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Sevcon Gen4 User Manual
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D
o
c
.
#
1
7
7
/
52701
R
e
v
3
3-
10
Cable sizes
CAUTION: W
hen deciding on po
wer cable diam
eter, consideration m
ust be given to cab
le
length, grouping of
cables, the m
aximum allowable tem
perature rise
and the
temperature
rating
of the chosen cable.
The following table
gives guidance
on the cable s
ize needed for var
ious currents in
welding
cable, not grouped
with other cables,
in 25
°C ambient
with 60°C tem
perature rise
on the cable
surface.
Gen4 average (rms)
current
Cable sizes
metric
US
(approx
equivalent)
180
A
25 mm
2
4 AWG
225
A
35 mm
2
2
AW
G
280 A
50 mm
2
1 AWG
3
50
A
70 mm
2
2/0 AWG
33
35
Table of Contents
Table of Contents
3
Chapter 1: Introduction
9
About Gen4 Documentation
10
This Version of the Manual
10
Copyright
10
Scope of this Manual
10
Related Documents
10
Drawings and Units
10
Dangers, Warnings, Cautions and Notes
11
Product Identification Label
12
Technical Support
12
Product Warranty
12
Chapter 2: About the Gen4
13
Introduction
14
Standard Features and Capabilities
14
Available Options
14
Intended Use of the Gen4
15
Available Accessories
15
Overview of a Truck Drive System
16
Principles of Operation
17
Functional Description
17
Interfaces
18
Master-Slave Operation
18
Torque Mode
19
Speed Mode
19
Safety and Protective Functions
20
General
20
On-Highway Vehicles
22
Fault Detection and Handling
24
Chapter 3: Installation
25
Mounting Gen4
26
Location
26
Protection from Chemical Contamination
26
Orientation
26
Clearance for LED Access
26
Mounting Hole Pattern
27
Equipment Required
27
Thermal Grease Application
27
Cooling Requirements
29
EMC Guidelines
30
General Measures
30
Measures Required for Specific Signals
31
Additional Measures
31
Problems to Avoid
32
Connecting Power Cables
33
Battery and Motor Connections
33
Cable Sizes
34
On-Board Fuse Mounting
35
Fuse Rating and Selection
36
Signal Wiring
37
Signal Wire Sizes
37
Canbus Termination
37
Signal Connections
38
Chapter 4: Specification
45
Electrical
46
Input Voltage
46
Output Protection
46
Output Ratings
48
CAN Interface
49
Control Inputs and Outputs
49
Isolation
50
Emc
51
Regulatory Compliance
51
Mechanical
52
Operating Environment
52
Shock and Vibration
52
Controller Weight
52
Dimensions
53
Size 2 Models
53
Size 4 Models
53
Size 6 Models
54
Chapter 5: System Design
55
Sizing a Motor
56
Information Required about the Application
56
Motor Maximum Speed
56
Torque Required between Zero and Base Speed
56
Torque Required at Maximum Speed
57
Continuous Power Rating
57
Peak Power Rating
58
Selecting the Correct Gen4 Model
58
Current and Power Ratings Considerations
58
Power Output Restrictions at Motor and Drive Operating Temperature Limits
58
Circuit Configuration
59
Single Traction Wiring Diagram
60
Single Pump Wiring Diagram
61
Twin Motor Systems
62
Auxiliary Components
62
Main Contactor
62
35 Way Ampseal Connector Kit
62
Emergency Stop Switch
62
On-Board Fuse
63
Key Switch Fuse F2
65
Motor Speed Sensor (Encoder)
65
Motor Commutation Sensor
66
Initial Power up Sequence
69
Checks Prior to Power up
69
Checks after Power Is Applied
69
Chapter 6: Configuration
71
Introduction
72
DVT Configuration Tool
72
DVT Functionality
72
Saving, Duplicating and Restoring a Node's Configuration
72
Data Logging
73
Canopen
73
Canopen Protocol
73
Object Dictionary
74
Communication Objects
74
Network Configuration
75
Configuration Process Overview
77
Access Authorization
77
How NMT State Affects Access to Parameters
77
Motor Characterization
78
Determining Motor Parameters
78
Self Characterization
79
Additional Motor Configuration
80
I/O Configuration
81
Object Mapping
81
Encoder
84
Digital Inputs
84
Analogue Inputs
84
Analogue (Contactor) Outputs
86
Vehicle Performance Configuration
88
Safety Interlocks
88
Torque Mode/Speed Mode
89
Throttle
90
Driveability Features
92
Acceleration and Braking
93
Footbrake
94
Steering Inputs - Twin Driving Motor Systems
94
Driveability Profiles
96
Smoothing Output Torque
98
Preventing Wheel Lock Scenarios
99
Controlled Roll-Off
100
Hill Hold
100
Inching
100
Belly Switch
101
Drivability Select Switches
101
Economy
101
Pump Configuration
101
Power Steer Configuration
103
Vehicle Features and Functions
104
Contactors
104
Line Contactor
104
Electro-Mechanical Brake
104
External LED
105
Alarm Buzzer
105
Brake Lights
105
Horn
105
Vehicle Speed Calculation
105
Distance Calculation
106
Service Indication
106
Traction Motor Cooling Fan
106
Controller Heatsink / Motor Cooling Fan
107
Motor Over-Temperature Protection
107
Motor Over-Speed Protection
107
Battery Protection
107
Displays
109
Chapter 7: Monitoring Gen4
111
Reading Status Variables
112
Motor Measurements
112
Heatsink Temperature
112
Identification and Version
112
Battery Monitoring
112
Hours Counters
113
Logging
113
FIFO Event Logs
113
Event Counters
114
Operational Monitoring
114
Canopen Abort Code
114
Faults and Warnings
116
Introduction
116
Fault Identification
116
Fault List
120
Upgrading the Controller Software
120
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Sevcon Gen4 Specifications
General
Brand
Sevcon
Model
Gen4
Category
Controller
Language
English
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