VERONTE MC110 User manual

MC110 Hardware Manual
Release 2.0
Embention
2023-11-06

CONTENTS
1 Introduction 3
2 Quick Start 5
2.1 First steps ................................................. 5
2.2 Warnings ................................................. 5
2.3 Requirements ............................................... 5
3 Technical 7
3.1 Main Features .............................................. 7
3.2 Mechanical Specifications ........................................ 9
3.3 Electrical Specifications ......................................... 9
3.3.1 Maximum continuous current ................................. 11
3.4 Interfaces ................................................. 11
3.4.1 HALL Inputs .......................................... 11
3.4.2 FAN_PWM ........................................... 12
3.4.3 Opto PWM Input ........................................ 12
3.4.4 NTC/PTC Input (External Temperature Sensing) ....................... 13
3.4.5 SIN/COS_SIGNAL ....................................... 13
3.4.6 RS-232 ............................................. 13
3.4.7 RS-485 ............................................. 14
3.4.8 Isolated CAN FD and Isolated CAN 2.0 ............................ 14
3.4.9 Mating connectors ....................................... 14
4 Hardware Installation 17
4.1 Mechanical Assembly .......................................... 17
4.1.1 Vibration Isolation ....................................... 17
4.2 ESC-Motor Wiring ............................................ 18
4.3 Pinouts .................................................. 20
4.3.1 User Connector ......................................... 20
4.3.2 Sensor Connector ........................................ 21
4.4 Cooling Circuit Sizing .......................................... 22
4.5 How to Turn On and Off ......................................... 24
4.6 Electrical Diagram of CAN Bus ..................................... 25
5 Software Installation 27
6 Maintenance 29
7 Troubleshooting 31
7.1 How to confirm that the MC110 is able to read a PWM signal ..................... 31
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8 FAQ 33
8.1 Is it possible to use a standard PWM servo tester to control the MC110? ................ 33
9 Acronyms and Definitions 35
10 Contact Data 37
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Veronte MC110 is a motor controller designed for aircraft motors up to 110 kW.
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2 CONTENTS

