Italsea 7CH4Q107 User manual

7CH4Q107_E_4 DATE : 28/06/2013 REV. 4.0
7CH4Q107
MICROPROCESSOR FOUR QUADRANT CONTROLLER FOR
PM DC MOTORS EXTERNAL PROGRAMMER
- USER’S GUIDE -

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CONTENTS
INTRODUCTION
Page 2
FEAUTURES
Page 2
SAFETY, MODELS
Page 2
MECHANICAL DRAWINGS
Page 3
INSTALLATION
Page 4
WIRING DIAGRAM
Page 5
I/O CONNECTOR
16 pin connector
Page 6,7
4 pin connector
Page 7
power screws
Page 7
CONTROLLER SETTING
7PROGLCD HANDHELD PROGRAMMER
Page 8
TESTER MODE
Page 9
ALARMS
Page 10,11
PARAMETERS
PARAMETRS
Page 12
RESET TO DEFAULT
Page 13
GENERAL SETTING
Page 13,14
SPEED REFERENCE SETTINGS
Page 15
ELECTROBRAKE OUT PUT SETTING
Page 18
MULTIMODE INPUTS SETTING
Page 19
BACKWARD SAFETY SETTINGS
Page 19
OVERLOAD PROTECTION
Page 20
ENGEERING PROTECTED PARAMETERS
Page 21

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INTRODUCTION
The controller 7CH4Q107 is a 4 quadrant chopper for PMDC motors powered by battery
24/36V for traction applications.
The chopper is equipped with a powerful microprocessor for digital control of the speed,
current regulation and failures of the motor ; an efficient diagnostics of the failures and
wrong wiring connections, programmability of the main parameters .
The MOSFET power stage is an “H bridge” configuration operating with PWM.
The ripple of the current is very low so the efficiency of the system is very high .
The chopper is designed in accordance with the most important EC standards.
FEATURES
POWER SUPPLY BATTERY 24 – 36 V
RATED CURRENT 30A
MAX CURRENT ( Ta = 25°C) 120
FREQUENCY 16 KHz
MAX HEATSINK TEMPERATURE 90 °C
OPERATING TEMPERATURE -10°C / 40°C
SPEED REFERENCE Voltage (0,5-4,5Vdc) or potentiometer 1-10 KΩ
ON BOARD MAIN CONTACTOR 24V-80A CONTINUOS
REGENERATIVE BRAKING
PARAMETERS PROGRAMMABLE
SAFETY:
•OUTPUT SHORT CIRCUIT PROTECTION
•MOSFET SHORT CIRCUIT PROTECTION
•THERMAL PROTECTION
•LOW VOLTAGE AND OVERVOLTAGE PROTECTION
•REVERSE BATTERY PROTECTION
•OVERCURRENT PROTECTION FUNCTION OF TEMPERATURE
•POTENTIOMETER AND WIRINGS FAULT

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MECHANICAL DRAWING
fig.1

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INSTALLATION
fig.2
Locate the chopper in a place protected against mechanical abuse, water and dirty.
Fix it with all the screws on a metal surface (aluminum if possible) to reduce the heath and
so for longer period of work.
If during the standard operations the thermal protection is activated very often an
additional heath-sink or fan is requested to assure longer periods of work.

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COMPLETE WIRING DIAGRAM

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I/O CONNECTOR
16v Molex connector (Molex p/n.39012160, contacts p/n.39000038)
fig.4
Pin 1: HI –POT. INPUT
Positive Potentiometer Supply
Pin 2: C-POT.INPUT
Central Potentiometer, or Voltage (0,5-4,5Vdc) Speed Reference Input
Pin 3: LO-POT.INPUT
Negative Potentiometer Supply, or Gnd Voltage Speed Reference Input
Pin 4: Pin 2:V_MAX (OPTIONAL)
Max speed input potentiometer (>100 KΩ).
Pin 5: PUSH
Default N.O. input contact ( +V_Batt/Pin14) for Backward safety. This input is
active when close.
Pin 6: DISABLE
Default N.C. input contact. When the contact is open the controller will decelerate
(Neutral Ramp) , will check if the motor voltage is near zero (motor stopped) and
after the electro-brake delay will inhibit the motor : appear the alarm A12 (to reset
switch-off and on again the key). If the contact will be close before the motor stop,
the machine will restart at the desired speed.
Pin 7: ELECTROBRAKE COIL ( - )
Output active low 2 Amps max (short circuit protected) and internal diode.
Pin 8: ELECTROBRAKE / HORN COIL (+)
Common +V battery for electro-brake and horn coils.
Pin 9: HORN ( - )
Output active low ( close to –Battery) for the horn or light backward direction
(2 Amps max, short circuit protected, and internal diode).

