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Table of Contents
Related Manuals for Sevcon MillipaK
Summary of Contents for Sevcon MillipaK
- Page 2 Date 10/08/01 00.01 Original. Updated the Fault list, calibrator map and 16/11/01 0.50.00(A) added personalities. Added omitted Flash Faults and seat 23/04/04 0.50.00 (B) functionality description. 07/11/05 0.50.00(C) Clarified Digital I/O configuration table MillipaK PUMP Controller Manual Page 2 07/11/05...
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Page 3: Table Of Contents
Maximum Temperature Logging ...........................35 Timed Current Cutback ............................36 Safe Operating Area (SOA) ...........................37 Under-voltage protection............................38 COMMISSIONING CHECKLIST ..........................40 ...............................41 ERSONALITY ECORD FAULT FINDING ...............................42 ..............................43 AULT LEARANCE ..........................43 SING TATUS AND ENUS ............................45 AULT EPORTING MillipaK PUMP Controller Manual Page 3 07/11/05... - Page 4 ....................46 OFTWARE ERSION AND ERIAL UMBER INDICATION SPECIFICATIONS ..............................47 ............................47 OWER ONFIGURATIONS ...............................47 STANDARDS ..............................47 OCKET PROTECTION ............................47 ONTACTOR DRIVE RATINGS ...........................47 NALOGUE NPUT MPEDANCE ............................47 IGITAL NPUT MPEDANCE EMC GUIDELINES..............................48 ORDERING INFORMATION...........................49 MillipaK PUMP Controller Manual Page 4 07/11/05...
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Page 5: Introduction
_____________________________________________________________________________________ Introduction The MillipaK PUMP (series motor) range of controllers provides a new range of power frames for 24V-48V, 180A - 600A in one of two 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 truck may not drive. The MillipaK controller may be used with suitable onboard chargers, as supplied by Sevcon. -
Page 7: Installation
Installation Mounting _____________________________________________________________________________________ Installation The small footprint of the MillipaK controller gives maximum flexibility to the user for mounting options. The following section gives details of certain criteria that should be considered when situating the controller on a vehicle. Mounting The MillipaK and MillipaK HP units provide 4 x M6 clearance holes for mounting. -
Page 8: Millipak Pump Power Wiring
Installation Wiring/Power _____________________________________________________________________________________ MillipaK Pump Power Wiring NOTE: The Pump battery positive power terminal may be wired directly to the battery positive (via a suitable fuse) or via a line contactor if used in a Traction / Pump system. It should be considered whether or not pump operation is required if a traction fault causes the line contactor to drop out. -
Page 9: Millipak Pump Light Wiring
Installation Wiring/Light ______________________________________________________________________________ MillipaK Pump Light Wiring NOTES: The line and auxiliary contactors coils are wired to B+, on the switched side of the key-switch. The second analogue input on pin 11 is also available for use as a digital input. See system configuration section for how to configure the second analogue input as a digital switch input. -
Page 10: 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 11: Calibrator Security Levels
If the password was incorrect or no password was entered, the system always defaults to 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 PUMP Controller Manual Page 11 07/11/05... -
Page 12: Navigation
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 – Lift Speed 1). The items which are displayed depends on the current system configuration and the Security Level. MillipaK PUMP Controller Manual Page 12 07/11/05... -
Page 13: Adjustments
System Set-up 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. MillipaK PUMP Controller Manual Page 13 07/11/05... -
Page 14: Status And Test Information
Digital inputs available on connector B. Also displays unit Test Menu information such as the Software Version, Controller Serial Number and the Personality Checksum. Refer to the appropriate sections for more information on each of these items. MillipaK PUMP Controller Manual Page 14 07/11/05... -
Page 15: 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, lift control switches, accelerator and the pump motor. -
Page 16: 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: 12.05 Minimum Maximum Step Size Default MillipaK PUMP Controller Manual Page 16 07/11/05... -
Page 17: System I/O Configuration
MillipaK HP. Normal switch inputs are used for lift switches. Power Steer Trigger is available via the last switch input on the MillipaK Core or via the second analogue input on the MillipaK HP. 4 of the normal switch inputs are used for lift switches. Power Steer Trigger is available on a normal switch input. -
Page 18: Analogue Functions
Lift Accelerator 2 Ana.2 (B11) Digital Ana.2 (B11) Digital Configuration Power Up Calibrator Menu Reference: 12.02 Minimum Maximum Step Size Default Analogue Configuration Power Up Calibrator Menu Reference: 12.03 Minimum Maximum Step Size Default MillipaK PUMP Controller Manual Page 18 07/11/05... - Page 19 Current Limit Immediate Calibrator Menu Reference: 0.01 Minimum Maximum Step Size Typical Value Where CBR is Controller Block Rating. MillipaK PUMP Controller Manual Page 19 07/11/05...
