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Sevcon Gen4 User Manual

Sevcon Gen4
123 pages
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Gen4
Applications
Reference
Manual
Document no:
177/52701
Rev. 3.3

Table of Contents

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Sevcon Gen4 Specifications

General IconGeneral
BrandSevcon
ModelGen4
CategoryController
LanguageEnglish

Summary

Introduction to Gen4 Controllers

About Gen4 Documentation

Information on the manual's scope, copyright, and related documents.

Dangers, Warnings, Cautions and Notes

Explains the meaning of danger, warning, caution, and note symbols used in the manual.

Product Identification Label

Details on the product identification label and its components.

Technical Support and Warranty

Information on obtaining technical assistance and product warranty details.

About the Gen4

Introduction to Gen4 Controllers

Overview of Gen4 controllers for traction and pump applications.

Intended Use and Accessories

Lists applications and available accessories for Gen4 controllers.

Principles of Operation

Functional description of Gen4 controllers, including power conversion and control.

Safety and Protective Functions

General safety precautions and protective functions of the Gen4 controller.

Fault Detection and Handling

Categories of faults and how they are detected and handled.

Installation

Mounting and Environmental Considerations

Guidelines for controller mounting, location, and chemical protection.

Cooling and EMC Requirements

Ensuring performance through cooling and meeting EMC guidelines.

Power and Signal Wiring

Instructions for connecting power cables and signal wiring.

On-board Fuse Mounting

Procedures for mounting the main input protection fuse onto the controller.

Specification

Electrical Specifications

Details on input/output voltage, CAN interface, and protection.

Output Ratings and Performance

Table and graph showing output current ratings for various durations.

Isolation and EMC Standards

Electromagnetic compatibility and isolation specifications.

Mechanical and Environmental Specs

Specifications for operating environment, shock, vibration, and dimensions.

Dimensions

Physical dimensions for different Gen4 models.

System Design

Motor Sizing and Selection

Information required for selecting an appropriate induction motor.

Gen4 Controller Selection

Considerations for choosing a Gen4 controller based on ratings.

Circuit Configuration

Defining application circuit configuration for traction and pump systems.

Motor Speed and Commutation Sensors

Details on encoder and commutation sensors for motor control.

Initial Power Up Sequence

Checklist for applying power and initial checks after power-up.

Configuration

Introduction to Configuration

Overview of Gen4 software configuration, tools, and process.

DVT Configuration Tool

Sevcon's proprietary tool for monitoring and configuring parameters.

CANopen and Network Setup

Introduction to CANopen, object dictionary, and network configuration.

Motor Characterization

Determining motor parameters and self-characterization process.

I/O Configuration and Mapping

Setting up and mapping input/output signals for system functions.

Vehicle Performance Configuration

Configuring safety interlocks, throttle, and driveability features.

Driveability Profiles and Torque Control

Setting profiles for speed, torque, acceleration, and smoothing output.

Wheel Lock Prevention and Roll-Off

Measures to prevent wheel locking and controlled roll-off features.

Pump and Power Steer Configuration

Configuring pump and power steering functions.

Vehicle Features and Functions

Configuring contactors, brakes, horn, and speed calculations.

Battery Management and Displays

Battery protection, BDI, current limits, and display compatibility.

Monitoring Gen4

Reading Status Variables

Accessing Gen4's object dictionary for status information.

Motor and Heatsink Measurements

Reading motor parameters and heatsink temperature.

Hours Counters and Logging

Using hours counters and logging system events and parameters.

Faults and Warnings

Identifying and handling faults using LED flashes and configuration tools.

Upgrading Controller Software

Field updating firmware using Sevcon's DVT configuration tool.

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