PCpak Manual - Thunderstruck
Contents
1. It will show the text as displayed on the Calibrator for controller system information on PowerpaK systems or An Error Message will be displayed PCpaK Manual 50 10 12 05 PCpaK Status Bar PCpaK Status Bar This is displayed at the very bottom of the Main Window See Figure 21 Offline No nodes Ready Figure 21 PCpaK Status Bar The status bar gives the following information from left to right Connection Status This is the first item in the Status Bar PCpaK will show Offline if there is no controller system connected or Online if there is a controller system connected Node Pointer This indicates which node PCpaK is communicating with If PCpaK is offline then this will display No Nodes otherwise it displays the node number of the active node PCpaK Status Indication This provides information about the current status of the PCpaK application PCpaK will display one of the status codes listed in Table 4 Status Message Ready Description Normal operation MillipaK Flash Program Utility Flash Programming utility is active Rapid download Rapid Download utility is active Saving controller snapshot Saving information on connected Controller System to Controller System Profile file Printing Printing information on connected Controller System if Online or displayed Controller System Profile file if Offline Clearing service log Waiting for confirmation2. log information etc This file can then be viewed later using PCpaK This can be a useful tool for recording the status of a system during development or whilst servicing a vehicle However this snapshot can also be used for a second purpose The personalities are stored in the file along with the other system information These personalities can be extracted by PCpaK and can be used to configure other identical systems For example for the Rapid Download PCpaK takes a System Profile file extracts the personality information and downloads this to the Controller System System Profile files can be used to either store a snapshot of the current system for future reference or it can be used as a repository for a standard system configuration which can be downloaded to other systems at a later date PCpaK Manual 52 10 12 05 Features Controller System Profile Files Flash Programming Some Sevcon products are flash programmable meaning that the software in the controller can be upgraded to support new features or enhance the existing control system Enhanced versions of PCpaK allow the user to flash program a controller with new software by connecting the controller to the PC using the Interface Module as normal If the controller is flash programmable then you can upgrade the software by connecting it to PCpaK and selecting the flash programmer from the tools menu If you do not see any flash programmer options from the tools menu
3. refer to the PCpaK Menus and PCpaK Toolbar sections respectively PCpaK Manual 14 10 12 05 Features Main Window Title Bar Menu Bar Toolbar Nodes and Menus Menu Items Language Selection Status Bar Figure 5 PCpaK Main Window Layout The centre of the window is the main working area The left hand pane is a Tree structure used to display all the nodes in the controller system and the available menus for that node The right hand pane displays all the items for the selected menu Refer to the Node and Menu Item Panes section The bottom of the window contains the Language Selection drop down box and the Status Bar The Language Selection box is used to select the required language to display the menu information in The Language Selection box is described in the PCpaK Language Selection section The Status Bar is used to show the current status of the system For example this shows if PCpaK is connected to a controller online or not offline The Status Bar is described in the PCpaK Status Bar section PCpaK Manual 15 10 12 05 Main Window Nodes and Menu Item Panes Node and Menu Item Panes The two panes in the centre ofthe Main Window are used to show the Nodes and Node Menus left hand pane and the menu items for the selected Node menu right hand pane Refer to Figure 4 and Figure 5 The functions of the two panes are explained in the following sections PCpaK Manual 16 10 12 05 Ma
4. Menus These display system test menu items See Figure 10 A Test Menu Test menus are used to allow the user to check the systems inputs and outputs and also to provide information on the unit These items are read only Only the current value is displayed for test menu items The Min Max Default and Information columns are not used The information in Test menus will only change if a controller system is connected i e online If PCpaK is in Offline mode the information displayed shows the last values received by PCpaK before it was disconnected from the controller system W Sevcon PCpaK 2 00 00 Cuy File View Connection Log Tools Help EM Traction E Personalities B Status peed Cutback 1 Switch peed Cutback 2 Switch Figure 10 A Test Menu PCpaK Manual 23 10 12 05 Main Window Nodes and Menu Item Panes Faultlog Menus These display Faultlog menu items See Figure 11 amp Sevcon PCpaK 2 00 00 Woe File View Connection Log Tools Help Fe jr ds ES Ev EE a pin TTL H Node 0 No Power Up Fit Traction High Cap Volts Al Personalities No MOSFET s c s E Status Line Cont o c Test B Ver up E Battery Volt E Motor Setup E Maintenance E Display E Configure Ready Node 0 Figure 11 A Faultlog Menu These items are read only Only PowerpaK systems support Faultlogs at present The fo
5. be on steady Click the go button to start flash programming The status of the system will be displayed When flash programming is complete you should remove the flash programming harness The controller should now be running the new software PCpaK Manual 55 10 12 05 Features Controller System Profile Files Notes about Flash Programming When a flash programming harness is connected to a controller all control functions will be unavailable and drive is inhibited This is normal operation You should always use the file information displayed by PCpaK to ensure you are sending the correct information to the controller Sevcon publish checksum and file information for each version of software produced for flash programmable controllers If there are any differences in the checksum then this indicates file corruption and the controller may not function correctly Once a controller has been programmed with new software it may require new personalities This is indicated by the presence of a pers fault or aCRC fault when the new software is first run To rectify this problem use PCpaK to check which personalities or set up items are at fault and reset them to their correct values This mechanism protects controllers from using invalid personality values Software versions can be checked before and after flash programming using either the calibrator or the node information screen of PCpaK PCpaK Manual 56 10 12 05 F
