Electric Drive Engineering EDE Installation instructions

Installation &
Operating Manual
48kW EDE Electric Drive Kit

48kW EDE Electric Drive Kit
Electric Drive Engineering
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Installation & Operating Manual
Contents
Safety Disclaimer...................................................................................................................................... 2
Technical Support and Warranty.................................................................................................. 3
Introduction..................................................................................................................................................4
Packing List ...................................................................................................................................................5
System Overview ......................................................................................................................................6
Components................................................................................................................................................ 7
Assembly...................................................................................................................................................... 15
Operating Guide.......................................................................................................................................17
Troubleshooting ...................................................................................................................................... 18
Contact Information
Electric Drive Engineering
10/52 Kent St, Cannington, Western Australia 6107
[email protected]
www.electricdriveengineering.com.au

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Electric Drive Engineering
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Installation & Operating Manual
Safety Disclaimer
Electric motors and inverters are high powered devices which involve
potentially lethal voltages and currents. Proper precautions and electrical
safety procedures should always be observed.
Never touch or work on this equipment live.
Please read this manual carefully before using this equipment to ensure
correct installation and operation. If you are unsure of anything, please
contact us before proceeding.
User Responsibility
We have endeavoured to make a safe and reliable product however since
Electric Drive Engineering has no control over the integration of its products,
we can assume no responsibility for the safety or functionality of the
completed vehicle/machine. It is up to the end user to determine the
suitability of the products for the purpose employed, and the end user
assumes all risks associated.
Qualified Personnel Only
This product should only be installed by suitably qualified and experienced
persons and should always be used in a safe and lawful manner. Please
check your state or territories electrical regulations to ensure you are
suitably qualified to install/use this product.

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Electric Drive Engineering
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Technical Support and Warranty
This product is covered by a 12-month warranty against manufacturing
faults or failures under normal operating conditions. The warranty does not
cover misuse of the product, including but not limited to:
•Modifications made to the harness (e.g. cutting the harness)
•Modification made to the DCF
•Excessive voltage or reversed polarity on input terminals
•Short circuits on output terminals
•Excessive voltages applied to control wiring
•Opening of housing and/or modification of internals
•Severe impact damage
•Exposure to water
We have taken great care to design a safe and reliable product, but faults
can happen. If you believe this product has a fault, please contact us via our
website to discuss.
If you have any questions not covered by this manual, please contact us at
[email protected]

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Electric Drive Engineering
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Installation & Operating Manual
Introduction
Thank you for your purchase of an Electric Drive Engineering 48kW EDE
Electric Drive Kit . Please notify us immediately if any damage has occurred
during shipping.
About This Guide
This installation guide provides instructions and guidelines for assembling,
mounting, starting, and operating your 48kW EDE Electric Drive Kit .
This guide is intended to be used in conjunction with the following:
• Sevcon Gen4 Applications Reference Manual
• Sevcon Clearview Display Reference Manual

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Electric Drive Engineering
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Packing List
The standard packaging for the 48kW EDE Electric Drive Kit consists of two
parcels with a combined weight of 33kg.
Package 1
Weight: 26kg
Dimensions: 370mm x 370mm x 320mm
Item #
Description
Quantity
Purpose
1a
Motenergy ME1616
1
Traction motor
1b
Phase cables
3
Cable between motor and
controller
1c
Mounting Bolts and
washers
4
Secure motor
Package 2
Weight: 8kg
Dimensions: 390mm x 290mm x 120mm
Item #
Description
Quantity
Purpose
2a
Sevcon Gen4 Size 6
Controller
1
Inverter/Controller
2b
Multi leaf
Connector
1
Connect B+ and Contactor
2c
500A Fuse
(attached to
controller)
1
Battery fuse
2d
Gigavac GV200PA
1
Contactor to switch ON/OFF
battery power
2e
Wire Harness
1
Control/Aux Power/CAN
2f
Throttle
1
Control
2g
Sevcon Clearview
1
Dashboard, Modify driveability
parameters
2h
Battery Cable
2
Connect battery to controller
(via contactor and fuse)
2i
Coolant Pump
1
Circulate coolant through motor

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Installation & Operating Manual
System Overview

