SME AC-X1 User manual

AC Asynchronous/Synchronous Motor Controller
U
US SE ER R M MA AN NU UA AL L
(
(R Re ev v. . 1 1. .0 0: : M Ma ar rc ch h 2 20 01 17 7) )
M
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A
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C
C-
-X
X1
1
SME S.p.A.
Via della Tecnica, n° 40
36071 Arzignano (VI) - ITALY
Phone [phone]
Fax [phone]
E-mail [e-mail]
www.sme-group.com

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
Table of Con en s
Table of Contents .............................................................................................................................................. 2
1. Introduction .............................................................................................................................................. 4
1.1 About SME Company ....................................................................................................................... 4
1.2 About this manual ............................................................................................................................ 4
1.3 About warning, caution and information notices ............................................................................ 4
1.4 Product warranty information ......................................................................................................... 5
1.5 How to find us .................................................................................................................................. 5
2. AC SmartMotion AC-X1 Overview ............................................................................................................ 6
2.1 Product description .......................................................................................................................... 6
2.1.1 Product Indication Label .............................................................................................................. 7
2.2 General Specifications ...................................................................................................................... 8
2.3 Electrical Specifications .................................................................................................................... 8
2.3.1 Input and Output Ratings ............................................................................................................ 8
2.3.2 Signal Inputs and Outputs........................................................................................................... 9
2.3.3 Interfaces ................................................................................................................................... 12
2.3.4 EMC ............................................................................................................................................ 12
2.3.5 Safety ......................................................................................................................................... 12
2.4 Operating Environment Specifications .......................................................................................... 12
3. Installation and Wiring ............................................................................................................................ 13
3.1 Controller ....................................................................................................................................... 15
3.2 Power Terminals ............................................................................................................................ 19
3.3 Main Contactor .............................................................................................................................. 20
3.4 Fuse ................................................................................................................................................ 21
3.5 Signal .............................................................................................................................................. 22
3.5.1 Digital Inputs .............................................................................................................................. 24

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
3.5.2 Analog Inputs ............................................................................................................................. 25
3.5.3 Driver Outputs (PWM) ............................................................................................................... 26
3.5.4 Digital Outputs (ON/OFF)........................................................................................................... 27
3.5.5 Speed/Position Sensor Inputs .................................................................................................... 28
3.5.6 Thermal Probe ........................................................................................................................... 29
3.5.7 Serial .......................................................................................................................................... 30
3.5.8 CAN Network ............................................................................................................................. 31
3.6 SME external devices description .................................................................................................. 32
3.6.1 Quad Encoder ............................................................................................................................ 32
3.6.2 Sin/Cos Encoder ......................................................................................................................... 32
3.6.3 Displays ...................................................................................................................................... 33
4. Graphical Interface ................................................................................................................................. 33
5. Diagnostic and troubleshooting .............................................................................................................. 34
5.1 Overview ........................................................................................................................................ 34
6. EMC suggestions ..................................................................................................................................... 35
6.1 General overview on EMC .............................................................................................................. 35
6.2 EM emissions ................................................................................................................................. 35
6.3 Immunity to EM disturbances ........................................................................................................ 36
Appendix B Document History ....................................................................................................................... 37