6. from Controller System that the Service Log has been cleared Clearing fault log Waiting for confirmation from Controller System that the Fault Log has been cleared Closing communications Disconnecting from Controller System Writing cached data back to controller If the user has changed a personality then immediately tried to disconnect from the Controller System PCpaK will maintain the connection until the personality is successfully written This message is displayed during this time Opening communications Table 4 Status Messages Attempting to connect to Controller System PCpaK Manual 51 10 12 05 Features Controller System Profile Files Controller System Profile Files The files used by PCpaK are called Controller System Profile Files These files contain all the information PCpaK requires about any Controller System When the user connects to a Controller System PCpaK uploads all the information it requires from the Controller System and displays it in the Main Window This information includes configuration items such as personalities and other information such as status or test information If the user selects the Save command from the File menu a snapshot of the current system is saved to a System Profile file This snapshot contains all the information PCpaK has about the system This will include current personality values status and test information fault and service
7. information Faultlog Faultlog menus Information Any menus which do not fall into one of the above categories Note that the information in Status Test Faultlog and Information menus will only change if a controller system is connected i e Online If PCpaK is in Offline mode the information displayed shows the last values received by PCpaK before it was disconnected Configuration Menus These menus display personality and setup menu items See Figure 8 File View Connection Log Tools Help Sm TTL ftem vawe min Max pefaut information Node 0 Armature Current Limit 400A 150A 500 A 50A E Traction Field Current Limit 30A 10A 40A 10A Personalities Direction Brake Level 25 5 100 5 E Status Neutral Brake Level 25 1 100 1 E Test Reduction Brake Level 20 1 100 1 AccelerationDelay 1 4s 01s 508 0 18 Creep Speed fo 0 25 0 peed 5 Additive to Speed 3 500 Hours 0 Hours 500 Hours 0 Hours 498 Hours 0 Hours 500 Hours 0 Hours Maximum Spesa 100 0 100 0 Maximum Reverse Speed 30 0 100 0 peed 100 0 100 0 cutback 2 Speed 100 0 100 0 Power Steer Timer 0s Os 60s Os Seat Dela 158 01s 5 08 0 18 Spee eos 1s 60s 1s English Online Node 0 Ready Figure 8 A Configuration Menu PCpaK Manual 20 10 12 05 Main Window Nodes and Menu Item Panes If the security level allows the user can click on the value to be changed using th
8. items or an individual menu in the Tree structure to display further information in the Menu Items pane right hand pane See the next section for more information PCpaK Manual 17 10 12 05 Main Window Nodes and Menu Item Panes Menu Items Right Hand Pane The right hand pane displays information on a selected node sub node or menu using a table format Node Items Selecting a Node item in the left hand pane will display the information shown in Figure 6 amp Sevcon PCpaK 2 00 00 Jo File View Connection Log Tools Help u Status for this node i o E Traction MillipaK Regen SEM Ride On E Personalities 07040676 E Status RS232 protocol ver 2 E Test US004802 Line Contactor did not Close Fault 23 194 OK OEMFFFF English y i Node 0 Ready Figure 6 Node Information Screen The information displayed here is Node Number Node Number for the selected node Model Description of the node e g PowerpaK Traction Series or MillipaK Traction SEM Serial Number Node serial number Protocol Version Version of protocol used to communicate with node Software Version Node software version Status Status of node This item will show if there is any fault currently active on the node Pers CRC If the node supports this facility the node personality CRC will be displayed here Refer to the product manual for more information PCpaK Manual 18 10 12 05 Main Wind
9. minimum A 266MHz Pentium with 64MB of RAM is recommended Operating System PCpaK will operate on Microsoft Windows 95 98 NT 2000 XP Storage PCpaK is supplied via CD ROM therefore a CD ROM drive is required PCpaK can be copied to a local hard disk drive or can be executed directly from the CD ROM It is recommended that PCpaK is installed on a hard disk since the Cache function will not work if PCpaK is running from the CD ROM drive PCpaK requires approximately 7MB of disk space Serial Port PCpaK requires one free Serial Port capable of operating at 115KBaud Screen Resolution Minimum resolution is 640 x 480 with 16 colours 800 x 600 resolution is recommended Table 1 System Requirements PCpaK Manual 7 10 12 05 Installation Software Installation Software Installation Follow this procedure to install the PCpaK application on your hard disk 1 Insert the PCpaK CD ROM 2 Run the PCpaK_setup exe application on the CD 3 PCpaK will be installed to the hard disk and will be able to run without the CD To start the program select the PCpaK program option which has been added to the start menu 4 When the software runs for the first time you will be asked to enter a configuration ID You should find this information supplied with PCpaK Enter the ID provided exactly as it is displayed it is case sensitive Configuration gt Please enter the configuration ID supplie
10. of controller structure Offline viewing of previously stored configurations Refer to controller product manual for details of controller features and programming options Compatibility We are constantly updating our systems to allow PCpaK to interface to more of our controllers Refer to the appropriate Product Manual to determine if your Controller System is compatible with PCpaK or contact SEVCON for a complete list of controllers which support PCpaK Important Safety Notice WARNING Care must be taken when operating using PCpaK on any system Changes to personalities can change vehicle performance and operation If the controller system is fitted to a vehicle ensure no movement is possible before using PCpaK to make any changes Do not connect your PC to a controller if the controller does not have an adequate ground connected to B This is because the ground from the controller follows through the serial port through the PC You can damage the PC if the controller pulls sufficient current e g when charging capacitors and no other ground path is available PCpaK Manual 5 10 12 05 Installation Installation This section describes the steps necessary to install the PCpaK application and the recommended system requirements memory disk space etc required to operate it PCpaK Manual 6 10 12 05 Installation System Requirements System Requirements System A 486 machine is required as a
