Service and Fault logs yes yes yes

Setup menu on calibrator to enable various options yes yes yes

4TECHNICAL SPECIFICATIONS

4.1 Electrical

4.1.1 Voltage specifications:

Model Voltage Nominal battery voltage Absolute operating voltage range

PXX3xxXX 36V Units 24-36V 14.5 - 50.0V

PXX4xxXX 48V Units 24-48V 14.5 - 63.0V

PXX8xxXX 80V Units 72-80V 43.0 - 97.5V

PXX9xxXX 96V Units 96-120V 60.0 - xx.0V (tbd)

4.1.2 Current specifications:

Model Power Current

limit

(1 min)

Continuous current 1 hour rating. Unit

mounted on an sufficient heatsink, at 20°C

ambient.

PXX410XX 48V 100A 100A 45A

PXX412XX 48V 125A 125A 55A

PXX425XX 48V 250A 250A 80A

PXX445XX 48V 450A 450A 180A

PXX465XX 48V 650A 650A 260A

PXX835XX 80V 350A 350A 120A

PXX845XX 80V 450A 450A 160A

PXX850XX 80V 500A 500A 180A

PXX865XX 80V 650A 650A 240A

PXX950XX 96V 500A 500A 200A

Switching Frequency: SR, PM, SEM: 14.5 KHz Traction/Regen/Pump Drive and 8KHz Plug Braking.

AC, BPM: Controller frequentie is 8KHz, motor frequentie is 16KHz.

Electrical Isolation: Enclosure to any live part = 1KV. Controller internal insulation specified at >

10MΩ @500V DC. Dielectric strength 6000V.

Reverse Battery Polarity: Not protected.

I/O details: See light wiring diagram.

4.2 Environmental

Impact Protection (IP): The enclosure is protected to IP55 (varnished PCB)

Vibration: 6G, 40-200Hz for 1 hour, in x, y and z planes.

Operating Temperature: -30oC to +40oC ambient around controller.

Storage Temperature: -40oC to +70oC.

Humidity: 95% maximum, non-condensing.

Humidity Resistance: Varnished PCB stops water damaging the controller.

4.3 Mechanical

Details: See mechanical drawings.

Enclosure: Aluminium heat sink with ABS plastic cover.

Power connections: Vertical Copper studs.

Hexagonal: Recommended fixing torque 9.5Nm (Slot screws are recommended!)

Slot screw: Recommended, fixing torque 9.5Nm (Brass)

Bolt length: Max 16mm incl. washer and spring washer

Weight: Small: 1.2Kg; Medium: 4.1Kg; Large: 6.1Kg

•Always use a torque wrench when fixing the power terminals.

•Exceeding the maximum specified torque can cause serious damage to the

controller and warranty might be void.

•To long bolts damage the controller.

5CALIBRATOR AND ADJUSTMENTS

5.1 The Calibrator

General

The DMC Calibrator is designed for Setting up the Pro-Series

controller range. It also has a build-in interface for controller and

calibrator software updates via RS232. This guarantees maximum

flexibility and no waste of hardware when only the software must be

updated.

Software updates

On the top-right-hand side a 3-way switch is used to select the

operating mode. For normal operation it must be in position 2. For

flashing new controller software it must be moved to position 1 and for

new calibrator software it must be moved to position 3.

To be able to update the software it is necessary to have a software

package installed and off course a copy of the new DMC software

release. For detailed information on updating software please contact

your DMC supplier.

CAN Node Setup

When connecting the Calibrator to a controller it will ‘scan’ the CAN

bus for all available Nodes, to enable calibration of all DMC controllers

on the same bus. All controllers are by factory default set to Node 0.

Therefore before using this feature, give all controllers on the bus a

unique Node number. To do this, the calibrator must be plugged in to

the controller you want to adjust the Node number on (menu item 3.17)

Adjustments

The calibrator is easy to use. The up and down buttons are used for

scrolling up and down. Selections can be made with the SEL-button.

The plus- and minus-buttons are used to increase or decrease the

parameters.

5.2 Calibrator map

•The calibrator remembers the cursor position in the submenus until key-off.

•When connecting more then 1 node to the CAN bus, the calibrator will react slightly

slower.

5.3 Traction Controller: “1 Adjustments”

Cal

Ref

Parameter Calibrator

text

Controller

type

Min.

adjust

Max.

adjust

Step size

DMC

default

Actual

setting

1 Acceleration delay Accel All 0.1 S 10.0 S 0.1 S 2.0 S S

EPS 25 ms 1000 ms 25 ms 100 ms ms

2 Deceleration delay Decel All 0.1 S 10.0 S 0.1 S 0.3 S S

EPS 25 ms 1000 ms 25 ms 100 ms ms

3 Creep speed Creep AC 0 Hz 16 Hz 0.0625 Hz 0 Hz Hz

SR, SE, PM 0 % 25 % 1 % 0 % %

4 Maximum speed forward SpdMaxF AC 0 Hz 300 Hz 1.0 Hz 300 Hz Hz