Sevcon Gen4 - Isolation and EMC Standards

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Doc. # 177/52701

Rev3

4-6

Isolation

Any terminal to the

case:

Meets EN1175-1:1998 and ISO3691

Complies with IEC-60664

Main Page

Table of Contents3
Chapter 1: Introduction9
About Gen4 Documentation10
This Version of the Manual10
Copyright10
Scope of this Manual10
Related Documents10
Drawings and Units10
Dangers, Warnings, Cautions and Notes11
Product Identification Label12
Technical Support12
Product Warranty12
Chapter 2: About the Gen413
Introduction14
Standard Features and Capabilities14
Available Options14
Intended Use of the Gen415
Available Accessories15
Overview of a Truck Drive System16
Principles of Operation17
Functional Description17
Interfaces18
Master-Slave Operation18
Torque Mode19
Speed Mode19
Safety and Protective Functions20
General20
On-Highway Vehicles22
Fault Detection and Handling24
Chapter 3: Installation25
Mounting Gen426
Location26
Protection from Chemical Contamination26
Orientation26
Clearance for LED Access26
Mounting Hole Pattern27
Equipment Required27
Thermal Grease Application27
Cooling Requirements29
EMC Guidelines30
General Measures30
Measures Required for Specific Signals31
Additional Measures31
Problems to Avoid32
Connecting Power Cables33
Battery and Motor Connections33
Cable Sizes34
On-Board Fuse Mounting35
Fuse Rating and Selection36
Signal Wiring37
Signal Wire Sizes37
Canbus Termination37
Signal Connections38
Chapter 4: Specification45
Electrical46
Input Voltage46
Output Protection46
Output Ratings48
CAN Interface49
Control Inputs and Outputs49
Isolation50
Emc51
Regulatory Compliance51
Mechanical52
Operating Environment52
Shock and Vibration52
Controller Weight52
Dimensions53
Size 2 Models53
Size 4 Models53
Size 6 Models54
Chapter 5: System Design55
Sizing a Motor56
Information Required about the Application56
Motor Maximum Speed56
Torque Required between Zero and Base Speed56
Torque Required at Maximum Speed57
Continuous Power Rating57
Peak Power Rating58
Selecting the Correct Gen4 Model58
Current and Power Ratings Considerations58
Power Output Restrictions at Motor and Drive Operating Temperature Limits58
Circuit Configuration59
Single Traction Wiring Diagram60
Single Pump Wiring Diagram61
Twin Motor Systems62
Auxiliary Components62
Main Contactor62
35 Way Ampseal Connector Kit62
Emergency Stop Switch62
On-Board Fuse63
Key Switch Fuse F265
Motor Speed Sensor (Encoder)65
Motor Commutation Sensor66
Initial Power up Sequence69
Checks Prior to Power up69
Checks after Power Is Applied69
Chapter 6: Configuration71
Introduction72
DVT Configuration Tool72
DVT Functionality72
Saving, Duplicating and Restoring a Node's Configuration72
Data Logging73
Canopen73
Canopen Protocol73
Object Dictionary74
Communication Objects74
Network Configuration75
Configuration Process Overview77
Access Authorization77
How NMT State Affects Access to Parameters77
Motor Characterization78
Determining Motor Parameters78
Self Characterization79
Additional Motor Configuration80
I/O Configuration81
Object Mapping81
Encoder84
Digital Inputs84
Analogue Inputs84
Analogue (Contactor) Outputs86
Vehicle Performance Configuration88
Safety Interlocks88
Torque Mode/Speed Mode89
Throttle90
Driveability Features92
Acceleration and Braking93
Footbrake94
Steering Inputs - Twin Driving Motor Systems94
Driveability Profiles96
Smoothing Output Torque98
Preventing Wheel Lock Scenarios99
Controlled Roll-Off100
Hill Hold100
Inching100
Belly Switch101
Drivability Select Switches101
Economy101
Pump Configuration101
Power Steer Configuration103
Vehicle Features and Functions104
Contactors104
Line Contactor104
Electro-Mechanical Brake104
External LED105
Alarm Buzzer105
Brake Lights105
Horn105
Vehicle Speed Calculation105
Distance Calculation106
Service Indication106
Traction Motor Cooling Fan106
Controller Heatsink / Motor Cooling Fan107
Motor Over-Temperature Protection107
Motor Over-Speed Protection107
Battery Protection107
Displays109
Chapter 7: Monitoring Gen4111
Reading Status Variables112
Motor Measurements112
Heatsink Temperature112
Identification and Version112
Battery Monitoring112
Hours Counters113
Logging113
FIFO Event Logs113
Event Counters114
Operational Monitoring114
Canopen Abort Code114
Faults and Warnings116
Introduction116
Fault Identification116
Fault List120
Upgrading the Controller Software120

Sevcon Gen4 - Isolation and EMC Standards

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