11. the following section PCpaK Manual 39 10 12 05 PCpaK Menus Log Clear Log Clear Log This option only becomes available if the current item selected in the main window is a log which can be reset For example on the PowerpaK range of controllers resettable logs are the Fault Log and Service Log Refer to the product manual for the controller for a list of what logs are available and which can be reset When the user has highlighted a resettable log and selects the Clear Log option PCpaK sends a command to the Controller System to reset the chosen log PCpaK Manual 40 10 12 05 PCpaK Menus Tools Tools Menu The Tools Menu has the following options Rapid Download Flash Programming Options Each menu item is explained more fully in the following sections PCpaK Manual 41 10 12 05 PCpaK Menus Tools Rapid Download Rapid Download This option allows the user to download personality information to a controller system without having to go through the connection procedure described in the previous section Open Connection This feature is particularly useful when setting up a number of controller systems with the same configuration The feature uses a Wizard to setup and perform the rapid download function The steps are 1 Choose Source and Destination Parameters In this step select the Controller System Profile file which contains the system personalities to download Click on Next
12. then you must contact Sevcon for an upgrade Flash programmer utilities are only available in enhanced versions of PCpaK The following sections explain how to flash new software into your controller PCpaK Manual 53 10 12 05 Features Controller System Profile Files MillipaK Connection The MillipaK can be flash programmed using the standard RS232 TTL Interface Module However you must also connect the MillipaK Flash Programming Harness in line to the 16 way Molex connection on the controller The vehicle light wiring that would normally be connected to the 16 way Molex connection should now go through the harness The controller needs to be keyed on to be flash programmed Program Interface MillipaK Flash Programmer Pa Flash Programmer Setup 1 Select MillipaK software Enter the software filename here Click the icon to browse for the file Filename C sevsoft s19 fl 2 Check file information File Size 76578 bytes Tuesday May 25 2004 310 File Checksum 2CD4 WARNING Unknown target controller type Ensure the details displayed here match those provided by Sevcon 3 Program Unit Click the go button to start the flash programming process Ensure unit to be programmed is connected correctly then click Exit To start the flash programmer select Flash Programmer from the tools menu in PCpaK Start by entering the filename of the so
13. this for future use error occurs Data being loaded onto a controller must come from a controller of the same type and with the same software version If the profiles do not match then this error will occur Check you have selected the correct file and have the correct controller connected 410 Bad Profile A cache does not exist for the The system will create a cache 500 No cache controller you have connected for you 3 The cache for the controller The system will refresh the 501 Invalid cache RR contains invalid data cache for you Table 5 Fault Codes Descriptions and Recommended Action PCpaK Manual 59 10 12 05 Ordering Information Ordering Information To order PCpaK and or its associated hardware use one of the part numbers specified in Table 6 Part Number Description PCpaK CD ROM PCpaK CD ROM and interface module to communicate 661 30088 RS 232 to CANbus with PowerpaK MicropaK PowerpAC Controller Interface Module Systems PCpaK CD ROM PCpaK CD ROM and interface module to communicate op D2009 RS 232 to TTL with MillipaK Controller Systems Interface Module Some MillipaK Controller variants require Battery Voltage to be applied to pin 16 on their customer connector to put the controller into Program Mode Refer to the controller product manual for more information MillipaK 184 21869 Flash Program Enable Harness Table 6 PCpaK Part Numbers Software Up
14. C now Click download to send the information to the controller You may also choose to have these logs reset when rapid download is complete IV Fault log Service log Download Status Ready click download to begin You may repeat this step as often as you need in order to program all of your controllers When you are done you can click finish to return to the main program Exit lt Back Finish Figure 17 Rapid Download Wizard Step 3 PCpaK Manual 43 10 12 05 PCpaK Menus Tools Rapid Download 4 Finish Once all the controller systems have been updated click on Finish to return to the main menu PCpaK Manual 44 10 12 05 PCpaK Menus Tools Options Options This option allows the user to configure PCpaK for their installation When this menu item is selected the following dialog box is displayed Options ni Protocol Password gt COM Port Specify COM port to be used when connecting to a controller com 1 Cache Specify cache operation when connecting Cache Data Keep a local copy of the controller structure recommended C Refresh Data Update cached information with that in the controller Ignore Cache Do not use or keep a local copy of the controller structure Figure 18 Options Dialog Box This dialog is split into two sections COM Port and Cache See the sections COM Port and Cache below for more informat
15. TECHOPS SEVCON SEVCON PCpaK User Manual Version 2 00 00 UK0052 Document History Document History Author Reviewer Version Reason for Modification Initials Date Initials Date CEH 27 09 01 1 0 0 21 Original CEH 05 10 01 UK0030 Added MillipaK Functionality PS 06 11 01 UK0030 Changed MillipaK Functionality PS 7 1 02 UK0049 Added Config ID Functionality PS 8 2 02 UK0052 Added SEM flash prog and protocol select PS 24 10 02 UK0052 Renamed PowerpaK SEM programmer TSN 27 09 05 2 00 00 Revised for formal release Contents Contents INTRODUCTION r a a wre ne 5 COMPATIBILITY u aaa 5 IMPORTANT SAFETY NOTICE 0ccccccccccssssseeeecssseseeeecesseeeeenecenseeeescuasseeeeeeeeeseeeseneneas 5 INSTALLATION cocoa tdi ea diia 6 System Requirements cussussnssossossonssnennssnnsnnsnnsnnssnnsnnsnnsnnsnnssnnsnnsnnssnssnnsnnsnnssnnsnssnnssnssnssnnsnnsnnssnssnnsnnsnnssnnsnssnnssnssnssnssnnnnn 7 Software Installation AAA OA aiis 8 Hardware Requirements sussossossonssnssnssnnsnnsnnssnssnnsnnsnnssnsnnssnnsnnsnnnsnssnnsnnsnnssnnsnssnnssnsnnssnnsnnsnnssnssnnsnnsnnssnnsnssnnssnssnssnssnnsnnn 9 Interface Modules scale a E O ARA a E E AEA EEEO RE ATSB a Be 10 Connection sen A na AAA EE A A Et 11 FEATURES cuina aa een 12 System Start Up esssossossonssnssnssnssnnsnnssnssnnsnnsnnssnsnnssnnsnnsnnssnnsnnsnnssnssnnsnssnnssnssnssnnssnsnnssnssnnsnnsnnssnnsnssnnssnssnssnnsnnssnssn
16. ault Finding Fault Messages Table 5 outlines the major error conditions that can arise in the program as well as steps that can be taken to rectify the problem EEPROM An event occurred from which 1 Unknown Error the system is unable to recover An event occurred which Connect to a controller press F8 100 Not Connected requires a controller to be to open the connection dialog connected and retry the operation The system is trying to process Wait for the first command to 101 Sendrec In Use more than one command at a i complete and then continue time Check other processes are not Only one Windows process can trying to use the same COM port 12 SOM portas own a COM port at a time as PCpaK e g modems mouse etc Try another COM port The COM port you have 103 Bad COM port specified cannot be accessed by Select a different COM port Windows The system is attempting to Check the controllers are communicate with a controller connected properly Check both 104 Node unavailable but the controller is not controllers are compatible with responding PCpaK 105 Exception Raised An SSP OD e ea DyANe Check the exception message communication system No controllers are connected or Check the connection Ensure 106 No Controller the controllers are not the controllers are compatible compatible with PCpaK with PCpaK 109 Malformed Data The PC did not receive data in Chace e connection Packet th
