Plettenberg MST 400-160 SIC Operating Manual
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Plettenberg MST 400-160 SIC Operating Manual

With dual isolated can interface and isolated 28v power supply
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H I G H - E N D E L E C T R I C D R I V E S O L U T I O N S
Operating Manual
MST 400-160 SIC
with dual isolated CAN interface
and isolat ed 28V power supply
OM_MST400-160 SIC_EN | Version 9.01 | 2023.10.23

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Summary of Contents for Plettenberg MST 400-160 SIC

  • Page 1 H I G H - E N D E L E C T R I C D R I V E S O L U T I O N S Operating Manual MST 400-160 SIC with dual isolated CAN interface and isolat ed 28V power supply OM_MST400-160 SIC_EN | Version 9.01 | 2023.10.23...

  • Page 2: Table Of Contents

    Table of contents Table of contents ................. 2 1. About this document ............. 3 Legal provisions ............... 3 Liability ..................3 Scope of validity ..............4 Target group ................5 Updated additional information ..........5 Symbols ................... 5 Nomenclature ................5 2.

  • Page 3: About This Document

    Plettenberg Elektromotoren GmbH & Co. KG ("Plettenberg”). Publication, in whole or in part, requires the express written consent of Plettenberg. An internal company duplication, which is intended for the evaluation of the product or for the appropriate assignment, is permitted and not subject to approval.

  • Page 4: Scope Of Validity

    Rostocker Straße 30 34225 Baunatal, Germany T: +49 (0) 56 01 97 96-0 www.plettenbergmotors.com sales@plettenbergmotors.com © 2023 Plettenberg Elektromotoren GmbH & Co. KG. All rights reserved. Scope of validity This document applies for the following devices: Device type MST 400-160 SiC V2.00...

  • Page 5: Target Group

    Target group The activities described in this document must only be executed by qualified, skilled electrician. The qualified, skilled workers must possess the following qualifications: Knowledge regarding the functional methods and operation for ⚫ the product Knowledge and observation of these instructions with all safety ⚫...

  • Page 6: Safety

    Safety Intended use The area of validity is defined as: Motor control unit ⚫ The following are considered improper use in the sense of a foreseeable misuse: Using the motor controller in manned vehicles ⚫ Using the motor controller in public vehicles and transport ⚫...
  • Page 7 The phase cables must not touch any conductive surfaces. ⚫ Minimum distance 2cm to conductive surfaces. (Capacitive and inductive coupling) The phase cables must not be laid as a coil. ⚫ The Phase cables must be laid twisted. (One turn every ⚫...
  • Page 8 When using motor from other suppliers, it is essential that this ⚫ is approved by Plettenberg. If the battery for the drive is not able to accept braking energy, ⚫ the motor controller will shut down, but can be damaged.

  • Page 9: Product Overview

    Product overview Type designation MST 400-160 SiC Max. continuous current [A] Controller type Motor controller Figure Technical data Weight Approx. 3.3kg Length 250mm (without connectors) Width 118mm Height 118.5mm (without screw heads) Max. rotational speed: 240,000rpm (electrical) Max. continuous power 46kW Max.

  • Page 10: Environmental And Climatic Conditions

    Continuous current 160A (at 25°C ambient temperature) 130A (at 40°C ambient temperature) Power dissipation at 160A Approx. 600W Analog inputs for accelerating 0 - 5V and braking Analog input for motor core NTC 47kOhm temperature Analog input for motor copper PT1000 temperature Digital input...

  • Page 11: Block Diagram

    Block diagram The block diagram (see ) serves to illustrate the functionality and the functional relationships of the Plettenberg motor control. Figure 1 Block Diagram Plettenberg Motor Controller Operational Manual OM_MST400-160_SiC_V9.01_EN...

  • Page 12: Installation

    Installation Safety during installation Severe, moderate, or minor injuries. Destruction or damage to the product Safety instructions from Chapter “Safety Information” must be ⚫ complied with! The battery must only be connected to the motor controller ⚫ immediately before use. During motor operation with airscrews, it is essential to ensure ⚫...

  • Page 13: Connection And Assembly

    Plettenberg motors. The motor sensor cable (Binder M9 8-pole) must be connected to the motor controller (sensor). The MST 400-160 SiC motor controller has been developed specially for the use of brushless Plettenberg electric motors with sensors. If motors from other manufacturers are used, the following points must be observed.

  • Page 14: Protection

    Figure 2: MST 400-160 SiC motor connection side Figure 3: MST 400-160 SiC battery connection side Protection As a safety disconnect switch (emergency stop) we recommend Tyco Electronics AMP + EVC135 and KILOVAC EV200 series contactor. A protective diode must be installed which, when the connection...
  • Page 15 The protective diode must be installed in parallel with the serial circuit fuse and safety disconnect switch (see Figure 4). Anode to plus motor controller and cathode to battery plus. We recommend a DSEI2X101-06A diode. A suitable pre charging circuit is necessary. Figure 4: schematic drawing protection Operational Manual OM_MST400-160_SiC_V9.01_EN...

