Zeva MC1000C User manual

Zero emission
Vehicles AustrAliA
http://www.zeva.com.au
MC1000C
150VDC 1000A motor controller
for Series DC and PM DC motors
TABLE OF CONTENTS
page
1) Introduction 1
2) Safety Warning 1
3) Tech Support and Warranty Information 1
 4)FeaturesandSpecications   2
5) Installation 3
6) Power Wiring 4
7) Control Wiring 6
8) Operation 8
9) CAN Bus Communications 10
INTRODUCTION
Thank you for your purchase of a ZEVA MC1000C motor controller. The MC1000C was designed
to be one of the best value, most reliable and easiest to use motor controllers available for electric
vehicles.Itutilisesthelatestinpowersemiconductorstomakeitoneofthemostefcientmotor
controllers available – over 99% at all times. Featuring dual microprocessors for redundant safety,
an advanced throttle algorithm for the smoothest driving experience, silent operation at all times,
a compact weather-resistant air-cooled housing, and industry-standard CAN bus connectivity for
monitoring operation, programming settings, and even optional throttle control over CAN bus.
We hope it provides you years of reliable service.
SAFETY WARNING
Electric vehicle motor controllers are high powered devices which involve potentially lethal
voltages and currents. Proper precautions and electrical safety procedures should always be
observed, voltages above 110VDC should be considered dangerous, and vehicles should never
be worked on while contactor(s) are engaged. Please read this manual carefully before using
the controller to ensure correct installation and operation. If you are unsure of anything, please
contact us before proceeding.
We have endeavoured to make a safe and reliable product which performs as described, however
since ZEVA has no control over the integration of its products into a vehicle, we can assume no
responsibility for the safety or functionality of the completed vehicle. 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.Productsshouldonlybeinstalledbysuitablyqualiedandexperiencedpersons,
and should always be used in a safe and lawful manner.
TECH SUPPORT AND WARRANTY INFORMATION
The MC1000C motor controller 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: Excessive voltage or reversed polarity on input terminals, short
circuits on output terminals, excessive voltages applied to control wiring, opening of housing and/
ormodicationofinternals,severeimpactdamage(e.gduetovehiclecrashes),submersion in
water.
We have taken great care to design a safe and reliable product, but faults can happen. If you
believe your motor controller has a fault, please contact us via our website to discuss. If it is
determined that a hardware fault is the likely cause, we will provide an RMA number and return
address to proceed with repairs.
If you have any questions not covered by this manual, please contact us via our website:
http://www.zeva.com.au/Contact
1

FEATURES AND SPECIFICATIONS
FEATURES:
Smooth, hybrid throttle algorithm for familiar driving feel•
Thermal cutback and over-temp protection•
CongurableoperatingparametersviaCANbusinterface•
Multicolour status LED for visual status feedback•
Durable weather-resistant extruded aluminium housing (approx IP44)•
Compatible with optional fan-forced air or water cooling blocks for higher sustained power•
Adjustable motor idling function for automatic gearboxes or maintaining auxiliaries•
Supportformostthrottletypesincluding3-wire0-5V,2-wire0-5KΩ,andHEPApedals.•
Fully isolated logic and power electronics•
Robust I/O protects controller against external wiring faults•
Highpedallockout(protectsagainstnon-zerothrottleonstartup)•
Self diagnostics with error detection including overcurrent, low voltage on power and logic•
supplies, internal programming corruption, and internal sensor faults.
Independent hardware overcurrent protection system (“desat” detection)•
SPECIFICATIONS:
Battery voltage range: 12-144V nominal (9-175V absolute maximum)•
Up to 45x LiFePO4 cells, 40x LiCo cells or 12x 12V lead acid•
Current rating: 1000A peak (1 minute), 300A continuous•
Power: 150kW peak, 45kW continuous•
Power device type: MOSFET•
On-state voltage drop: 0.6V at full power, 0.15V at continuous rating•
Switchingfrequency:16KHz•
Operatingtemperature:-20˚Cto90˚C(thermalcutbackfrom70˚C)•
Logic power supply: 12V nominal (8-18V range), 200mA max, internally fused•
Dimensions: 310x130x95mm housing only, 365x156x106mm inc terminals and brackets•
Weight: 4.5kg•
PACKAGE CONTENTS:
1x MC1000C motor controller•
4x M8x25 bolts, washers, and nuts•
1x 4-pin plug, 1x 5-pin plug•
1x User manual•
INSTALLATION
The motor controller may be installed in any orientation. Usually, installation close to the motor
is best in order to keep power wiring to the motor short. The enclosure is weather resistant but not
fully waterproof, so it is best installed in a location with some protection from the elements. If it
may be in the direct path of water, splash guards are recommended.