17. d controller system with the new configuration item value as soon as the user changes it and it has been validated Status Menus These display system status menu items See Figure 9 A Status Menu These items are read only Status menus also display service log information The following information is displayed for each menu item in a Status menu Current Value The current value of the status item Highest Value If the system supports a Service Log a log is maintained of the highest value seen for some status information For example PowerpaK systems log the highest Battery Voltage If logged the highest value seen for the item is displayed in this field Lowest Value If the system supports a Service Log a log is maintained of the lowest value seen for some status information For example PowerpaK systems log the lowest Heatsink Temperature If logged the lowest value seen for the item is displayed in this field PCpaK Manual 21 10 12 05 Main Window Nodes and Menu Item Panes The information in Status menus will only change if a controller system is connected i e online If PCpaK is in Offline mode the information displayed shows the last values received by PCpaK before it was disconnected from the controller system TTL Node 0 Traction m Personalities Status B Test Figure 9 A Status Menu PCpaK Manual 22 10 12 05 Main Window Nodes and Menu Item Panes Test
18. d with PCpak 5 Press OK when you have entered the ID If it is accepted you will be taken to the main PCpaK interface If it is not accepted you must enter it again The configuration ID only needs to be entered once Once the ID has been accepted you do not need to enter it again PCpaK Manual 8 10 12 05 Installation Hardware Connections Hardware Requirements This section explains how to connect up the system hardware to use PCpaK to communicate with a Controller System PCpaK Manual 9 10 12 05 Installation Hardware Connections Interface Modules Interface Modules Connection between the PC and the controller systems must be done via the appropriate interface module There are two interface modules currently available RS 232 to CANbus interface and RS 232 to TTL interface See Figure 1 and Figure 2 ses RS 232 RS 232 CANbus CANbus or Laptop 9 way Interface Module 6 way MOLEX D type PowerpaK Traction Master PowerpaK Pump Slave Figure 1 RS 232 to CANbus Interface PEO ED RS 232 RS 232 TIL TIL MillipaK Dae 9 way Interface Module 6 way Controller D type MOLEX Figure 2 RS 232 to TTL Interface Table 2 shows which interface module to use for each product range Product Range Interface Module PowerpaK RS 232 to CANbus MillipaK RS 232 to TTL Table 2 Interface Modules for each Product Range Ordering information for these interface mod
19. dates Software upgrades can be requested by contacting SEVCON Refer to Contact Details PCpaK Manual 60 10 12 05 Contact Details Contact Details Sevcon Limited Kingsway Gateshead NE11 0QA England Tel 44 191 497 9000 Fax 44 191 482 4223 Email sales sevcon com Sevcon Asia Limited 4FL Eun Hae Building 463 1 Sahng dong Wonmee Gu Bucheon City Kyunggi Do 420 030 Korea Tel 82 32 215 5070 Fax 82 32 215 8027 Email sevcon asia sevcon com Sevcon Inc 155 Northboro Rd Southborough MA 01772 USA Tel 1 508 281 5500 Fax 1 508 281 5341 Email sales us sevcon com Website www sevcon com Sevcon SA 12 Rue Jean Poulmarch 95100 Argenteuil France Tel 33 1 34 1095 45 Fax 33 1 34 10 61 38 Email gesevcon O world net net Sevcon Japan 1 22 10 303 Setagaya Daita Setagaya Ku Tokyo Japan 155 0022 Tel 81 3 5430 8001 Fax 81 3 5430 4001 Email sevcon japan sevcon com TECH OPS SEVCON PCpaK Manual 10 12 05
20. e sev Refer to the Controller System Profile Files section for more information about Controller System Profile files A standard windows Open dialog box is displayed to allow the user to select the required file If PCpaK is not currently connected to a controller system the System Profile file is opened as read only It is not possible to make any changes but all the information can be viewed If PCpaK is connected to a controller system PCpaK will attempt to open the System Profile file and update the connected system with the information contained within the Profile Before downloading the data PCpaK will check that data stored in the System Profile is compatible with the connected system If the data is incompatible an error will be displayed and the file open is aborted Once the data in the file has been downloaded PCpaK will interrogate the Controller System to read all the dynamic data 1 e Voltages Currents Faultlog information etc WARNING If PCpaK is connected to a Controller System when a Controller System Profile File is opened it will automatically attempt to download the data in the file to the Controller System If this is not required ensure that the Controller System is disconnected before the Controller System Profile File is opened PCpaK Manual 28 10 12 05 PCpaK Menus File Save Save This option allows the user to save the information from the connected controller system to a Control
21. e correct format 201 Cannot read The system cannot read the mes u EEPROM EEPROM on the controller 8 8 calibrator 202 Cannot write The system cannot write to the Check the connection Try EEPROM on the controller writing settings with a calibrator PCpaK Manual 57 10 12 05 Fault Finding The system needs the communications to be open to continue Comms are closed 300 Open communications and try again The system needs the 301 Comms are open communications to be closed to continue Close communications and try again Try using refresh cache and The system is not receiving valid opening the connection again If 203 Bad Response data from the controller while the problem persists inform trying to connect Sevcon of the controller model and software version 303 Cannot Read Data Data cannot be read from the Check the connection controller annot Write j Ensure you are changing the 304 ie WN Data is read only HEES ON nangmg Data correct personalities Data Out Of The data being written to the Ensure the data you are entering a0 Range controller is out of range is within the specified ranges The system must be able to read back information for verification purposes Check the connection Try the operation using a calibrator Data that was written to the 306 Write Verify Fail controller cannot be read back You are attempting to save data 400 No Data To Save when offli