  • Page 16: Connectors

    Destruction of / damage to the motor controller due to poor- quality or high-resistance connections. Crimping pliers can be ordered from Plettenberg as an accessory. If the motor and the motor controller are ordered together, there is an option to have the cable fully finished.
  • Page 17 M12 A coding connector Pin Designation Description Brake input Analog input 0-5V (Aux) Throttle/Impulse input Analog/Digital input 0-5V RS232 receiver signal do not connect RS232 transmitter signal Reverse switch 0V forwards / 5V reverse Signal Ground Potentiometer supply (max. 30mA) Figure 6: M12 A coding connector M8 4-pole CAN &...
  • Page 18 Phoenix contact SAC-4P- 3,0-PUR/M 8FS SH - 1521928(short straight IP67 plug with shielded AWG24 PU cable 3m) If using the RS232 of the MST 400-160 SiC we recommend the following M12 A-coding 8-pole male connectors: TE connectivity 1838275-4 (short straight IP67 solder plug)

  • Page 19: Power Cable Lengths

    Power cable lengths Destruction of / damage to the motor controller due to the connection cable between the motor controller and the battery being too long. Burns Carelessly touching hot surfaces The maximum cable length from the motor controller to the battery is dependent on the maximum phase current required.

  • Page 20: Commutation Sequences

    Commutation sequences Destruction of / damage to the motor controller due to short- circuits or incorrect wiring. Block commutation with sensors The feedback of the rotor position is implemented through three sensors integrated into the motor. The sensors are electrically offset by 120°...

  • Page 21: Mains Adapter Operation

    The throttle back must be very slow to avoid recuperation in the ⚫ mains power supply, as the MST 400-160 SiC uses active free wheel 6-step commutation. Please use the parameter “td” “rd” to limit the throttle decrease. Be careful with no load operation and attached high inertia at the shaft.

  • Page 22: Rs232 Connection

    RS232 connection Additional required material (not included): USB serial adapter (USB to RS232 Adapter) ⚫ serial cable, if required (not null modem cable) ⚫ The minimal wiring of the MST in conjunction with a PC. M12 Pin-3 RxD – SUB-D Pin-3 M12 Pin-5 TxD –...
  • Page 23 The cable length and cable quality influence the signal quality. Observe the following cable requirements! With line lengths over 2m, screened CAT5 cable must be used. The following cable types are available from Plettenberg and can be ordered by the metre: Alpha Wire 3306 SL005 sensor cable, 6 x AWG28 Alpha Wire 3308 SL005 sensor cable, 8 x AWG28 All cables fulfil the MIL-W 16878 type B specification.
  • Page 24 Read Parms FDCAN1->NBTR=0x00090903 Device ID=0x00000469, REV=0x00002003 FLASH size= 128kByte, Package=0x002 CPU ID=0x203139374156500B00200049 MST400-160 SiC V2.02 Input = CAN AnalogStop/Start/Full/BrakeMax = 500mV/ 549mV/4499mV/4499mV ImpulsStop/Start/Full = 1150µs/1200µs/1900µs Hold Time(Impuls/CAN) = 2500ms Throttle Expo For+Rev = For. Throttle Inc/Dec = For. Throttle Max/Min = 100% / Rev.
  • Page 25 RS232 interface protocol Output on the RS232 interface with control via CAN input: T=0.013V,a=0.009V,PWM= 0,U=301.5V,I= 0.0A,RPM= 0,con= 25°C,Fe= 30°C,Cu= 31°C,LV=15.3V C=0.013V,a=0.009V,PWM= 0,U=301.5V,I= 0.0A,RPM= 0,con= 25°C,Fe= 30°C,Cu= 31°C,LV=15.3V F=4.815V,a=0.014V,PWM=1000,U=300.2V,I=198.4A,RPM= 3442,con= 42°C,Fe= 57°C,Cu= 66°C,LV=15.3V Index Description Unit C/F/R Command input T/F/R Value throttle input Volt analog Aux input / Brake...
  • Page 26 The following 1-byte commands are possible in serial operation (only possible if no CAN communication is present): Command Description Changeover to serial RS232 input Changeover from serial to analog input (Potentiometer) Changeover to CAN input Forward Reverse Stop Brake 100% PWM (max.) 90% PWM 80% PWM 70% PWM...

  • Page 27: Can Connection

    CAN connection Basic knowledge of CAN is assumed! Only CAN2.0 protocol is supported. CAN 2.0A specification of the motor controller: 100kbit-1Mbit 11bit Identifier All telegrams have 8 data bits. It exists one command message from the main control to the MST 400-160 SiC and two status/feedback messages from the MST 400-160 SiC to the main control.
  • Page 28 CAN_ID_RX 0x510 // DLC8 fast status from the MST Status 1 message every 10ms Byte Description bit0 = 0: Inverter off, bit0 = 1: Inverter on bit1 = 0; Angle control, bit1 = 1; PWM control bit2 = 0: Reverse direction, bit2 = 1: Forward direction bit3: toggle signal feedback bit4 = 1: Inverter output over current fault bit5 = 1: Inverter battery over voltage fault...
  • Page 29 CAN_ID_RX 0x511 // ISO-TP Controller Name & Version Status 1 message every 1000ms The MST 400-160 SiC sends the MST name & Version every 1000 ms via the CAN port in ISO-TP format. Operational Manual OM_MST400-160_SiC_V9.01_EN...

