EVTV GEVCU Operation Manual

Generalized electric vehicle control unit

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Operation M anual

GEVCU 5 .22

August 2 015

Generalized Electric Vehicle Control Unit

GEVCU

Version 5.22

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Page 1 Operation M anual GEVCU 5 .22 August 2 015 Generalized Electric Vehicle Control Unit GEVCU Version 5.22 Copyright 2013. EVTV LLC 1 ...
Page 2 ttp://github/collin80/GEVCU. T his s oftware, c reated e ntirely b y e nthusiasts o utside o f t he control o f E VTV, c an b e d ownloaded a s s ource c ode i n i ts l atest v ersions, m odified b y a nyone ...
Page 3: Table Of Contents
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Table of Contents 1. Introduction 2. Specifications 3. Wiring and Connections 4.
Page 4: Introduction
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 1 Introduction For 4 0 y ears a nd m ore, i ndividual t inkerers a nd i nnovators h ave b een m odifying e xisting ...
Page 5 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 recompiling, a nd h aving t he c ontroller r eflashed w ith t he n ew b inaries a t t he d ealership d uring ...
Page 6 EVTV a dopts i n t heir r elease o f t he p roduct. B ut b y n ecessity, i t c annot ...
Page 7: Specifications
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 2 Specifications ...
Page 8 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Table 1 . A MPSEAL 3 5 P in W ire H arness D escription ...
Page 9 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Table 2 . A bsolute M aximum R ating ...
Page 10 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 MICROCONTROLLER Atmel SAM3X8E ARM Cortex-M3 CPU 32-bit core CPU Clock at 84Mhz.
Page 11: Wiring And Connections
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 3 Wiring and Connections 11 ...
Page 12 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The G EVCU m ust o f c ourse b e c onnected t o t he c ar a nd t he i nverter/controller b y w ire. T he e ntire ...
Page 13 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 While t he G EVCU h as a l imited n umber o f d igital a nd a nalog i nputs a nd o utputs, t hey a re r eally q uite ...
Page 14 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 available o n s everal p ins f or c onvenience – i n t his c ase p in 2 4. T he o ther e nd o f t he p ot i s t ied t o o ur ...
Page 15 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 But m any w ant r egenerative b raking t o a ssist s lowing t he c ar w hen u sing t he b rake a nd s ome d o ...
Page 16 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 16 ...
Page 17 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 17 ...
Page 18: Serial Port Interface
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 4 USB SERIAL PORT INTERFACE The k ey c oncept i n t he G ENERALIZED v ehicle c ontrol u nit i s t hat i t i s g eneralized. T hat i s, i t c an b e ...
Page 19 GEVCU w as b orn o f t he A rduino D ue e ducational p latform a nd m any a ctually d evelop C ++ ...
Page 20 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Once t he p ort i s s elected, u se t he s ame T OOLS m enu t o s elect ...
Page 21: Module Selection
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 5 MODULE SELECTION AND INITIALIZATION With p ower a nd f lexibility, u nfortunately c omes c omplexity. G EVCU i s i nitially d esigned t o d rive t he ...
Page 22 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Power r eset Enable t he D MOC645 i nverter ...
Page 23: Precharge Considerations
The SAM3X microcontroller, when first powered up, sets ALL digital outputs to ON for about 80 milliseconds. This has the effect of closing all contactors if the GEVCU precharge procedure is used as designed and tends to destroy the contactors with capacitor inrush current.
Page 24 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 So f or e xample, i f w e h ave a 4 00v p ack, a nd w e p recharge t hrough a 1 00 o hm r esistor, w e l imit t he ...
Page 25 G EVCU s oftware t o a ccommodate p recharging. T o s et t hese, b ring u p t he s erial t erminal o n t he GEVCU a nd e nter t he f ollowing v alues: ...