22. e mouse and modify the personality information using one of the following methods Two methods are available to change numerical information Simply type in the new value Note that values will always be rounded to the nearest allowed number When a configuration item is selected and buttons appear at the right hand side of the selected item These and buttons can be used to increase and decrease the value Items which require the user to select an option provide a drop down list from which the user can make their selection The following information is displayed for each menu item in a Configuration menu Value The current value of the configuration item Min The allowed minimum for the configuration PCpaK will not allow the value to decrease below this value This field is blank for items which use drop down list boxes Max The allowed maximum for the configuration PCpaK will not allow the value to increase above this value This field is blank for items which use drop down list boxes Default If the configuration item is shown as being out of range this is the default value which will be entered when the range error is first corrected Information This provides further information about the menu item For example this indicates if the value is out of range Information in Configuration menus can only be changed if a controller system is connected i e online PCpaK will update the connecte
23. e node After setting up the nodes as required click Next See Figure 16 PCpaK Manual 42 10 12 05 PCpaK Menus Tools Rapid Download Rapid Download El gt Rapid Download Wizard Step 2 Check node compatibility The file you have opened contains information about the following nodes Please map these onto the nodes of the system you are downloading to Src node Al 0 1 2 a 4 5 6 7 8 8 in v When you are ready click next Exit lt Back Next gt Figure 16 Rapid Download Wizard Step 2 3 Download to Controllers The system now has all the information it requires Ensure that the Controller System is connected to the PC and is powered up ready for the download Click on the Download button to download the information to the controllers PCpaK will automatically connect to the controllers download the information and then disconnect from the controllers Once this is complete the user may plug their Interface Module into a new controller system and repeat the download simply by clicking on Download again This may be performed as often as is necessary The user may also if they wish choose to have the fault or service logs reset after a rapid download operation These logs will only be reset if rapid download completes successfully See Figure 17 Rapid Download El gt Rapid Download Wizard Step 3 Download to controllers Connect the controller to the P
24. er system and will create a fresh cache file even if a file already exists The old file is over written If Ignore Cache is selected PCpaK will always upload all the information from the controller system whether or not a Cache file exists for this setup Also a new Cache file is not created Protocol Options x Password a Protocol Selection Protocol 1 e g PowerpaK Protocol 2 e g MillipaK Access Level Controller access level Type 00 Write Protect Check box to prevent controller configuration from being changed Protocol selection allows PCpaK to communicate with a range of controllers e Protocol 1 should be selected when using the RS232 CAN Interface Module when connecting to CAN based controllers such as PowerpaK or MicropaK e Protocol 2 should be selected when using the RS232 TTL Interface Module when connecting to TTL based controllers such as MillipaK PCpaK Manual 46 10 12 05 PCpaK Menus Tools Options Access Level allows you to choose the level of access to the controller menu structure Type 00 gives access to standard controller menus and allows configuration of controller features Other types may be available depending on your installation to allow access to service and engineering functions The write protect button may be ticked to prevent accidental modification of any setup or personality values It does however allow you to use rapid dow
25. ftware in the filename field This file will be in s19 format You may browse for the file by clicking the icon When you have selected a file you can check the file information to verify the software integrity The file size and timestamp allow you to verify you have the correct file and the checksum can be used to check the software file is not corrupt Sevcon publish file checksums with each version of software The target controller type informs the user what controller the software is for Clicking the go button starts the flash programming process Flash programming is done in two stages e Stage 1 involves booting the controller and erasing the existing software from the controller You can monitor the progress of this stage on screen Once the erase is complete the controller must be restarted PCpaK will prompt you to cycle the key switch when this happens At the start of stage 2 the controller contains no software PCpaK will reboot the controller and begin to download the new user software Once this stage is complete the software will be ready to run PCpaK Manual 54 10 12 05 Features Controller System Profile Files PowerpaK MicropaK Connection Some PowerpaK MicropaK controllers are flash programmable using the standard RS232 CAN Interface Module To flash program a controller you must connect the PowerpaK flash programming harness to socket A on the controller and connect the Interface Module to the harness W
26. gramming dialog box depending on the controller protocol selected Protocol 1 for PowerpaK and MicropaK and Protocol 2 for MillipaK Load Settings Initiates Rapid Download dialog box if offline or opens a previously saved personality profile 1f connected Reset 1000000 Clear Log Refer to the Clear Log section PCpaK Manual 49 10 12 05 PCpaK Language Selection PCpaK Language Selection PCpaK allows the user to select one of several languages in which to display all PCpaK menus dialog boxes and the controller system information To change language selection simply select the required language from the Language Selection drop down list on the Main Window PCpaK will then update all displayed text appropriately for the new language New languages can easily be added without the need for changes to PCpaK The language files are stored as text files in the Languages sub directory There is one file per language When it starts up PCpaK scans this directory and builds a list of the available language files New languages can be added simply by ensuring the required language file exists in this directory Contact SEVCON for a list of all supported languages If PCpaK detects an error in any language file other than the English one then the text displayed will default to the appropriate entry in the English Language file If PCpaK detects an error in the English language file then PCpaK will do one of the following