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Page 20: Accelerator Full /Zero Setting
Typical Value 0.00V 4.50V 0.02V 3.50V The PWM demand will vary between the Creep level and Maximum Speed for that lift accelerator as the accelerator voltage varies between “Accelerator Zero” and “Accelerator Full”. MillipaK PUMP Controller Manual Page 20 07/11/05... -
Page 21: Performance
Power Steer Ramp Up Immediate Calibrator Menu Reference: 9.02 Minimum Maximum Step Size Typical Value 0.1S 5.0S 0.1S 1.5S Ramp Down Immediate Calibrator Menu Reference: 9.03 Minimum Maximum Step Size Typical Value 0.1S 0.5S 0.1S 0.1S MillipaK PUMP Controller Manual Page 21 07/11/05... -
Page 22: Creep Speed
The motor voltage is rapidly ramped to the creep level (equivalent to a 100mS ramp time). Creep Speed Immediate Calibrator Menu Reference: 8.01 Minimum Maximum Step Size Typical Value MillipaK PUMP Controller Manual Page 22 07/11/05... -
Page 23: Maximum Speed
Typical Value 100% 100% Speed 6 Immediate Calibrator Menu Reference: 5.01 Minimum Maximum Step Size Typical Value 100% 100% Speed 7 Immediate Calibrator Menu Reference: 6.01 Minimum Maximum Step Size Typical Value 100% 100% MillipaK PUMP Controller Manual Page 23 07/11/05... -
Page 24: 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 fault conditions. These features can be split into three categories – standard controller features, safety features and controller protection features. -
Page 25: Lift Switch Inputs - Priority
6.02 Options Default Priority Additive Priority For example, if switches 5 – 7 are set as priority then activating all switches will result in the speed demand set for switch 5 being used. MillipaK PUMP Controller Manual Page 25 07/11/05... -
Page 26: Lift Switch Inputs - Additive
20% and switch 5 is active and programmed as additive and with a speed setting of 30 % then the final demand would be 50% (lift accelerator 1 demand + switch 5 demand). MillipaK PUMP Controller Manual Page 26 07/11/05... -
Page 27: Compensation
Minimum Maximum Step Size Default 200% Compensation 4 Immediate Calibrator Menu Reference: 3.02 Minimum Maximum Step Size Default 200% Power Steer Compensation Immediate Calibrator Menu Reference: 10.03 Minimum Maximum Step Size Default 200% MillipaK PUMP Controller Manual Page 27 07/11/05... -
Page 28: Seat Switch
Calibrator (Seat Switch Delay). Seat Delay Immediate Calibrator Menu Reference: 11.02 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 PUMP Controller Manual Page 28 07/11/05... -
Page 29: Power Steer Input
Power Steer Compensation Immediate Calibrator Menu Reference: 10.03 Minimum Maximum Step Size Default 200% The power steer delay is the length of time the demand will remain active after the trigger signal is removed. MillipaK PUMP Controller Manual Page 29 07/11/05... -
Page 30: Lift Inhibit Input
One of the digital inputs may be configured as Lift Inhibit. When the inhibit input is active then no lift functions are allowed to start. Any lift functions already active will not be affected. MillipaK PUMP Controller Manual Page 30... -
Page 31: Cooling Fan
______________________________________________________________________________ Cooling Fan There is a facility provided on the standard MillipaK Pump controller which allows a traction motor cooling fan to be activated via a contactor drive output. The output is activated when the Seat Switch input is active. The seat switch input must be configured using the digital i/o configuration item. -
Page 32: Pump Hours Meter
______________________________________________________________________________ Pump Hours Meter The MillipaK maintains a log of the number of hours during which the controller is providing Pump functionality. The Pump Hours Meter runs whenever the pump motor speed is greater than zero. The current number of logged Pump hours can be viewed using the Calibrator. Refer to the Calibrator section for more information. -
Page 33: 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 34: Safety Features
The controller’s safety system includes a microprocessor watchdog which can detect software failure, and a hardware fail-safe system. 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 PUMP Controller Manual Page 34 07/11/05... -
