Sevcon MillipaK User manual

Document History
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MillipaK PUMP Controller Manual Page 2 07/11/05
Document History
Author Reviewer
Initials Date Initials Date Version Reason for Modification
PB 10/08/01 00.01 Original.
PR 16/11/01 0.50.00(A) Updated the Fault list, calibrator map and
added personalities.
DC 23/04/04 0.50.00 (B) Added omitted Flash Faults and seat
functionality description.
DC 07/11/05 0.50.00(C) Clarified Digital I/O configuration table

Contents
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CONTENTS
INTRODUCTION .........................................................................................................................................................5
SAFETY .........................................................................................................................................................................6
INSTALLATION...........................................................................................................................................................7
MOUNTING ...................................................................................................................................................................7
MILLIPAKPUMP POWER WIRING .................................................................................................................................8
MILLIPAKPUMP LIGHT WIRING...................................................................................................................................9
CALIBRATOR ............................................................................................................................................................10
CALIBRATOR SECURITY LEVELS ................................................................................................................................11
NAVIGATION ..............................................................................................................................................................12
ADJUSTMENTS ............................................................................................................................................................13
STATUS AND TEST INFORMATION...............................................................................................................................14
CONFIGURATION ....................................................................................................................................................15
SYSTEM CONFIGURATION...........................................................................................................................................15
System Voltage.......................................................................................................................................................16
System I/O Configuration ......................................................................................................................................17
Analogue Functions...............................................................................................................................................18
Accelerator Full /Zero Setting ...............................................................................................................................20
PERFORMANCE ...........................................................................................................................................................21
Lift and Power Steer Ramps ..................................................................................................................................21
Creep Speed...........................................................................................................................................................22
Maximum Speed.....................................................................................................................................................23
FEATURES..................................................................................................................................................................24
STANDARD CONTROLLER FEATURES..........................................................................................................................24
Lift Switch Inputs - Priority ...................................................................................................................................25
Lift Switch Inputs - Additive ..................................................................................................................................26
Compensation ........................................................................................................................................................27
Seat Switch.............................................................................................................................................................28
Power Steer Input ..................................................................................................................................................29
Lift Inhibit Input.....................................................................................................................................................30
Cooling Fan...........................................................................................................................................................31
Pump Hours Meter ................................................................................................................................................32
Personality Checksum ...........................................................................................................................................33
System State ...........................................................................................................................................................33
SAFETY FEATURES .....................................................................................................................................................34
Fail-safe.................................................................................................................................................................34
CONTROLLER PROTECTION FEATURES .......................................................................................................................35
Temperature Monitoring .......................................................................................................................................35
Maximum Temperature Logging ...........................................................................................................................35
Timed Current Cutback .........................................................................................................................................36
Safe Operating Area (SOA) ...................................................................................................................................37
Under-voltage protection.......................................................................................................................................38
COMMISSIONING CHECKLIST ............................................................................................................................40
PERSONALITY RECORD...............................................................................................................................................41
FAULT FINDING .......................................................................................................................................................42
FAULT CLEARANCE ....................................................................................................................................................43
USING STATUS AND TEST MENUS ..............................................................................................................................43
FAULT REPORTING FORM ...........................................................................................................................................45

Contents
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SOFTWARE VERSION AND SERIAL NUMBER INDICATION ............................................................................................46
SPECIFICATIONS .....................................................................................................................................................47
POWER CONFIGURATIONS ..........................................................................................................................................47
EMC STANDARDS.......................................................................................................................................................47
SOCKET BPROTECTION ..............................................................................................................................................47
CONTACTOR DRIVE RATINGS ......................................................................................................................................47
ANALOGUE INPUT IMPEDANCE...................................................................................................................................47
DIGITAL INPUT IMPEDANCE........................................................................................................................................47
EMC GUIDELINES....................................................................................................................................................48
ORDERING INFORMATION...................................................................................................................................49

Introduction
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Introduction
The MillipaK PUMP (series motor) range of controllers provides a new range of power frames for
24V-48V, 180A - 600A in one of two small, highly efficient packages. This is achieved using a
Sevcon patented power switching scheme and radical new construction techniques, which enable
large powers to be incorporated into very small packages.
The MillipaK provides a completely sealed (IP66) unit containing both power and logic circuitry,
as well as all suppression components.
MillipaK supports Sevcon’s existing MOS90 calibrator for adjustment of pump characteristics.
Controllers are FLASH microprocessor based enabling field re-programming for new features and
have numerous user set-up options. The MillipaK uses high frequency (silent) MOSFET power
switching technology, to control a Series power frame comprising Armature circuit only.
Armature currents are monitored. Controllers have been designed to satisfy the requirements of
the relevant UL and EC standards.

