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MillipaK PMAC Manual

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Summary of Contents for MillipaK PMAC

  • Page 2 Reason for Modification Initials Date Initials Date 04 Jan 06 UK0157.04 Original. 16 Feb 06 UK0157.05 Update 05 Apr 06 UK0157.07 Removal of Walkie Functionality 24 Apr 06 UK0157.08 Added proportional direction braking MillipaK PMAC Controller Manual Page 2 26/04/06...
  • Page 3 Power Steer................................38 Seat Switch................................39 Handbrake Switch ..............................40 Cutback speeds ................................41 Reverse Speed................................42 Pump Contactor...............................43 External LED Drive..............................44 Traction Motor Over-Temperature Input.......................45 Drive Hours Meter ..............................46 Personality Checksum .............................47 Line Contactor Drop out ............................48 MillipaK PMAC Controller Manual Page 3 26/04/06...
  • Page 4 EPORTING .....................72 OFTWARE ERSION AND ERIAL UMBER INDICATION Specifications..........................73 .............................73 OWER ONFIGURATIONS .................................73 STANDARDS ..............................73 OCKET PROTECTION ............................73 ONTACTOR DRIVE RATINGS .............................73 NALOGUE NPUT MPEDANCE ............................73 IGITAL NPUT MPEDANCE EMC Guidelines..........................74 MillipaK PMAC Controller Manual Page 4 26/04/06...

  • Page 5: Introduction

    ______________________________________________________________________________ Introduction The MillipaK PMAC (Permanent Magnet AC) range of controllers provides a new range of power frames for 24V-36V, 250A and 48V, 200A in small highly efficient packages. This is achieved using a Sevcon patented power switching scheme and radical new construction techniques, which enable large powers to be incorporated into very small packages.

  • Page 6: Safety

    Safety ______________________________________________________________________________ Safety The MillipaK controller contains a triple fail-safe system to give a high level of safety. If the diagnostic LED is not illuminated or flashes, the safety circuit may have tripped and the motor may not drive. The controller must be used with a line contactor as indicated in the wiring diagrams.

  • Page 7: Installation

    Mounting The MillipaK PMAC unit provides 4 x M6 clearance holes for mounting. The controller should be mounted onto a metal base plate, as large as possible to provide heat-sinking. The surface finish should be flat, clean and burr free and thermal compound should be applied to the controller base before fitting.

  • Page 8: Millipak Pmac Power Wiring

    Installation Wiring/Power ______________________________________________________________________________ MillipaK PMAC Power Wiring Fuse Line Contactor BPM Motor Battery Supply Figure 2: MillipaK PMAC Power Wiring MillipaK PMAC Controller Manual Page 8 26/04/06...

  • Page 9: M Illipa K L Ight W Iring Example

    **Extra Suppression and Horn Suppression inputs to be used as show n below : Extra Suppression 1 or 2 Battery +ve or Horn Suppression External Contactor / Horn Battery -ve Figure 3: MillipaK Light Wiring MillipaK PMAC Controller Manual Page 9 26/04/06...
  • Page 10 Pins 13,14 & 15 are general-purpose suppression connections and may be used to suppress spikes generated by contactors opening / closing. The internal configuration is shown below: Pin 16 is used to select FLASH memory program update mode and should normally be left unconnected. MillipaK PMAC Controller Manual Page 10 26/04/06...

  • Page 11: Calibrator

    The Calibrator is a hand-held adjustment unit which can be used to configure and test the system. The MillipaK is designed to work with the Calibrator currently in use with SEVCON's MOS90 system. See diagram below. The menu structure is shown in the Calibrator Map located near the end of this manual.

  • Page 12: Drive Hour Counter

    Keyswitch. This is also the point at which you can enter a password to enable different levels of access to personalities. Refer to the section below on Calibrator Security Levels for more details. MillipaK PMAC Controller Manual Page 12 26/04/06...

  • Page 13: C Alibrator S Ecurity L Evels

    Service mode. After the Security Level has been displayed, the system enters the normal menu structure shown in the Calibrator Map. To change the password level, you need to recycle the Keyswitch. MillipaK PMAC Controller Manual Page 13 26/04/06...

  • Page 14: N Avigation

    Pressing the SELECT button at any time exits the Test menu and moves to the first item in the menu structure (menu item 0.01 - Armature Current Limit). The items which are displayed depends on the current system configuration and the Security Level. MillipaK PMAC Controller Manual Page 14 26/04/06...

  • Page 15: A Djustments

    System Setup any of the other personalities. Unlike the personalities in the other menus, changes to items in this menu do not take affect until the Keyswitch is recycled. Table 2: Adjustment Menus MillipaK PMAC Controller Manual Page 15 26/04/06...

