Sevcon Gen4 Applications Reference Manual
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Sevcon Gen4 Applications Reference Manual

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

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Summary of Contents for Sevcon Gen4

  • Page 1 Gen4 Applications Reference Manual Document no: 177/52701 Rev. 3.3...
  • Page 2 St Ouen l’Aumône 95041 Cergy Pontoise Cedex France Tel +33 (0)1 34 30 35 00 Fax +33 (0)1 34 21 77 02 sales.fr@sevcon.com Sevcon Japan K.K. Kansai Office 51-26 Ohyabu Hikone Shiga Japan 522-0053 Tel +81 (0) 7 49465766 jp.info@sevcon.com Sevcon Asia Ltd Room No.202...

  • Page 3: Table Of Contents

    About the Gen4 Introduction ................2-2 Standard features and capabilities ..........2-2 Available options ........................ 2-2 Intended use of the Gen4 ....................2-3 Available accessories ......................2-3 Overview of a truck drive system ..........2-4 Principles of operation ............... 2-5 Functional description ......................
  • Page 4 Chapter 3: Installation Mounting Gen4 ................3-2 Location ..........................3-2 Protection from chemical contamination ................3-2 Orientation ......................... 3-2 Clearance for LED access ....................3-2 Mounting hole pattern ......................3-3 Equipment required: ......................3-3 Thermal grease application ....................3-3 Cooling requirements ..............3-5 EMC guidelines .................
  • Page 5 Torque required at maximum speed .................. 5-3 Continuous power rating ....................5-3 Peak power rating ......................5-4 Selecting the correct Gen4 model ..........5-4 Current and power ratings considerations ................. 5-4 Power output restrictions at motor and drive operating temperature limits ....... 5-4 Circuit configuration ......................
  • Page 6 Motor commutation sensor ....................5-12 Initial power up sequence ............5-15 Checks prior to power up ....................5-15 Checks after power is applied ..................5-15 Chapter 6: Configuration Introduction ................6-2 DVT configuration tool ............... 6-2 DVT functionality ........................ 6-2 Saving, duplicating and restoring a node’s configuration ............. 6-2 Data Logging.
  • Page 7 Driveability Features ......................6-22 Acceleration and braking ....................6-23 Footbrake .........................6-24 Steering inputs – twin driving motor systems ..............6-24 Driveability profiles ......................6-26 Smoothing Output Torque ....................6-28 Preventing Wheel Lock Scenarios ...................6-29 Controlled roll-off ......................6-30 Hill hold ..........................6-30 Inching ..........................6-30 Belly Switch........................6-31 Drivability select switches ....................6-31 Economy ..........................6-31 Pump configuration ......................6-31 Power steer configuration ....................6-33...
  • Page 8 Chapter 7: Monitoring Gen4 Reading status variables ............7-2 Motor measurements ......................7-2 Heatsink temperature ......................7-2 Identification and version ....................7-2 Battery monitoring ......................7-2 Hours counters ........................7-3 Logging ..................7-3 FIFO event logs ......................... 7-3 Event counters ........................7-4 Operational monitoring ......................

  • Page 9: Chapter 1: Introduction

    Chapter 1: Introduction...

  • Page 10: About Gen4 Documentation

    About Gen4 documentation This version of the manual This version of the Gen4 manual replaces all previous versions. Sevcon has made every effort to ensure this document is complete and accurate at the time of printing. In accordance with our policy of continuing product improvement, all data in this document is subject to change or correction without prior notice.

  • Page 11: Dangers, Warnings, Cautions And Notes

    A CAUTION indicates a hazard with a low level of risk, which if not avoided, could result in a minor or moderate injury. A NOTE indicates a risk of damage to the process, product or surroundings or other important information that helps you make better use of your Sevcon product. Doc. # 177/52701 Rev. 3.3...

  • Page 12: Product Identification Label

    Alternatively you can submit enquiries and find the details of the nearest support centre through the Sevcon website, www.sevcon.com. Product warranty Please refer to the terms and conditions of sale or contract under which the Gen4 was purchased for full details of the applicable warranty.

  • Page 13: Chapter 2: About The Gen4

    Chapter 2: About the Gen4...

