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NetGain Motors HYPER-DRIVE X1 User Manual

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USER MANUAL
HYPER-DRIVE X1 INVERTERS
HYPER 9™
HYPER 9HV™ SYSTEMS
FOR USE WITH
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  • Page 1 USER MANUAL HYPER-DRIVE X1 INVERTERS HYPER 9™ HYPER 9HV™ SYSTEMS FOR USE WITH &...

  • Page 2: Table Of Contents

    Compact Display - wiring instructions ............................18 Compact Display Mating Female Plug ............................18 Compact Display - 8 Position Connector ..........................18 Software Files .................................... 19 Page 2 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 3 Motor Information Data Type .............................. 42 Controller Specifications ................................44 Controller Communication ............................... 44 Controller EMC ..................................44 Controller Safety Certification ..............................44 Page 3 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 4 Datalogging Guide: ................................... 48 Troubleshooting - Diagnostic Codes ............................50 Fault Levels ................................... 50 Fault Code List ..................................50 Additional Support ................................... 71 Page 4 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 5: Inverter Models (Isolated Vs Non-Isolated Logic)

    INVERTER MODELS (ISOLATED VS NON-ISOLATED LOGIC) This document covers all HyPer-Drive X1 Inverter models with nominal voltages ranging from 36V-144V. The terms HyPer-Drive™ Isolated Logic (ISO) vs Non-Isolated Logic (NON-ISO) are critical in identifying different inverters types. • Isolated Logic: The ISO logic board is energized with 12-24Vdc+. These inverters can be identified by their separate Catastrophic failure will occur if >24V is supplied to any K1...

  • Page 6: Warning And Caution

    Block the non-drive wheels if they remain in contact with the floor so that the vehicle cannot roll in either direction. Page 6 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 7: Disclaimer

    DISCLAIMER: NetGain Motors, Inc. has no control of third-party installation procedure or the use of this motor and control system. Accordingly NetGain Motors, Inc. assumes no liability for vehicle functionality or safety during or after third party installation of the motor and controller.

  • Page 8: Standard K1 Wire Harness - Pinout

    STANDARD K1 WIRE HARNESS - PINOUT Must Be Assigned Page 8 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 9: Wiring Diagram Overview

    2. Copy all parameters from the commissioned clone file’s Spin Sensor tab into the un-commissioned clone you are installing. 3. Commission the spin sensor again after installing a different clone file. Page 9 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 10: Isolated Logic - Standard Wiring Diagram

    ISOLATED LOGIC - STANDARD WIRING DIAGRAM ISOLATED LOGIC ONLY! If your Inverter has a terminal between V-W phases - use this diagram. Page 10 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 11: Non-Isolated Logic - Standard Wiring Diagram

    NON-ISOLATED LOGIC - STANDARD WIRING DIAGRAM NON-ISO ONLY! If your Inverter has a Precharge terminal between V-W phases - use Wiring Diagram for Isolated Logic Page 11 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 12: Wiring Instructions - Hyper Motor Plugs

    15. After the pre-start up steps are complete, and correct system operation is verified, apply heat to heatshrink using a heat gun. Adhere the heatshrink as close to the plug as possible without putting strain on the inserted wires. Page 12 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 13: Motor Plug Pinout - Hyper Motors

    Plug Part# 282080-1 Pin Part# 282110-1 Seal Part# 281934-2 K1-32 K1-12 THERMISTOR PIN # NAME K1 POSITION Motor Thermistor K1-32 Analog Ground K1-12 Page 13 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 14: Isolated Logic - Main Contactor Wiring

    High Voltage pack. The key switch must have an On position that energizes the HV Precharge Relay coil before the key is turned to the Start position, which will close 12V+ to K1-24. Page 14 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 15: Non-Isolated - Main Contactor Wiring

    K1-24 to lower voltage for internal inputs and outputs. K1 Ground pins trace internally to the X1 inverter’s B- terminal. Page 15 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 16: Main Contactor - Internally Economized Option