  • Page 30: Configuration

    Configuration After you have put the motor control unit into operation, you could have to make various settings via the RS232 connection, this is only possible if no CAN communication is present. This chapter describes the configuration procedure and provides an overview of the steps to be carried out and the specified order.
  • Page 31 5 Byte commands Command Description Value range Default Unit RPM limit 001 to 240 [1000rpm] Current limit 010 to 260 Input current limit 010 to 260 Undervoltage 010 to 300 Overvoltage 024 to 400 Motor copper temperature 070 to 255 [°C] limit Motor iron temperature limit...
  • Page 32 You need to save the values by the command wp if you want to store the parameters to the non-volatile memory of the MST 400- 160 SiC. To save and exit the adjust mode, send a wp To exit Adjust mode without saving, send a e, then the MST 400- 160 SiC leaves the Adjust mode and is still in RS232 command mode, you can switch from the RS232 command mode to CAN by sending a c.

  • Page 33: Expanded Description

    RPM limit Expanded description revolutions per minute The rotational speed limitation restricts the shaft speed by the controller throttling back. This is primarily intended to protect the motors and airscrews so that the highest permissible rotational speed of the motor or the airscrew will not be exceeded. Attention! First set the number of pole pairs and then the rotational speed limiting.
  • Page 34 Overvoltage limit over voltage limit The overvoltage limit function prevents the input voltage exceeding the chosen limit voltage. This causes the controller to switch of the power stage to protect the battery and the controller. Motor copper temperature limit motor copper temperature limit The temperature limit of the motor copper can be set between 70°C and 200°C.
  • Page 35 Throttle decrease forward throttle decrease The throttle decrease determines how quickly the controller follows a decrease in throttle. The higher the value, the faster the controller reacts to the throttle decrease. Throttle restriction forward throttle limit The throttle limit restricts the maximum throttle position. Minimum throttle forward throttle minimum Minimum throttle forward describes the starting throttle, at which...
  • Page 36 Brake acceleration brake increase The brake increase determines how quickly the controller follows an increase in braking. The higher the value, the faster the controller reacts to the braking decrease. Brake deceleration brake decrease The brake decrease determines how quickly the controller follows a decrease in braking.
  • Page 37 Stop analog input analog halt This parameter defines the voltage value at the analog input for 0% throttle. Attention! If this value is set too low, a throttle grip with a Hall sensor could cause the control unit not to detect a stop after switching on the supply voltage and not release it.
  • Page 38 V-Factor Angle control v-Factor angle control The V-factor Angle control parameter is the speed compensation factor of the angle control loop. Allowed values are from 0 to 999, a good value to begin the optimization of the control loop is 0. It can be used to reduce the maximum speed in angle control, another option is to use the RPM Limit to limit the maximum speed during movement.
  • Page 39 Hold time hold time The hold time is the hold time in 1/10 seconds, it defines the time in which the controller holds the throttle / angle/POS values before switch off the output stage. Examples of the hold time 600 = 60.0s 100 = 10.0s 050 = 5.0s 025 = 2.5s...
  • Page 40 CAN Command Address can command address The CAN command Address is changed in Hex numbers. The address must be different from the CAN fast status address and different from the CAN slow status address. Only valid address will be accepted. The new CAN command Address will used after the next power up.

  • Page 41: Check Display

    Check display The motor controller has a status LED. This is located on the connection side. LED behaviour Explanation Error message LED illuminates No fault steadily LED flashes 1x Undervoltage 0x0001 LED flashes 2x Overvoltage 0x0002 LED flashes 3x Overcurrent 0x0004 LED flashes 4x Controller...

  • Page 42: Protective Functions

    Protective functions Overvoltage protection With input voltage over 370V, the controller shuts down due to overvoltage. If the voltage exceeds 400V, the controller could be damaged. Undervoltage protection If the LV input voltage is below 10V, the controller shuts down in order to guarantee the stability of the internal power supply voltages.

  • Page 43: Repetitive Handling

    Plettenberg Elektromotoren GmbH & Co. KG Rostocker Straße 30 34225 Baunatal, Germany T: +49 (0) 56 01 97 96-0 www.plettenbergmotors.com...

  • Page 44: Eu Declaration Of Conformity

    • Low Voltage Directive 2014/35/EU Appendix IV • RoHS Directive 2011/65/EU Appendix I Plettenberg Elektromotoren GmbH & Co. KG Rostocker Straße 30 34225 Baunatal, Germany hereby declares, as the manufacturer, that the articles and objects described below comply with the provisions of the relevant community harmonisation legislation referred to above.
  • Page 45 The sole responsibility for drawing up this declaration of conformity lies with the manufacturer. This declaration of conformity will lose its validity when the product is converted, extended, or altered in any other manner without the express consent of Plettenberg Elektromotoren GmbH &...

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