  • Page 14: Introduction

    Standard features and capabilities Available options There are three mechanical package options (Figure 2) for the Gen4 controller at various voltage and current ratings. Size 2 models Size 4 models...

  • Page 15: Intended Use Of The Gen4

    About the Gen4 Intended use of the Gen4 The Gen4 motor controller can be used in any of these main applications for both pump and traction control:  Counterbalanced, warehouse and pedestrian fork lift trucks (Classes 1 to 3, FLT1, 2 & 3) ...

  • Page 16: Overview Of A Truck Drive System

    No external in-rush current limiting is needed as long as Gen4 is used to control the line contactor and hence the timing of its closure. The software controls the start up sequence in this order: 1.

  • Page 17: Principles Of Operation

    Principles of operation Functional description The main function of Gen4 is to control the power to 3-phase squirrel-cage AC induction or PMAC motors in electric vehicles. Four-quadrant control of motor torque and speed (driving and braking torque in the forward and reverse directions) is allowed without the need for directional contactors.

  • Page 18: Interfaces

    A variety of digital and analogue input sources are supported, as listed in ‘Signal connections’ on page 3-14. Voltage and current control of up to three contactors or proportional valves is provided by Gen4, and includes built-in freewheeling diodes for spike suppression. All I/O on the Gen4 controller is protected against short-circuit to the battery positive and negative terminals.

  • Page 19: Torque Mode

    In this mode Gen4 maintains the motor at a constant speed for a given throttle position as long as sufficient torque is available. Speed mode differs from torque mode in that the torque value applied to the motor is calculated by the controller based on the operator’s requested speed...

  • Page 20: Safety And Protective Functions

    Possible measures include adding a disconnect switch between the motor and controller on at least 2 out of the 3 phases, or adding fuses in each phase. Contact your local Sevcon representative for further information and guidance. CAUTION: Ensure that contactors with blow-out magnets are wired with the correct polarity to...
  • Page 21 As a major electrical control component, the role of the Gen4 motor controller should be carefully considered and relevant safety precautions taken. The Gen4 has several features which can be configured to help the system integrator to meet vehicle safety standards.

  • Page 22: On-Highway Vehicles

    18) for more information. Notes on Features The Gen4 is a generic motor controller intended for use in both highway AND non-highway industrial applications. Not all of the controller features are suitable for an on-highway vehicle. Some features, if activated, could lead to the controller forcing a motor condition that is not directly requested by the throttle, such as undesired drive or harsher than expected braking.
  • Page 23 About the Gen4 NOTES: 1. These features can cause the traction motor/wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and/or mechanical braking. 2. These features can cause unexpected drive if accidentally activated.

  • Page 24: Fault Detection And Handling

    7-10. Fault severity Controller latched off Consequences until Return to base Cleared by Sevcon Immediate shut down of the system with the (RTB) personnel exception of the power steering if needed. Power is removed to nearly all external components.

  • Page 25: Chapter 3: Installation

    Chapter 3: Installation...

  • Page 26: Mounting Gen4

    Protection from chemical contamination The Polycarbonate cover of Gen4 controllers are designed for good all-round protection of the electronics. However the controller should be sited so it cannot come into contact with significant quanties of industrial chemicals. The following have shown to be damaging to the cover:- ...

  • Page 27: Mounting Hole Pattern

    Equipment required:  4 x M6 socket cap head bolts, nuts and spring washers. Bolts need to be long enough to pass through 12 or 20 mm of Gen4 base plate (depending on controller type) and your mounting surface thickness. ...
  • Page 28  The controller should then be placed onto the vehicle/panel/heatsink.  It is important that the two surfaces are then rubbed together in order to help transfer the thermal compound between the two surface.  The entire assembly is then bolted together at all mounting holes. An example of a good thermal compound spreading can be seen in the photo below:- How effective the spreading technique is can be checked by removing the controller and inspecting the paste residue left on the mounting faces.