    K1-25 & K1-26, as shown in the diagram below. Your Clone File's Main Contactor voltages, frequency, and pull in time may require reconfiguration to match the specification of your cascaded relay: Page 16 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 17: Hv Relay - Wiring Instructions

    HV RELAY TERMINAL NAME TERMINATION HV OUT to Inverter HV IN 12V Coil - 12V Key Switch - 12V Coil + 12V Key Switch + Page 17 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 18: Compact Display - Wiring Instructions

    K1 POSITION +12V Out K1-10 I/O Ground K1-12 Not Connected LIN-BUS K1-15 Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Page 18 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 19: Software Files

    DOWNLOAD THE CLONE FILE FOR YOUR SYSTEM: http://www.go-ev.com/downloads/clone_files.html DOWNLOAD THE FTDI DRIVER FOR SERIAL TO USB ADAPTERS: https://www.go-ev.com/downloads/ftdi.zip 1. DOWNLOAD 2. EXTRACT Page 19 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 20 3. OPEN UNZIPPED FILE FOLDER 4. OPEN VOLUME FOLDER 5. OPEN SETUP – APPLICATION 6. INSTALL 7. RESTART PC Page 20 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 21: Pre-Startup Steps

    PIN3 is connected to K1-33 (Encoder Cos 1). PIN4 is connected to K1-9 (Encoder I/O Ground). 6. Check that Contactor Positive Coil is connected to K1-25 (Coil Return). Page 21 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 22 Your COM port number set is listed in the Windows Device Manager. ii. Verify that the COM port number is not already used by another software when TAU SmartView is opened. Page 22 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 23 Once this .bin file is selected and shown in the Firmware Path, Click PROGRAM and let progress load to 100%. If PC to Inverter connection is lost while load progress is between 0%-100%, the inverter will be Page 23 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 24 Low voltage faults are to be expected, as high voltage is still disconnected. With TAU SmartView’s home screen active, click: Monitor - Real-Time Data - Inputs – Page 24 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 25 60 seconds from key on, click YES. The motor will spin slowly for about 1 minute, so please be sure it is safe to do so with minimal load (Neutral and/or wheels suspended off ground). Page 25 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 26 Controller. This means that the encoder wiring or motor phases are wrong. Please, check them. 23. Continue to Post-Startup Steps. Page 26 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 27: Post-Startup Steps

    Starting Cutback points (B & C) to map out a current derating structure that will protect your battery. The Cutback is the maximum % of current allowed at the ending cutback point. Page 27 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 28: Battery Mapping

    9. In HyPer-Drive X144 Clone files, changing the Nominal Voltage from 144.00V will trigger an AL52 Wrong Parameter fault. If the nominal voltage is set to 144.00V, do not modify. Page 28 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 29: Throttle Mapping

    5. A quick jump up to 4-9% torque helps to smooth out low torque jittering. 6. If you intend to implement Single Pedal Driving, leave >250mV between resting throttle and first torque request. Page 29 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 30: Brake Regen Mapping

    3. Press on the brake pedal and note the change in this Analog Input mV value. 4. Adjust the map accordingly, starting from the lowest left capture point, working right to the highest. Page 30 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 31: Operating Profiles - Regen On Neutral

    Regen torque between resting throttle and the first drive torque request. Copy to Reverse Map and adjust as desired. SAVE Page 31 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 32 4. Limit Below First Point: Set to Maximum Regen Torque in Torque Limits - By Other tabs. Setting First Point to 100% will not allow for utilization of the full map, this value is further limited By Operating Page 32 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 33 Do not decrease Deceleration Rate below 90%/s. A deceleration rate >90%/s will allow a vehicle to stop appropriately after throttle is released. A deceleration rate <90%/s will cause a dangerous delay in deceleration. Page 33 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 34: Digital Outputs