Thecontroller’scontinuouspowercapabilitiesdependsomewhatontheamountofairowaround
thecaseforconvectioncooling.Iftheinstalllocationhasverylittleairow,thecontrollermay
benetfromaddedconvectioncoolingviafansorducting.(Orforhighestsustainedpower,the
controller may be base-mounted to a fan-forced convection or water cooling block.)
Controller dimensions and mount locations
The motor controller comes with brackets for mounting with four 6mm or 1/4” bolts on a 142 x
260mm spacing. Spring washers under the heads of mounting bolts are recommended to prevent
the bolts from loosening over time due to vibration.
Alternatively the mounting brackets may be removed, and the four holes underneath the housing
used to fasten to a panel from beneath. The holes are M6 thread on a 70 x 260mm spacing.
Caution: Since these threaded holes penetrate the housing, ensure that bolts do
not extend more than 20mm into the case or they may damage components inside!
32

POWER WIRING
REMEMBER..
The traction circuits in electric vehicles involve very high power levels, with potentially lethal
voltages and currents involved. Always observe proper precautions and safety procedures when
working on electric vehicles. Always wear safety glasses, use insulated tools where possible, and
check for dangerous voltages with a multimeter before undertaking any maintenance!
If you are unsure, always consult with an experienced EV technician before proceeding.
TYPICAL WIRING DIAGRAM
The diagram below shows the basic power wiring. Orange lines represent power cables, which
shouldbe50sqmmor1/0AWGinsize,orlarger.Controlwiringto/fromcontrollernotshown.
Basic power wiring diagram for MC1000C controller
Caution: Always double check power wiring before turning the system on for the
rst time, because reversed polarities or short circuits can do a lot of damage!
When rst powering up the completed system, wiring mistakes or faulty throttle
devices could cause unexpected power to the motor, which risks injury or vehicle
runaway. It is highly recommended that the drive wheels be off the ground, and
that nobody is standing in front of or behind the vehicle at the time.
TIPS FOR BEST PERFORMANCE
Power cables around 50sqmm or 1/0AWG in size are recommended for all power wiring•
between batteries and motor controller, and 50-95sqmm (1/0 to 4/0 AWG) cable between the
motor controller and motor, where average currents are higher. It is best to use double insulated
cable with an orange sheath for compliance with electrical standards.
Ensure all power terminals and connections in your traction circuit are clean and tight. Always•
use either spring washers or Nyloc nuts to ensure connections will not loosen from vibration
over time. Poor connections have a higher resistance, which can cause them to become hot
when conducting large currents – potentially damaging components.
It is essential to have a precharge device to charge up the motor controller’s internal capacitor•
bankbeforeclosingthemaincontactor.Closingthemaincontactorwithoutrstprecharging
the controller causes a huge current spike which can damage contactors, often welding their
contactstogether.A1KΩ10Wprechargeresistorpermanentlyacrossthemaincontactorcan
work, but is not the safest solution as it does not truly isolate the controller when the key is off.
A better solution is a 2-stage automatic precharger such as our ZEVA Smart Precharger, or an
EVMS with built-in precharger.
Ensure you have an appropriately rated main contactor and fuse protecting your traction circuit.•
Examples of suitable contactors are the Kilovac EV200 or LEV200, Gigavac GX14, Albright
SW200, or Nanfeng ZJW400A.
Forafuse,a500AsemiconductortypewithsufcientDCvoltageratingisrecommended,such•
asthosefromBussmann,Ferraz-Shawmut,Mersen,Littelfuse,etc.Largefusestendtobevery
slow to blow, typically able to carry twice their rated current for about 1 minute. As such it is
best to use a fuse with a rating slightly above the continuous rating of the motor controller, rather
than one rated for the maximum motor controller current.