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1. In roduc ion
1.1 Abou SME Company
SME group,
founded in 1974, is a high technology company, manufacturer of electronic controllers
and related products for application in battery powered vehicles, particularly forklift trucks and
specialized in the development of AC power controllers.
The group
provides intelligent and innovative solutions to satisfy market requirements, achieving
worldwide customer satisfaction.
SME group is able to offer a complete motion system for the different industrial lift truck ranges
guaranteeing a high and safe perform
1.2 Abou his manual
This manual presents important information on configuring traction or pump systems using the
SmartMotion AC-X1
as well as details on sizing and selecting system components, options and
acce
ssories in an electrically powered vehicle.
This version replaces all previous existing versions of the manual, if any.
1.3
Abou warning, cau ion and informa ion no ices
Special attention must be paid to the information presented in Warning, Caution and other
of information notices when they appear in this manual.
Failure to follow those recommendations may result in dangerous situations or in damages to the
components, for which SME will not respond.
Warnings.
A Warning informs the user of a hazard or a potential hazard
which could result in serious or fatal injury if the precautions or instructions
given in the warning notice are not observed.
Cau ions.
A caution informs the reader of a hazard or a potential hazard
which could result in a serious damage to the appliance.
Informa ion No ices.
essential pieces of information to complete or to clarify
paragraph they are placed into.
In erac ive Documen a ion Tips:
section in the Interactive Documentation
founded in 1974, is a high technology company, manufacturer of electronic controllers
and related products for application in battery powered vehicles, particularly forklift trucks and
specialized in the development of AC power controllers.
provides intelligent and innovative solutions to satisfy market requirements, achieving
worldwide customer satisfaction.
SME group is able to offer a complete motion system for the different industrial lift truck ranges
guaranteeing a high and safe perform
ance customized to the client's requirements.
This manual presents important information on configuring traction or pump systems using the
as well as details on sizing and selecting system components, options and
ssories in an electrically powered vehicle.
This version replaces all previous existing versions of the manual, if any.
Abou warning, cau ion and informa ion no ices
Special attention must be paid to the information presented in Warning, Caution and other
of information notices when they appear in this manual.
Failure to follow those recommendations may result in dangerous situations or in damages to the
components, for which SME will not respond.
A Warning informs the user of a hazard or a potential hazard
which could result in serious or fatal injury if the precautions or instructions
given in the warning notice are not observed.
A caution informs the reader of a hazard or a potential hazard
which could result in a serious damage to the appliance.
Informa ion No ices.
An information notice contains additional, not
essential pieces of information to complete or to clarify
the meaning of the
paragraph they are placed into.
In erac ive Documen a ion Tips:
An advice about where to find the related
section in the Interactive Documentation
SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
founded in 1974, is a high technology company, manufacturer of electronic controllers
and related products for application in battery powered vehicles, particularly forklift trucks and
provides intelligent and innovative solutions to satisfy market requirements, achieving
SME group is able to offer a complete motion system for the different industrial lift truck ranges
ance customized to the client's requirements.
This manual presents important information on configuring traction or pump systems using the
AC
as well as details on sizing and selecting system components, options and
Special attention must be paid to the information presented in Warning, Caution and other
kinds
Failure to follow those recommendations may result in dangerous situations or in damages to the
A Warning informs the user of a hazard or a potential hazard
which could result in serious or fatal injury if the precautions or instructions
A caution informs the reader of a hazard or a potential hazard
An information notice contains additional, not
the meaning of the
An advice about where to find the related

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
1.4 Produc warran y informa ion
SME offers a two-year warranty on all the products, unless a different agreement has been put in
place. Refer to the sales agreement or contract under which the AC SmartMotion was purchased
for a complete statement of the product warranty.
1.5 How o find us
For any information on commercial and technical issues, please contact either your dealer or SME
at the following address for your region
SME Group
Head Office
(Europe
)
Via della Tecnica, n°40
36071 Arzignano (VI), Italy
Phone:[phone]
Fax: [phone]
E-mail: [e-mail]
[email protected]
SME Shangai Co. L d
(Asia)
No 2, Bldg. 8, 1
st
floor,
388, Xujing Shuanglian Road
201702 Qingpu District
Shanghai, China
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
SME NA Inc
(America)
1404 King St N, Box 154,
St Jacobs
Ontario, Canada
N0B 2N0
Phone: [phone]
E-mail: [e-mail]

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
2. AC Smar Mo ion AC-X1 Overview
Figure 1 - AC-X1
2.1 Produc descrip ion
The AC-X1 Controller is designed to control AC asynchronous and synchronous motors.
Being based on high reliable DCB technology and exceptionally stable Field Oriented Control (FOC)
Algorithm, AC-X1 Controller is a revolutionary and high quality solution for medium power
applications.
The product is suitable for the following range of applications Counterbalanced Lift Trucks,
Cleaning Machines, Golf cars, Aerial Lifts, Tractors, Utility Vehicles, Tow Trucks.