Page 26 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 MRELAY=1 This s ets t he m ain c ontactor r elay t o D OUT1 o n p in 4 . ...
Page 27 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The s implified t wo c ontactor p recharge c ircuit s hown h ere h as s everal a dvantages f or h igh v oltage ...
Page 28 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Once t he p recharge d elay h as b een a ccomplished, t he m ain c ontactor o n t he p ositive p ole i s t hen ...
Page 29: Throttle Calibration And Mapping
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 7 THROTTLE CALIBRATION AND MAPPING The c oncept o f a “ vehicle c ontrol u nit” c an c over a m ultitude o f s ins. B ut t he m ost c entral i ssue, ...
Page 30 GEVCU d etects t hrottle p osition b y v oltage. T hrottles m ay b e p otentiometers, h all e ffect d evices, ...
Page 31 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 To g et t he n umeric v alues, w e h ave t o u se o ur U SB s erial p ort t erminal p rogram t o v iew t he d igital ...
Page 32 GEVCU a ctually p rovides a r ich s et o f v ariables t o m ap t hat 0 -‐100% i n a n ...
Page 33 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 33 ...
Page 34 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The f irst t hing t o u nderstand a bout t he t hrottle m ap i s t hat r egenerative b raking i s a f unction o f t he ...
Page 35 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Note t oo t hat ...
Page 36: Brake Calibration And Mapping
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 8 BRAKE CALIBRATION AND MAPPING Brake c alibration a nd m apping i s v ery s imilar t o t hat f or t he t hrottle, b ut m uch s impler a s t here i s ...
Page 37 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 To u se r egenerative b raking o n t he b rake, y ou w ill n eed s ome s ort o f 5 v s ensor i ndicating b rake ...
Page 38 GEVCU m akes p rovisions f or t his w ith t he B RAKE L IGHT o utput. Y ou c an d esignate ...
Page 39 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 In t his w ay, w hen s lowing t hrough r egenerative b raking, y ou W ILL l ight t he b rake l ights o n t he r ear ...
Page 40: Power Values
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 9 POWER VALUES There a re a c ouple o f v ariables h aving t o d o w ith m aximum p ower a nd r pm f or t he m otor o verall. ...
Page 41 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 RPMS=6000 For e xample t his c ommand w ould s et t he m ax r pm a t 6 000 r pm. ...
Page 42: Analog Inputs
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 10 Analog Inputs Since t he c entral r ole o f t he G EVCU i s t o a llow c ontrol o f t he p ower a pplied t o t he m otor a s d irected ...
Page 43 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 This s ignal o f c ourse d rives a l ight e mitting d iode. A n a ssociate p hoto t ransistor t hen c onducts i n a ...
Page 44: Digital Inputs
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 11 Digital Inputs 44 ...
Page 45 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The G EVCU p rovides f our o ptically i solated d igital i nputs. B y d igital, i n t his c ase w e a re n ot r eferring t o ...
Page 46 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 REVERSE INPUT The d efault m ode o f t he G EVCU i s t o t urn t he m otor i n t he f orward d irection o nly. B ut w e c an u se o ne o f ...
Page 47: Digital And Analog Outputs
GEVCU p rovides 8 d igital o utputs a ny o f w hich can a lso b e u sed a s P ulse W idth M odulated ...
Page 48 NOTE The GEVCU 5 series and earlier has a design flaw effecting digital outputs. When power is first applied to the GEVCU, the digital output MOSFETs may cycle ON for slightly over 80 milliseconds. Operation is normal thereafter. This generally precludes GEVCU outputs from being used for pre-charge duties or any application where a brief ON output on powerup poses a problem.
Page 49 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 49 ...
Page 50: Cooling Control - Adigital Output Example
Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 13 COOLING CONTROL – A DIGITAL OUTPUT EXAMPLE ...