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Pin 10: ALARM
Connection for the diagnostic Blinking Led indicator (5Vdc-10mA) output : the
number of blinks means the alarm type (example 5 blinks means Alarm 5).
Pin 11: MODE 1
Default N.O. input to +V battery.
Pin 12: FORWARD SWITCH
N.O. input to +V battery.
Pin 13: BACKWARD SWITCH
N.O. input to +V battery.
Pin 14: COMMON HIGH
+V battery output for switches.
Pin 15: KEY IN
Key switch input (+V battery).
Pin 16: HOURMETER
Hour-meter output ( +V battery when running, 100mA max).
4v Molex connector (Molex p/n.3901240, contacts p/n. 39000038)
Used for handheld programmer
M5 power screws (M5)
+ B: Positive DC power supply input,
- B: Negative DC power supply input,
M1: Positive Motor output
( in forward direction ),
M2: Negative Motor output
( in forward direction )
F1: Power fuse 150A.
F2: Fuse 10A.
fig.5

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7PROGLCD HANDHELD PROGRAMMER:
fig.8
LCD 16X2:
Displays parameters, alarms and measures (description and
value).
UP Key:
Rolls up parameters and increases values.
MODE Key:
Confirms a selection and the change of value.
UP Key:
Rolls down parameters and decreases values.
At power-on, handheld programmer displays the “Tester Mode” page. In this pages , you’ll
find the motor current and voltage, speed reference input, internal aluminum heat-sink
temperature, battery voltage, hour-meter and software release.
To start the programming function push the button “MODE” .Will appear the first
parameter; pushing the “UP” button the number of the parameter will be increased and
with the “DOWN” button the number will be decreased. When a parameter is selected ,
push the button “MODE” to enter in the change menu, change the value with the buttons
“UP” and “DOWN”, then confirm the parameter with the button “MODE”. To return to the
TESTER menu push together the buttons “MODE “and “UP”, or wait few seconds.
=
fig.9
=

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HANDHELD TESTER MODE
MOTOR CURRENT
Imot= ## Amps
Motor current measure (measure unit=Amperes).
MOTOR VOLTAGE
Vmot = ##.# Volts
Motor voltage measure (measure unit=Volts).
REFERENCE INPUT
Vref = #.#Volts
Speed reference voltage (measure unit=Volts);
potentiometer or voltage (0-5V) speed reference.
HEATSINK TEMP.
T°= ##°C / ###°F
Internal heat-sink temperature (measure unit C°and F°
degrees)
BATTERY VOLTAGE
Vbatt= ##.# Volts
Battery supply voltage (measure unit=Volts)
SW RELEASE
7CH4Q###_#
Software’s release number.

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ALARMS
Onboard programmer can display the failures or alarms: in the following table there is the
list, the meaning of this alarms, and how to solve the problem.
HANDHELD
PROGRAMMER
ALARM WHAT TO DO
ALARM A1
FORW. SW CLOSED
Forward switch
closed at power-on
Put the speed reference
to zero and open the FW
switch.
ALARM A2
BACK SW CLOSED
Backward switch
closed at power-on
Put the speed reference
to zero and open the BW
switch.
ALARM A3
POT FAULT
Potentiometer
fault
Check the
potentiometer’s wires.
ALARM A4
POTI OUT OF ZERO
Potentiometer
out of neutral
position at
power-on
Move the potentiometer
to neutral position or, if it
is in neutral position yet,
calibrate the speed
reference.
Thermal
protection
Wait few minutes and
check the motor current.
ALARM A5
OVERTEMPERATURE
ALARM A6
POWER STAGE
Controller’s
power stage
damaged
Change the controller.
Overcurrent 1:
short circuit
Check the motor’s wires:
if ok, and the controller
repeats this alarm,
change it.
ALARM A7
OVERCURRENT 1

