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SME AC-M1 Manual

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AC-M1
AC-M1
PRELIMINARY VERSION

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Summary of Contents for SME AC-M1

  • Page 1 AC-M1 AC-M1 PRELIMINARY VERSION...

  • Page 2: Table Of Contents

    3.3.1 AC-M1 with Heat Sink..................12 3.3.2 AC-M1 with Aluminium Baseplate..............12 3.3.3 Clearances......................12 ..........................13 3.4 List of complete pin-out...................14 3.4.1 AC-M1 pin-out for PUMP application.............14 3.4.2 AC-M1 pin-out for DRIVE application............17 3.4.3 Connector Parts....................19 3.5 Typical connection diagrams...................20 3.5.1 General electrical vehicle................20 3.5.2 Pump motor application in a twin drive system..........20...
  • Page 3 7.3 Immunity to EM disturbances..................47 8 Maintenance........................49 8.1 Spare part list......................49 9 Appendix A. General technical overview of SME technology........50 9.1 History of AC induction motors and AC controllers..........50 9.2 Technical advantages of AC induction motors............50 9.3 AC motor general description and principles of operation ........51 9.3.1 General description of an AC motor..............51...

  • Page 4: Introduction

    The group provides intelligent and innovative solutions to satisfy market requirements, achieving worldwide customer satisfaction. SME group is able to offer a complete motion system for the different industrial lift truck ranges guaranteeing a high and safe performance customized to the client's requirements.

  • Page 5: How To Find Us

    All the World Regions (except Asia): For any information on commercial and technical issues, please contact either your ● dealer or directly SME Headquarter at the following address: SME S.p.A. Via della Tecnica, n° 40 36071 Arzignano (VI) - ITALY...

  • Page 6: Ac_Smartmotion Ac-M1 Overview

    The AC-M1 Controller is designed to control AC motors up to 10kW. Being based on high reliable DCB technology and exceptionally stable ITC Control Algorithm, AC-M1 Controller is a revolutionary and high quality solution for medium power applications. AC-M1 Controller can be easily connected to other peripherals to perform a complex network in which all nodes can communicate with the others via CAN bus.

  • Page 7: General Technical Specifications

    2.2 General Technical Specifications AC-M1 has the following remarkable features: Low R MOSFET ✔ DS,on 16 bits DSP controlling 1 AC motor ✔ High Speed FLASH Memory ✔ Switching Frequency: 9kHz ✔ Integrated Hall Effect Current Sensors ✔ Communication: RS232, LIN and CAN-Bus ✔...

  • Page 8: Packaging Configuration

    AC-M1 72/80V 450A 450 A 41.6 kVA 2.3 Packaging configuration AC-M1 is available in one of the following packages: 1. with an Aluminum baseplate, or 2. with a heat sink, which uses the convection and therefore requires a fan. PRELIMINARY VERSION...
  • Page 9 Figure 1: AC-M1 . All the dimensions are in millimetres. PRELIMINARY VERSION...

  • Page 10: Product Indication Labels

    2.4 Product indication labels The product label shows important data regarding the specific product. The product label is placed in the same position for all the versions of AC-M1 (see fig. 1). The meaning of each field is described in the table below.

  • Page 11: Installation And Wiring

    3 Installation and wiring 3.1 General description The AC-M1 is composed by a control section and a power section, both enclosed in a plastic cover with an aluminium baseplate or a heat sink on the bottom of the enclosure. There is a power module which can be connected to a three-phase AC motor through the power outputs labelled as U, V, W.

  • Page 12: Cooling Requirements

    In this case, AC-M1 is cooled by the surface contact to the vehicle body, so it is important to pay much attention to the flatness and the roughness of the surface of the vehicle frame where AC-M1 is mounted.
  • Page 13 Figure 2: Planarity specifications for the AC-M1with aluminium baseplate. PRELIMINARY VERSION...

  • Page 14: List Of Complete Pin-Out

    3.4 List of complete pin-out 3.4.1 AC-M1 pin-out for PUMP application K1 connector pin-out for AC-M1 : PUMP application Pin Name Specification Function Supply Rated battery +25/-30%, Positive supply of the control +KEY (B) input 6Amax section of the AC-M1...
  • Page 15 K1 connector pin-out for AC-M1 : PUMP application Pin Name Specification Function termination resistor) output Low side 2A Reserve command output Low side 1,5A Reserve command 18 GND Negative logic supply 19 FAN output Low side 1,5A FAN command 20 OUT1...
  • Page 16 K2 connector pin-out for AC-M1 : PUMP application Pin Name Specification Function GND ENC Negative logic supply analogue Pull-up Reserve input analogue Analogue input for pump motor T. MOTOR 1 Pull-up input thermal sensor 4mA pull-up, digital Reserve VL<=1V, input VH>=3,5V...