27. hen the harness is connected to the controller the controller will be ready to accept new software from PCpaK The controller must be keyed on to be flash programmed Program Interface PowerpaK MicropaK Flash Programmer Pa Flash Programmer Setup 1 Select PowerpaK MicropaK software Enter the software filename here Click the Icon to browse for the file Filename LJ C sevsoft s19 2 Check file information Size 62415 bytes Timestam Thursday March 10 2005 6 23 30 AM Checksum ADSC Ensure the details displayed here match those provided by the software vendor 3 Program unit E it to b di ted tly then click go F nsure unit to be programmed is connected correctly then click go Click the go Briton io start the flash programming process Exit To start the PowerpaK MicropaK flash programmer select PowerpaK MicropaK flash programmer from the tools menu Enter the name of the software file or click the icon to browse PowerpaK and MicropaK software is supplied in binary format bin file Once the file name has been entered the file information will be displayed This information should be checked against the information provided by the Sevcon PowerpaK and MicropaK flash programming unlike MillipaK flash programming can be done in one stage To start flash programming ensure the controller is keyed on The LED on the Interface Module should
28. in Window Nodes and Menu Item Panes Node and Node Menus Left Hand Pane The left hand pane uses a Tree structure to show all the Nodes in the system and the available menus for each node Note that menus may themselves have sub menus The Tree structure may be expanded and collapsed as required by clicking on the and items The Tree structure is always fully expanded when a new connection is established Not all menus have data associated with them Some menus e g traction are only displayed to show sub menus If a menu has no data associated with it then it will be displayed with a red icon Other menus will appear with a green icon From the communications bus all the nodes in the system are listed in numerical order In SEVCON systems node numbers are allocated according to the units function Table 3 shows how node numbers are allocated Node Number Node Function 0 Master or Standalone Traction or Combined Traction and Pump for Aerial Lift systems 1 Slave Traction on Dual Motor Systems 2 Pump Power Steer Controller 3 onwards Reserved Table 3 Node Number Allocation Each node shows all of its sub nodes e g Traction or Pump or in some cases both and each sub node shows all the menus and sub menus it has available On some systems e g Aerial Lift systems or MillipaKs with Pump Soft Start both the Traction and Pump function can be performed on the same node The user can select the Node or sub Node
29. ion COM Port In this section the operator can select the COM port e g COM1 COM2 etc Cache The first time PCpaK connects to a new controller system it must upload a lot of information regarding menu structure display formats etc This information is used to build up a map of the controller system s menu structure For a specific controller type e g PowerpaK Traction Series and software version e g V4 06 the menu structure will never change It is hard coded into the system s memory Therefore once PCpaK has uploaded the structure information it does not need to upload it again PCpaK Manual 45 10 12 05 PCpaK Menus Tools Options This section allows the user to specify if this structure information should be stored or cached for future reference The user has three options Cache Data Refresh Data Ignore Cache If Cache Data is selected PCpaK will check to see if it has uploaded data from this type of system before If it has PCpaK only needs to upload dynamic data such as personality values status information etc The menu structure information is already stored in a Cache file This can greatly improve the speed of the upload If PCpaK has not uploaded data from this type of system before it uploads all the information it requires including structure information and creates a cache file for future reference If Refresh Data is selected PCpaK will upload all the information from the controll
30. ler System Profile file sev Refer to the Controller System Profile Files section for more information about Controller System Profile files A standard Windows Save dialog box is displayed to allow the user to name and save the System Profile If PCpaK is not connected to a controller system then this option is not available PCpaK Manual 29 10 12 05 PCpaK Menus File Print Print This option allows the user to print the displayed System Profile to a printer Figure 13 shows the Print Dialog Box Select Print Options gt Print Controller Calibration Content Print adjustable values only Identification Enter your name here la Smith Controller Description Customer Configuration Print Figure 13 Print Dialog Box The Print Dialog Box allows the user to specify what is to be printed and also to include some information about the User and the Controller System description onto the printed sheets If the Print Adjustable Values Only check box is not checked PCpaK will Print all the information about the connected controller system if Online or Print all the information in the Controller System Profile file if Offline The printout will include all configuration information personalities setup items etc and the information in the Status Test Faultlog and other Information menus If the Print Adjustable Values Only box is checked PCpaK will only print the values of configura
31. llowing information is displayed for each menu item in a PowerpaK Faultlog menu Item The flash fault group Faults are grouped by flash fault group e g 1FF 3FF etc in the PowerpaK Faultlog Last Fault Message The last fault message displayed on the Calibrator for this flash fault group Time The Keyswitch hours when the last fault was logged Count The number of faults logged in this flash fault since the last Faultlog reset Information Menus These display general information menu items See Figure 12 These items are read only Only the current value is displayed for information menu items The Min Max Default and Information columns are not used PCpaK Manual 24 10 12 05 Main Window Nodes and Menu Item Panes H Node 0 E Traction Personalities Status Test B Ver BDI Fault Log Setup Battery Volt Motor Setup Maintenance Display Configure Figure 12 An Information Menu PCpaK Manual 25 10 12 05 PCpaK Menus PCpaK Menus This section explains the function of each of the Menu options in PCpaK PCpaK Manual 26 10 12 05 PCpaK Menus File Menu File Menu The File Menu has the following options Open Save Print Exit Each menu item is explained more fully in the following sections PCpaK Manual 27 10 12 05 PCpaK Menus File Open Open This option allows the user to open an existing Controller System Profile fil
32. ne or no nodes in the system 401 Could Not Open The system cannot open the file Check the disks access File you have specified permissions Could Not Read The system cannot read from the Check the disks access 402 E File file you have specified permissions Could Not Write The system cannot write to the Check the disks access 403 a Bpr File file you have specified permissions 404 No Filename You have not specified a Ensure you have specified valid filename filenames where required Ensure a connection is open and try again The system requires 405 communications to be closed for Open a connection Communications are Open E P 1t to continue PCpaK Manual 58 10 12 05 Fault Finding The system requires communications to be open for it Close the connection to continue 407 Bad Data In File The file you have specified does Ensure you have selected the not contain valid data correct file 408 File Doesn t Exist No file exists with the filename Ensure you have entered the you have specified correct filename Communications 206 are Closed When data is written to the controller the CRC value is Manually check the personalities checked to ensure it was written were correctly written You may 409 Bad CRC check correctly If the value on the wish to save a new file that controller differs from the value contains the correct CRC value recorded in the file then