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
2.1.1 Produc Indica ion Label
The product label shows important data
regarding the specific product.
The meaning of each field is described in the table below.
Field Description
Model Product description.
Type Code SME code for the specific product.
Rating Data It contains the indication of the input voltages and the output currents supplied
by the product.
Batch Number Production batch number (the same value as in barcode below).
Lot Production Month and Year

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
2.2 General Specifica ions
• Mo or Type: AC Asynchronous/Synchronous 3-Phase
• Braking: Regenerative
• Modula ion: PWM (Pulse Width Modulation)
• Swi ching Frequency: 9kHz
• Low R
DS,on
MOSFET
• 16 bi s DSP controlling 1 AC motor
• In egra ed Hall Effec Curren Sensors
2.3 Elec rical Specifica ions
2.3.1 Inpu and Ou pu Ra ings
Model Char for 100V version
Model Name AC Inver er Max Arms(2’) Max Power(2’) a 100V
AC-X1 100V 250A 250 A
rms
29.3kVA
AC-X1 100V 375A 375 A
rms
44.0kVA
AC-X1 100V 500A 500 A
rms
58.7kVA
AC-X1 100V 625A 625 A
rms
73.1kVA
AC-X1 100V 750A 750 A
rms
88.1kVA

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
2.3.2 Signal: Inpu s and Ou pu s
• Digi al Inpu s: 9
• Analog Inpu s: 5
• Digi al Ou pu s (ON/OFF): 2
• Driver Ou pu s (PWM): 4
• Mo or Speed/Posi ion Sensor Inpu s: 2 (A+B Channels/Sin+Cos Analog)
Refer to following tables for a complete AC-X1 controller K1 and K3 connectors pin-out.
K1 connec or pin-ou for AC-X1 SPECIFICATIONS
Pin Name I/O Specifica ion Typical Func ion
1 GND I/O Ground Do not exceed 0.5A Negative Logic Supply
2 CAN-L CAN BUS CAN-BUS 1 MBit/s max CAN L (No internal termination
resistor)
3 CAN-L RES CAN BUS Connected to CAN-L with a series
120Ohm Termination resistor
4 DIGITAL INPUT 1 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
5 DIGITAL INPUT 2 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
6 DIGITAL INPUT 3 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
7 DIGITAL INPUT 4 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
8 DIGITAL INPUT 5 Digital Input
VL<=2V,VH>=4.5V; resistor pull-
down(active high) or pull up(active
low)
ON rated voltage +12V/24V
TO BE ASSIGNED
9 I/O GROUND I/O Ground Do not exceed 0.5A Negative Logic Supply
10 +12V OUT Supply Output 12V ±5% 200mA 12V Supply
11 ANALOG INPUT 1 Analog Input 0÷12V 125KΩ pull-down TO BE ASSIGNED