    1. On the TAU SmartView DLR Sys home screen, select Configure - System – Generic Outputs. Select an Output Function from the drop-down list. Page 34 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 35 Motor and Controller Temperature Derating specifications. 8. Save. A fault condition will occur if a Generic Output is assigned without the correct wiring to match. Page 35 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 36: Temperature Derating - X1 Inverter

    Linear power derating: +135°C (100% current) to +155°C (30% current) Thermal Shut Down: +165°C Suggested Cooling Activation: +110C* Suggested Cooling Deactivation: +90C* * Varies by application Page 36 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 37: Can Network Configuration

    WARNING: Before starting the system, check that all Nodes are properly connected to CANOpen network to avoid wrong net starting sequence or faults. The Baud Rate of all Nodes in the network must be the same. Page 37 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 38: Configuration - Can Network Settings

    PC. The Baud Rate of the network is the same set in Network Configuration. Page 38 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 39 In the following example, you can see a real system configuration. In an electrical vehicle you usually need to see: Speed of the vehicle, Battery State of Charge, State of Brakes (available in System Flags), Active Fault Code. Page 39 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 40: Tpdo Structure

    Empty word introduced in the message NAME SIZE UNIT REMARKS RANGE [-32768; +32767] ↔ [-327.68; Key Switch Voltage Word Controller Supply Voltage +327.67]V Page 40 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 41 0 = FALSE; 1 = TRUE BIT6 Controller is in Overtemperature BIT7 Key Switch Overvoltage BIT8 Key Switch Undervoltage BIT9 Vehicle is Running BIT10 Traction is Enabled Page 41 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 42: Inverter Information Data Type

    BIT7 Motor2 in Overtemperature BIT8÷BIT15 Reserved Motor 1 - Temperature Byte °C Motor 1 Temperature (offset of 40°C) [0; +255] ↔ [-40; +215]°C Page 42 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 43 Byte Minute Motor 1 Operating Time Minutes [0; +255] ↔ [0; +255]Minute Motor 1 - Operating Time Byte Second Motor 1 Operating Time Seconds [0; +255] ↔ [0; +255]Second Page 43 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 44: Controller Specifications

    Cold & Heat: Tested under conditions suggested by EN60068-2-1 Mechanical size: 210 x 160 x 85 [mm] • Weight: 3.5 kg Switching Frequency: 9 kHz Internal Pre-charge Capacitance: 4428uF (ACX1T50000I00 (144x500)) Page 44 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 45: Pre-Programmed I/O - Hyper-Drive Inverter

    Analog Input 0÷12V 125KΩ pull-down Throttle Wiper 1 / Analog Regen Limit I/O GROUND I/O Ground Do not exceed 0.5A Negative Logic Supply Page 45 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 46 No internal DIGITAL OUTPUT 2 Digital Output Buzzer-Fan-Deceleration Lights diode to coil return MOTOR THERMAL Analog Input 1KΩ pull-up Motor Temperature Probe PROBE Page 46 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 47 Encoder Cos ANALOG INPUT 5 Analog Input 0÷12V 125KΩ pull-down Any Analog Input Function +5V OUT Supply Output 5V ±5% 200mA 5V+ Output Page 47 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 48: Datalogging

    Toggle through multiple tabs and select Checkboxes as you go. A list of common troubleshooting parameters is provided in Figure 11. Page 48 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 49 Your Logfile can be viewed using a spreadsheet software. The opensource software “LibreOffice” is an option that opens the logfile in proper format. You can also attach this file in an E-mail addressed to the party whom it was requested by. Page 49 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 50: Troubleshooting - Diagnostic Codes