Page 51 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The d iagram a bove s hows t he e xternal c onnections t o t he G EVCU. W hen D OUT7 i s s et t o O N, i t ...
Page 52 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 COOLFAN=7 This s ets t he s pecific d igital o utput t o u se f or c ooling ( 0-‐7). ...
Page 53: Wireless Configuration
GEVCU f eatures a n o nboard W iFi 8 02.11b/g/n r eceiver/ t ransmitter w ith a ctually a f ull T CP/IP stack o n i t a llowing b ridge c ommunications, f tp, h ttp, e -‐mail a nd r eally a v ery c apable s et o f o ther ...
Page 54 GEVCU s ets u p a w ireless 8 02.11b/g A ccess P oint ( AP) w ith a s ervice s et i dentifier ...
Page 55 A r elated D ASHBOARD s creen s hows l ive c ontroller d ata i n s omewhat m ore g raphic f orm. GEVCU a lso p rovides t hree c onfiguration s creens: T HROTTLE, O UTPUTS, a nd I NPUTS. THROTTLE ...
Page 56 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 There a re a f ew s pecial c ases w e s hould d iscuss h ere. ...
Page 57 GEVCU c alculates t he r unning t otal o f k Wh c onsumed i n o peration a nd d isplays i t o n ...
Page 58 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 You w ill f ind t hen t hat t he m eter s imply r eads z ero u ntil y ou’ve d riven t he c ar s ufficiently t o g et t he ...
Page 59 GEVCU p rovides f our b uffered i solated d igital i nputs D IN0 t hrough D IN3 w hich y ou c an u se ...
Page 60 GEVCU f eatures a n o bject-‐oriented a rchitecture a llowing c reation o f a n umber o f “ object m odules” t o ...
Page 61 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The s creen a bove s hows t he c urrently a vailable s election – w hich w ill u ndoubtedly g row w ith f uture ...
Page 62 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 ABOUT The a bout p age a ppears b elow. I t i s t he u sual g ratuitous v anity a nd p ablum r egarding l egal i ssues ...
Page 63: Canbus Communications And Obdii
GEVCU u ses t wo T exas I nstruments I SO1050 g alvanically i solated C AN t ransceivers t hat m eet t he specifications o f t he I SO11898-‐2 s tandard. T he d evice h as t he l ogic i nput a nd o utput b uffers ...
Page 64 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 Note t he j umpers ...
Page 65 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 The d etails o f t he C AN t ransmission a re b asically h andled f irst a t t he t ransceiver l evel, a nd t hen a t ...
Page 66 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 data o n i nverter t emperature, m otor t emperature, m otor c urrent, m otor v oltage, p ack v oltage, p ack ...
Page 67 GEVCU, b ut o n i ntelligently d esigning a nd p lacing d evices i n t he c ar t o t alk o ver ...
Page 68: Can Control Of Input And Outputs
GEVCU i s c onfigured t o u se f our C AN b us m essage I Ds t o d eal w ith i nputs ...
Page 69 GEVCU n ormally h as t wo C AN b usses c onfigured a nd t hey m aybe c onfigured a t d ifferent s peeds. ...
Page 70 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 0x606 88 88 FF FF FF 88 88 FF ...
Page 71 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 READING GEVCU DIGITAL INPUTS Anytime G EVCU r eceives a ...
Page 72: Updating Gevcu Software
EVTV m aintains a g ithub a ccount w ith t he l atest s ource c ode f or G EVCU t hat i s ...
Page 73 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 For t he p rogramming s avvy, t his e asily a ccomplished b y d ownloading t he d esired v ersion o f G EVCU ...
Page 74 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 logout [Process completed] Basically t his i ndicates t hat t he ...
Page 75 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 If t hat d oesn’t w ork, n ote t hat t he A rduino D ue b oard u sually f eatures T WO U SB p orts. N otice t hat ...
Page 76 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 8. Once y ou s ee t he p roper r esponse a nd c an l oad t he m enu, r einstall t he r ear p anel a nd s ecure ...
Page 77 Y our n ewly u pdated w ebsite s hould a ppear. GEVCU s oftware u pdate i s n ow c omplete. ...
Page 78 Operation M anual GEVCU V ersion 5 .20 N ovember 2 014 at ttp://media3.ev-‐tv.me/GEVCUupdate.zip 78 ...