Cascadia PM500 Hardware User Manual
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Cascadia PM500 Hardware User Manual

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7929 SW Burns Way
Phone: 503 344-5085
Suite F
Wilsonville, OR
sales@cascadiamotion.com
PM/RM/CM200
Hardware User Manual
Revision 3.3
0A-0001-01
Everything you need to know to install, set up, and calibrate the PM and
RM family of AC drives on asynchronous and PM synchronous motors
in your Electric or Hybrid vehicle
1/14/2021
RMS PM Hardware User Manual
1 of 54

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  • Page 1 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com PM/RM/CM200 Hardware User Manual Revision 3.3 0A-0001-01 Everything you need to know to install, set up, and calibrate the PM and RM family of AC drives on asynchronous and PM synchronous motors in your Electric or Hybrid vehicle 1/14/2021 RMS PM Hardware User Manual...

  • Page 2: Table Of Contents

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Table of Contents SAFETY FIRST: ......................3 FUNCTIONAL OVERVIEW: ..................4 INSTALLING THE PM DRIVE: ..................5 3.1 Liquid Cooling Connections: ........................7 3.2 PM100/PM150 External Signal Connectors: ..................10 3.2.1 J1 –...

  • Page 3: Safety First

    CAUTION this User’s Manual. Safety is entirely the responsibility of the installer of this equipment. Cascadia Motion has done everything it can to ensure that the traction controller itself conforms to international standards for safety. This does NOT mean that your installation will be safe, or that it will not interfere with other systems on board your vehicle.

  • Page 4: Functional Overview

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com the specifications for this product and that it meets international safety standards when used in accordance with the instructions in this Manual. 2. Functional Overview: The PM controller family is intended as a traction controller for EV and HEV drive systems, and includes both the motor control function and a rudimentary vehicle controller strategy in the same box.

  • Page 5: Installing The Pm Drive

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3. Installing the PM Drive: The PM controller has 4 mounting locations, one at each corner. Mounting orientation is not critical. The controller should be mounted in a location that is not exposed to direct spray from water.
  • Page 6 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com PM150 Dimensions – top and side views 1/14/2021 RMS PM Hardware User Manual 6 of 54...

  • Page 7: Liquid Cooling Connections

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.1 Liquid Cooling Connections: The controller must be cooled by passing liquid through it. The controller includes two ports to be used for liquid cooling. The fluid direction for the PM250 inverter is marked into the case of the inverter.
  • Page 8 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com RM300, Custom O-ring port. The RM300 comes standard with an adapter that has a 25.4mm / 1 inch hose barb. The cooling port adapters are included in kit p/n G1-0031-01. CM200, SAE ORB -06 RM100 Coolant Port Options (Does not apply to PM100/PM150/PM250/RM300/CM200) ARaymond NT100 / J20 Straight, CM Kit G1-0023-01...
  • Page 9 There are many ways that coolant flow could be measured. A flow sensor could be added to the cooling loop. Often these types of sensors produce a pulse output. To read the pulse output would require the use of a device to interpret this signal (Cascadia Motion does not supply this).

  • Page 10: Pm100/Pm150 External Signal Connectors

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Another option is to monitor the pressure in the cooling system. Typically the inverter would be placed near the end of the cooling loop, just before the radiator. So a typical cooling loop might look like pump outlet, inverter, radiator/reservoir, pump inlet.
  • Page 11 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com GEN2 AOUT Analog Output 0 – 5V GEN3 RTD2 1000 Ohm RTD Input GEN2 Available for user-defined AIN6 Analog Input 6 0-5V GEN3 functionality RTD3 1000 Ohm RTD Input GEN2 Available for user-defined RLY6...

