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Rev XX
Date XX-XX-XXXX
Proprietary
DMOC445 Manual
&
Operating Instructions
Azure Dynamics Inc.
9 Forbes Road
Woburn MA 01801 USA
781-932-9009
Or Fax: 781-932-9219
Customer Service only
customersupport@azuredynamics.com
APPROVALS:
Project Engineer _____________________
Customer Service_____________________
Date _____________________
Date _____________________
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Table of Contents
Summary of Contents for Azure Dynamics DMOC445
- Page 1 Proprietary DMOC445 Manual & Operating Instructions Azure Dynamics Inc. 9 Forbes Road Woburn MA 01801 USA 781-932-9009 Or Fax: 781-932-9219 Customer Service only customersupport@azuredynamics.com APPROVALS: Rev XX Project Engineer _____________________ Date XX-XX-XXXX Date _____________________ Customer Service_____________________ Date _____________________...
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Page 2: Table Of Contents
INSTALLATION REQUIREMENTS ..............24 Mounting .................................24 Electrical Connections .............................25 Connecting the 14-pin, AMP, Motor Sensor ....................25 Connecting the 35-Pin AMP, Vehicle Interface Cable ..................25 Connecting the 8-pin AMP Connector, Communications ................25 Connecting the Motor Cable..........................26 DMOC445 Manual and Operating Instructions... - Page 3 Figure 5..................................29 Connecting the High Voltage Battery Pack .....................34 Water Ingress Prevention..........................34 Grounding and Shielding..........................35 DMOC445 Manual and Operating Instructions...
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Page 4: Foreword
No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of Azure Dynamics Inc. This applies to all text, illustrations, tables, and charts. DMOC445 Manual and Operating Instructions... -
Page 5: Safety
Safety For your safety and the safety of others, please read and understand this entire manual before installing. If you have any questions regarding the contents of this manual, please call the Azure Dynamics Customer Service Department before proceeding. 1. Warning Labels Labels will be located on the right–hand side of the page to indicate areas in a procedure where you... -
Page 6: Overview
Proprietary Overview The Azure Dynamics Digital Motor Controller (DMOC) is a rugged traction inverter for controlling 3-phase AC motors and generators. A flexible control-software architecture allows for application-specific customization by loading software application modules. These application modules communicate with the motor-control core and implement the interface to the higher level controls or directly to the driver inputs and outputs. - Page 7 DMOC and ESS. On the AC-side, the DMOC connects to a Azure Dynamics supported three-phase motor, such as an AC Induction Motor or Permanent Magnet Motor. Specific instructions on how to safely install the DMOC and make the necessary electrical connections are given in this document.
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Page 8: Specification
280A rms Peak Power 78kW @ 312V Continuous Power 38kW @ 312V Max. Voltage “On Charge” 450VDC Minimal Auxiliary Supply Input Voltage 11 VDC 12 VDC Maximal Auxiliary Supply Input Voltage 15 VDC 30 VDC DMOC445 Manual and Operating Instructions... -
Page 9: Dimensions
Proprietary Battery Voltage vs. Peak Power DMOC445 Battery Voltage (V) Dimensions DMOC445 Manual and Operating Instructions... -
Page 10: Figure
Proprietary 1. FIGURE 2. FIGURE DMOC445 Manual and Operating Instructions... -
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Proprietary 3. FIGURE 4. FIGURE DMOC445 Manual and Operating Instructions... -
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Proprietary 5. FIGURE 6. FIGURE DMOC445 Manual and Operating Instructions... -
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Proprietary 7. FIGURE DMOC445 Manual and Operating Instructions... -
Page 14: General Information
Since the DMOC is only indented to be used with Azure motors, the motor wiring will be “dressed-up” appropriately for connecting with the DMOC. Do not shorten or lengthen the motor cables without duplicating the original connection and shielding configuration. DMOC445 Manual and Operating Instructions... -
Page 15: Low Voltage Power Connections
The third and largest connector has 35 pins and carries general digital and analog IO pins as well as the inputs for the auxiliary 12/24V power supply. Application specific connections to the 35-pin connector are described in the applications user manuals. DMOC445 Manual and Operating Instructions... - Page 16 Brake pedal pot signal ANAIN0 Analog input 0-5V PEDAL_HI Accelerator pot high FORWARD- Forward direction DRIVE_ENABLE- Interlock NONISO_ADIO1 Analog/digital I/O AHC_DATA_+ Amp-hour counter input AHC_NEG Amp-hour counter input ANAIN2/LED_MALFN Analog input or LED GND_D Top Board Gnd DMOC445 Manual and Operating Instructions...
- Page 17 Digital Output J5: Communications Connector (8-pin Amp seal) RS232_TXD RS232 Tx RS232_RXD RS232 Rx GND_B Comm. GND (RS232 & CAN) CANH CAN High GND_B Comm. GND CANL CAN Low GND_B Comm. GND Chassis GND Chassis GND DMOC445 Manual and Operating Instructions...