  • Page 16: S Tatus And T Est I Nformation

    Software Version, Controller Serial Number and the Personality Checksum. Refer to the appropriate sections for more information on each of these items. Table 3: Status and Test Information Menus MillipaK PMAC Controller Manual Page 16 26/04/06...

  • Page 17: Configuration

    Configuration System ______________________________________________________________________________ Configuration Configuration of the MillipaK controller is split into two categories – system and performance, which will be discussed in turn. System Configuration The MillipaK system configuration items relate to how the MillipaK will interface with connected hardware such as the system battery, vehicle control switches, accelerator and the traction motor.

  • Page 18: System Voltage

    The system voltage usually refers to the main system supply battery voltage. The controller uses this information to ensure low and high voltage settings are within an appropriate range. System Voltage Power Up Calibrator Menu Reference: 12.16 Minimum Maximum Step Size Default MillipaK PMAC Controller Manual Page 18 26/04/06...

  • Page 19: System I/O Configuration

    If your application doesn’t fit any of the above, please contact Sevcon with details of your requirements. Each of the above configurations allocates the controller i/o as shown below: Digital Value of Digital I/O Configuration Item Function Forward Reverse Seat Speed Cutback 1 Speed Cutback 2 MillipaK PMAC Controller Manual Page 19 26/04/06...
  • Page 20 Table 6 details which analogue functions are configured for each value of the Analogue Input Configuration Item. Digital Configuration Power Up Calibrator Menu Reference: 12.14 Minimum Maximum Step Size Default As Required Analogue Configuration Power Up Calibrator Menu Reference: 12.15 Minimum Maximum Step Size Default As Required MillipaK PMAC Controller Manual Page 20 26/04/06...
  • Page 21 Seek advice from SEVCON before changing these two personality values. Changing these can affect the capability of the current limit function which could damage the unit due to over-current. The factory set values should be suitable for most applications MillipaK PMAC Controller Manual Page 21 26/04/06...

  • Page 22: Contactor Chopping

    When the electric outboard solenoid is configured, both the line contactor and electric outboard solenoid coil voltage will be battery voltage for 100ms during energisation and then reduced to 16 volts. Chop Select Power Up Calibrator Menu Reference: 12.01 Options Default MillipaK PMAC Controller Manual Page 22 26/04/06...

  • Page 23: Accelerator Full /Zero Setting

    Note that a 6 flash fault will occur if the full and zero levels are set within 0.50V of each other. The PWM demand will vary between the Creep level and Maximum Speed level as the accelerator voltage varies between “Accelerator Zero” and “Accelerator Full”. MillipaK PMAC Controller Manual Page 23 26/04/06...

  • Page 24: Motor Poles

    The motor poles refer to the number of poles in the motor. The motor poles are used to calculate the mechanical speed of the motor. Motor Poles Power Up Calibrator Menu Reference: 8.01 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 24 26/04/06...

  • Page 25: Maximum Motor Rpm

    The maximum motor RPM is the maximum RPM when the motor is unloaded and maximum voltage is applied to the motor. The value is in 100rpm per step size. Maximum Motor RPM Power Up Calibrator Menu Reference: 8.02 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 25 26/04/06...

  • Page 26: Phase Adjustment

    NOTE: If this feature is disabled, the phase current could be higher than that measured by the system. Only disable this feature if it is known high phase currents can not occur. Power Factor Phase Correction Power Up Calibrator Menu Reference: 12.13 Options Default MillipaK PMAC Controller Manual Page 26 26/04/06...

  • Page 27: P Erformance

    In Closed Loop Speed Control mode, the speed of the vehicle is controlled to the speed demand from the operator. The controller will increase or decrease power to the motor or will initiate braking to maintain the target speed. MillipaK PMAC Controller Manual Page 27 26/04/06...

  • Page 28: Speed Control Pi Gains

    4. Reduce the speed target to approximately 5%. 5. Check that the motor control is still smooth. If the control is unstable, decrease the proportional gain until the control is stable. MillipaK PMAC Controller Manual Page 28 26/04/06...
  • Page 29 The following two personalities can be used to setup the control loop. Speed Proportional Gain Immediate Calibrator Menu Reference: 2.07 Minimum Maximum Step Size Typical Value Speed Integral Gain Immediate Calibrator Menu Reference: 2.08 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 29 26/04/06...

  • Page 30: Acceleration Delay

    Neutral Deceleration Delay Immediate Calibrator Menu Reference: 2.04 Minimum Maximum Step Size Typical Value 0.1S 10.0S 0.1S 0.1S MillipaK PMAC Controller Manual Page 30 26/04/06...