  • Page 17: Ac-M1 Pin-Out For Drive Application

    3.4.2 AC-M1 pin-out for DRIVE application K1 connector pin-out for AC-M1 : DRIVE application Pin Name Specification Function Supply Rated battery +25/-30%, Positive supply of the control +KEY (B) input 6Amax section of the AC-M1 4mA pull-up, Safety contact signal; the safety...
  • Page 18 K1 connector pin-out for AC-M1 : DRIVE application Pin Name Specification Function 18 GND Negative logic supply 19 FAN output Low side 1,5A FAN command 20 OUT1 output Low side 1,5A Reserve command auxiliary 21 +12V 12V 300mAmax 12V supply...

  • Page 19: Connector Parts

    K2 connector pin-out for AC-M1 : DRIVE application Pin Name Specification Function analogue Analogue input for drive motor T. MOTOR Pull-up input thermal sensor 4mA pull-up, digital Reserve VL<=1V, input VH>=3,5V analogue Reserve 0/12V pull-down input 4mA pull-up, digital VL<=1V,...

  • Page 20: Typical Connection Diagrams

    3.5 Typical connection diagrams 3.5.1 General electrical vehicle Figure 3 shows a connection diagram of a general electrical vehicle using the AC-M1 as control board and traction motor drive. Pump motor is not present. 3.5.2 Pump motor application in a twin drive system Figure 4 shows a typical connection diagram showing AC-M1 control powering an A.C.
  • Page 21 Figure 3: General electrical vehicle. PRELIMINARY VERSION...
  • Page 22 Figure 4: Connection scheme of AC-M1 controlling a pump motor in a twin drive system PRELIMINARY VERSION...

  • Page 23: External Devices Description

    Channel A has to be connected to pin K2-5 and Channel B to pin K2-4. The environmental protection rating is IP65. If you need to make use of other types of encoder, please contact SME in order to verify the technical feasibility.

  • Page 24: Compact Display

    3.6.2 COMPACT Display SME manufactures a LCD instrument panel known as COMPACT display. It is an optional device which shows overall information about the system main analogue and digital signals (see page 33). It is an optional device, that has to be connected to AC- M1 board via LIN interface.

  • Page 25: Programmable Parameters

    3.7 Programmable parameters AC-M1 controller has a number of parameters that can be calibrated both using SME COMPACT display and SME Eyeplus software utility run on a P.C. These programmable parameters allow the truck’s performance to be customized to fit the needs of different vehicle applications or individual vehicles.
  • Page 26 -40/+50° C Maximum case temperature: 100° C EN1175 for safety EN12895 for for Electromagnetic comp ability Regulation compliance: UL Recognized Component; meets UL583 dielectric test Technical specifications for the 36V – 48V AC-M1 Battery voltage: 36V – 48V PRELIMINARY VERSION...
  • Page 27 -40/+50° C Maximum case temperature: 100° C EN1175 for safety EN12895 for for Electromagnetic comp ability Regulation compliance: UL Recognized Component; meets UL583 dielectric test Technical specifications for the 72V – 80V AC-M1 Battery voltage: 72V – 80V PRELIMINARY VERSION...
  • Page 28 Maximum impulsive inverter current (2'): AC-M1 72/80V 350A 350Aac AC-M1 72/80V 450A 450Aac Motor switching frequency: 9KHz Efficiency: Protection level: IP65 Mechanical size: 210x145x91 mm Weight: 3.8 kg Vibration: 5g 10/500Hz 3 axis Working temperature range: -30/+40° C Storage temperature range: -40/+50°...

  • Page 29: Main Function Management

    4 Main function management 4.1 Static return to off When switching on the lift truck, a number of inputs are analysed to ensure the operator's safety; if one of these signals indicates a wrong start condition or any likely dangerous situation, the main breaker is not closed and all the system modes are disabled.

  • Page 30: User Interfaces

    It can be run from a PC with serial or USB (1.x or 2.x) port, using an interconnection cable (SME Code IV049A, see fig. 5). The connection between PC and SME Control board is characterized by a 38,4 k Baud Baud-rate.