CHAPTER
ONE
INTRODUCTION
Veronte MC110 speed controller is capable of driving any type of 3-phase PMSM motor. It can be used with a
wide variety of UAVs or eVTOL vehicles and also in automotive applications (Bikes, Karts, Cars). MC110 uses FOC
algorithm for motor control together with IGBTs.
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CHAPTER
TWO
QUICK START
2.1 First steps
To connect the MC110 to a PC, use the RS-232 or RS-485 port. If the computer has not a serial port, a RS-232 or
RS-485 to USB converter can be employed. The serial pins are explained in the Pinout section.
2.2 Warnings
When installing the MC110 speed controller in the vehicle, the following limitations shall be considered:
•The distance between the battery, the controller system and the motor should be as short as possible in order
to maximize the efficiency. It is preferable to place the controller system as close to the battery as possible and
extend the cables from the controller to the motor. Calibration will be needed depending on the final setup.
•Wire connections between power devices must be crimped not soldered.
•The cold plate is integrated with the MC110, but it requires the rest of refrigeration elements. To know how to
choose them, read the Cooling Circuit Sizing section.
•PID tuning is strongly not recommended, since it nullifies the warranty.
•An unappropriated use of the MC110 exempts Embention from responsabilities related to any damage.
•Embention shall have no responsibility, obligation or liability in any manner for and in respect of any
inappropriate use by the client, such as (including but not limited to) not implementing an appropiate cooling
circuit, applying according to the indications given by Embention.
2.3 Requirements
Acooling circuit is required to refrigerate the MC110, since the cold plate is integrated, but not the rest of elements.
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CHAPTER
THREE
TECHNICAL
3.1 Main Features
•Configuration parameters: for reduced power consumption.
The block diagram of the system is shown below.
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Peripheral used for motor control:
•PWM signal, optocupled inside the MC110
•CAN bus
•CAN FD bus
Peripheral use for ESC telemetry:
•Serial RS-232
•Serial RS-485
Any of the serial interfaces can be used to configure the internal variables of the MC110.
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3.2 Mechanical Specifications
•Weight: 2900 g
•Maximum speed (for 1 pair of poles) 50,000 RPM (depending on the acquisition frequency)
•Dimensions:
Fig. 1: Dimensions in mm
3.3 Electrical Specifications
•Power: up to 110 kW *
•Peak Current (<5 s): 280 A *
•Input current (continuous): 200 A *
•PWM Frequency: 5-24 kHz
•HV range: 100 V to 800 V
•LV range: 8Vto36V
•Regenerative brake: 60 A maximum
•Sensorless mode: MC110 is able to operate with sensorless motors with maximum efficiency.
The sensorless mode does not require a minimum speed to measure it and operate, as long as MC110 provides
current to the motor phases (since the speed is measured with the current)
Note: Features with * depend on voltage and switching frequency. Read Maximum continuous current to know
more.
•Protections:
–Protection agains in-rush current when turned on (at low and at high voltage sides)
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–Ground fault detection
–Protection against overcurrent at power input and phases
•Sensored motors:
–Hall sensors
–Digital incremental encoders
–Analog SIN/COS
•Reverse rotation: MC110 can operate in any direction of rotation without additional configuration.
•Configurable:
–Type of Observer
–Programmable acceleration curve
–Motor direction
–Overvoltage threshold
–Overcurrent threshold
–Overtemperature threshold
–Max. RPM (limit)
–Braking force
–Duty Cycle
•Communications:
–CAN Bus
–CAN FD Bus
–PWM optocupled inside the MC110
–RS-232
–RS-485
•Redundant control
•Telemetry:
–Motor & ESC temperature
–RPM
–Input voltage
–Input and output current
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3.3.1 Maximum continuous current
The relationship between maximum input current and battery voltage depends on the switching frequency of the DC/AC
converter. The following figure shows this relationship for different switching frequencies.
Fig. 2: Maximum Continuous Current vs Battery Voltage
3.4 Interfaces
3.4.1 HALL Inputs
Warning: The employed hall sensors must not exceed 5 V.
These inputs are used to add to the system a feedback in sensored mode (incremental type, usually magnetic).
The 3 Hall effect sensors must be placed at 120°(electrical degrees) from each other. The following is a simple formula
for obtaining the mechanical degrees of separation when installing the sensors:
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝐷𝑒𝑔𝑟𝑒𝑒𝑠 =𝑃 𝑜𝑙𝑒 𝑃 𝑎𝑖𝑟𝑠 ×𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐷𝑒𝑔𝑟𝑒𝑒𝑠
So the sensors must be placed one of each other at:
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐷𝑒𝑔𝑟𝑒𝑒𝑠 () = 120
𝑃 𝑜𝑙𝑒 𝑃 𝑎𝑖𝑟𝑠
For example, for 10 pole pairs:
120
𝑃 𝑜𝑙𝑒 𝑃 𝑎𝑖𝑟𝑠 =120 10 = 12
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Fig. 3: Example diagram
Tip: The arc length between sensors can be calculated as follows:
𝐴𝑟𝑐 𝐿𝑒𝑛𝑔𝑡ℎ =2×𝜋×𝑀𝑜𝑡𝑜𝑟 𝑅𝑎𝑑𝑖𝑢𝑠 ×𝑀 𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐷𝑒𝑔𝑟𝑒𝑒𝑠 ()
360
3.4.2 FAN_PWM
This Open-Drain output is used to control an external fan if needed. External power for the fan and an aditional pull-up
resistor is required. Maximum voltage in this signal is 60 V and 360 mA for maximum sink current. It is important
that the GND connection of this supply is the same as the GND connection for the supply of the control group (user
connector).
3.4.3 Opto PWM Input
This input is an optocoupled control digital signal.
The input is interpreted as 0-100 % of the maximum RPM. An initial dead band can be configured to prevent the engine
from starting.
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Table 1: Electrical Characteristics
Type Specification
Input voltage range 0-5 V
Minimum input current 2.5 mA
Pulse length 1-2 ms
Frequency 40-250 Hz
3.4.4 NTC/PTC Input (External Temperature Sensing)
A PTC or NTC can be integrated.
Warning: The PTC or NTC must not exceed 5 V.
The PTC/NTC should be connected on the low side of an external resistor divider. This is the configuration by default.
A high side connection can be used too, but a custom modification is needed.
The isolated Voltage_ref output should be left floating in default mode. The iso_ground is the return path of the
NTC/PTC sensor.
3.4.5 SIN/COS_SIGNAL
These signals are those dedicated to the SIN / COS type analog sensor.
Warning: SIN/COS signals must not exceed 5 V.
3.4.6 RS-232
Single ended serial type protocol:
Table 2: Electrical Characteristics
Type Specification
ESD Protection ±15 kV (HBM)
Requirements TIA/EIA-232-F and ITU v.28
Speed Max. 250 kbit/s
Input Voltage -25 to 25 V
Output Voltage -13.2 to 13.2 V
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3.4.7 RS-485
Differential serial type protocol:
Table 3: Electrical Characteristics
Type Specification
ESD Protection ±15 kV (HBM)
Requirements TIA/EIA-485-A
Speed Max. 25 Mbit/s
Input Voltage(D) -0.5 to 7 V
Output Voltage (D) 1.5 to 2.4 V
3.4.8 Isolated CAN FD and Isolated CAN 2.0
Differential communication protocol with flexible data rate:
Table 4: Electrical Characteristics
Type Specification
ESD Protection ±4 kV (HBM)
Requirements ISO11898-2
Speed Max. 5 Mbit/s
Max CAN 2.0 Speed 1 Mbit/s
Input Voltage(D) -12 to 12 V
CAN H Voltage 2.75 to 4.5 V
CAN L Voltage 0.5 to 2.25 V
3.4.9 Mating connectors
Power connectors:
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Number Name Recommended connector
1 HV negative Tubular cable lugs of Würth with
M6.
The recommended reference
depends on wire section:
•10 mm2: 5580610
•16 mm2: 5580616
•25 mm2: 5580625
•35 mm2: 5580635
2 HV positive
3 Phase U
4 Phase V
5 Phase W
Electronic connectors:
Number Name Mating connector Pin Size
6 Sensor connector Molex: 90142-0012 Molex: 90119-2109 22AWG to 24AWG
7 User connector Molex: 90142-0030
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