33. nload and to load a configuration from file If you use PCpaK to write pre set configurations to controllers and want to be sure you don t accidentally change any settings then we recommend this option is set Password Protection Options Connection Protocol Password Password Protection Use this to password protect options Y Enable Protection Enter password XXXXXX Enter again to confirm XXXXXX Password set You will be prompted for this password next time you attempt to access program options The password protection option allows you to protect the options screen and prevent users from modifying the configuration of PCpaK This is particularly useful if you want to restrict the access users have to controller functionality To set a password check the enable protection box and enter your chosen password into the text box You need to enter the password twice for confirmation When the password is set you will see a confirmation message The next time you access the options dialog you will be prompted for the password To remove password protection clear the enable protection checkbox OK Click the OK button to save settings Clicking the OK button also saves the main window position so it will return next time the program starts PCpaK Manual 47 10 12 05 PCpaK Menus Help About Help Menu The Help Menu has only the following option e About This display
34. o the Controller System is optional at start up however the Controller System should be connected to the Interface Module before trying to establish a connection To start PCpaK select the PCpaK option from the start menu When PCpaK starts the initial window to be displayed is the Main Window See Figure 3 for Main Window at Start up From this point the user can use PCpaK to interrogate and configure Controller Systems Sevcon PCpaK 2 00 00 Jay File View Connection Log Tools Help t here is no information to show in this view No nodes Ready Figure 3 PCpaK Main Window at Start Up PCpaK Manual 13 10 12 05 Features Main Window Main Window PCpaK has one main window which is used to display all the information about a connected controller system if Online or to display a previously saved Controller System Profile file if Offline Sevcon PCpaK 2 00 00 Eile View Connection Log Tools Help Status Test B Ver BDI Fault Log Setup E Battery Volt Motor Setup Maintenance Display Configure Figure 4 PCpaK Main Window This window uses a layout similar to Windows Explorer to allow the operator to edit personalities and view controller system information The window is split into different panes as shown in Figure 5 At the top of PCpaK s main window there is the standard Title Bar Menu Bar and Toolbar For further description of the Menu Bar and Toolbar
35. ow Nodes and Menu Item Panes Range Check If any personalities are out of range this item will show which one it is This information is read only and cannot be changed Sub Node Items Selecting a sub Node item in the left hand pane may display the following information in the right hand pane for some PowerpaK units Note that whether or not this information is displayed depends on the security level of the PCpaK installation and also the controller variant Configure Node software version number and personality checksum Debug Debug information for system development and analysis amp Sevcon PCpaK 2 00 00 Qu File View Connection Log Tools Help te m Personalities Status Test B Ver BDI Fault Log Setup B Battery Volt Motor Setup Maintenance Display Configure Node 0 Ready Figure 7 A Sub Node Menu This information is read only and cannot be changed There is no sub Node information displayed for MillipaK systems PCpaK Manual 19 10 12 05 Main Window Nodes and Menu Item Panes Menu Items Selecting a Menu item in the left hand pane will display information in the right hand pane depending on the type of menu which is displayed The different types of menus available are Configuration Menus containing personality or setup information Status Menus containing system status information and the service log Test Menus containing system test
36. s a dialog box which gives information about this release of the PCpaK program See Figure 19 The about dialog box displays the current version of PCpaK and the type of installation Sevcon PCpak Programmer Copyright 2000 2005 Sevcon Ltd 2 00 00 15 Sep 2005 PCP072 F Release version Config ID Sevcon engineering Sevcon Engineering allows full access to MillipaK and Powerpak Micropak Programmer connect to any MillipaK or PowerpaK Micropak controller which is PCpak enabled Figure 19 About Dialog Box PCpaK Manual 48 10 12 05 PCpaK Toolbar PCpaK Toolbar This section describes the PCpaK Toolbar in more detail See Figure 20 Each item in the toolbar is a short cut for an existing menu item The toolbar items are listed below and their corresponding menu item in the PCpaK Menus section is shown Refer to the appropriate menu item section for more information Figure 20 PCpaK Toolbar a geh There are three items in the Toolbar The Toolbar items from left to right are Fs E Open Connection Refer to the Open Connection section Shortcut key f8 7 m 7 Close Connection Refer to the Close Connection section Shortcut key f7 o Open File Opens a previously saved sev personality profile for loading into a controller or for viewing offline g Save Snapshot Saves the current personality profile into a sev file Flash Program Initiates flash pro
37. ssnnsnnsnnse 13 META O A O 14 Node and Men Item Panes crscscdecsccesscansniccbscsoccssvicensccecesesstesdvscceseccsonateuscssscescessvansecesvsesonivevauses sbessecwotsesdsedesecensnacesdess Node and Node Menus Left Hand Pane Menu Items Right Hand Pane grenerien aa A R Aa E AR E E E a a EEES ANA A OA 26 File Menu Edit Menu Flash Programming c su200s00ssosssnssnssnnsnnsnnssnsnnssnnsnnsnnssnnsnnsnnssnsnnnsnnsnnsnnssnssnnsnnsnnnsnssnnsnnsnnssnnsnssnnssnssnssnnsnnsnnssnssnnsnnsnnse MillipaK 0 0 PowerpaK Micropak Notes about Flash Programming PCpaK Manual 3 10 12 05 Contents FAULT MESSAGES curarlo ati 57 ORDERING INFORMATION 4 een 60 SOFTWARE UPDATES ae 60 CONTACT DETAILS Eee 61 PCpaK Manual 4 10 12 05 Introduction Introduction PCpaK allows a PC to communicate with an individual controller or a controller system comprising of more than one controller if they are inter connected via a communications bus The software provides many advantages over using the standard calibrator hand set and offers the following features Connection to multiple nodes where the nodes are connected to each other via a common bus Ability to save and load configurations to and from file Rapid download of system configurations Fault and service log analysis where the controller system supports them Controller status checking View