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Page 18: Modes Of Operation
At its core, the DMOC is a voltage source inverter (VSI) with high-bandwidth synchronous frame current regulation. Synchronous Frame Current Regulator Speed DC Voltage Torque Command Torque & Flux Controller Motor & IGBT Protection Current Limit Power Limit Battery Protection Torque Controller with Protections DMOC445 Manual and Operating Instructions... -
Page 19: Variables And Calibration
Bit 9: Phase over-current (software protection) • Bit 10: Over-voltage DC link (software protection) • Bit 11: Current sensor offset calibration error (software protection) • Bit 12: Over-speed protection (software protection) • Bits 13-15: Reserved DMOC445 Manual and Operating Instructions... -
Page 20: Status Code
Bit 2: 0=power stage OK, 1=power stage faulted Bit 3: 0=more torque available, 1=max torque limit reached Bit 4: 0=more power available, 1=max power limit reached Bit 5: 0=no thermal limit active, 1=thermal limit active Bits 6-7: reserved DMOC445 Manual and Operating Instructions... -
Page 21: Finite State Machines (Fsm)
Power stage faulted and will stay in this state until POWER_STAGE_FAULT fault is acknowledged by system controller POWER_STAGE_FAULT_ACKN Temporary state after fault has been acknowledged Power stage is in critical fault state (which can not POWER_STAGE_CRITICAL_FAULT be cleared by software) DMOC445 Manual and Operating Instructions... -
Page 22: Principal Variables
Actual torque command to current regulator ISR2RelayState State of relay FSM ISR2SpeedLimit Torque limiting based on speed (100% = no limit) ISR2SpeedRegTorqueDesired Output from speed regulator (before limits) ISR2TorqueDesired Torque desired by speed regulator (after all limits) DMOC445 Manual and Operating Instructions... -
Page 23: Main Parameters
Maximal negative motor speed EE2NoAccelBat Minimal battery voltage (zero power is provided below) EE2NoRegenBat Maximal battery voltage (zero power is provided above) EE2PosOverspeed Maximal positive motor speed EE2RegenBatRamp Over voltage ramp EE2ShaftDirection Direction of positive speed (CW, CCW) DMOC445 Manual and Operating Instructions... -
Page 24: Installation Requirements
(see figure 6). Grommet should meet IP57. DMOCs with extensive water damage may not be repairable. DMOCs returned to Azure Dynamics with the factory seal broken will be ineligible for warranty service All electronic systems must be isolated from vehicle vibration. -
Page 25: Electrical Connections
5. Connecting the 8-pin AMP Connector, Communications To connect the 8-pin, AMP, Communication (RS232/CAN) Connector to the DMOC, push the connector head into the 8-Pin connector port, located to the left of the 35-Pin connector port. DMOC445 Manual and Operating Instructions... -
Page 26: Connecting The Motor Cable
Shock Hazard: Extreme caution should be used whenever working on or near the high voltage system. • Do not connect or disconnect while high-voltage is present It is important that all cables be properly crimped. DMOC445 Manual and Operating Instructions... - Page 27 Proprietary Improper crimping can lead to failures and fires. Use a Thomas & Betts TBM5 Crimper or equivalent. Use two opposing wrenches so that you will not apply torque to the controller terminal. DMOC445 Manual and Operating Instructions...
- Page 28 EXCESS SHIELDING INSIDE TERMINAL BOX CAN CREATE A ELECTRIC SHOCK HAZARD. Finally, install the entrance fitting cap (nut, Fig 9) and tighten using a suitable wrench to ensure that adequate compression of the rubber seal is achieved. Make sure to put the black plastic flange washer DMOC445 Manual and Operating Instructions...
- Page 29 Proprietary underneath the fitting cap. The flange washer (Fig.10) makes contact with the shield and rubber seal. RUBBER SEAL CABLE SHIELD ENTRANCE FITTING Figure 5. Shielded AC motor cable connection at DMOC terminal box. DMOC445 Manual and Operating Instructions...
- Page 30 Proprietary Figure 6. Shows fitting rubber seal slid underneath cable shield. Figure 7. Shows AC motor cable inserted into entrance fitting with 360 degree connection of the cable shield to the inside wall of fitting. DMOC445 Manual and Operating Instructions...
- Page 31 Figure 8. Trim off excess cable shielding inside terminal box. If excess cable shielding makes contact with DMOC AC terminals then a shock hazard will be created. Make sure that no shielding enters into terminal box. DMOC445 Manual and Operating Instructions...
- Page 32 Proprietary Figure 9. Screw on entrance fitting cap (nut) with black plastic flange washer underneath cap. DMOC445 Manual and Operating Instructions...
- Page 33 Proprietary PLASTIC FLANGE WASHER Figure 10. Shows black plastic flange washer. DMOC445 Manual and Operating Instructions...
- Page 34 Cable fittings for the HV battery cables and motor cable need to be tightened-up to ensure liquid tight seal between cable jackets and fitting grommets. Illustrations below demonstrate proper cable fitting installation. Figure 7. HV Battery Cable Fittings. Figure 8. Motor Cable Fitting. DMOC445 Manual and Operating Instructions...
- Page 35 Figure 9. DMOC Grounding and Shielding. 4AWG CASE R 2AWG 4AWG STATOR BK 2AWG 4AWG DMOC 445 AC MOTOR 5/8 TB BR 4AWG CASE VEHICLE SHLD CASE CHASSIS Figure 10. Example of the DMOC Grounding Strap Connection. DMOC445 Manual and Operating Instructions...
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