  • Page 31: Regen Braking

    Performance/Regen Braking ______________________________________________________________________________ Regen Braking All braking types are implemented using regenerative braking in the 4QPM MillipaK. Braking can be initiated in one of 4 ways: Direction Braking. Initiated when the direction switch inputs are reversed during drive. i.e., Reverse is selected when driving in Forward or Forward is selected when driving in Reverse.

  • Page 32: Footbraking

    As the input voltage varies from the Zero level to the Full level, the footbrake demand varies from 0% to 100%. When the footbrake demand is at 0%, there is no footbraking. As the footbrake MillipaK PMAC Controller Manual Page 32...
  • Page 33 Footbrake priority can be set to drive or brake and this determines the controller action in the case of the accelerator and footbrake pedal both being active at the same time. Footbrake Priority Power Up Calibrator Menu Reference: 12.11 Options Default Drive Brake Drive MillipaK PMAC Controller Manual Page 33 26/04/06...

  • Page 34: Creep Speed

    The motor voltage is rapidly ramped to the creep level (equivalent to a 100mS acceleration delay). Creep Speed Immediate Calibrator Menu Reference: 3.01 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 34 26/04/06...

  • Page 35: Maximum Speed

    Adjustment limits the maximum applied voltage to the armature in Torque mode or the maximum speed as a percentage of the maximum speed (rpm) in Speed mode. Maximum Speed Immediate Calibrator Menu Reference: 5.01 Minimum Maximum Step Size Typical Value 100% 100% MillipaK PMAC Controller Manual Page 35 26/04/06...

  • Page 36: Accelerator Characteristics

    If a valid direction is selected and the accelerator demand is at 0%, the speed demand will be set to the Creep Speed personality. As the accelerator demand is increased to 100%, the speed demand increases linearly to the Maximum Speed personality. MillipaK PMAC Controller Manual Page 36 26/04/06...

  • Page 37: Features

    ______________________________________________________________________________ Features The MillipaK controller has several features designed to offer the user maximum flexibility, safety and performance whilst ensuring the controller is protected against adverse or harsh driving conditions. These features can be split into three categories – standard controller features, safety features and controller protection features.

  • Page 38: Power Steer

    Immediate Calibrator Menu Reference: 9.01 Minimum Maximum Step Size Typical Value Power Steer Trigger Power On Calibrator Menu Reference: 12.10 Minimum Maximum Step Size Default See also contactor drive output configuration (System/Digital IO). MillipaK PMAC Controller Manual Page 38 26/04/06...

  • Page 39: Seat Switch

    Seat Delay Immediate Calibrator Menu Reference: 10.01 Minimum Maximum Step Size Typical Value 0.1S 5.0S 0.1S 5.0S Seat Cuts Pump Power On Calibrator Menu Reference: 12.04 Options Typical Value MillipaK PMAC Controller Manual Page 39 26/04/06...

  • Page 40: Handbrake Switch

    Features Standard Features/Handbrake Switch ______________________________________________________________________________ Handbrake Switch An input is provided for the connection of a handbrake switch, which if operated will disable armature pulsing. MillipaK PMAC Controller Manual Page 40 26/04/06...

  • Page 41: Cutback Speeds

    Cutback Speed 1 Immediate Calibrator Menu Reference: 6.01 Minimum Maximum Step Size Typical Value 100% 100% Cutback Speed 2 Immediate Calibrator Menu Reference: 7.01 Minimum Maximum Step Size Typical Value 100% 100% MillipaK PMAC Controller Manual Page 41 26/04/06...

  • Page 42: Reverse Speed

    This can be achieved by enabling the reverse speed limit and setting the Maximum Reverse Speed personality accordingly. Maximum Reverse Speed Immediate Calibrator Menu Reference: 5.02 Minimum Maximum Step Size Typical Value 100% 100% Reverse Speed Limit Enable Power Up Calibrator Menu Reference: 12.05 Options Default MillipaK PMAC Controller Manual Page 42 26/04/06...

  • Page 43: Pump Contactor

    The Pump Contactor drive will activate when the Pump Trigger switch is active and will deactivate 0.5s after the Pump Trigger switch is deactivated. The 0.5s delay is used to de-bounce the Pump Trigger switch. MillipaK PMAC Controller Manual Page 43 26/04/06...

  • Page 44: External Led Drive

    Any flash faults shown on the LED can also be shown via this output. If Contactor Chopping is set to On or 24V, the output will only pulse at 24V to prevent the lamp brightness from varying when other contactor outputs are activated. MillipaK PMAC Controller Manual Page 44 26/04/06...