Safety
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Safety
The MillipaK controller contains a triple fail-safe system to give a high level of safety. If the
diagnostic LED is not illuminated or flashes, the safety circuit may have tripped and the truck
may not drive.
The MillipaK controller may be used with suitable onboard chargers, as supplied by Sevcon.

Installation Mounting
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Installation
The small footprint of the MillipaK controller gives maximum flexibility to the user for mounting
options. The following section gives details of certain criteria that should be considered when
situating the controller on a vehicle.
Mounting
The MillipaK and MillipaK HP units provide 4 x M6 clearance holes for mounting. The
controllers should be mounted onto a metal base plate, as large as possible to provide heat-
sinking. The surface finish should be flat, clean and burr free and thermal compound should be
applied to the controller base before fitting.
MillipaK HP Controller Dimensions
Maximum terminal torque: M8 terminals – 10NM
M6 terminals – 7NM

Installation Wiring/Power
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MillipaK Pump Power Wiring
NOTE: The Pump battery positive power terminal may be wired directly to the battery positive
(via a suitable fuse) or via a line contactor if used in a Traction / Pump system.
It should be considered whether or not pump operation is required if a traction fault causes the
line contactor to drop out.

Installation Wiring/Light
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MillipaK Pump Light Wiring
NOTES:
The line and auxiliary contactors coils are wired to B+, on the switched side of the key-switch.
The second analogue input on pin 11 is also available for use as a digital input. See system
configuration section for how to configure the second analogue input as a digital switch input.
Pin 12 on the Core and Standard HP variants is available for 100mA supply, typically used for
(but not limited to) accelerator modules.
Pins 13,14 & 15 are general-purpose suppression connections and may be used to suppress spikes
generated by contactors opening / closing. The internal configuration is shown below:
Pin 16 on the Core and Standard HP variants is used to select FLASH memory program update
mode and should normally be left unconnected.

Calibrator Calibrator/General
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Calibrator
The Calibrator is a hand-held adjustment unit which can be used to configure and test the system.
The MillipaK is designed to work with the Calibrator currently in use with SEVCON's MOS90
system. See diagram below. The menu structure is shown in the Calibrator Map located near the
end of this manual.
C AL IB R A TOR
Sevcontrol
+
-
SELECT
1.8.8.8

Calibrator Calibrator/Security Levels
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Calibrator Security Levels
Which personalities and status items which can be viewed on the Calibrator is restricted using
passwords. There are three levels of Calibrator access. These are shown in the table below:
Access Level Text Password Description
Service Ser -
Default. This level is selected when no password or an
invalid password is entered. Only items shown in the
Calibrator Map with a thick solid border are displayed.
Engineering Eng 1645 Only items shown in the Calibrator Map with a thick or
thin solid border are displayed.
All Adjust All Contact
SEVCON All items are displayed.
Note, in Service or Engineering mode, only items appropriate to the current system configuration
are displayed. For example, if lift switch 5 is not configured, then the Speed personality will not
be displayed for that switch. In All Adjust mode, all items are shown regardless of configuration.
The password can only be entered just after power up when the Pump Hours Counter is displayed.
The '+'and '-'buttons are used to enter the password. The first digit is entered by pressing the '+'
button the appropriate number of times (i.e. once to enter 1). The second digit is entered by
pressing the '-'button the appropriate number of times (i.e. 6 times to enter 6). The third digit is
entered using the '+'button again and the final digit is entered using the '-'button again. Note that
when the '+'or '-'buttons are pressed, the display still changes to show hours or 1000 x hours.
When the password has been completely entered press either the '+'button or the SELECT button
to initiate verification. If the password has been entered correctly, the text shown in the table
above appropriate to the required level will be displayed for 1s indicating the password was
accepted. If the password was incorrect or no password was entered, the system always defaults to
Service mode.
After the Security Level has been displayed, the system enters the normal menu structure shown
in the Calibrator Map. To change the password level, you need to recycle the Keyswitch.