  • Page 29: Cooling Requirements

    To obtain maximum performance it is important to keep Gen4’s base plate within the operating temperature range. To do this, mount Gen4 to a surface capable of conducting away the waste heat. Finned heatsinks are considerably better at doing this than flat plates. For example, a finned heatsink used at Sevcon has a footprint of 330mm x 200mm and thermal resistance of 0.3°C/W, whereas a plate approximately 420 mm x 270 mm x 9.5 mm will give approximately the...

  • Page 30: Emc Guidelines

    EMC guidelines The following guidelines are intended to help vehicle manufacturers to meet the requirements for Electromagnetic Compatibility. Any high speed switch is capable of generating harmonics at frequencies that are many multiples of its basic operating frequency. It is the objective of a good installation to minimise, contain or absorb the resultant emissions.

  • Page 31: Measures Required For Specific Signals

    Ensure that there is a common ground connection for all nodes on the CAN bus. If there is a node on the bus which is galvanically isolated from the Gen4 controller then the CAN ground on this node must be connected to the Gen4 controller B-. The cable screen should be connected to...

  • Page 32: Problems To Avoid

    Beware of devices that are connected to the small signal wiring which have a significant (>10nF) capacitance to vehicle chassis. The capacitance to vehicle chassis can cause currents to flow out of the Gen4 controller along the signal wiring to the device and back to the controller via the vehicle chassis.

  • Page 33: Connecting Power Cables

    Installation Connecting power cables See also ‘EMC guidelines’ on page 3-6. Battery and motor connections CAUTION: Cables carrying high AC currents are subject to alternating forces and may require support in the cable harness to avoid long-term fatigue. Equipment required for size 4 or 6 models: ...

  • Page 34: Cable Sizes

    The following table gives guidance on the cable size needed for various currents in welding cable, not grouped with other cables, in 25°C ambient with 60°C temperature rise on the cable surface. Gen4 average (rms) Cable sizes current metric...

  • Page 35: On-Board Fuse Mounting

    Installation On-board fuse mounting You can mount your main input protection fuse directly onto the controller body as shown below . Select the appropriate fuse from the table below. Connect the battery positive cable to the B+ terminal. Connecting to the end marked ‘+’ (or un-named in the case of size 2) will leave your installation without a fuse unless located elsewhere in the system.

  • Page 36: Fuse Rating And Selection

    Figure 7 On-board fuse mounting – size 6 models Fuse rating and selection On-board fuse dimensions are in accordance with DIN43560/1 Gen4 input voltage Gen4 peak output current Fuse rating Sevcon part number 300 A 325 A 858/32044 24V/36 V...

  • Page 37: Signal Wiring

    (Figure 8) and terminate the connections of the two end nodes with a 120  resistor. If the end node is a Gen4, link pins 2 and 24 on the customer connector, a 120  resistor is built into the controller.

  • Page 38: Signal Connections

    Signal connections are made to Gen4 via a 35 way AMPSeal connector. Figure 9 Customer Connector Pins are protected against short-circuits to the battery positive or negative terminals.
  • Page 39 Installation Name Type What to connect Maximum Comment rating Contactor To the switched low 2.0A per This output provides low out 1 side of contactor or output, side voltage or current valve coil. subject to a control to the load limit of 6A for depending on configuration.
  • Page 40 (internally signals have the correct limited) number of pulses per V = 8 V (for revolution. current- Check Gen4 is configured source for the type of encoder you encoders) are using (open-collector or V = 2.5V or current-source) 5V (for open-...
  • Page 41 500 Ω to 10 kΩ, Zin = 82 kΩ wiper in wiper. (24V/36V and or voltage-output device 36V/48V (e.g. Sevcon linear models) accelerator) Zin = 100 kΩ 0 to 5 V or 0 to 10 V. (24V/36V and Ensure that at least 0.5V...
  • Page 42 V = 5V or you use is compatible with supply + encoder 10V software Gen4. See page 6-14 for selectable configuration details. CAN Low Comms CANbus Low signal V = 5 V Maximum bus speed 1 Mbits/s.
  • Page 43 2.2 kΩ at 100°C will give internal pull- up resistor) best sensitivity. Connect the other lead of the thermistor to the B- terminal of the Gen4 controller. Can also be used as an additional analogue input Pot. 1 Power Supply feed to...
  • Page 44 Table 3: Impedance at Digital Input Pins Note to Table 3: Configure the digital input switches as active-high (switched to Vb) or active-low (switched to battery negative). Configuration applies to all digital input switches (1 to 8) i.e. they are all active- high or all active-low.