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
K1 connec or pin-ou for AC-X1 SPECIFICATIONS
Pin Name I/O Specifica ion Typical Func ion
12 I/O GROUND I/O Ground Do not exceed 0.5A Negative Logic Supply
13 CAN-H CAN BUS 1 MBit/s max CAN H (No internal termination
resistor)
14 CAN-H RES CAN BUS Connected to CAN-H Connected to CAN-H
15 LIN Com
Input/Output
19.2KBit/s 12V 1,1KΩ Pull-up RX
VL<=3.0V dominant, VH>=7.0V
recessive
LIN Display Connection
16 DIGITAL IN 6 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
17 ANALOG INPUT 2 Analog Input 0÷12V 125KΩ pull-down TO BE ASSIGNED
18 DIGITAL IN 7 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
19 DIGITAL IN 8 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
20 DIGITAL IN 9 Digital Input
VL<=2V,VH>=4.5V
Resistor pull-down(active high) or pull
up(active low)
ON rated voltage +12V/24V
TO BE ASSIGNED
21 ENCODER 1A /
ENCODER 1 Sin Peripheral Input
4V 470Ω pull-up, VL<=1.5V, VH>=3.4V /
0,5 – 4,5 mV input
Quad Encoder Channel A /
Sin/Cos Encoder Sin
22 ANALOG INPUT 3 Analog Input 0÷12V 125KΩ pull-down TO BE ASSIGNED
23 ANALOG INPUT 4 Analog Input 0÷12V 125KΩ pull-down TO BE ASSIGNED
24 KEY SWITCH IN Supply Input
+ Battery supply Max = Rated +20%,
Min Batt = Rated -30%,
Supply consumption logic board 2A
Max + coil return 8A max
Positive Supply of the control
section of the AC-X1
25 COIL RETURN Supply Output (+KEY ±0.3V) Do not exceed 8A Positive Common of Auxiliary
26 DRIVER OUTPUT 1 PWM Output Active low
Internal diode to coil return Main Contactor, Brake, Valve
27 DRIVER OUTPUT 2 PWM Output Active low
Internal diode to coil return Main Contactor, Brake, Valve
28 DRIVER OUTPUT 3 PWM Output Active low
Internal diode to coil return Main Contactor, Brake, Valve

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
K1 connec or pin-ou for AC-X1 SPECIFICATIONS
Pin Name I/O Specifica ion Typical Func ion
29 DRIVER OUTPUT 4 PWM Output Active low
internal diode to coil return Main Contactor, Brake, Valve
30 DIGITAL OUTPUT 1 Digital Output active low
No internal diode to coil return Buzzer-Fan-ON/OFF valve
31 DIGITAL OUTPUT 2 Digital Output active low pull-down
No internal diode to coil return Buzzer-Fan-ON/OFF valve
32 MOTOR THERMAL
PROBE Analog Input 5V 1KΩ pull-up Motor Temperature Probe
33 ENCODER 1B /
ENCODER 1 Cos Peripheral Input
4V 470Ω pull-up, VL<=1.5V, VH>=3.4V /
0,5 – 4,5 mV input
Quad Encoder Channel B /
Sin/Cos Encoder Cos
34 ANALOG INPUT 5 Analog Input 0÷12V 125KΩ pull-down TO BE ASSIGNED
35 +5V OUT Supply Output 5V ±5% 200mA 12V Supply
K3 connec or pin-ou for AC-X1 SPECIFICATIONS
Pin Name I/O Specifica ion Typical Func ion
1 - - - -
2 DIAGNOSTIC RX Input 38.4-115.2 KBit/s, RS232 output
compatible levels Rx Diagnosis
3 DIAGNOSTIC TX Output 38.4-115.2 KBit/s, RS232 output
compatible levels Tx Diagnosis
4 - - - -
5 I/O GROUND I/O Ground Do not exceed 0.5A Negative Logic Supply
6 - - - -
7 - - - -
8 - - - -
9 +5V Out Bluetooth
Supply ±10% 50mA 6Ω output impedance -

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
2.3.3 In erfaces
• Serial Communica ion: RS-232
• CAN:
 Pro ocol: CAN Open
 Physical layer: ISO11898-2
 Baud ra es: 1Mbps, 800kbps, 500kbps, 250kbps, 125kbps, 50kbps
• Lin Bus
2.3.4 EMC
• EN12895 (Industrial Trucks – Electromagnetic Compatibility)
2.3.5 Safe y
• EN1175-1 (Safety of Industrial Trucks – Electrical Requirements)
The vehicle OEM takes full responsibility of the regulatory compliance of the
vehicle system ith the controller installed.
2.4 Opera ing Environmen Specifica ions
• S orage ambien empera ure range: -40°C ÷ +70°C
• Opera ing ambien empera ure range: -40°C ÷ +55°C
• Hea sink opera ing empera ure range: -40°C ÷ +95°C
 With linear derating: +80°C ÷ +95°C
• Pro ec ion Level: IP65
• Vibra ion: Tested under conditions suggested by EN60068-2-6 [ 5g, 10÷500Hz, 3 axes]
• Shock & Bump: Tested under conditions suggested by EN60068-2-27
• Cold & Hea : Tested under conditions suggested by EN60068-2-1
• Mechanical size: 210 x 160 x 85 [mm]
• Weigh : 3.5 kg