  • Page 12: J2 - 23P Ampseal Plug 770680-1 With Crimp Contact 770854-1

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com DIN3 Digital Input 3 - STG Brake Switch DIN4 Digital Input 4 - STG REGEN Disable Input (if used) DIN5 Digital Input 5 – STB Ignition Input (if used) DIN6 Digital Input 6 - STB Start Input (if used)

  • Page 13: Pm250 External Connections

    J2 contains mostly signals that would go to the vehicle harness. J1 contains mostly signals that would go to the motor. A connector kit that contains both J1 and J2 can be purchased from Cascadia Motion as G1-0016-01. J1 Connections...
  • Page 14 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com RTD1N RTD1 Negative Encoder GND HALL C Hall Input C HALL A Hall Input A For use with certain motors that support Hall encoders. ENCZ Encoder Channel Z input (Index) ENC A Encoder Channel A input...
  • Page 15 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com CANB_H CAN Channel B Hi CANB_L CAN Channel B Low RLY2 Hi-Side Relay Driver Main Relay Drive RLY3 Lo-Side Relay Driver OK Indicator Drive / 12V Power Relay Drive Available for user-defined RLY5 Hi-Side Relay Driver...

  • Page 16: Rm100 Signal Connections

    Tyco part number 776164-1, mating contact is 770854-3 for 16-20 AWG wire. Must use Tyco crimper 58529-1 (AMP Pro-Crimper II). A kit of the connector and contacts is available from Cascadia Motion as part number G1-0021-01. Pin # Pin Name...
  • Page 17 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com CANB_H CAN Channel B Hi Secondary CAN Communications channel, currently not used. CANB_L CAN Channel B Low CAN Shield Connection of CAN cable shield. RS-232 Transmit Used for RMS GUI and C2prog RS-232 Receive Used for RMS GUI and C2prog RS-232 Ground...

  • Page 18: Rm300 Signal Connections

    776273-1, mating contact is 770854-3 for 16-20 AWG wire. Must use Tyco crimper 58529-1 (AMP Pro-Crimper II). A kit of the connector and contacts is available from Cascadia Motion as part number G1-0030-01. “I/O” Connector – Input / Output Connector...
  • Page 19 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com BATT+ 12V/24V Input Redundant connection can be used if desired of needed for additional current capability. BATT_RTN 12/24V Return Normally tied to vehicle power system chassis. BATT_RTN 12/24V Return Redundant connection can be used if desired of needed for additional current capability.
  • Page 20 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com RS-232 Transmit Used for RMS GUI and C2prog DIN1 Digital Input 1 – STG Forward Enable Switch RLY1 High Side Driver If pre-charge function is used this (Pre-charge) output serves as the pre-charge contactor output.

  • Page 21: Pm500 Signal Connections

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Resolver SIN winding Resolver COS winding RTD1+ Positive side of RTD1 Temperature Sensor software configurable for PT100 or PT1000. Resolver excitation SHIELD Resolver Cable Shield Resolver cable shield should connection connected to this pin.
  • Page 22 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com M1_CANA_H CAN Channel A High M1_CANA_L CAN Channel A Low M2_RLY6 Hi-Side Relay Driver M1_RLY1 Hi-Side Relay Driver Pre-Charge Contactor Drive AGND Analog Ground For both M1 and M2 AIN3 Analog Input 3 0-5V Brake Pedal...
  • Page 23 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com AI or i M2_TXD RS-232 Transmit AJ or j M2_CANA_LO CAN Channel A Low AK or k M1_TXD RS-232 Transmit AM or m M1_RXD RS-232 Receive AN or n M2_XDCR_PWR +5V @ 80mA max M1_/PROG_ENA Serial Boot Loader enable...