The MC1000C motor controller uses aluminium busbars. Aluminium itself is a good conductor•
of electricity, but unfortunately the (invisible) aluminium oxide which forms on its surface is
a poor conductor. The power terminals are supplied cleaned and with a thin layer of Noalox
contact paste applied to prevent re-oxidation. This paste should be left on the terminals when
are attaching power cables. The force of tightening the bolts will displace the grease and seal the
contact area to prevent corrosion over time.
The power cables in electric vehicles carry a large amount of power, and can emit a lot of•
electromagnetic interference (EMI) depending on their physical layout. To minimise EMI, it is
best to keep the positive and negative cables close together – both the power cables from battery
pack to controller, and controller to motor. To further reduce EMI, the cables may be twisted
around each other. (For further details on why twisting cables together is helpful for EMI, refer to
http://www.wikipedia.com/wiki/Twisted_Pair)
54

CONTROL WIRING
PLUG IDENTIFICATION
The MC1000C uses two aviation-style screw-lock plugs for all control/low power connections –
one with 4 pins for the throttle and one with 5 pins for power input and CAN bus connections.
Thediagrambelowshowspinidenticationsas viewed on the controller case, or from the back
of the plug.
Shield
CAN L
5V Out Thr A CAN H
Gnd
Thr B 12V in Gnd
Pin identication for control wiring plugs
Plug 1: Throttle
5V: Output power supply for throttle. Max•
50mA output (internal self-resetting fuse)
Gnd: Ground connection for throttle•
Throttle A: First throttle input, usually the•
analog level, 0-5V input
Throttle B: Second throttle input, either•
enable switch or 2nd analog, 0-5V input
Plug 2: Power and CAN
12V In: Connect to a key-switched 12V•
supply so the controller comes on when
the key is turned on. Often wired in parallel
with your main contactor. Maximum voltage
range 8-18V input, approx 200mA draw.
Gnd: Connect to ground / vehicle chassis•
CANLandCANH:TwowiresforCANbus•
communications
Shield: Not required (usually for pass-•
through of shielding on CAN-bus cables)
WIRING UP THE PLUGS
The plugs are opened using a small jewellers screwdriver to remove the screw on the side of the
rear shell, which then comes away with a small counterclockwise twist.
Feed wires through the back of the rear shell before attaching to the pins to ensure the case can
go together again after wires are attached. For reliable connections, be sure to “tin” (add solder to)
both the wires and the contacts before soldering them together.
The shell also has a cable stress relief clamp at the rear which should be fastened down to hold the
cables. If your cables are too small for the clamp to engage, you can wrap some insulation tape
around them to increase the diameter and ensure the clamp is able to hold them in place.
Example wiring of aviation plugs: Disassembled (left), wiring (middle), complete (right)
Since the logic wiring is necessarily quite close to the traction circuit power cables, to avoid•
Electromagnetic Interference (EMI) it is best to use shielded cables, or twist wires (such as 12V
and Ground) together. Also avoid running logic wiring in parallel with power cables for long
distances, as it increases noise due to crosstalk.
The logic board only requires 200mA current, so as small as AWG28 wire may be used for the•
powersupply.However,ifnotenclosedinashieldedsheath,itisbesttouselargercablearound
18AWG+ for better mechanical strength/durability.
All control wiring is galvanically isolated from the power terminals. In most cases the control•
wiring will share a common ground (the vehicle chassis) with your vehicle’s existing 12V system,
and the traction circuit should remain electrically isolated for safety.
THROTTLE DEVICE
The MC1000C controller supports a variety of different throttle types, which may be selected via
CAN bus interface. (Controller expects Type 1 throttle by default.)
Type 1, 0-5V + Enable:• Any throttle device which outputs a 0-5V level representing 0-100%
throttlemaybeused.Non-contactHallEffecttypesarethebestoptionduetotheirreliabilityand
virtually unlimited lifespan. They should have three wires to connect to Gnd, 5V and Throttle
A (0-5V level). The Throttle B pin should be connected to 5V through the enable switch on the
potbox (COM and NC terminals) for redundant safety in case of hall sensor fault.