  • Page 45: Chapter 4: Specification

    Chapter 4: Specification...

  • Page 46: Electrical

    Note 2: Working voltage range outside which the controller will be non-operational.  Upper working voltage limits for 72V/80V Gen4 is being increased to 120V and will be rolled out when possible in future Gen4 variants for both PMAC and Induction motor firmware.
  • Page 47 Specification CAUTION: Repetitive short circuits may damage the controller. Doc. # 177/52701 Rev. 3.3...

  • Page 48: Output Ratings

    Output ratings Input Function Short term Continuous (Vdc) rating* (A rms) rating** (A rms) Single traction size 2 24/36 Single traction size 4 Single traction size 6 Single traction size 2 36/48 Single traction size 4 Single traction size 6 Single traction size 2 72/80 Single traction size 4...

  • Page 49: Can Interface

    Specification CAN interface CAN protocol: CANopen profiles DS301, DS401 and DSP402 are supported. Physical layer uses ISO11898-2. Baud rates 1 Mbits/s (default), 500 kbits/s, 250 kbits/s, 125 kbits/s, 100 supported: kbits/s, 50 kbits/s and 20 kbits/s. Control inputs and outputs Digital inputs: 8 digital switch inputs (software configurable polarity).

  • Page 50: Isolation

    Isolation Any terminal to the Meets EN1175-1:1998 and ISO3691 case: Complies with IEC-60664...

  • Page 51: Emc

    Specification EN12895 (Industrial Trucks – Electromagnetic Radiated emissions: Compatibility) EN 55022:1998, 6, class B EN 12895:2000, 4.1 Emissions. When part of a system with a motor operating, FCC Part 15, Radiated Emissions. Meets the standards given in FCC Part 15, Section 15.109: Conducted No mains port, therefore not required emissions:...

  • Page 52: Mechanical

    Mechanical Operating environment Operating -30°C to +25°C (no current or time derating) temperature: +25°C to +80°C (no current derating, but reduced time at rated operating point) +80°C to +90°C and -40°C to -30°C (with derating) Non-operation -40°C to +85°C (can be stored for up to 12 months in this temperature: ambient range) Humidity:...

  • Page 53: Dimensions

    Specification Dimensions Size 2 models Size 4 models Doc. # 177/52701 Rev. 3.3...

  • Page 54: Size 6 Models

    Size 6 models 4-10...

  • Page 55: Chapter 5: System Design

    Chapter 5: System design...

  • Page 56: Sizing A Motor

    Up to rated speed the peak torque that can be supplied when using a correctly specified Gen4 is equal to the breakdown torque. Select a motor with a breakdown torque rating greater than the...

  • Page 57: Torque Required At Maximum Speed

    System design Torque required at maximum speed Calculate the torque as above. As speed increases beyond base speed the maximum torque an induction motor can supply falls as defined by the following two equations: In the constant power region;  ...

  • Page 58: Peak Power Rating

    Selecting the correct Gen4 model Matching motor and controller ratings is not an exact exercise and therefore you may need to perform iterative calculations. The main considerations when choosing an appropriate Gen4 controller are described below. Current and power ratings considerations Consider the following when choosing the appropriate Gen4 controller: ...

  • Page 59: Circuit Configuration

    System design The Gen4 also looks at a number of internal temperature measurements and estimates. These can also influence the thermal cutback operation, depending on installation and operating duty cycle Circuit configuration Once motor size is determined the application circuit configuration can be defined. A basic single traction configuration (Figure 13) is provided as a starting point for new designs.

  • Page 60: Single Traction Wiring Diagram

    Single traction wiring diagram Figure 13 Single traction wiring diagram...

  • Page 61: Single Pump Wiring Diagram

    System design Single pump wiring diagram Figure 14 Stand-alone pump wiring diagram Doc. # 177/52701 Rev. 3.3...