  • Page 24: Cm200 Signal Connector

    Blind plug, CP 0.6: Molex 643251010 Blind plug, CP 1.5: Molex 643251023 Please refer to the Molex web site for details on the connector. Cascadia Motion highly recommends the use of the factory crimper for the contacts. Note that this connector has two different contacts sizes, A1 thru K4 are the CP 0.6 size, L1 thru M4 are the CP 1.5 size.
  • Page 25 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com I/O Connector – 48 pin Pin # Pin Name Description Notes /SIN Resolver Sine winding - CANA_H CAN Channel A High CAN high Port A RTD1P RTD1 Positive Allows connection of PT100 or PT1000 RTD for temperature monitoring.
  • Page 26 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Pin # Pin Name Description Notes /EXC Resolver excitation return CANB_H CAN Channel B High DIN2 Digital Input 2 - STG Reverse Enable Switch (if used) RS232_GND RS232 Ground Normally connected to pin 5 of DB9 connector.
  • Page 27 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Pin # Pin Name Description Notes RLY1 High Side Driver If pre-charge function is used this output serves as the pre-charge contactor output. RLY2 (Main) High Side Driver If the pre-charge function is used this output serves as the main contactor output.

  • Page 28: External Power Connections

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.8 External Power Connections: 3.6.1 DC+ / DC-: DC/Battery power is provided to the controller via two wire ports located at the rear of the controller (PM100 and PM150 shown) or front (PM250/RM100/RM300).
  • Page 29 References in documentation to Phase A refer to Phase U, Phase B to Phase V, and Phase C to Phase W. The PowerLok™ 300 is available for many different sizes of wires. Contact Cascadia Motion for more information about ordering connectors/cables. Please refer to the RM100 HV Connection Manual for more details on how to connect to the RM100.

  • Page 30: Phase A / Phase B / Phase C

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.6.2 Phase A / Phase B / Phase C: Phase A, Phase B, and Phase C are wired to the motor. It is important the 3 wires be wired to the motor such that they give the proper direction of rotation.
  • Page 31 0.9 seconds for the pre-charge to complete. Cascadia Motion can provide the following parts if needed. Reference the following: • Pre-charge Relay (30A, 12V COIL): p/n 77-0026 for DX inverters •...

  • Page 32: Main Contactor

    Cascadia Motion has successfully used the following: Gigavac GX14BA, Cascadia Motion p/n 77-0035. The contactor must be rated to handle DC voltage, AC only rated contactors and relays must not be used.

  • Page 33: Power

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com PM100DX/PM100DXR 120K ohms 440uF 158 s PM100DZ/PM100DZR 120K ohms 280uF 101 s PM150DX/PM150DX 120K ohms 880uF 317 s PM150DZ/PM150DZR 120K ohms 560uF 202 s PM250DZ 188K ohms 645uF 364 s PM250DX 188K ohms...
  • Page 34 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com pin list for pin designation). For normal applications only one pin is necessary. If necessary more than one pin can be used for applications that push higher 12V or GND currents through the controller.

  • Page 35: Grounding

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com RM300DX @ 24V, non-operating TBD A RM300DX @ 24V, operating TBD A RM300DZ @ 12V, non-operating TBD A RM300DZ @ 12V, operating TBD A RM300DZ @ 24V, non-operating TBD A RM300DZ @ 24V, operating TBD A...

  • Page 36: Typical Application Wiring Diagram

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.9 Typical Application Wiring Diagram: The wiring diagrams covers following areas: • Starter & Power Generation • Precharge Circuit • Motor & Encoder • Transmission Control • RS232 Programming •...

  • Page 37: Controller 12V Power Wiring

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.7.1 Controller 12V Power Wiring This circuit can be configured in two different ways: NOTE: RM100 can only use the Simple ON/OFF Configuration. Simple ON/OFF Configuration In this configuration an external switch or controller is responsible for control of the 12V power.
  • Page 38 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Typical Ignition Configuration (PM Products Only) In this configuration an external, user supplied relay, diode, and switch are used to control power. When the Ignition Switch is put into the IGN position power is supplied through the diode.

  • Page 39: Pre-Charge Circuit

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.7.2 Pre-charge Circuit Note: Only PM100/PM150 Connections shown, refer to PM250/RM100 connector for equivalent pins. 1/14/2021 RMS PM Hardware User Manual 39 of 54...

  • Page 40: Analog/Digital Vehicle Control

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.7.3 Analog/Digital Vehicle Control If using VSM Mode then analog / digital signals can be used to control the operation of the inverter. The limited I/O of the RM100 prevents this functionality. XDCR_PWR Accel AIN1...