Calibrator Calibrator/Navigation
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Navigation
The Calibrator uses all three buttons for navigating through the menu structure.
Use the SELECT button to move through the menu structure. When the SELECT button is
pressed the next menu item is displayed. The default direction is from left to right, top to bottom.
If the '+'and '-'buttons are held down together, the ID of the currently displayed menu item is
shown. For example, if the Current Limit personality was selected, then the ID would be 0.01
(menu 0, item 1). This allows the operator to locate where they are in the map.
If the '+'and '-'buttons are held down together for more than 3 seconds, the direction through the
menu structure is reversed. Now when the SELECT button is pressed the direction is from right to
left, bottom to top. In this mode, the LED on the Calibrator will flash. If the '+'and '-'buttons are
held down together for more than 3 seconds again, the direction reverts back to the first direction
and the Calibrator LED stops flashing.
The SELECT button is used to navigate through most of the menu structure, however, the Test
menu (menu 19) is slightly different. Pressing the SELECT button will take you to the first item
in the Test menu, (item 19.01 - Accelerator Demand). To navigate the Test menu, you need to use
the '+'and '-'buttons. The '+'button moves up the Test menu and the '-'button moves back down.
Pressing the SELECT button at any time exits the Test menu and moves to the first item in the
menu structure (menu item 0.01 – Lift Speed 1).
The items which are displayed depends on the current system configuration and the Security
Level.

Calibrator Calibrator/Adjustments
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Adjustments
Menus 0 to 12 are primarily used for configuring the system. All the personalities that the system
uses to configure each function are in one of these menus. A brief description of the purpose of
each menu is listed below. For more complete descriptions of each personality refer to the
appropriate section in this manual.
Menu Name Purpose
0 Speed 1 Used to set pump speed for lift accelerator 1.
1 Speed 2 Used to set pump speed for lift accelerator 2.
2 Speed 3 Used to set pump speed for switch input 3.
3 Speed 4 Used to set pump speed for switch input 4.
4 Speed 5 Used to set pump speed for switch input 5.
5 Speed 6 Used to set pump speed for switch input 6.
6 Speed 7 Used to set pump speed for switch input 7.
7 Unused Unused.
8 Creep Speed Used to set creep speed.
9 Ramps Used to set lift and power steer ramp times.
10 Power Steer Used to set-up power steer function.
11 Current Limit Used to set motor current limit, seat delay and low voltage start
and cut levels.
12 System Set-up
Used to configure the system at a high level. Items to configure
the system I/O and performance are located in here. It is
recommended that items in this menu are configured first before
any of the other personalities. Unlike the personalities in the
other menus, changes to items in this menu do not take affect
until the Keyswitch is recycled.

Calibrator Calibrator/Status and Test Information
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Status and Test Information
Menus 13 to 19 are primarily used for providing information about the system. Every parameter
which the system measures in located in one of these menus. A brief description of the purpose of
each menu is listed below.
Menu Name Purpose
13 System Status
If there is a fault active in the system, this menu provides
information about what the fault is. Refer to the Diagnostics
section for more information.
14 - Reserved for future use.
15 System Voltages
Used to display Battery and Capacitor Voltage measurements.
The Battery Voltage measurement shows the voltage measured
at the Keyswitch pin (pin 1 on connector B). The Capacitor
Voltage measurement shows the voltage measured at the B+
terminal.
16 Motor Voltages Used to show the voltage measured at the Point A terminal.
17 Motor Current Used to show the PUMP motor current Measurement.
18 Heatsink
Temperature
Used to access the Heatsink Temperature measurement and the
Maximum Heatsink Temperature log. Refer to the Temperature
Monitoring section.
19 Test Menu
Used to access items which allow for testing of all the Analogue
and Digital inputs available on connector B. Also displays unit
information such as the Software Version, Controller Serial
Number and the Personality Checksum. Refer to the appropriate
sections for more information on each of these items.

Configuration System
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Configuration
Configuration of the MillipaK controller is split into two categories – system and performance,
which will be discussed in turn.
System Configuration
The MillipaK system configuration items relate to how the MillipaK will interface with connected
hardware such as the system battery, lift control switches, accelerator and the pump motor.

Configuration System/Voltage
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System Voltage
The system voltage usually refers to the main system supply battery voltage. The controller uses
this information to ensure low and high voltage settings are within an appropriate range.
Power UpSystem Voltage
Calibrator Menu Reference: 12.05
Minimum Maximum Step Size Default
24v 48v 2v 24v