  • Page 62: Twin Motor Systems

    Twin motor systems A twin motor system may be powered by two Gen4 controllers operating in master–slave configuration. In this case the necessary commands are transmitted by the master node to the slave node via the CANbus. Motors may be operated independently in a combined traction-pump application or operated in tandem where each motor drives a separate wheel.

  • Page 63: On-Board Fuse

    System design On-board fuse See ‘On-board fuse mounting’ on page 3-11. Doc. # 177/52701 Rev. 3.3...
  • Page 64 Figure 15 Dual traction wiring diagram 5-10...

  • Page 65: Key Switch Fuse F2

    2 A: Device Current Line contactor Pump contactor Gen4 control circuits Pre-charge circuit Fuse choice: 7A. Motor speed sensor (encoder) A 4-wire connection is provided for open-collector or current-source quadrature pulse encoder devices (software configurable). These types of encoder are optimized for accurate speed measurement, required for efficient control of induction motors.

  • Page 66: Motor Commutation Sensor

    The Gen4 controller provides inputs for both digital UVW style position sensors and analogue sin-cos sensors. Either of these can be used for control of permanent magnet motors.
  • Page 67 System design Figure 18 - Example pulse train from a UVW commutation sensor UVW encoder power supply can be configured with 5V or 10V supply voltage. For 10V supply the low to high transition threshold is 5.3V and for 5V supply it is 2.7V Sin-Cos Commutation Sensor Analogue sin-cos encoders should provide one sine wave and one cosine wave per mechanical rotation of the motor.
  • Page 68 5V on pin 26. This should be done by setting the encoder configuration object dictionary entry at 4630 NOTE: The standard Gen4 build does not provide inputs for the sin and cos signals. Therefore, if operation with a sin-cos analogue encoder is required then this must be specified as a hardware build option.

  • Page 69: Initial Power Up Sequence

    Checks after power is applied Apply power and do the following:  Use Sevcon DVT (see page 6-2), the Sevcon Calibrator handset or any configuration tool to complete the configuration process which starts on page 6-7.  Using the drive controls ensure the wheels rotate in the expected direction. If they do not, check the motor wiring, encoder wiring and encoder configuration (page 6-14).

  • Page 71: Chapter 6: Configuration

    Chapter 6: Configuration...

  • Page 72: Introduction

     Restore a configuration to a node. For example, if you want to save the Gen4 controller configuration, you will need to create a DCF file. To do this, open the helper by clicking the icon at the top of the DVT main...

  • Page 73: Data Logging

    Configuration Data Logging. You can use DVT to monitor data or parameters of a Sevcon node in real time and graph the data. CANopen This section assumes you have an understanding of CAN and are familiar with its use. If you are new to CAN or CANopen please refer to the CiA (CAN in Automation) website, www.can-cia.org...

  • Page 74: Object Dictionary

    These are SDO (service data object) and PDO (process data object) as described below. There is a third object, VPDO (virtual PDO), used by Gen4 which is not a CANopen object. It is described here because its function is important and similar to that of a PDO.

  • Page 75: Network Configuration

    Configuration VPDO (Virtual Process Data Object) VPDOs do a similar job as PDOs for data exchange, but internal to a single Sevcon node. They are unique to Sevcon and are not part of CANopen. Network Configuration General If non-Sevcon nodes need to be added, use the following procedure to setup the network: 1.
  • Page 76 Party CANopen Devices At power up, the Gen4 master will communicate with all slave nodes to identify which nodes are Sevcon devices and which are not using the vendor ID in 1018 . This instructs the Gen4 how to handle EMCY messages from each node.

  • Page 77: Configuration Process Overview

    To prevent unauthorized changes to the controller configuration there are 5 levels of accessibility: (1) User, (2) Service Engineer, (3) Dealer, (4) OEM Engineering and (5) Sevcon Engineering. The lowest level is (1), allowing read only access, and the highest level is (5) allowing authorization to change any parameter.

  • Page 78: Motor Characterization

    Motor characterization Ensure you have completed the CANopen network setup process. Determining motor parameters To provide optimum motor performance Gen4 needs the basic motor information normally found on the name plate as well as the following information:  A value for each of the electrical parameters of the induction motor as shown in Figure 21.