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HANDHELD
PROGRAMMER
ALARM WHAT TO DO
Overcurrent 2:
short circuit
Check the motor’s wires:
if ok, and the controller
repeats this alarm,
change it.
ALARM A8
OVERCURRENT 2
Undervoltage.
Check battery’s charge.
ALARM A9
UNDERVOLTAGE
Overvoltage.
Battery voltage upper
than 45V: check the
battery.
ALARM A10
OVERVOLTAGE
Overload
protection.
Check the motor working
current and parameters
“rated current” and
“overload time”.
ALARM A11
OVERLOAD CURRENT
Disable switch
on.
Check the input switch:
this alarm will reset by
power-off.
ALARM A12
DISABLE ON
Key-off sequence
detected.
Check the key switch
connections.
ALARM A13
KEY-OFF
E² prom fail.
Check your settings: if
the controller repeats this
alarm, change it.
ALARM A14
EEPROM FAIL

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HANDHELD PROGRAMMER PARAMETERS
Parameter Default Min Max Description
F0 0 0 2 Default parameters (F0=2)
SWITCH-OFF AND ON THE KEY TO CONFIRM
F5 3.0 0.5 5.0 Acceleration ramp [s]
F6 1.5 0.5 5.0 Reverse deceleration ramp [s]
F7 1.0 0.5 5.0 Neutral deceleration ramp [s]
F8 120 0 120 Current limit [A] - Imax
F9 60 0 100 Backward speed reduction [%]
F10 s-en s-en w-w2 Speed reference
s-en =single ended potentiometer with FW,BW
switches
w-w1 =wig-wag potentiometer with EN switch
w-w2 =wig-wag potentiometer without EN switch
F15 2.0 0.0 10.0 Brake delay [s]
F16 0 0 20 Min speed ( % of max speed)
F17 25 0 40 Motor’s rated current – In
F18 60 0 60 Motor’s overload time [s] – t
F19 200 50 500 Dead band of the speed reference [V]
F21 0 0 100 Backward safety time
F22 100 0 100 Forward maximum speed [%]
F24 50 0 100 Multimode input = speed reduction [% ]
F25 60 0 120 Multimode input = current limit [A]
F26 0.0 0.0 10.0 RxI [100=10% at 120A (5% 60A)]
F27 0 0 100 Backward safety speed [% of max speed]
F28 V24 V24 V36 Battery voltage
AFTER CHANGE SWITCH-OFF AND ON THE KEY
--- no no --- Enable potentiometer calibration
--- ITAL. ITAL. ENGL. Selected language
SWITCH-OFF AND ON THE KEY TO CONFIRM
F30 --- --- --- Access key for engeneering parameters

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RESET TO DEFAULT:
To reset all the parameters, set 2 and power-off; at the next power-on, the controller will
update the defaults settings.
GENERAL SETTINGS:
ACCELERATION RAMP:
Acceleration ramp: time in seconds from stop position to max settled speed.
REVERSE RAMP:
Reverse direction deceleration ramp: time in seconds from the current direction to reverse
direction.
NAUTRAL RAMP:
Deceleration ramp: time in seconds from max settled speed to stop position.
RESET TO DEFAULT
F0= #
DEFAULT:
0
MIN: 0
MAX:
2
ACELERATION RAMP
F5= #.#s
DEFAULT:
3.0
MIN: 0.5
MAX:
5.0
REVERSE DEC RAMP
F6= #.#s
DEFAULT:
1.5
MIN: 0.5
MAX:
5.0
NEUTRAL DEC RAMP
F7= #.#s
DEFAULT:
1.0
MIN: 0.5
MAX:
5.0

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FORWARD SPEED:
Forward direction maximum speed: value in percent of battery voltage.
BACKWARD SPEED:
Backward direction maximum speed: value in percent of forward direction max speed.
MINIMUN SPEED:
Minimum speed: value in percent of battery voltage.
BATTERY VOLTAGE:
Battery supply voltage: set the value between options 24V or 36V
RxI COMPENSATION (further improve) :
FW MAX SPEED
F22= ###%
DEFAULT:
100
MIN: 0
MAX:
100
BACKWARD SPEED
F9= ###%
DEFAULT:
60
MIN: 0
MAX:
100
MIN. SPEED
F16= ##%
DEFAULT:
0
MIN: 0
MAX:
20
NOMINAL VOLTAGE
F28= V##
DEFAULT:
V24
MIN: V24
MAX: V36
RxI
F26= ###%
DEFAULT: 0
MIN: 0
MAX: 100