Page 35: Controller Protection Features
Controller Protection/Thermal Cutback ______________________________________________________________________________ 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°C its maximum available current will be reduced. -
Page 36: Timed Current Cutback
40°C. If this situation was allowed to arise damage may result in the controller. In order to prevent this situation a timed current cutback feature is incorporated in the MillipaK controller, which works as described below: The controller monitors the power through the armature MOSFETs during a 60 second period and uses the average current seen over this time to determine the new current limit. -
Page 37: Safe Operating Area (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. 24-48V Controllers % On MillipaK PUMP Controller Manual Page 37 07/11/05... -
Page 38: Under-Voltage Protection
Minimum Maximum Step Size Typical Value Low V System 0.5V 18.0V Cutout Voltage Low Voltage Cutout Immediate Calibrator Menu Reference: 11.04 Minimum Maximum Step Size Typical Value 14.5V Low V Start 0.5V 16.0V MillipaK PUMP Controller Manual Page 38 07/11/05... - Page 39 3 (16) 4 (17) 5(1 8) Calibrat or Nacco Calibrator Map for MillipaK Series Pump - 9/11/2001 T OP Descript io n Service Level Access Referen ce Navigation Lift T he operat or m oves t hrough t he Calibrat or Map by pressin g t he SELECT key. T he solid line shows t he pat h t he...
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Page 40: Commissioning Checklist
Power wiring checked, shortest routes taken where possible ? Light wiring checked, use calibrator to verify controller correct switch operation. Accelerators set-up and checked 0 – 100% ? Personalities all set, checked and record filled out ? MillipaK PUMP Controller Manual Page 40 07/11/05... -
Page 41: Personality Record
Low V Start Low V Cutout System 0.5V Low V Voltage Cutout 11.04 Low V Cutout 14.5V Low V Start 0.5V 14.5V 12.01 Chop Select Off/On/24V 12.02 Digital I/O 12.03 Analogue I/P 12.04 System Voltage MillipaK PUMP Controller Manual Page 41 07/11/05... -
Page 42: 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 43: Fault Clearance
S/W Version 00.00 19.99 0.01 00.00 19.12 S/W Sub-Revision xx00 19.13 SN Date Code 0100 1299 0000 19.14 SN ID 1 xx00 19.15 SN ID 2 xx00 19.16 Pers Checksum 19.17 System State MillipaK PUMP Controller Manual Page 43 07/11/05... - Page 44 ______________________________________________________________________________ Also available is information regarding the software revision and manufacturing date (serial number) – items 19.11 – 19.15. The personality checksum and system state are available on items 19.16 and 19.17 respectively. MillipaK PUMP Controller Manual Page 44 07/11/05...
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Page 45: Fault Reporting Form
______________________________________________________________________________ Fault Reporting Form Sevcon is committed to improving the quality of all its products. Please help us by using this form to report faults to Sevcon. Please give as much detail as possible. Use extra sheets if required. Fax this form to +44 191 482 4223. -
Page 46: Software Version And Serial Number 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 47: Specifications
Specifications ______________________________________________________________________________ Specifications The following specifications apply to all MillipaK Pump controllers. Power Configurations At present the MillipaK PUMP controller is available in the following power configurations: Housing Armature (CORE) Small 180A (CORE) Small 300A (HP) Large 600A (HP) Large 450A All the MillipaK PUMP range of controllers operate from 24-48v batteries. -
Page 48: 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 PUMP Controller Manual Page 48 07/11/05... -
Page 49: Ordering Information
HP = High Power For panels then the voltage, current and logic numbers should be used to describe the traction controller. Examples: 300A SEM plugging controller with soft start 633C43101 600A SEM plugging controller 633T46101 MillipaK PUMP Controller Manual Page 49 07/11/05...