  • Page 79: Self Characterization

    Voltage cutback map showing voltage versus torque reduction 4612 factor. 2. Use the motor name plate data and the self characterization routine provided by Gen4 and DVT (described below). The flux vector variant of software includes motor temperature compensation which can be used to adjust rotor resistance (4641 ,8) with motor temperature.

  • Page 80: Additional Motor Configuration

    At time of writing, SCWiz is not yet compatible with 110V version of Gen4. Induction motor parameter characterisation therefore needs to be carried out using a lower voltage ( 48V or 80V) Gen4 controller. Additional Motor Configuration The motor algorithms can be further configured using 4650 .

  • Page 81: I/O Configuration

    (e.g. a measured input signal mapped to a steer operation). This is achieved by setting up PDOs (node to node mapping) and VPDOs (internal mapping on each controller) as described below. Apply mapping to Gen4 as follows:  Standalone controllers: setup VPDOs only ...
  • Page 82 To help understand how to map internal objects an example VPDO mapping is shown in Figure 22. A digital switch input is mapped to the seat switch function to control the traction application, i.e. with no seat switch input the vehicle is prevented from moving. Master seat switch...
  • Page 83 Figure 23 Example of a digital input mapped to the seat switch object via PDO and the CANbus Gen4 supports RPDO timeout fault detection. This can set a warning, drive inhibit or severe fault depending on the configuration in 5902 NOTE: RPDO timeout can be used for non-CANopen systems which do not support heartbeating.

  • Page 84: Encoder

    Encoder WARNING: It is important that the number of encoder pulses per revolution is entered correctly. If this information is not correct, the controller may not be able to brake the motor effectively. To configure the encoder: 1. Enter the resolution pulses/rev at 6090 2.
  • Page 85 For non-KTY84, KTY83 PTC thermistors, set the PTC type to User Defined and then set the expected voltages at 100ºC (high temperature voltage) and 0ºC (low temperature voltage). The Gen4 will linearly interpolate temperature with voltage.  If you are using a switch select the digital input source ...

  • Page 86: Analogue (Contactor) Outputs

     Choose voltage control or current control for each analogue output at 46A1 (At the time of writing, current controlled devices can only be operated from Gen4 by mapping a signal input to the controller from an external 3 party node).
  • Page 87 Configuration  CANbus communication error lamp on slave node. If CANbus communication is lost, it may be desirable to activate an output on the slave device. In this case, enable error control in 6C43 and set the error value in 6C44 to an appropriate voltage for the lamp.

  • Page 88: Vehicle Performance Configuration

    Vehicle performance configuration Ensure you have completed the CANopen network setup, Motor Characterization and I/O Configuration processes described above. Safety Interlocks The FS1 switch is normally part of the throttle assembly. It closes when the throttle is pressed. The throttle voltage is ignored until FS1 is closed. FS1 features are configured at 2914 ...

  • Page 89: Torque Mode/Speed Mode

    The Gen4 controller provides both torque and speed control modes. Objects 2900 and 6060 are used to set which mode to use. The default setting is torque mode.

  • Page 90: Throttle

    Throttle General The controller can use 2 or 3 wire throttle inputs of the following types:  Linear potentiometer in the range 470  to 10 k  Voltage source in the range 0V to 10V: compliant with the standard 0..5 V, 0..10 V or 3.5..0 V ranges To setup throttle inputs see ‘Analogue’...
  • Page 91 Configuration Figure 25 Directional throttle configuration  Define the input characteristic: this is a profile to the throttle value and can be linear, curved, crawl or user-defined as shown in Figure 26. The curved and crawl characteristics give greater throttle control at low speeds. Figure 26 Input characteristics The throttle value calculated from the voltage can be read at 2620 Doc.

  • Page 92: Driveability Features

    Dual Throttle Inputs Single and dual throttle inputs are supported. Single throttle inputs are normally used with other interlock inputs (eg FS1, deadman, etc) and use a single input voltage to determine driver demand. Dual throttle inputs use two separate input voltages, each of which is converted to a throttle value using 2910 , sub indices 3 to 6 (throttle input 1) and sub indices 7 to 10 (throttle input 2).