    Symptom: Key-Switch Voltage or Capacitors Voltage is above the maximum level allowed for the Controller. This value is obtained by hardware comparator and is Blocking Over Voltage not configurable. Page 50 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 51 1. Battery resistance too high while regenerating. 2. Battery disconnected while regenerating. 3. Too low Over Voltage Limit defined by the user. Test: Page 51 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 52 4. Inverter 1 power module damaged. Test: 1. Check if there's an incorrect wiring to Motor 1 phases. 2. Verify Motor Parameters. 3. Verify Motor Current Limit Map. Page 52 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 53 Limiting Temperature 2. Operation with high load. 3. Wrong Installation of the Controller heat sink. 4. Wrong working of Controller cooling system. Test: Page 53 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 54 Test: If the Controller detects such a fault, replace it. Inverter 2 Temp Difference between Inverter 2 and microprocessor temperature greater than 70°C. Stopping Sensor Fault See AL17 Page 54 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 55 2. With a handheld multimeter you have to measure the impedance between the two wires of the thermal probe (perform the measurement at standard ambient temperature). If the measure is different from the Page 55 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 56 Braking and Reverse Rate. 3. Verify the Controller Starting Cutback Voltage 4. Replace the Controller. Page 56 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 57 +5V Supply Failure 1. External load impedance on +5V output is too low. 2. +5V output damage caused by short with external voltage source. Test: Page 57 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 58 4. If the wirings and signal are correct but diagnosis is not, replace the Controller. Encoder 2 Fault Blocking Sin/Cos inputs values are above/below the fault thresholds. See AL30 Page 58 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 59 1. Load default values for EEPROM variables with SmartView, using the button "Restore Factory Settings" in Manage\Restore. 2. If this fault remains after 2 or more default restoring, replace the Controller. Page 59 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 60 1. Check all high voltage connectors and terminations in series with B+ & B- 2. Verify that there's no external load in parallel with Precharge (K1-24 or B+ Precharge) & B-. Page 60 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 61 1. Incorrect Clone file. Can be configured, though default clones disable “Static Return to Off for Traction”. 2. Traction Throttle, Traction Inhibit or Direction Selector are active: At key on. Page 61 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 62 Controller. Symptom: A fault condition of hydraulic/pump throttle is detected. Hydraulic Throttle Stopping Fault Possible causes: Page 62 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 63 Symptom: Battery State of Charge estimated is lower than minimum value defined Low Battery State by the user via related parameter. Limiting of Charge Possible causes: Page 63 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 64 CAN H and CAN L should read 60Ω. 2. Check if all network nodes are correctly powered up. 3. Verify that all network nodes have the same baud rate configuration. Page 64 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 65 Symptom: At least one PDO hasn't been received. Possible causes: Stopping Net RPDO Timeout 1. Temporary loss of communication. Test: 1. Check if all network nodes are correctly powered up. Page 65 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 66 QuickStart of CO Network. Net Mains Manager Symptom: DC Bus Voltage will not increase after discharging phase. Blocking Precharge Too Slow Page 66 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 67 Symptom: Node is stopped because another node has a stopping/blocking fault condition. Stopped For Stopping System Fault Possible causes: Node Stopped for System Fault. Test: Page 67 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 68 2. If the BMS doesn't require a current limit, verify the correct status of PDO. Steering Sensor Symptom: A fault condition of steering sensor is detected. Limiting Fault Page 68 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 69 Symptom: Motor spin sensor commission is in progress. Commission In Warning Progress Possible causes: Spin sensor commission is in progress. Page 69 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.
  • Page 70 Internal Error. See AL103 Fault 2 Internal Hardware Blocking Internal Error. See AL103 Fault 3 Internal Hardware Blocking Internal Error. See AL103 Fault 4 Page 70 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

  • Page 71: Additional Support

    4. Screenshots of the Active Faults Tab in DIAGNOSE 5. Screenshots of the Faults History Tab in DIAGNOSE 6. Screenshots of the Time/Distance Tab in MONITOR Page 71 of 71 HyPer-Drive User Manual Rev.A.1 Copyright © 2023 NetGain Motors, Inc. All Rights Reserved.

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