Type 2, 0-5KΩ + Enable: • Although not considered a great option due to their tendency to wear
outandbecomeunreliableovertime,legacy2-wireresistive0-5KΩpotboxes(suchastheCurtis
PB-6) can be used. The two throttle wires connect to Throttle A and 5V (either polarity). The
enable switch should be wired between 5V and Throttle B, using the COM and NC terminals.
Type 3, Hall Effect Pedal Assembly (HEPA):• HEPApedalsarebecomingtheindustrystandard
for throttle devices in vehicles as they offer high reliability and safety through the use of dual
(redundant)halleffectsensors.AvarietyofdifferentHEPApedalsareavailable,typicallyhaving
6 wires for two independent 3-wire hall effect type throttles. The MC1000C was designed to
work with pedals providing dual analog outputs of around 0.7V–3.5V and 1.4V–4.2V. Use the
Gnd and 5V pins on Plug 2 to provide power to both sensors. The 0.7-3.5V signal connects to
ThrottleAandthe1.4V-4.2VsignaltoThrottleB.WithaHEPAthrottle,thecontrollercandetect
a throttle fault if any four of the wires are disconnected, or if either of the throttle sensors are
faulty.
76

THROTTLE ALGORITHMS
The MC1000C supports a range of different throttle algorithms to suit different applications and
motortypes.ThesecanbeconguredoverCANbus,withanEVMSMonitor,orpre-congured
from the factory by request. Adjustable parameters are ramp rate, speed control type and torque
control type.
Ramp rate is represented as a value of 0-4, being the rate of change of the throttle output, where 0
is fastest (near instant response) and 4 is slowest (several seconds to ramp up to full throttle). The
default value of 1 is suitable for most applications.
Speed Control and Torque Control can be
individually set to either Linear, Semiquadratic,
Quadratic or Off. The response curves for
each are shown in the graph to the right.
Linear control gives an output proportional to
input. Semiquadratic and Quadratic control
are typically used where gentler low throttle
response is desired. If both Speed Control and
Torque Control are enabled, the output is limited
to whichever is lower at any time. If one of the
two is set to Off, it is effectively unrestricted/
uncontrolled, so only the other parameter has an
effect. If both Speed and Torque Control are Off,
the controller’s output will be disabled.
The default setting of Linear for both speed and torque is suitable for most series DC motors, giving
a familiar driving experience. For permanent magnet motors, usually semiquadratic torque control
works well, with speed control either Off or in Linear mode. Speed only control is not normally
suited to traction applications (cars/bikes) but can be useful for aircraft or boats.
OPERATION
TIPS FOR BEST PERFORMANCE
Many drivers are accustomed to keeping revs low in their petrol vehicles in order to maximise
efciency,sincepetrolenginesareveryinefcientathighrevs.Well,electricdrivesystemsarethe
other way around! The single most effective way to maximise performance from your motor and
controller is to keep your motor revs high – around 3000-4000rpm with most Series DC motors.
For a given power output, driving a motor at higher speed uses more voltage but less current,
which reduces copper losses in the motor and resistive heating in the controller. Dropping down
a gear reduces motor amps by about 30%, which can actually halve the heat generated in your
controller – and hence double the continuous power capability. (Caution: Most Series DC motors
are rated to 5000rpm max so be careful not to exceed this speed.)
THERMAL PROTECTION
Ifyourcontrollerheatsinktemperaturereachesabout70˚C(150˚F),thecontrollerwillcommence
thermalcutback,smoothlyreducingpowertomitigatefurtherheating.ThestatusLEDwillash
green/redwhileinthisstate.Ifthecontrollertemperaturereachesabout90˚C(200˚F),thecontroller
will shut down completely to avoid overheating which could damage components.
The controller’s power rating depends somewhat on airow to cool the housing. If you are
experiencingthermalcutbacks,itmaybeusefultoaddfansorductstoincreaseairow.Driving
more slowly and keeping motor revs high will also help keep the motor controller cooler. If
thermal problems persist, it may be useful to add an external water cooling system or external
heatsink,whichcanbematedtotheataluminiumbaseofthecontroller(withthermalpastein
between).
12V LOGIC SUPPLY
The MC1000C has an internal regulated power supply on its 12V input which allows it to operate
safely and correctly over an input voltage range of 8-18VDC. As a safety precaution, the controller
will shut down if it detects the control voltage input dip below 8V.
