edrive 400 motor controller Datasheet V1.0

Transcription

1 edrive 400 motor controller Datasheet V1.0 Date

2 General Advanced motor controller for e-drive systems supporting o PMSM (permanent magnet synchronous motor) o PMSM with field weakening o Induction motor with field weakening o BLDC (driven with sinusoidal current) Optimized for up to 45 kw continuous motor drives Canopen compatible (profile DS402) Multiple rotor angle sensors supported Galvanic isolation between control and power stage Galvanic isolation between power supply and control Motor control features True sinus mode motor currents with hall sensors (observer for rotor angle) Vector current control minimizes torque ripple and vibrations of motor. No motor audible noise. Vector current control with inexpensive hall sensors in motor. Four quadrant control (forward/backward with regeneration). Field weakening for PMSM and induction motors. Automatic entry into filed weakening zone when synchronous RPM is reached. Integrated velocity & position regulator. Throttle input controls motor torque, motor velocity or combination of both. Latest option gives similar control response as internal combustion engine. Synchronous rectification, ultra low drop, fast PWM to achieve efficiency > 97 %. Rotor angle sensors Supported rotor angle sensors o Standard three hall sensors with 60 or 120 degree configuration o Absolute digital SSI encoder with RS422 interface (recomended model RM44SC0013B20F2F10) o Resolver o 5V analogue sin/cos (not recomended for high pole count motors) o AB incremental encoder (only for induction motors) Auto tunning for measuring rotor angle sensor offset and direction Protection functions Maximum motor current protection. Thermal protection of motors (input for temperature sensor in the motor). Gradual decrease of maximum motor current when motor temperature reaches limit. Controller thermal protection. Gradual decrease of maximum motor current. Rotor angle sensor failure detection. Low battery protection with battery voltage measurement. Gradual decrease of maximum current when battery voltage indicates empty battery. High voltage battery protection. Prevents over voltage situations when regenerating with full or damaged battery. Motor stall protection limits motor current if motor is blocked for certain time. Motor maximum RPM protection. Decrease motor current if maximum is reached.

3 Input for Emergency stop button Optional throttle out of range detection for detecting of damaged throttle or broken wire. Full self-test at start. Check all MOSFET-s, motor connection and battery connection Logging functionality Internal FLASH memory for storing last 2 hours of all important values (battery voltage, battery current, motor current, speed, motor and controller temperature ) Fast oscilloscope functionality. Used for current and velocity regulators tuning Additional functions Optional control for magnetic brake. Output for brake light, active when regenerating. Spare analog inputs Set up and customization All settings are stored as parameters and can be changed. No»hard-wired«limits and settings. RS232 / Canopen connection for adjustment of settings. Settings are adjusted with text commands or GUI configuration SW. Support any number of motor poles. Electronic design All connections have automotive EMC protection. All control connections are protected against short circuit to ground or battery voltage. Reverse battery protection (main fuse will blown). Low EMC design, with proper cable wiring easily reaches class B EMC emission regulations. Integrated capacitor bank for reduced harmonic current in battery connection. Main contactor not required Communication interfaces 1 x RS232 interface, 1 x CAN 2.0V interface CAN 2.0B interface with optional galvanic isolation Canopen protocol (full DS402 compatible) Housing Aluminum base plate for heat sink, plastic top cover High current screw terminals for battery connection and motor phases Dimensions 200x150x50 mm (preliminary) IP 54 protection Optional IP65 protection controller potted with PU compound (except connectors)

4 Specifications Maximum battery voltage 120 V. Battery overvoltage protection at 125 V. Motor phase current (rms): o at battery voltage < 100 V = 400A, 1 minute up to 500 A. o at battery voltage > 100 V = 300 A, 1 minute up to 400 A Switching frequency 16 khz. Dimensions 280 x 205 x 50 mm, weight 3,7 kg Operating temperature -20/+65 o C. Maximum back plate temperature 50 C.

5 Connectors System connector 16 pin Molex Mini-Fit Jr. Mating part Molex Pin Name Description 1 Ignition Power supply for control part. Usually connected to ignition switch. Galvanic isolation from control part. Input voltage 40 to 150 V. 2 Ignition GND Negative power supply line for pin 1 - Ignition GND. 3 GND Reference for digital and analogue inputs 4 FWD Forward. Active when connected to pin 3 GND. 5 REW Reverse. Active when connected to pin 3 GND. 6 BRAKE 7 EMG_STOP Must be connected to pin 3 GND for operation. Use for emergency switch 8 DIN1 Digital input 1 9 DIN2 Digital input 2 10 DIN3 Digital input 3 11 AD_THROTLE Analogue input 0-5 V for throttle. Input impedance 20 kohm 12 AD_BRAKE Analogue input 0-5 V 13 AD_AUX Analogue input 0-5 V 14 VCC_5V Use for powering throttle. Maximum 50 ma 15 DOUT1 Low side switch to GND. Maximum 0.5 A/120 V. Use external protection diode for inductive loads 16 DOUT2 Low side switch to GND. Maximum 0.5 A/120 V. Use external protection diode for inductive loads Input levels for pins 3,4,5,6,7,8,9,10: 0-4 V active >6 inactive. Hall (rotor angle) connector 12 pin Molex Mini-Fit Jr. Mating part Molex Pin Name Description Optional resolver 1 GND 2 5V For powering angle sensors / hall. Maximum 50 ma 3 Temperature Motor temperature sensor. NTC10k or KTY Hall 1 5 Hall 2 6 Hall 3 7 SSI clock + RS422 levels. Internal 120 Ohm termination Ref + 8 SSI clock - RS422 levels. Internal 120 Ohm termination Ref - 9 SSI data + RS422 levels. Internal 120 Ohm termination Sin + 10 SSI data - RS422 levels. Internal 120 Ohm termination Sin - 11 Sin Sinus for analogue Sin/Cos sensor. 0-5V. 20 k impedance Cos + 12 Cos Cosine for analogue Sin/Cos sensor. 0-5V. 20 k impedance Cos -

6 Communication connector 10 pin Molex Mini-Fit Jr. Mating part Molex Pin Name Description 1 Boot Connect to GND for SW upgrade over RS232 2 RS232 1 Tx Transmit data for RS232 port 1 3 RS232 1 Rx Receive data for RS232 port 1 4 CAN_GND GND for CAN. Optional galvanic isolated. 5 CAN L CAN low 6 GND 7 RS232 2 Rx Receive data for RS232 port 2 8 RS232 2 Tx Transmit data for RS232 port V Used for powering external interfaces. Max 50 ma 10 CAN H CAN high