Page 40 SC2000 Manual – 177/52301 Rev G 22
nd
October
2004
13 INSTALLATION
13.1 The controller should be bolted down to a flat (0.2mm max. deviation) paint free
surface that
has been lightly coated with a thermal transfer compound, such as G6451 or Dow Corning
heatsink compound, by the 6 fixing holes provided. Care should be taken not to trap any
wires, etc., under the controller. The mounting surface MUST be a substantial metal section
of the truck for the full controller ratings to be achieved.
13.2 Power connections should be made with flexible heat resisting cables of suitable cross-
sectional area for the current to be carried. These should be terminated in soldered or
crimped lugs attached to controller and the contactors. Note that nuts and washers are
supplied for the M8 connections on the controller. A battery-disconnect switch should be used
(EC Directive).
13.3 The contactors specified for use with the controller are Albright SW180 series (Pump and
Traction Bypass and Regen), Albright SW80 (Power Steer and Field Weakening), Albright
SW200 (Line) and Albright DC182 (Forward/Reverse). Contactors are to be rated for
intermittent use with the exception of the Line and Power Steer contactors which must be
rated for continuous use. When alternative manufacturers contactors are used, coil currents,
pull-in and drop-out times should be investigated to ensure compatible operation.
13.4 The contactor mounting plane can affect performance, contactors should never be mounted
with their terminal studs vertically down. For further applications information on contactors,
please consult SEVCON.
13.5 The controller may be supplied as a stand-alone unit or pre-wired onto a baseplate with
contactors etc. If the controller is 'stand-alone', both Connectors 1 and 2 will be used. If a
'panel' is supplied, only Connector 1 will be used as Connector 2 will contain the contactor
wiring. The mating halves of the connectors can be supplied with the controller as a 'loose
equipment kit'.
13.6 Control wiring connections should be made using 1.00mm
2
(AWG#18) or equivalent stranded
wire. The correct pressure release crimping tools MUST be used for long term connection
reliability.
13.7 The main battery cable should be fused with a suitable air-break fuse. The keyswitch line
must also be fused at a level not exceeding 10 A when using the specified Albright
contactors. The BDI measure input, connector B pin 10 should have a series 1 amp fuse
fitted
13.8 The return wiring for the accelerators should be connected to the B- terminal on the controller
to prevent large currents altering accelerator signals.
13.9 Fixing torque for power connectors
M10 terminals 14NM ±0.6NM
M8 terminals 11NM +0.5NM, -0.2NM
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