  • Page 93: Acceleration And Braking

    Configuration Set the following driveability features at 2910  Enable/disable proportional braking. If enabled, the braking torque during direction braking is proportional to the throttle.  Enable/disable directional throttle. If configured as a directional throttle, the throttle voltage indicates the direction as well as the speed demand. This removes the need for forward and reverse direction switches.

  • Page 94: Footbrake

    Some vehicles can exhibit shock due to the rapid reversal of torque after a direction change. 2909 can be set to force the vehicle to remain stationary for a period before driving in the new direction. To prevent early exit from neutral braking, a debounce timer can be set at 290D .
  • Page 95 Object Dictionary:  Setup the voltages corresponding to fully left, fully right and straight ahead. Using this information, Gen4 calculates the steering angle based on the voltage from a steering potentiometer.  Setup the steering map. This map defines the relationship between the inner and outer wheel speeds and the steering angle.

  • Page 96: Driveability Profiles

    If steering switches are used instead of a steering potentiometer, only part of the steering map is used as shown in Table 6. Value Description 2913 Outer wheel speed during inner wheel cutback 2913 Outer wheel speed during inner wheel reversal 2913 Inner wheel cutback speed 2913...
  • Page 97 Configuration Figure 30 Torque mode acceleration/deceleration In Torque mode, the acceleration and deceleration rates control the rate of change of torque. In Speed mode, the acceleration and deceleration rates control the rate of change of speed. You can select reverse while driving in the forward direction with your foot still on the throttle. In this situation the controller applies braking in the form of a direction change deceleration rate down to zero speed.

  • Page 98: Smoothing Output Torque

    Torques in driveability profiles are in 0.1%/bit resolution. These are converted to Nm using the motor rated torque value at object 6076 Ramp rates in driveability profiles are in either RPM/s for speed mode, or %/s for torque mode. In speed mode, RPM/s becomes “User Defined Units” / s if the gear ratio is used to rescale the driveability profile speeds.

  • Page 99: Preventing Wheel Lock Scenarios

    Configuration Curve applied within 0.4% of target Curve applied within 0.8% of target Curve applied within 1.6% of target Curve applied within 3.2% of target This table continues, with each increment in 2933 doubling the range over which the curve is applied.

  • Page 100: Controlled Roll-Off

    Set a roll-off maximum speed  Set a roll-off maximum torque Alternatively, Gen4 can apply an electromagnetic brake if one is mapped and roll-off is detected. Refer to ‘Electro-mechanical brake’ on page 6-34 for more information. Hill hold WARNING: Hill Hold is not recommended for on-highway vehicles as it can cause the traction motor/wheel to remain locked or brake severely if the wheel is momentarily locked due to loss of traction on a slippery surface and/or mechanical braking.

  • Page 101: Belly Switch

    Configuration Belly Switch WARNING: Ensure the belly switch is only mapped to a digital input when required. Activation of this input can cause a drive condition to occur. The belly switch is normally connected to the end of the tiller arm on class 3 vehicles. When activated it forces a drive condition in forward at a user specified throttle value and maximum speed for a specified time.
  • Page 102 General Setup Configure the pump features at 2A00  Inhibit pump when BDI drops below cut-out level. If already operating when the cut-out occurs, the pump will continue to operate until all pump inputs are inactive.  Drive Enable switch and/or Seat switch input disables pump. ...

  • Page 103: Power Steer Configuration

    Variable Assist Power Steering Gen4 supports a variable assist power steering algorithm which can be used to reduce the power steering speed as vehicle traction speed increases to a user configurable level. Set the reduction factor and traction speed in 2B02 .

  • Page 104: Vehicle Features And Functions

    Where more than one controller is present, the pre-charge circuit on each must be used. If an Gen4 is configured as the vehicle master, it controls the pre-charge of all slave nodes automatically.

  • Page 105: External Led

    Configuration To prevent vehicle roll away on inclines, the electro-mechanical brake normally does not release until the traction motor(s) are producing torque. This feature can be disabled using 2903 External LED This mirrors the operation of the controller’s on board diagnostic LED. The external LED object 2401 can be mapped to an analogue output to drive a lamp on a vehicle dashboard.