38. tion items personalities setup items etc PCpaK always prints to the default printer PCpaK Manual 30 10 12 05 PCpaK Menus File Exit Exit This option allows the user to exit PCpaK PCpaK Manual 31 10 12 05 PCpaK Menus Edit Menu Edit Menu This menu option is not yet available PCpaK Manual 32 10 12 05 PCpaK Menus View Menu View Menu The View Menu has the following options Update Dynamic Data Show Hide Communication Status Each menu item is explained more fully in the following sections PCpaK Manual 33 10 12 05 PCpaK Menus View Update Dynamic Data Update Dynamic Data This option allows the user to force a refresh of all the data currently displayed Function key F5 can be used to access this function PCpaK Manual 34 10 12 05 PCpaK Menus View Show Hide Communication Status Show Hide Communication Status The Communication Status dialog box see Figure 14 shows when PCpaK is downloading and uploading data to and from the controller system This option can be used to hide or show this dialog box Communication Status Searching for node 15 A ey Display comms status Figure 14 Communication Status Dialog Box Function key F12 can also be used to show hide the Communications Status dialog box PCpaK Manual 35 10 12 05 PCpaK Menus Connection Menu Connection Menu The Connection Menu has the follo
39. ules can be found in the Ordering Information section WARNING TO PREVENT POTENTIAL DAMAGE TO YOUR PC ENSURE THE CONTROLLER BATTERY NEGATIVE B AND BATTERY POSITIVE B CONNECTIONS ARE MADE PRIOR TO CONNECTING TO YOUR PC PCpaK Manual 10 10 12 05 Installation Hardware Connections Connection Connection Once you have the appropriate interface module for your Product Range you can connect up the system as described below Interface Module to PC Connection All interface modules have one 9 way D type connector This should be plugged into a free serial port on your PC or laptop The 6 way Molex connector should be plugged into the controller as follows PowerpaK Controller System to Interface Module Connection The PowerpaK range of controllers use a serial communications bus called CAN CAN allows many nodes to be easily connected together If your PowerpaK Controller System is setup to run in CANbus mode then you only need to connect the 6 way Molex connector from your module to any point on the CANbus to be able to access all the nodes The Interface Module is supplied with 2 Molex connectors one male and one female This is a straight through connection and is intended to be inserted into any point on the CANbus Typically if there is more than one node in a PowerpaK system it will be configured to run in CANbus mode This can be easily determined by checking if there is a wiring harness connecting allthe CANb
40. us outputs on the controllers together Refer to the appropriate Product Manuals for your PowerpaK system for more information MillipaK Controller System to Interface Module Connection The MillipaK range of controllers does not use CANbus and is not designed to communicate with other nodes The Serial Port is only used by the Calibrator or PCpaK If there is more than one MillipaK Controller on your vehicle you will need to connect the 6 way Molex connector from the Interface Module to the Serial Port of the controller you want to access information from Protocol Selection The 2 Interface Modules run using different protocols Protocol selection is made in the PCpaK options screen which can be found in the tools menu You must check you are using the correct protocol otherwise you will not be able to open communications PCpaK Manual 11 10 12 05 Features Features This section describes the features provided by PCpaK and gives instructions on how to operate the program PCpaK Manual 12 10 12 05 Features System Start Up System Start Up If PCpaK is to be used simply to view existing Controller System Profile files see section on Controller System Profile Files then no connection to an Interface Module is necessary However if PCpaK is to be used to communicate with a Controller System ensure that the Interface Module is connected to the serial port on the PC or Laptop before starting PCpaK The connection t
41. when ready See Figure 15 Rapid Download gt Rapid Download Wizard Step 1 Choose source and destination parameters First select the previously saved controller calibration file you want to download to the controller File C My Documents sample data sev E When you have selected your file click next Exit Next gt Figure 15 Rapid Download Wizard Step 1 2 Check Node Compatibility On Multi Node systems it is possible to individually select or de select which nodes are to be updated For example on a Traction and Pump system it is possible to request that both the nodes are updated or only the Traction Node or Pump Node is updated In some exceptional circumstances the user may have a system where the Destination Nodes of the target Controller System are different to the Source Nodes defined in the Controller System Profile file PCpaK allows the user to map a source node to a different destination node or to ignore a node altogether The Dest Node column is used to change the destination node Setting the Dest Node to Ignore will exclude that node from the Rapid Download updated It is recommended that only advanced Users change destination nodes In most circumstances the destination node should be identical to the source node By default PCpaK will assume all nodes in the Controller System Profile file are to be included in the Rapid Download and the destination node is the same as the sourc
42. wing options Open Connection Close Connection Each menu item is explained more fully in the following sections PCpaK Manual 36 10 12 05 PCpaK Menus Connection Open Connection Open Connection This option allows the user to connect PCpaK to a controller system Function key F8 can also be used to open a connection PCpaK will attempt to connect using the COM Port specified in the Options dialog box Refer to the Options section Whilst the connection is established PCpaK will display the Communication Status dialog box Refer to the Show Hide Communication Status section The first step is to try to detect what controllers are present On a multi node system where the controllers are all connected viaa common communications bus PCpaK will attempt to detect all the controllers on the bus PCpaK will try to connect three times before aborting and displaying an error message to the user If one or more controllers are found PCpaK will upload all the information it requires and displays the information in the Main Window PCpaK Manual 37 10 12 05 PCpaK Menus Connection Close Connection Close Connection This option allows the user to disconnect PCpaK from the Controller System Function key F7 can also be used to close the connection PCpaK Manual 38 10 12 05 PCpaK Menus Log Menu Log Menu The Log Menu has the following options Clear Log This menu item is explained more fully in
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