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3. Ins alla ion and W
iring
For specific application, refer to the
Interactive Documentation
Figure 2a -
AC
iring
For specific application, refer to the
About Controllers
Area of the
Interactive Documentation
.
AC
-X1 with Asynchronous Motor
iring Diagram
SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
Area of the
iring Diagram

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
Figure 2b - AC-X1 with Synchronous Motor iring Diagram

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3.1 Con roller
The C
ontroller contains
connecting,
disconnecting, and handling it
Mechanical Drawing
Working on electrical systems is potentially dangerous; you should protect yourself against
Uncon rolled opera ion
disconnect the motor or jack up the vehicle and get the drive wheels off the ground before
attempting any work on the motor control circuitry.
Vol age hazard and high curren arcs
and arcs can occur if they are short circuited. Always disconnect the battery circuit before
working on the motor control circuit.
Wear safety glasses and use properly insulated tools to prevent shorts.
Never energi
ze the system if the terminals
Lead acid ba eries
charging or discharging generates hydrogen gas, which can build up and
go around the batteries. Follow the battery manufacturer’s safety recommendations and
wear safet
y glasses.
For high resolution diagram, refer to the About Controllers Area of the
Interactive Documentation.
Figure
3
ontroller contains
ESD-sensi ive componen s.
Use appropriate precautions in
disconnecting, and handling it
.
AC -
Working on electrical systems is potentially dangerous; you should protect yourself against
Uncon rolled opera ion
some
conditions could cause the motor to run out of control
disconnect the motor or jack up the vehicle and get the drive wheels off the ground before
attempting any work on the motor control circuitry.
Vol age hazard and high curren arcs
batteries can
supply high voltage and very high power,
and arcs can occur if they are short circuited. Always disconnect the battery circuit before
working on the motor control circuit.
Wear safety glasses and use properly insulated tools to prevent shorts.
ze the system if the terminals
–
B and +B are not tightly connected.
charging or discharging generates hydrogen gas, which can build up and
go around the batteries. Follow the battery manufacturer’s safety recommendations and
y glasses.
For high resolution diagram, refer to the About Controllers Area of the
Interactive Documentation.
–
Top View
SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
Use appropriate precautions in
X1 Top View
Working on electrical systems is potentially dangerous; you should protect yourself against
conditions could cause the motor to run out of control
disconnect the motor or jack up the vehicle and get the drive wheels off the ground before
supply high voltage and very high power,
and arcs can occur if they are short circuited. Always disconnect the battery circuit before
B and +B are not tightly connected.
charging or discharging generates hydrogen gas, which can build up and
go around the batteries. Follow the battery manufacturer’s safety recommendations and
For high resolution diagram, refer to the About Controllers Area of the

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
AC - X1 General View
AC - X1 Side View
AC - X1 Back View
Figure 4 – Side View
Figure 3 – General View
Figure 5 - Back View