  • Page 45: Traction Motor Over-Temperature Input

    Traction Motor is over heating. If the Traction Motor Over-Temperature Input is active, the armature current limit is reduced to of the Armature Current Limit personality. MillipaK PMAC Controller Manual Page 45 26/04/06...

  • Page 46: Drive Hours Meter

    ______________________________________________________________________________ Drive Hours Meter The MillipaK maintains a log of the number of hours during which the controller is providing Drive functionality. The Drive Hours Meter runs whenever the vehicle is driving or braking. The current number of logged Drive hours can be viewed using the Calibrator. Refer to the Calibrator section for more information.

  • Page 47: Personality Checksum

    ______________________________________________________________________________ Personality Checksum As you can see from this Manual and the Calibrator Map, the MillipaK employs quite a few personalities to give the user as much flexibility as possible in setting up their system. After the personalities have been setup to give the desired functionality and performance, most customers will request the same setup for each subsequent controller they purchase.

  • Page 48: Line Contactor Drop Out

    Line contactor dropout operation can be selected in the PERS set up: Line Contactor Drop out Power Up Calibrator Menu Reference: 12.09 Options Default Line Contactor Drop out Delay Immediate Calibrator Menu Reference: 11.01 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 48 26/04/06...

  • Page 49: Alarm Buzzer

    Basically, the Buzzer Output is active whenever the vehicle is moving. Alarm Buzzer Power Up Calibrator Menu Reference: 12.12 Options Default MillipaK PMAC Controller Manual Page 49 26/04/06...

  • Page 50: Electric Outboard Drive And Low Battery Warning

    Calibrator Menu Reference: 11.09 Minimum Maximum Step Size Typical Value 0.0V 70.0V 0.5V 16.0V Low Battery Warning Timer Immediate Calibrator Menu Reference: 11.10 Minimum Maximum Step Size Typical Value 0.0s 20.0s 0.1s 0.0s MillipaK PMAC Controller Manual Page 50 26/04/06...

  • Page 51: Temporary Current Boost

    Armature Current Limit personality. Temporary Armature I Limit Immediate Calibrator Menu Reference: 0.04 Minimum Maximum Step Size Typical Value 100A Temporary Armature I Limit Timer Immediate Calibrator Menu Reference: 0.05 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 51 26/04/06...

  • Page 52: S Afety F Eatures

    Alternatively, the system may be programmed not to check the Direction switches at power on. This option is programmable: Direction Switch Checking Power Up Calibrator Menu Reference: 12.07 Options Default MillipaK PMAC Controller Manual Page 52 26/04/06...

  • Page 53: Fs1 Recycle

    This feature is implemented as an option. FS1 Recycle Power Up Calibrator Menu Reference: 12.06 Options Default MillipaK PMAC Controller Manual Page 53 26/04/06...

  • Page 54: Sro (Static Return To Off)

    FS1 is active for more than the SRO delay with no direction selected. In this case the FS1 will need to be recycled. Static Return to Off Power Up Calibrator Menu Reference: 12.02 Options Default SRO Delay Immediate Calibrator Menu Reference: 11.03 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 54 26/04/06...

  • Page 55: Anti-Rollback

    This is a standard SEVCON feature and is used to help prevent roll back conditions on ramps. If the driver reselects the previous direction after a neutral condition, braking is not attempted, and full drive power is available to restart on a hill. MillipaK PMAC Controller Manual Page 55 26/04/06...

  • Page 56: Anti-Rolloff

    The vehicle has to be stationary at least once after power up before the feature is applied. The Roll-Off strength is not adjustable but can be enabled and disabled using the Roll-Off Enable option. Roll-Off Enable Immediate Calibrator Menu Reference: 11.01 Options Default MillipaK PMAC Controller Manual Page 56 26/04/06...

  • Page 57: Idle Fault

    The above conditions are both true continuously for the time specified by the Idle Timer personality. Setting the Idle Timer personality at zero disables the feature. Idle Timer Immediate Calibrator Menu Reference: 11.04 Minimum Maximum Step Size Typical Value 255s 240s MillipaK PMAC Controller Manual Page 57 26/04/06...

  • Page 58: Motor Stall Protection

    Maximum Step Size Typical Value Stall Motor Voltage Immediate Calibrator Menu Reference: 8.06 Minimum Maximum Step Size Typical Value Stall Motor Current Immediate Calibrator Menu Reference: 8.07 Minimum Maximum Step Size Typical Value MillipaK PMAC Controller Manual Page 58 26/04/06...