  • Page 106: Distance Calculation

    Configure the following at object 2850  Service indication: via an analogue (contactor) output (e.g. to drive a dashboard lamp) and/or Gen4’s LED.  Source hours counter: selects the hours counter and is used to determine when a service is required.

  • Page 107: Controller Heatsink / Motor Cooling Fan

    Configuration Controller heatsink / motor cooling fan An external fan to cool the controller heatsink or a motor may be connected to one of the analogue outputs. The fan will be turned on by the controller when either the heatsink temperature or the motor temperature exceed a specified temperature.
  • Page 108 Protection delay: the time it takes for the controller to cut-out after the under voltage limit has been reached (2C03h). Battery Discharge Indicator (BDI) Monitor battery voltage using Gen4’s Battery Discharge Indicator (BDI). The BDI presents the driver with a percentage remaining charge figure and has become an industry standard in recent years.

  • Page 109: Displays

    Clearview displays use the CANopen protocol. To use, set up TPDOs to transmit the required data for the display. Smartview displays use Sevcon’s proprietary CAN protocol. To use set the CAN baudrate to 100kHz at 5900 , enable Smartview and select hours counter and/or real speed at 2E00 Doc.

  • Page 111: Chapter 7: Monitoring Gen4

    Chapter 7: Monitoring Gen4...

  • Page 112: Reading Status Variables

    Reading status variables All status variables are in Gen4’s object dictionary. They can be accessed using SDOs. Some can be mapped to PDOs for continuous transmission to remote nodes such as displays and logging devices. Motor measurements The following status objects can be read: ...

  • Page 113: Hours Counters

    The controller supports many different hours counters for various functions. Some counters run on all units and some only run on the Gen4 configured as the vehicle master. Hours counters are preserved with a minimum resolution of 15 seconds when the system is powered down.

  • Page 114: Event Counters

    Two instances of the operational monitoring log are maintained. Service engineers can access and clear the first log; the second is accessible and clearable only by Sevcon engineers. The Customer copy is normally recorded and reset each time the vehicle is serviced. The Sevcon copy records data over the controller’s entire working life.
  • Page 115 Monitoring Access level too low GIO module error failed Checksum calculation failed Login failed Backdoor write failed PDO not copied Range underflow Reserved for future use Range overflow Cannot write to DSP Doc. # 177/52701 Rev. 3.3...

  • Page 116: Faults And Warnings

    You can identify a fault as follows:  Check the number of LED flashes and use below to determine what action can be taken. A complete and comprehensive fault identification table will be available from Sevcon in due course. ...
  • Page 117 Monitoring Fault Leve Set conditions Operator action flashe SRO fault FS1 active for user configurable Deselect FS1 and delay without a direction select drive selected. FS1 recycle FS1 active after a direction Reset FS1 change Seat fault Valid direction selected with Must be seated with operator not seated or operator switches inactive...
  • Page 118 Fault Leve Set conditions Operator action flashe Line contactor did not Line contactor did not close Check line contactor close when coil is energized. condition/wiring. PST fault Fault detected on PST power Check PST condition. steer module. Motor open circuit Unable to establish current in Check motor motor.
  • Page 119 Monitoring Fault Leve Set conditions Operator action flashe Controller high voltage Battery voltage or capacitor Isolate controller and protection with line voltage is above the maximum investigate high contactor open. level allowed for the controller battery voltage with line contactor open. Battery voltage below Battery voltage is below the Increase battery...

  • Page 120: Fault List

    Fault Leve Set conditions Operator action flashe Encoder fault Speed measurement input wire- Check encoder off is detected. wiring. Calibrate analogue encoder Or encoder signals out of range signals for sin/cos. or misaligned. Over current Software has detected an over Check motor load current condition and wiring.
  • Page 121 Monitoring It is possible to field update the firmware of the Gen4 controller , typically using Sevcon’s DVT configuration tool. Please contact Sevcon for assistance with this process. Doc. # 177/52701 7-11 Rev. 3.3...
  • Page 123 Monitoring Doc. # 177/52701 Rev. 3.3...

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