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
Moun ing and Replacemen
The Controller meets IP65 environmental protection rating against dust and water.
The mounting location should be carefully chosen in order to be clean and dry, to minimize shock,
vibration, temperature changes and exposure to water & contaminants. If this kind of location
can’t be ensured, then a cover should be used to shield the controller. Cables must be routed to
prevent liquids flowing into the connections. The mounting location should also allow access to all
connections.
The replacement of the Controller must be done with the hand brake engaged, the drive wheels
off the ground, the key switch in off position, battery plug disconnected and the capacitors of the
inverter completely discharged.
The capacitors in the inverter can be discharged by connecting a load across the inverter’s +B and
–B terminals.
Cooling
It is recommended that the Controller is assembled to a flat, free of paint surface preferably lightly
coated with a thermal transfer compound using the 4 holes provided. Ideally, this surface will
provide maximum heat dissipation and ensure full rated power output. When designing a cooling
system, please refer to the following step
1. Apply thermal grease to the Controller before mounting for better cooling effect.
2. The Controller is cooled by the surface contact to the vehicle body, so it is important to pay
much attention to the flatness and the roughness of the surface of the vehicle frame where
it is mounted. The roughness R
z
should be between 1.6 μm and 3.2μm, while the planarity
of the surface should be under 0.5mm, as shown in the following image
Planari y specifica ions for he AC-X1
wi h aluminium basepla e.
3. Any airflow around the controller will further enhance the thermal performance.
Figure
6
-
Planarity

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
4. Additional heatsink could be necessary to meet the desired continuous ratings. The heat
sink material and system should be sized on the performance requirement of the machine.
We recommend ambient temperature air to be directed over the heatsink fins to maintain
heatsink temperature below 75 °C.
5. In systems where either ventilation is poor, or heat exchange is difficult, forced air
ventilation should be used.
Clearances
For all AC-X1 models 50 mm clearances in front of and behind the AC-X1 are required for airflow;
50 mm clearance above the AC-X1 is required for installation/removal of interface connectors and
wiring.

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SME S.p.A. Via della Tecnica 40 Z.I.
36071 ARZIGNANO (VI) ITALY
Phone [phone] - Fax [phone]
[email protected] - www.sme-group.com
3.2 Power Terminals
Wiring
The Controller has five Power Terminals, which are clearly marked on Controller’s body as B+, B-,
U, V, W (figure 4).
Power Terminals on Con roller
Terminal
Meaning
B+ Positive Battery coming from the Main Contactor
B- Negative Battery
U U Motor Phase
V V Motor Phase
W W Motor Phase
The recommended screw orque for fixing the Power Terminals is 6.5 Nm. This value is reported
on the label placed on the cover, exceeding the recommended value may cause damages.
Sizing
The environment conditions strongly affect the current carrying capacity of a single wire.
Temperature and wire length can decrease the cable performance and other factors such as
Controller duty cycles and airflow should also be taken into consideration when sizing the power
cables.
The following formula gives an advice on the cable size needed in welding cable, not grouped with
other cables




•Ambien Tempera ure = 25°C
•Maximum Tempera ure rise on he cable surface = 60°C
•Sugges ed Curren Densi y [A
rms
/mm
2
] = 5 A
rms
/mm
2

ACX1_TAU_SYNC_UserManual_En
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The following table shows you the most common cases
S andard Wire Dimensions
Average Curren [Arms]
Minimum Wire
Sec ion Sugges ed
[mm
2
]
Wire Size
mm
2
AWG
100 20 21.1 4
150 30 33.6 2
200
40 42.4 1
250
50 53.5 0
300
60 67.4 2/0
350
70 85 3/0
3.3 Main Con ac or
The Controller must be connected to one Main Contactor for two basically reasons
•Capaci ors Pre-Charge The Controller handles all this phase internally by
discharging/charging its DC-Bus through the Key Input. As soon as a certain voltage value is
reached by the DC-Bus, the Controller can close the Main Contactor connecting it to the
Battery. In this way dangerous shocks on Controller's capacitors are avoided.
•Safe y In case of dangerous situations, the Main Contactor must be opened disconnecting
the Battery from Controller. If he main con ac or coil is no connec ed o he con roller,
he sys em will no mee EEC safe y requiremen s.
Sizing
In order to select the Main Contactor, it must be considered the Controller Ratings, the Duty Cycle
of the System and several other working conditions. The following empirical formula can be useful
to quickly find the Main Con ac or minimum ra ing I
MC


 
 



   


with   