In most installations this will never happen, but if your 12V battery and/or DC/DC converter is very
weak, the voltage may dip when loads such as headlights are turned on, which can trip out the
motorcontroller.Thisshouldberectiedbybyttingastrongerbatteryand/orDC/DCconverter.
MOTOR IDLING FUNCTIONALITY
The MC1000C includes a basic motor idle functionality, based on a low target speed with low
torque limit. It does not use an RPM sensor for speed feedback, so the speed may vary depending on
load.HoweveritisasimpleandeffectivesolutionforEVconversionswithautomatictransmissions
which require the motor to keep turning to maintain oil circulation in the gearbox, or for vehicles
using OEM power steering pumps, air-conditioning compressors, alternators, etc.
TheidlespeedandtorqueareconguredviaCANbus.Voltageeffectivelycontrolstargetmotor
speed and current controls the torque it will use to get there. Ideal values will depend on your
motor and vehicle, but a good starting point is 6V idle voltage and 100A idle current.
Caution: Electric motors can suffer damage if they remain stalled with current
owing for extended periods of time. Idle functionality is NOT recommended for
“direct drive” vehicles, and in the case of vehicles with manual transmissions, be
sure to put the clutch in when coming to a stop.
98

INTERNAL CAPACITOR WARNING
Motor controllers have a large bank of capacitors on their input, which can remain charged for a
long time after the controller is powered off. Exercise caution if undertaking vehicle maintenance
soonafterdriving,astheremaybesignicantvoltageacrossthecontroller’sinputpowerterminals,
even if your main contactor is open. Always measure the voltage across the controller with a
multimeter before performing any maintenance.
LED STATUS AND ERROR CODES
The MC1000C has a multicolour LED on its front panel for providing visual feedback on the
controller’s operating status. The following table summarises the codes you may encounter
(multipledotsrepresentingaashsequence):
LED Code Condition Comment
Controller on (No errors)
Thermal cutback Controllertemperatureabove60˚C.Powerreduces
slowly towards thermal shutdown threshold.
Thermal shutdown Controllertemperatureabove90˚C.Thermal
shutdown until temperature reduces.
Battery voltage low Voltage at power terminals below minimum setting.
Power stage disabled until voltage increases.
Supply voltage low Supply voltage below 8VDC. Latches on for safety.
Fix 12V supply then power cycle controller.
Throttle error Invalid voltage or level mismatch on throttle. Error
latchesonforsafetyuntilzerothrottleisdetected.
Highpedallockout Non-zerothrottledetectedatstartup.Mayindicate
foot on pedal, or a faulty throttle device.
Corrupt settings Fault in the internal memory. Will automatically
revert to default settings on next startup.*
Desat error Hardwareovercurrentfault.Mayindicatedamageto
internal power devices or short circuit in motor.*
Internal sensor fault An internal sensor returned an invalid value.*
* These rare errors may indicate a hardware fault in the controller – please contact us!
Caution: There are no user-serviceable parts inside the controller.
Do not attempt to open the controller as this will void warranty!
CAN BUS COMMUNICATIONS
The MC1000C includes an industry-standard CAN bus interface, allowing the user to monitor
and/or log information in realtime from the controller such as voltages, currents, throttle levels,
controller temperature, and a variety of possible error conditions. It also supports throttle control
over CAN bus, and the reprogramming of controller settings.
The easy way to interface with the MC1000C over CAN bus is to use our EVMS Monitor.The Monitor
will automatically detect the motor controller on the bus and display operating information on its
3.2” colour touchscreen. (An EVMS Core or Lite can share the same CAN bus and EVMS Monitor if
present, but is not required.) The Monitor will also automatically add a page to its Setup mode for
modifying controller settings. The CAN plug wiring for the EVMS Monitor is shown below. Please
refer to the EVMS Monitor manual for more detailed information, available at our website: www.
zeva.com.au
Shield
CAN L
CAN H Gnd
12V
CAN bus wiring as viewed on Monitor case
The following settings are available:
Minimum battery voltage: This setting can be useful to avoid overworking or over-discharging•
yourbattery,bysettingittowhatevervoltagerepresentsalowstateofcharge(atbattery).Note
that this cannot replace a proper battery management system for protecting your cells!