  • Page 41: Motor Control (Typical Wiring)

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.7.4 Motor Control (Typical Wiring) Only PM100/PM150 Pins are shown. Refer to motor specific manuals for details. 1/14/2021 RMS PM Hardware User Manual 41 of 54...

  • Page 42: Can Interface

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 3.7.5 CAN Interface The controllers have one active CAN interface CAN A. The controller contains hardware to support a second CAN interface (CAN B), but currently only CAN A is active. CAN B is reserved for future use.

  • Page 43: Encoder Interface (Not Included On Rm100/Rm300)

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Note: Only PM100/PM150 Connections shown, refer to PM250/RM100/RM300 connector descriptions for equivalent pins. 3.7.7 Encoder Interface (Not included on RM100/RM300): The induction motor control software currently mandates the use of a position encoder on the motor.

  • Page 44: Resolver Interface

    Digital Converter (RDC). For RM and Gen 5 the target SIN/COS voltage is 3.15Vpk-pk ± 27%. For CM200 the target SIN/COS voltage is dependent on how the RDC is configured. Contact Cascadia Motion for more information. 1/14/2021 RMS PM Hardware User Manual...

  • Page 45: Vehicle Interface Setup

    7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 4. Vehicle Interface Setup 4.1 Analog Inputs: There are 4 analog inputs on GEN 2 units (AIN1-4), 6 analog inputs on GEN 3 units (PM100/PM150/PM250) as AIN1-6, and 3 analog inputs on the RM100 (AIN1-3) and 5 analog inputs on the RM300 (AIN 1-4 and AIN6).
  • Page 46 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Not assigned. For some motor types may be assigned to a AIN4 secondary motor temperature. AIN5 Not assigned. AIN6 Not assigned. The CM200 provides programmable pull-up resistors (1K) on AIN1, AIN2, and AIN3. These pull-ups can be turned on and off via software.
  • Page 47 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com The controller uses two-wire type RTDs. One side of the RTD should be connected to the RTD input. The other side should be connected to Analog Ground or the dedicated RTD ground pin (RTDxN).
  • Page 48 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 4.2 Digital Inputs: There are up to 8 digital inputs for general interface to the vehicle and for feedback from external contactors and switchgear as required in the application. Some inputs are “Switch To Battery”...
  • Page 49 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com The vehicle control system software currently assigns these inputs as follows: Input Type Signal Name Function This input should be connected to a switch that grounds DIN1 FWD_ENA this input when the user is commanding forward direction.
  • Page 50 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Description Parameter Value Switch to Ground Inputs ( DIN1-4 ) Voltage level for “ON” <0.9 V STG-ON Voltage level for “OFF” >4.2 V STG-OFF Pull-up resistor to 5V 2.4 kΩ...
  • Page 51 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com 4.3 Digital Outputs There are up to 6 digital outputs available. See the table below for more specifics on availability across each model. There are two types of outputs available depending on the particular model.
  • Page 52 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com The table below documents the availability of each output type across the different inverter models. Gen3 & Gen5 Input Type RM100 RM300 CM200 PM100 (Gen2) PM100/PM150/PM250 RLY1 RLY2 RLY3 RLY4 RLY5...
  • Page 53 7929 SW Burns Way Phone: 503 344-5085 Suite F Wilsonville, OR sales@cascadiamotion.com Revision History Version Description of Versions/ Changes Updated by Date Azam Khan 9/18/12 Added that RTDs should be connected to analog ground. • Updated diagrams that show the dimensions of PM100 and PM150 drives.
  • Page 54 Updated Digital outputs section to show which are available. Clarified analog inputs availability. Chris Brune 4/2/2019 Updates to include the RM300 Update formatting for Cascadia Motion. Add PM500 Chris Brune 11/13/2020 information. Add L100 information. Travis Gintz 1/14/2021...

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