Sevcon_MOS90_DC_Traction_and_Pump_Controller_datasheet1-1734225600.pdf
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PRODUCT
Tech/Ops
BULLETIN
MOS90 RANGE
The new Sevcon MOS Range of D.C. Traction
and Pump Controllera combines the latest
state-of-the-art Mosfel and Microprocessor
technologies.
The result is a highly efficient and flexible
range of controUers for small to medium sized
electric vehicles such as pallet. warehouse.
reach and low capacity fork 11ft trucks plus
personnel carriers.
The powerful microprocessor used in the
MOSSO range offers advanced features
previously unavailable in such a compact
controller.
PRODUCT
RANGE
The microprocessor software facilities within the MOSOO
range allow. significant number of features to be bullt
into the Controller ellminating additional hardware.
FEATURES:
Tripk
faibafp
Contactor chopping across
vo!tagp rangp
Built-in diagnostic L.E.!).
Environmental protection
Unckrvoltage
protf'ctioll
Ramp start
OvertelllpcrattllT l'utba('k
COlllroHe[ input protedl(lll
Built -in contador
",uppressioll
Mllllipk
i\{'(Til'ratO[
inputs
VOLTAGE
MAXIMUM
CURRENT
24-4BV
1BO-600
AMPS
OPTIONS:
At'('t']('rat(H" billlre
c\ejcctiOl]
Spc('d Clltback
USER/MANUFACTURER BENEFITS:
Quiet operallon
Increased battery shift life
Increased motor life
Increased conlaelor tip life
Simple Installation plus reduced set up time
Reduced maintenance troubleshooting time
Reduced peripheral hardware- costs
Waterproof
Suitable for cold storage applications
Designed to meet
U,L.
and
E.E.C.
Standards
Bypa,.,s
Field WeakeJlillg
Bdly switch control
Seat
switch
lilller
Hev{'rs{' battery protection
i'uw{'r s\{'er delay
Constant speed (paknt
pending)
Pump controllers (up to
~l
programmahlt' speeds)
Sevcontrol
I)
Te-ch/Ops
•••••• 11111111111. .
SpecificatiOilS
('ontitlued
overleaf
Sev{'Qn
r-l=~~~========================~~~~~~m
Sevcontrol
. . . .lllnIDIlI
0
1I11111111111••
n••••
IOJIUO:>A8
S
O.27~
e
24/36v
1A0590 °A"
_L_
mm
Inch
mm
M
13J
174
17'
l40mm
5. 1"
I,oh
5.24
5.24
6.BS
1.40590 "6"
1010590 ·C·
24/-48V
213 8.38
213 8..38
254 10.00
258 10.16
283 11.14
lJ6 13.23
'"
1.40S90 "6"
1.10590 ·C·
MOS90 "D"
7.00
20J 8.00
256
10.07
Outline Specification: MOS90 RANGE
Volu,e:
Current:
ContiD.uous Current:
Temperature:
Range:
OPTIONAL EgUIPMENT:
CaHbrator Unit:
MOS9OA
24-4SV
ISOA
7M
OperatlngAmblent
Storage
MOS90B
24-4SV
27M
12M
-30°C+4QOC
-40"C + 9O"C
MOS9OC
24-4SV
400A
17M
MOS90D
24-4SV
600A
22M
Provide.
dJJltal
adjutment of:
Current limit
Plugging level
Accelerator delay
Creep speed
Maximum
&
cutback speed
Bypass
&
field weakening levels
Power steer timer
Seat switch timer
Uft speeds (pump controllers)
Aleo act. . .
Dilltal
Volt Meter me_1II'InI:
Battery volts
Motor volts
Motor current
Heatslnk temperature
Vehicle diagnostics
AdjUllter
Module:
Acceuorlea:
------- Note:
Provides analog adjuatment of controller
parameten
Full
range of accelerators. contactors and contactor pane.. etc.
Sevcon i. constantly atrivln& to improve ita
product. and reserves the rlfht to alter
speclflcation. without Dotice.
This product bulletin is an outUne
specification only. For specific appUcation
data, tbe
full
enatneerlng specifications
available from 8eVCOD should
be
ued.
Tech/Ops
Sevcon Ltd
Gateshead
England NEll
OQA
Tel: (0191) 487 8516
Telex: 53328
Fax: (0191) 4.824223
Sevcon SA
Paris
France
95100
Tol:
(1)
3410 95 45
Telex: 698505
F",,: (1)_3410 6138
Sevcon Inc.
Burlington, Mass
U.SA 01803
Tel: (617) 272 3612
Fax: (617) 272 1953
Prmted
In
U.