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SPEED REFERENCE SETTINGS:
SPEED REFERENCE
F10: ##########
+
Choose “SPEED REFERENCE”
page, and confirm it by “MODE”
button
-
Single
-
ended potentiometer
:
potentiometer with two direction switches,
- Wigwag1 potentiometer:
potentiometer with middle stop position
and enable switches,
- Wigwag2 potentiometer:
potentiometer with middle stop position
without enable switches,

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HANDHELD PROGRAMMER SINGLE-ENDED CALIBRATION:
Step 1:
POTI COURSE
no
+
Choose “poti course
” option, and
confirm it by “MODE” button.
Step 2:
POTI COURSE
no
+
Choose “tar to set poti course
”
option, and confirm it by “UP” button.
Step 3:
POTI CALIBR.
Vzero = #.# V
+
Set the potentiometer or throttle at
STOP / NEUTRAL
position, and
confirm it by “MODE” button.
Step 4:
POTI CALIBR.
+Vmax = #.# V
+
Set the potentiometer or throttle at
MAX
position, and confirm it by
“MODE” button.
The single-ended reference range is calibrated.

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HANDHELD PROGRAMMER WIGWAGS CALIBRATION:
Step 1:
SPEED REFERENCE
F10 = s-en
+
Choose “single-
ended” option, and
confirm it by “MODE” button.
Step 2:
SPEED REFERENCE
F10= w-w1 o w-w2
+
Choose “wigwag 1” or “2” or “3”
option, and confirm it by “MODE”
button.
Step 3:
POTI COURSE
no
+
Choose “poti course
” option, and
confirm it by “MODE” button.
Step 4:
POTI COURSE
no
+
Choose “tar to set poti course
”
option, and confirm it by “UP” button.
Step 5:
POTI CALIBR.
Vzero = #.# V
+
Set the potentio
meter or throttle at
STOP / NEUTRAL
position, and
confirm it by “MODE” button.
Step 6:
POTI CALIBR.
-Vmax = #.# V
+
Set the potentiometer or throttle at
MAX BACKWARD
position, and
confirm it by “MODE” button.
Step 7:
POTI CALIBR.
+Vmax = #.# V
+
Set the potentiometer or throttle at
MAX FORWARD
position, and
confirm it by “MODE” button.
The wigwag reference range is calibrated.

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REFERENCE’S DEADBAND:
ELECTROBRAKE OUTPUT SETTING:
Controller supplies the electro-brake coil when the motor is running: the coil is powered-off
with delay when the speed reference and direction switches are in stop position .
Brake ON
Brake OFF
Motor ON
Motor OFF
Time
Time
← BRAKE DELAY →
BRAKE DELAY
#.# seconds
DEFAULT:
2.0
MIN: 0.0
MAX: 10.0
REF. DEADBAND
### mV
DEFAULT:
2.0
MIN: 0.0
MAX: 10.0

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MULTIMODE INPUT SETTINGS:
The input on pin 11 of the connector when closed activates a reduced speed
or current. This input activates:
- maximum motor speed;
- maximum motor current.
The input is always active.
Note: In the controller with handlhed programmer, the input on pin 11 activates
BACKWARD SAFETY SETTINGS (PUSH):
The function operate in the backward direction as a safety function for the operator. It is
realized by mean of a contact that activates the function when switched: the machine will
decelerate, will reverse the direction at a programmed speed for the programmed time,
then will stop.
The normal operation will be obtained resetting the input, the direction switches if present
and speed reference. The function is inhibit with the safety speed equal 0.
MULTIMODE SPEED
F24= ### %
DEFAULT: 50
MIN: 0
MAX: 100
MULTIMODE CURR.
F25= ## A
DEFAULT: 60
MIN: 0
MAX: 120
BW SAFETY TIME
F21= #.# s
DEFAULT: 0
MIN: 0
MAX: 100
BW SAFETY SPEED
F27= ### %
DEFAULT:
0
MIN: 0
MAX: 120