Gen4_Product_Manual_V3.0.pdf

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Gen4
Applications
Reference
Manual
Document no:
177/52701
Rev. 3.0
Sevcon Ltd
Kingsway South
Gateshead, NE11 0QA
England
Tel +44 (0)191 497 9000
Fax
+44 (0)191 482 4223
sales.uk@sevcon.com
Sevcon, Inc.
155 Northboro Road
Southborough, MA 01772
USA
Tel (508) 281 5500
Fax (508) 281 5341
sales.us@sevcon.com
Sevcon SA
12 Rue Jean Poulmarch
95100 Argenteuil
France
Tel +33 (0)1 34 10 95 45
Fax +33 (0)1 34 10 61 38
sales.fr@sevcon.com
Sevcon Japan
4-12-1 Shinbashi
Minato-Ku, Tokyo 105-0004
Japan
Tel +81 (0) 3 (5408) 5670
Fax +81 (0) 3 (5408) 5677
sales.jp@sevcon.com
Sevcon Asia Ltd
4th Floor, Eun-Hyae Building
463-1, Sang-dong
Wonmee-gu, Bucheon City
Kyunggi-do 420-030
Korea
Tel +82 (0)32 215 5070
Fax +82 (0)32 215 8027
sales.kr@sevcon.com
www.sevcon.com
Table of Contents
Chapter 1:
Introduction
1-1
About Gen4 documentation.......................................................................... 1-2
This version of the manual ............................................................................................................................... 1-2
Copyright............................................................................................................................................................... 1-2
Scope of this manual ........................................................................................................................................... 1-2
Related documents .............................................................................................................................................. 1-2
Drawings and units ............................................................................................................................................. 1-2
Warnings, cautions and notes .......................................................................................................................... 1-3
Product identification label ........................................................................... 1-4
Technical support ........................................................................................... 1-4
Product warranty ............................................................................................ 1-4
Chapter 2:
About the Gen4
2-1
Introduction ..................................................................................................... 2-2
Standard features and capabilities ............................................................... 2-2
Available options ................................................................................................................................................. 2-2
Intended use of the Gen4 .................................................................................................................................. 2-2
Available accessories ........................................................................................................................................... 2-3
Overview of a truck drive system ................................................................ 2-4
Principles of operation ................................................................................... 2-4
Functional description ....................................................................................................................................... 2-5
Interfaces ............................................................................................................................................................... 2-6
Master-slave operation ...................................................................................................................................... 2-6
Torque mode......................................................................................................................................................... 2-7
Speed mode ............................................................................................................................................................ 2-7
Safety and protective functions .................................................................... 2-8
General ................................................................................................................................................................... 2-8
On-Highway Vehicles ........................................................................................................................................ 2-9
Fault detection and handling ........................................................................................................................ 2-11
Chapter 3:
Installation
3-1
Mounting Gen4 ............................................................................................... 3-2
Orientation ............................................................................................................................................................ 3-2
Clearance for LED access .................................................................................................................................. 3-2
Mounting hole pattern ....................................................................................................................................... 3-2
Equipment required: ........................................................................................................................................... 3-2
Thermal grease application .............................................................................................................................. 3-3
Cooling requirements..................................................................................... 3-4
EMC guidelines ............................................................................................... 3-5
Connecting power cables............................................................................... 3-6
Battery and motor connections ........................................................................................................................ 3-6
Cable sizes ............................................................................................................................................................. 3-6
On-board fuse mounting ............................................................................... 3-8
Fuse rating and selection................................................................................................................................... 3-9
Signal wiring.................................................................................................. 3-10
Signal wire sizes ................................................................................................................................................ 3-10
CANbus termination........................................................................................................................................ 3-10
Signal connections ........................................................................................ 3-11
Chapter 4:
Specification
4-1
Electrical ........................................................................................................... 4-2
Input voltage ........................................................................................................................................................ 4-2
Output protection ................................................................................................................................................ 4-2
Output ratings ...................................................................................................................................................... 4-3
CAN interface ....................................................................................................................................................... 4-4
Control inputs and outputs ............................................................................................................................... 4-4
Isolation ................................................................................................................................................................. 4-4
EMC ........................................................................................................................................................................ 4-5
Regulatory compliance....................................................................................................................................... 4-5
Mechanical........................................................................................................ 4-6
Operating environment ..................................................................................................................................... 4-6
Shock and vibration ............................................................................................................................................ 4-6
Weight.................................................................................................................................................................... 4-6
ii
Dimensions ............................................................................................................................................................ 4-7
Size 2 models ........................................................................................................................................................ 4-7
Size 4 models ........................................................................................................................................................ 4-7
Chapter 5:
System design
5-1
Sizing a motor.................................................................................................. 5-2
Information required about the application .................................................................................................. 5-2
Motor maximum speed ...................................................................................................................................... 5-2
Torque required between zero and base speed ............................................................................................ 5-2
Torque required at maximum speed .............................................................................................................. 5-3
Continuous power rating ................................................................................................................................... 5-3
Peak power rating ............................................................................................................................................... 5-4
Selecting the Gen4 model ............................................................................. 5-4
Current and power ratings considerations ................................................................................................... 5-4
Power output restrictions at motor and drive operating temperature limits...................................... 5-4
Circuit configuration .......................................................................................................................................... 5-5
Single traction wiring diagram ........................................................................................................................ 5-6
Single pump wiring diagram ............................................................................................................................ 5-7
Twin motor systems ...................................................................................... 5-8
Auxiliary components .................................................................................... 5-8
Main contactor ..................................................................................................................................................... 5-8
35 Way AMPSeal Connector Kit .................................................................................................................... 5-8
Emergency stop switch ...................................................................................................................................... 5-8
On-board fuse ....................................................................................................................................................... 5-8
Key switch fuse F2 ........................................................................................................................................... 5-10
Motor speed sensor (encoder) ....................................................................................................................... 5-10
Motor commutation sensor (U, V, W and sin-cos) ................................................................................. 5-11
Initial power up sequence ............................................................................ 5-14
Checks prior to power up ............................................................................................................................... 5-14
Checks after power is applied ........................................................................................................................ 5-14
Chapter 6:
Configuration
6-1
Introduction ..................................................................................................... 6-2
Doc. # 177/52701
Rev. 3
iii

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