Configuration System/IO Configuration
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System I/O Configuration
The digital inputs, analogue inputs and contactor drive outputs available on socket B can be
configured in a number of ways to suit various applications. The table below shows a range of
pre-determined settings which are available to the user and should cover the majority of
applications, see below:
Digital I/O
Value
Description
1 Normal switch inputs are used for lift switches. Lift Inhibit is available via the last
switch input on the MillipaK Core or via the second analogue input on the
MillipaK HP.
2 Normal switch inputs are used for lift switches. Power Steer Trigger is available
via the last switch input on the MillipaK Core or via the second analogue input on
the MillipaK HP.
3 4 of the normal switch inputs are used for lift switches. Power Steer Trigger is
available on a normal switch input. Lift Inhibit is available via the last switch
input on the MillipaK Core or via the second analogue input on the MillipaK HP.
Lift Switch 5 is dropped to leave 2 switches with compensation and 2 additive
switches.
4 4 of the normal switch inputs are used for lift switches. Lift Inhibit is available on
a normal switch input. Power Steer Trigger is available via the last switch input on
the MillipaK Core or via the second analogue input on the MillipaK HP. Lift
Switch 5 is dropped to leave 2 switches with compensation and 2 additive
switches.
5 3 of the normal switch inputs are used for lift switches. Lift Inhibit and Power
Steer Trigger are available on normal switch inputs. Lift Switch 4 is available via
the last switch input on the MillipaK Core or via the second analogue input on the
MillipaK HP. Lift Switch 5 is dropped to leave 2 switches with compensation and
2 additive switches.
6 2 of the normal switch inputs are used for lift switches. Lift Inhibit, Power Steer
Trigger and Seat Switch are available on normal switch inputs. Lift Switch 4 is
available via the last switch input on the MillipaK Core or via the second analogue
input on the MillipaK HP. Lift Switches 5 and 7 are dropped to leave 2 switches
with compensation and 1 additive switches. There is one contactor drive, the
Cooling Fan Drive.
If your application doesn’t fit any of the above, please contact Sevcon with details of your
requirements.
Each of the above configurations allocates the controller i/o as shown below:
Digital Value of Digital I/O Configuration Item
Function 1 2 3 4 5 6
Lift Switch 3 B2 B2 B2 B2 B2 B2
Lift Switch 4 B3 B3 B3 B3 B3 B3
Lift Switch 5 B4 B4
Lift Switch 6 B5 B5 B5 B5 AD AD
Lift Switch 7 B6 B6 B6 B6 B6
Lift Inhibit AD AD B4 B4 B4
Power Steer Trigger AD B4 AD B5 B5
Seat Switch B6
Cooling Fan Drive B8

Configuration System/IO Configuration
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Notes:
1. Dx refers to Digital Switch input x.
2. Cx refers to Contactor Drive output x.
3. If the Analogue Input 2 is set to Digital, switch input D6 is read from the Analogue input and
not the switch input.
Analogue Functions
Analogue Value of Analogue Input Configuration Item
Function 1 2
Lift Accelerator 1 Ana.1 (B10) Ana.1 (B10)
Lift Accelerator 2 Ana.2 (B11)
Digital Ana.2 (B11)
Power UpDigital Configuration
Calibrator Menu Reference: 12.02
Minimum Maximum Step Size Default
1 6 1
Power UpAnalogue Configuration
Calibrator Menu Reference: 12.03
Minimum Maximum Step Size Default
1 2 1

Configuration System/Motor Set-up
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Current Limit
The current limit personality is provided to allow the user to limit the maximum current supplied
to the motor to a value lower than the peak rating of the controller.
ImmediateCurrent Limit
Calibrator Menu Reference: 0.01
Minimum Maximum Step Size Typical Value
50A CBR 10A CBR
Where CBR is Controller Block Rating.

Configuration System/Accelerator
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Accelerator Full /Zero Setting
The lift accelerator/analogue inputs are flexible in the range of signal sources they can
accommodate and can be adjusted to minimise dead-bands and mechanical tolerances. Each
analogue input has 2 adjustments associated with it to allow the input voltage range to be
determined.
The 2 adjustments are called the “Accelerator Zero Level” and the “Accelerator Full Level”. If
these were set to 0.20V and 4.80V then 0% demand would start at 0.20V at the input, increasing
to 100% demand at 4.80V. For accelerators with decreasing voltage outputs, the Zero adjustment
might be set to 3.5V and the Full adjustment to 0.0V. The Calibrator test menu shows the
instantaneous voltage reading, and the equivalent % “push” for each input.
ImmediateAccelerator 1 Zero Volts
Calibrator Menu Reference: 0.03
Minimum Maximum Step Size Typical Value
0.00V 4.50V 0.02V 0.20V
ImmediateAccelerator 1 Full Volts
Calibrator Menu Reference: 0.04
Minimum Maximum Step Size Typical Value
0.00V 4.50V 0.02V 3.50V
ImmediateAccelerator 2 Zero Volts
Calibrator Menu Reference: 1.03
Minimum Maximum Step Size Typical Value
0.00V 4.50V 0.02V 0.20V
ImmediateAccelerator 2Full Volts
Calibrator Menu Reference: 1.04
Minimum Maximum Step Size Typical Value
0.00V 4.50V 0.02V 3.50V
The PWM demand will vary between the Creep level and Maximum Speed for that lift accelerator
as the accelerator voltage varies between “Accelerator Zero” and “Accelerator Full”.