  • Page 59: Fail-Safe

    Every time the controller is powered-up, the software checks that the fail-safe circuit is able to switch off the MOSFETs and open the contactors. MillipaK PMAC Controller Manual Page 59 26/04/06...

  • Page 60: Controller Protection Features

    Temperature Monitoring ______________________________________________________________________________ Controller Protection Features There are several in built features which are designed to protect the MillipaK controller from damage due to excessive load currents, voltages and prolonged periods of high demand. Temperature Monitoring If the temperature of the power frame exceeds 75 o C its maximum available current will be reduced.
  • Page 61 During periods of high current usage the power components of the controller produce considerable heat. The controller monitors the power supplied over time and can reduce the power output if the maximum controller rating is exceeded. MillipaK PMAC Controller Manual Page 61 26/04/06...

  • Page 62: S Afe O Perating A Rea (Soa)

    For most applications SOA will have little or no effect on the operation of the controller. Its effect is more significant in protecting the controller against adverse loads such as damaged motors and static test rigs. MillipaK PMAC Controller Manual Page 62 26/04/06...

  • Page 63: U Nder - Voltage And Over - Voltage Protection

    The maximum High Voltage Cutout depends on the level of the System Voltage item. If the System Voltage is set to 36V or lower, then the maximum is 50.0V. If the System Voltage is set greater than 36V, then the maximum is 58.0V. MillipaK PMAC Controller Manual Page 63 26/04/06...
  • Page 65 Calibrator Map Calibrator Map for PMAC Controller System Version UK0157.08 - 24th April 2006 Reference T OP Description Navigation Current T he operator moves through the Calibrator Map by pressing the SELECT key. T he solid line shows the path the...

  • Page 66: Commissioning Checklist

    Power wiring checked, shortest routes taken where possible ? Light wiring checked, use calibrator to verify controller correct switch operation. Accelerator set-up and checked 0 – 100% ? Personalities all set, checked and record filled out ? MillipaK PMAC Controller Manual Page 66 26/04/06...

  • Page 67: P Ersonality R Ecord

    11.07 High Voltage Start System Voltage High V Cutout 11.08 High Voltage Cutout High V Start 50.0V or 70.0V 11.09 Low Battery Warning Level 14.5V 70.0V 11.10 Low Battery Warning Timer 0.0s 20.0s MillipaK PMAC Controller Manual Page 67 26/04/06...
  • Page 68 Power Steer Trigger FS1/SEAT/DIRECTION 12.11 Foot-brake Priority DRIVE/FOOTBRAKE 12.12 Buzzer Alarm Off/REVERSE+ROLLOFF/ALL 12.13 Power Factor Correction OFF/ON 12.14 Digital I/O 12.15 Analogue I/P 12.16 System Voltage 12.17 Proportional Dir Braking OFF/ON Table 8: Personality Record MillipaK PMAC Controller Manual Page 68 26/04/06...

  • Page 69: Fault Finding

    ______________________________________________________________________________ Fault Finding The MillipaK controller includes a number of features designed to help the user track down operational faults, wiring faults or internal controller faults. The Diagnostic LED mounted next to the calibrator connectors on the front of the controller...

  • Page 70: F Ault C Learance

    Drive 1 On checks (failsafe circuit disabled). Table 10: Fault Numbers and Descriptions Fault Clearance Any fault indication will be cleared by re-initiating the start sequence after the cause of the fault has been removed. MillipaK PMAC Controller Manual Page 70 26/04/06...

  • Page 71: Fault Reporting Form

    What happened to the vehicle when the fault occurred What is the status of the vehicle now? Is there a fault message at key- switch on? Can it be driven? Table 11: Fault Reporting Form MillipaK PMAC Controller Manual Page 71 26/04/06...

  • Page 72: S Oftware V Ersion And S Erial N Umber Indication

    9999. When giving the Serial Number, the entire number should be quoted (i.e. MMYYAABB). The MillipaK range of controllers use the latest FLASH technology to allow In System Reprogramming. This is achieved without having to remove the controller from its installation –...

  • Page 73: Specifications

    Specifications ______________________________________________________________________________ Specifications The following specifications apply to all MillipaK controllers. Power Configurations At present the MillipaK PMAC controller is available in the following power configurations: Housing Voltage Armature HP Large 24-36V 250A HP Large 200A Table 13: Power Configurations EMC standards All MillipaK variants are tested to and conform to EN12895.

  • Page 74: Emc Guidelines

    The complete installation should be documented, in detail, and faithfully reproduced on all production vehicles. When making changes, consider their effect on compliance ahead of any consideration of cost reduction or other “improvement”. MillipaK PMAC Controller Manual Page 74 26/04/06...

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