  • Page 31: Serial Interconnection Cable

    P.C. and control board when you use EyePlus utility. Refer to specific AC-M1 pin-out to wire properly your board Rx, Tx and ground terminals (“cons. prog.” terminal is optional) .We recommend you to use a shielded cable to avoid electromagnetic interference.
  • Page 32 Figure 5: Interconnection cable PRELIMINARY VERSION...

  • Page 33: Compact Display

    5.3.1 Overview COMPACT display is an optional device which can be connected to the AC-M1 via LIN network and can be used for diagnostic and calibration purposes; in fact it shows information about the system main analogue and digital parameters.

  • Page 34: Connections

    Supply Voltage: 12V ● Communication: LIN ● Working temperature: -20° C +50° C ● Environmental protection rate: IP65 ● 5.3.3 Connections. The following table describes COMPACT display connector pin-out. COMPACT Display Connector Name Type INPUT 1 DIGITAL INPUT with PULL-UP INPUT 2 DIGITAL INPUT with PULL-UP INPUT 3...
  • Page 35 Figure 7: COMPACT display seen from front view. Figure 8: Drawing of COMPACT display connector. PRELIMINARY VERSION...
  • Page 36 Figure 9: Drawing of COMPACT display slot . PRELIMINARY VERSION...

  • Page 37: Diagnostic And Troubleshooting

    6 Diagnostic and troubleshooting 6.1 Overview Diagnostic information about anomalous working condition is provided by COMPACT display or by PC (using EyePlus software utility). This chapter explains how to manage any detected fault and how to return to a normal working situation;...

  • Page 38: Alarm List And Description

    CRC fault alarm Bank CRC restored This is a general list of possible alarms, but their actual meaningfulness depends on the specific application. In particular some AC-M1 applications control one drive motor, other applications control one pump motor. PRELIMINARY VERSION...

  • Page 39: Maximum Battery Voltage

    Maximum battery voltage: Alarm code: 1 ● Alarm level: 1 ● Alarm cause: too high an inverter voltage. ● If the controller detects such a fault, follow these tips: 1. Such an alarm can be caused by the presence of braking currents; when the vehicle is on release or reverse braking ramp, motors work as generators, and battery voltage could exceed over-voltage limit.

  • Page 40: Capacitors Not Charged

    4. If the main breaker coils are correctly wired to their correspondent inputs, replace the main breaker; 5. If all the connections are good replace the AC-M1; the diagnosis shows that the command is present, but no voltage is present on the coil terminals, or no voltage appears on inverter DC bus .

  • Page 41: Low Battery Alarm

    36 ○ Alarm level: 1 ● Alarm cause: failure of current sensor ● In case of such alarm, call the service to trim values, or replace the AC-M1. Main breaker fault: Alarm code: 17 ● Alarm level: 1 ●...

  • Page 42: Panel Overtemperature

    2. Disconnect the battery, discharge the DC bus and remove the control board connector. If K1 coil terminals are in short , replace the AC-M1. Panel overtemperature: Alarm code: 20 ● Alarm level: 5 ● Alarm cause: the inverter temperature, measured with an internal probe, exceeds ●...

  • Page 43: Alarm On 12V Output Voltage

    5V exceeds 200mA. In that case, find and replace the defective device. 3. If no voltage is present on the the K2 terminal when all the loads are removed, replace the AC-M1. Alarm on 12V output voltage: Alarm code: 38 ●...

  • Page 44: Pump Motor Commands Active On Start

    4. If the potentiometer output voltage is correct and the measured value in the display is incorrect, and the proper terminals of the 23-way connectors are correctly wired to their correspondent inputs in potentiometer circuit, replace the AC-M1. Pump motor commands active on start: Alarm code: 50 ●...

  • Page 45: Encoder Alarm

    If the encoder is correctly wired and supplied, but the channels don't commutate from 0 to 5V, replace the encoder. 2. If the wirings and signal are correct but diagnosis is not, replace the AC-M1. Watchdog timer alarm: Alarm code: 18 ●...

  • Page 46: Crc Fault Alarm

    In case of such alarm, follow this procedure: 1. Restore EEPROM with EyePlus application software, using the “RESTORE” item present in the EyePlus main page; 2. If the alarm is still present, replace the AC-M1. Bank CRC restored Alarm code: 84 ●...

  • Page 47: Emc Suggestions

    The RF voltages and currents induced in each wire are applied to the controller pin to which the wire is connected. SME controllers include bypass capacitors on the printed circuit board’s wires to reduce the impact of this source of noise on the internal circuitry, but in some applications an additional filtering in the form of ferrite beads might also be required.
  • Page 48 several small holes instead of few larger holes is preferable, because holes reduce the shielding capabilities (remember that reduction in shielding is a function of the longest linear dimension of a hole rather than the area). The same concept applies to seams or joints segments of a shielded enclosure: it is important to minimize the open length between the points where good ohmic contact is made.