K. I P&S 12191
SECTION 1
CONTENTS
SECTION
INTRODUCTION & CONTENTS
SAFETY
TECHNICAL SPECIFICATIONS
FEATURES
INSTALLATION & MECHANICAL DRAWING
POWER WIRING - TRACTION
CONTROL & ACCELERATOR WIRING - TRACTION
ADJUSTER
&
CALIBRATOR
DIAGNOSTICS
PUMP CONTROLLER
APPENDIX I
APPENDIX II
APPENDIX III
APPENDIX IV
APPENDIX V
APPENDIX VI
APPENDIX VII
APPENDIX VIII
CALIBRATOR - MEASUREMENT
&
DIAGNOSTICS
FAULT FINDING FLOW CHARTS
SAFETY BUnON - METHOD OF OPERATION
APPLICATIONS GRAPHS
CONTACTORS AND FUSES
SPARE PART NUMBERS
SAMPLE PUMP CONTROLLER WIRING
SAMPLE TRACTION CONTROLLER WIRING
2
3
4
5
6
7
8
9
10
APP.I
APP.II
APP.III
APP.IV
APP.V
APP.VI
APP. VII
APP. VIII
This manual covers all MOS90 units produced from serial no. 0591---- onwards.
units, please consult Sevcon.
For details of earlier
Sec. 1-1
Rev5.1/92
THE
SEVCON MOS90 CONTROLLER
1.1
Thank you for buying a controller from the SEVCON family of MOS90 pump and traction
controllers. These controllers are designed with you the user in mind. They provide easy
installation, many new features not available before on DC motor controllers, and diagnostics of
drive system faults. They are designed and manufactured to the highest quality standards for long
life and low failure rate. Both pump and traction controllers are available which use the most
modern and efficient semiconductors available (MOSFETS), coupled with a state of the art
microprocessor system that allows more features per controller than ever before.
1.2
This manual has been specially prepared to make installation of your MOS90 controller easy and
trouble-free. It outlines all the major facilities available with this outstanding new controller.
1.3
If you have any questions or suggestions about this manual please contact any of the subsidiaries
of Tech/Ops Sevcon where our engineering staff will be happy to provide you with all possible
assistance.
Sec.1-2
Rev4.11.91
SECTION 2
SAFETY
2.1
Electric vehicles can be dangerous. All testing, fault finding and adjustment should be carried out
by competent personnel. Where possible, the drive wheels should be off the floor and free to rotate
during the following procedures THE VEHICLE MANUFACTURERS MANUAL SHOULD BE
CONSULTED BEFORE ANY OPERATION IS ATTEMPTED.
The MOS90 controller contains a triple failsafe system to give the highest level of safety. If the
green diagnostic light emitting diode (LED) is not illuminated or flashes on and off, the safety circuit
has tripped and the truck may not drive.
To ensure continued safety of the MOS90 system, the failsafe circuit should be checked whenever
the truck is serviced. The maximum period between checks should not exceed 3 months.
BATTERY MUST BE DISCONNECTED BEFORE REPLACING OR ATTEMPTING ANY REPAIRS OF
THE CONTROLS.
Pin 13 must be grounded if not being used as speed control input.
Note for 24/48v units without a line contactor fitted, never connect a battery to the controller with its
vent caps removed, as an arc may occur due to the controller's internal capacitance when it is first
connected.
Before handling controller cables on 24-48v units, disconnect battery and connect B
+
and B-
terminals via a t OR ohm 25 watt resistor to discharge the internal capacitor.
2.2
2.3
2.4
2.5
2.6
2.7
FAILSAFE
2.8
2.9
CHECK
Ensure drive wheels are clear of the floor and free to rotate.
Switch on, release brake and select drive, wheels should rotate and green LED on controller give a
steady illumination.
Switch off, disconnect battery and connect A and B- terminals with 10mm
2
or greater, cable,
ensure no other fault that would allow drive.
Reconnect battery, switch on key with direction in neutral. The LED should flash 3 times. Select a
direction and check that direction contactors do not close and wheels do not rotate.
Switch off at key, remove A/B- connection switch on at key. Reselect power up sequence, LED
should now illuminate and truck wheels rotate.
IF THE TRUCK DRIVES IN 2.11, THE CONTROLLER IS FAULTY AND MUST BE REPLACED.
2.10
2.11
2.12
2.13
NOTES:
2.13.1
As blowout magnets are fitted to contactors, ensure that no magnetic particles can
accumulate in the contact gaps and cause malfunction. Ensure that contactors are wired
with the correct polarny to their power terminals (as indicated by the
+
sign on the top
moulding).
The MOS90 MUST NOT be used with permanently connected on-board chargers or
damage to the system may result.
2.13.2
Sec.2-1
Rev4.11/91
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