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Electric Drive Engineering
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Components
Sevcon Gen4 Size 6
The SEVCON Gen4 Size 6 motor controller is designed to control 3-phase
Permanent Magnet Alternating Current (PMAC) motors for traction and
pump applications. A diagram of the unit is shown in Figure 1. There four
mounting holes, one in each corner of the metal heatsink. In the top left-
hand corner is a LED indicator. To the left side of the unit is a female
connector for a 35-way AMPSeal plug which is a commercially available
automotive plug developed by TE Connectivity. This plug is used to attach
input/output(I/O), communications, and control power. In the centre of the
unit are three terminals labelled M1, M2 and M3. These terminals are for
connecting each phase to the motor. At the bottom of the unit are three
terminals for connecting traction power. The left most terminal, labelled B-
is for connecting battery negative. The terminal labelled + is a dummy
terminal and is used to support a fuse between the line contactor and the
B+ terminal which is the right-most terminal.
Figure 1 Sevcon Gen 4 Size 6 Features

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Ensure battery positive is connected to the Gen4 through the
surface mounted fuse.
Motenergy ME1616
The Motenergy ME1616 is a water-cooled permanent magnet synchronous
motor. A diagram of the unit is shown in Figure 2. The ME1616 comes with the
phase cables and 8-way plug already attached. The 8-way plug passes
rotor position and temperature data to the Sevcon controller.
Figure 2 Motenergy ME 1616 Features

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Electric Drive Engineering
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The ME1616 is designed to operate with circulating coolant passing through
it. A coolant pump is supplied.
The motor must be adequately secured before being turned on.
Gigavac GV-200PA
The Gigavac GV-200PA is a hermetic sealed DC relay that allows the Sevcon
Gen4 controller to switch ON and OFF high-current battery power. A relay is
required so that the controller can remove power to itself as well as pre-
charge.
What is Pre-charge?
Motor controllers contain large capacitors which bring
about two problems. Firstly, when in a discharged state
they temporarily behave as a short circuit, drawing large
inrush currents until fully charged. These inrush current
can be many times greater than the rated capacity of
internal components and can cause serious damage. Secondly, when
power is removed the capacitors maintain stored energy that takes
time to discharge. This leaves a short time window where the unit is OFF
but still contains dangerous voltages.
Although inrush currents only last a short time their sheer magnitude
can cause permanent damage to components. Pre-charging is one
method of reducing this effect. Pre-charging works by applying battery
voltage to the capacitors through a large resistor. Once the capacitors
have reached an appropriate level of battery voltage (usually 90%), the
battery can be directly applied.

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Electric Drive Engineering
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Harness
The harness is made up of several components as shown in Figure 3 and
Figure 4.
Figure 3 Harness components A
Keep the harness wires separate from the phase and power
cables as much as practical to minimise electromagnetic
interference (EMI).
#
Component
Purpose
A
Auxiliary Power Supply Wires
Provide auxiliary power supply for
controller
B
Contactor Coil Wires
Allows the controller to apply power to
the relay coil to OPEN and CLOSE the
battery positive cable.
C
BMS Enable Wires
(Optional) Allows connection to
battery management system (BMS).
This must be connected if not used.

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D
Throttle Connector
Allow connection to throttle of choice
(5 types available)
E
5A Fuse
Short circuit protection
F
Motor Connector
Passes position and temperature data
to the controller
G
Programming Port
Allows connection to PC (IXXAT USB-
CAN interface, Sevcon DVT software
and licence required for use)
H
35-Way Connector
Connects harness to Sevcon Gen 4
controller
Figure 4 Harness components B
#
Component
Purpose
I
Ignition
Turn system ON and OFF
J
Forward/Neutral/Reverse
Switch
Change direction of motor rotation
K
Brake Regen Adjust
Control the level of regenerative braking

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L
Drive Select
Switch between Drive Mode 1 and Drive
Mode 2
M
Clearview Display Plug
Connect to Sevcon Clearview Display
Modifying/cutting the harness will void the warranty of the
harness component of this system.
How does regenerative braking work?
Regenerative braking is used to recover kinetic energy
which is converted into electrical energy for storage in
the battery. When an electric vehicle is moving it has
kinetic energy. The faster it is going and the heavier it is
the more kinetic energy it has. When you brake on a
traditional vehicle, that energy is converted into heat and sound by
brake pads, wheels etc. This essentially throws away all that energy and
wastes it. On an electric vehicle with regenerative braking, the
controller instead puts the electric motor in reverse and turns it into a
generator which generates power. The vehicle slows down gradually as
the kinetic energy is turned back into electrical energy and then stored
in the battery for later use.
The regen dial on the harness adjust the amount of regenerative
braking. It can be used as a dial or connected to a foot pedal.
Sevcon Clearview Display
The Sevcon Clearview Display is a colour display that shows information sent
from the Gen4 controller. The user can also change drivability
characteristics (such as ramp rate) from the Clearview.
The Clearview Display and the Gen 4 controller pass information between
each other via a CAN network. A CAN network requires both ends of the
signal wires to have signal termination. Signal termination prevents signals
from reflecting from each end of the cable causing interference. Both the
Gen4 controller and the Clearview have internal termination.