Maximum motor voltage: If using a motor rated to a lower voltage than your battery pack, you•
can use this setting to ensure that the motor controller will not overspeed the motor.
Maximum motor current: In vehicles with smaller motors, you may wish to reduce maximum•
motor current in order to avoid damaging your motor from overcurrent. Most 6” or larger Series
DCmotorswillbenewiththemaximum600Asetting.
Maximum battery current: If using small or weak batteries, you can adjust this setting to avoid•
overworking your batteries. (This typically does not effect acceleration when setting off, but may
reduce high speed performance.)
Throttle algorithm: The bottom four bits are for ramp rate, the next two bits for Speed Control•
type, and top two bits for Torque Control type. Please see section Throttle Algorithms for more
information.
Throttle type: The MC1000C supports three throttle types: (1) Three wire 0-5V analog plus Enable•
(2)Twowire0-5KΩplusenableand(3)HallEffectPedalAssembly(HEPA).Pleaserefertothe
Control Wiring: Throttle Device section for further details.
Idle voltage and current: These can be used to enable motor idling functionality. Be careful to•
leavetheseaszerounlessyouaresureyouneedthem,asitcancausethemotortorunnon-stop!
Refer to the Operation: Motor Idling section for more information.
1110

12
CAN PROTOCOL DESCRIPTION
This section describes the CAN communication particulars for those wishing to create their own
interface with the motor controller over CAN bus. Default CAN bus speed is 250kbps and uses
format2.0B.ThemotorcontrollerisintendedtoalwaysbeontheendofaCANbus,sohasa120Ω
termination resistor built-in. (Please contact us if you require a controller with different bus settings
or data formats.)
There are four different CAN frames used by the motor controller:
Frame ID Description Direction
50 Status / operating information Tx
51 Set Throttle Rx
52 Receive (or request) settings Rx
53 Transmit settings Tx
TheStatusframeistransmittedbythemotorcontrollerat10Hz,andcontains8unsignedbytes:
Byte Description
1 Low four bits are controller type (1 = MC600C, 2 = MC1000C, 3-15 reserved)
Highfourbitscontaincodeforanyerrors(seebelow)
2 Battery voltage, in volts
3 Battery current, x5 amps
4 Motor voltage, in volts
5 Motor current, x5 amps
6Internaltemperaturein˚C
7 Throttle level, 0-100%
8 Actual output to power stage (0-255)
The following error codes may be reported in the top four bits of status frame byte 1:
0 No error / all OK 6 OvervoltageonHV(>175V)
1 Controller sleeping 7 Low logic supply voltage (<8V)
2 Power stage “desaturation” 8 Throttle error / mismatch
3 Faulty current sensor 9 Thermalcutback(>70˚C)
4 Faulty temperature sensor 10 Thermalshutdown(~90˚C)
5UndervoltageonHV(<8V)
To set the controller’s throttle level via CAN bus, simply send a single unsigned byte on frame ID
51,witharangeof0(zerothrottle)to255(fullthrottle).Wheninuse,theCANthrottleoverrides
anythrottleconnectedtothecontroller’s4-pinplug.HoweverforsafetytheCANthrottlehasa
250 millisecond timeout – that is, if the controller does not receive a updated throttle information
within 250ms of the previous CAN throttle frame, it will revert to the primary throttle input. For
smoothnessandreliability,werecommendsendingCANthrottleupdatesataround10Hz.
Toaskthecontrollertotransmititscurrentsettings,sendazero-bytedataframeonID52
(Receive settings). The controller will return 8 unsigned bytes on frame ID 53 (Transmit Settings),
as described in the table below:
Byte Description Valid range
1 Minimum battery voltage (V) 8-150
2 Maximum motor voltage (V) 1-180
3 Maximum motor current (x10A) 0-100
4 Maximum battery current (x10A) 0-100
5 Throttle algorithm 0-4, 0-4, 0-4
6 Throttle type 1-3
7 Idle voltage (V) 0-12
8 Idle current (x10A) 0-20
The same 8-byte data format is used for sending new settings to the motor controller, using frame
ID 52 (Receive settings). Note that if any of the parameters are outside the valid ranges above,
the entire settings update will be rejected.