  • Page 49: Maintenance

    8 Maintenance 8.1 Spare part list The following items can be bought separately: Spare part list Part SME internal code to be determined (ask to our commercial department) PRELIMINARY VERSION...

  • Page 50: Appendix A. General Technical Overview Of Sme Technology

    9 Appendix A. General technical overview of SME technology 9.1 History of AC induction motors and AC controllers. The AC induction motor, which was invented in the 1880s, is the basic workhorse of industry; induction motors perform almost 90 percent of the electrical to mechanical power conversion in industrial machinery.

  • Page 51: Ac Motor General Description And Principles Of Operation

    9.3 AC motor general description and principles of operation 9.3.1 General description of an AC motor An AC motor has two main parts: a stator, which is fixed, and a rotor, which rotates with the shaft. The stator is the stationary part of the motor. Within the stator assembly there is an iron core constructed from thin iron sheets coated with insulation.
  • Page 52 The power supply generates a rotating magnetic flux whose angular speed (synchronous speed) is given by the following general formula: 2 f 60  where f is the three-phase frequency and p is the number of poles (in figure 10, p=2). If the rotor angular speed is different from the synchronous speed, a flux density derivative will appear in the rotor windings, which in turn will generate a current on those windings because they are shorted.

  • Page 53: Electrical Model

    9.3.3 Electrical model From an electrical point of view, an AC motor is a load which can be represented, in a fairly simplified and non-exhaustive model, as the network in figure 12 ( the real equivalent model is more complex). Figure 12: Simplified electrical model of an AC induction motor.

  • Page 54: Itc Vector Drive System

    9.4.1 Basic operation of ITC vector drive system The motor control algorithm used by SME is known as Field Orientated Control. A schematic block diagram of a flux vector control is reported in figure 13. The vector flux control used by SME motor drive systems involves the following blocks: Speed reference block.
  • Page 55 PRELIMINARY VERSION Figure 13...

  • Page 56: Main Itc Components

    (named EyePlus) developed by SME, or through the COMPACT display, a complete console capable of diagnostic and calibration functions engineered by SME. In both cases, you can obtain an exhaustive “on line” diagnostic of all the lift truck functional parameters and adjust them too.

  • Page 57: Itc Characteristics

    ● Short circuit protection. ● 9.4.4 ITC characteristics The system developed by SME allows you to get high performance, thanks to the following specific features: DSPs high performance control with custom software, loaded in the internal FLASH ● memory. One serial asynchronous RS232 interface for PC communication in order to obtain: ●...

  • Page 58: Appendix B: Programmable Parameters

    10 Appendix B: Programmable parameters Programmable parameters are here listed in functional groups. The possibility of interfacing by PC with the system allows to have an exhaustive real time analysis of the system working and of the condition of its components; moreover, you can choose among a wide range of parameters in order to reach the optimum operating of the system in compliance with your needs.
  • Page 59 PARAMETER NAME PARAMETER DESCRIPTION If parameter is set to 1, values are expressed in British British unit unit, otherwise in international ones. If parameter value is 0, display shows the hour meter. Time meter / odometer / weight If parameter is set to 1, odometer indication appears . of the load on the forks on If parameter value is 2, display shows weight on the display...
  • Page 60 TIMERS PARAMETER NAME PARAMETER DESCRIPTION Time interval between seat switch opening and drive Seat switch delay and pump motors stopping Time interval when pump motor works (with hydro Hydro time speed) after the end of a command Time delay between last command given to a drive Chat time or pump motor and chat mode signalling If operator stops on slop, after this time interval lift...
  • Page 61 PUMP MOTOR PARAMETER NAME PARAMETER DESCRIPTION Minimum lift speed Minimum lift speed Maximum lift speed Maximum lift speed Tilt speed Pump motor speed with speed function active Pump motor speed with lateral shift function (1 Lateral shift (AUX 1 function) speed auxiliary) active Pump motor speed with 2 auxiliary function...
  • Page 62 PARAMETER NAME PARAMETER DESCRIPTION Max. side shift speed when the forks are above High lift sw.2 AUX1 function max. speed the 2 critical height AUX2 function speed when the forks are above High lift sw.1 AUX2 function max .speed the 1 critical height AUX2 function speed when the forks are above High lift sw.2 AUX2 function max.

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