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If the Clearview is unplugged, you may require a 120ohm
resistor across the CAN high CAN low terminals.
Throttle
The throttle is used to send torque demands to the controller.
Water pump
The Water Pump specifically designed for cooling EV motors and controllers.
The recommended cooling arrangement is shown in Figure 5.
Do not run the water pump dry as this could lead to permanent
damage.
Figure 5 Recommended liquid cooling setup
The following are the recommended cooling system parameters:
•Aluminium corrosion and freezing preventing coolant (water/glycol
50/50 mix)
•Flow rate ≥6 l/min
•Inlet temperature ≤ 45°C

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Electric Drive Engineering
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Installation & Operating Manual
The chosen radiator needs to be dimensioned to dissipate the machine
losses at the specified flow rate and fluid temperature –generally a small
radiator from motorcycle is sufficient.

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Electric Drive Engineering
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Assembly
1. Ensure you have thoroughly read this manual and Sevcon Gen4
Applications Reference Manual before commencing assembly.
2. Securely mount the motor and set up coolant system. Ensure the bolts
do not penetrate too deeply into the motor casing. Failure to do so
could result in damage to the motor windings. Bolts should be
tightened to 22Nm.
3. Mount the controller. Ensure the controller is securely mounted from a
mechanical and thermal perspective. See Sevcon Gen4 Applications
Reference Manual for more details.
The provided bolts are suitable for a mounting plate thickness
of 10mm minimum. Please make alternative arrangements if
mounting plate thickness differs.
4. Terminate the motor phase cables to the controller as per Figure 6.
(11Nm ± 2Nm)
Figure 6 Correct cables and harness arrangement

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5. Connect the contactor to the controller via the multi leaf connector as
shown in Figure 6. Do not connect the battery side yet and ensure the
relay coil wires are disconnected. (8Nm for the contactor side, 11Nm ±
2Nm for the controller side)
6. Connect the 35-way plug into the controller. Connect the Clearview
display and throttle to the harness. Ensure the throttle is in the
minimum position, the key switch is in the OFF position, and the
forward/neutral/reverse switch is in neutral.
7. Connect the negative battery cable through an isolator (not supplied)
to the B- terminal of the controller as shown in Figure 6. At the same
time connect the negative auxiliary wire from the harness to the same
terminal.
8. Connect the positive battery cable through an isolator (not supplied)
to the contactor as shown in Figure 6. At the same time connect the
positive auxiliary power wire from the harness to the same terminal.
9. Confirm the isolator is open (i.e. no battery current can flow) and
double check steps 1-7 before connecting the relay coil wires to the
contactor as per Figure 6.

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Installation & Operating Manual
Operating Guide
Incorrectly wired or configured electric drives may behave in
unexpected ways. Always confirm correct operation before
connecting to a vehicle or machine.
Pre-start Checklist
•Confirm the throttle is in the minimum position, the key switch is in the
OFF position, and the forward/neutral/reverse switch is in neutral.
•Confirm battery isolator is open (i.e. no current can flow)
•Confirm all connections are tightened to specified level.
•Confirm all plugs are fully inserted.
•Confirm power wiring connections are made to the correct terminals
(B+, B-, +, M1, M2 and M3).
•Confirm the controller is securely mounted (from a mechanical and
thermal perspective).
•Confirm motor coolant system is operational.
•Confirm 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.
•Check motor drive shaft is clear of obstructions.
Start-up Procedure
1. Confirm the throttle is in the minimum position, the key switch is in the
OFF position, and the forward/neutral/reverse switch is in neutral.
2. Turn on main isolator switch to connect system to battery.
3. Turn the key switch to the ON position.
If the system is correctly installed, a loud click should be heard from the
contactor and the green LED on the controller should be constantly lit. If this
is not the case, the system should be powered down and the above checks
repeated.

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Electric Drive Engineering
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Troubleshooting
The following section describes some of the typical issues and how to
resolve them. If you have any questions not covered by this manual, please
contact us via [e-mail].
Avoiding Electromagnetic Interference
Some precautions can reduce the level of electromagnetic emissions:
•Keep signal wires (particularly the motor encoder) separate from
power cables as much as practical.
•Keep the controller and motor as close as practical to reduce power
conductor length.
•Keep all the motor phase cables as close together as practical in the
routing from controller to motor.
•Route DC conductors side by side.
•Always use proper grounding and shielding in the remainder of the
system.