SINUS PENTA USER MANUAL FOR TRACTION APPLICATION
Contents
1. 23 38 Bater 26 3 8 1 Desen OIA 9540 ee ct ggasi PR 26 3 8 2 Wis oi Parameters P969 72 secutae tdmen eee 26 3 8 3 Advice for ZEBRA Battery ene hse resi tnis reser ee rise rne resins 29 3 8 4 How to Charge Batteries 222 00 nennen hee hse nee nsn een eei ee tee ree ese res ee reser nene 29 3 8 5 Battery Discharge dtu dM ed nude Media dp pu PUE A Eus 29 3 8 6 GAN Botern e T TOT TNI 30 Tradion Mode ENG 33 3 10 Alarms for Sinus Penta Traction 35 3 10 1 ARTE LE EE AEE E 35 210 295 E E A S en eee ee 35 2 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION 2 ELETTRONICASANTERNO 0 1 Figures Figure l Block diagram of the traction esieses cerea vasos ext esca o Fel R00 Te QUE e 7 Figure 2 Inverner WING 8 Figure 3 Max torque pattern based on rpm 0 020000 2 000000000000 11 Figure 4 Limit pattern of the braking torque based on 12 Figure D Ze Dra MO2. b Ic U M d 35 3 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION Z ELETTRONICASANTERNO 1 OVERVIEW Special software is supplied with the inverters of the Sinus Penta series that can be used for particular applications The menu structure the programming mode and navigation mode of the Sinus Penta are used parameters or menus will be added removed whether required not required for the application This manual covers the wiring diagrams and the parameters relating to the application for any detail concerning option control boards and different parameters common to the Sinus Penta refer to Sinus Penta s User Manuals 4 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION 2 ELETTRONICASANTERNO 2 SOFTWARE DOWNLOAD FOR APPLICATION PROGRAMMING The Remote Drive software and the PXxxxxFO mot PXxxxxFl mot files of the application are required to download the application to a Sinus Penta inverter The download procedure is detailed in the following sections of this manual The PTxxxxFO mot and PTxxxxF1 mot files are required for the TRACTION application For different applications refer to the relevant manuals and to the updates available on Elettronica Santerno s website AY NOTE Refer to the User Manual of the Remote Drive software for more details The software of the Sinus Penta inverters consists of two files one containing the firmware and one containing the MMI table
3. 15Q0102B20 SINUS PENTA MULTIFUNCTION AC DRIVE USER MANUAL FOR TRACTION APPLICATION Upd 03 07 2006 R 00 English Software Version 1 6xx e This manual is integrant and essential to the product Carefully read the instructions contained herein as they provide important hints for use and maintenance safety e This device is to be used only for the purposes it has been designed to Other uses should be considered improper and dangerous The manufacturer is not responsible for possible damages caused by improper erroneous and irrational uses e Elettronica Santerno is responsible for the device in its original setting e Any changes to the structure or operating cycle of the device must be performed or authorized by the Engineering Department of Elettronica Santerno e Elettronica Santerno assumes no responsibility for the consequences resulting by the use of non original spare parts e Elettronica Santerno reserves the right to make any technical changes to this manual and to the device without prior notice If printing errors or similar are detected the corrections will be included in the new releases of the manual e Elettronica Santerno is responsible for the information contained in the original version of the Italian manual e The information contained herein is the property of Elettronica Santerno and cannot be reproduced Elettronica Santerno enforces its rights on the drawings and catalogues according to the law EL
4. Default Level ENGINEERING Address This parameter is used for the dynamic control of the torque limit while braking If Function it is enabled the max current for the battery charge is limited from the information sent by the MBS P365 Torque Reduction Enable for Current Limits Range Default ES ENGINEERING Address This parameter enables the torque reduction for discharge current limits If it is set to 1 Yes torque is reduced to the min value between torque limitation due to Function current limits and torque limitation due to voltage limits P370 P371 Voltage limits can be disabled torque limitation can then depend on current limits only see parameters P370 P371 26 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION 2 ELETTRONICASANTERNO P366 Power Reduction with One Battery Range 0 100 0 100 90 Default Level ENGINEERING Address If only one battery is operating the MBS sends the following signal sys_reducedNumberOfBattery the system reduces the maximum power that the motor can absorb from the batteries The power that can be absorbed is reduced of this value percent which is computed based on the motor rated power Function P367 Torque Reduction with One Battery 0 100 O 100 90 Default Level Address If only one battery is operating the system reduces the maximum torque that the Function motor can produce The produced torque is then reduc
5. Figure 7 Monitoring menu O Testing menu detects the contactor status zs 1 Battery real time a 2 Battery setup 3 Battery lifedata dq 4 Battery parametrization 5 Monitoring 1 0 Testing Diagnostic faults 4 8 Diagnostic values LE 9 Last 20 errors detected 1 Ignition Key fl S1 Precharge OPEN S2 gt Battery CLOSE S3 Battery CLOSE S4 gt Charge OPEN 6 Disconnection relay CLOSE 7 Emergency NORMAL 8 Fan OFF 9 Reset input OFF 10 test FALSE 11 Manual switch off error FALSE Figure 8 I O testing menu 31 35 SINUS PENTA USER MANUAL FOR 9 TRACTION APPLICATION A ELETTRONICASANTERNO e Diagnostic Fault menu Some faults are automatically reset some faults are to be reset by the user and the remaining faults are to be cancelled via computer To cancel faults via computer access the key icon select Level 1 and enter zeb001 password An icon with a appears press the to cancel the alarm When Level 1 is selected for certain parameters in the Battery Parameterization menu and the Battery Setup menu those parameters are highlighted by a W and can be altered after entering the password Other parameters can be altered but their alteration is to be enabled by calling the Customer service e Diagnostic Values menu Last 20 Errors Detected menu Fan Test Isolation Test menu The Fan Test menu allows to test the fan operation for approx 30s the Isolatio
6. CAN baudrate 125 Kbps 2 l 250 Kbps Connection channel 500 Kbps Channel Channel 2 Transmission retry 3 Cancel Multi 250K CAN USB Access level 7 Figure 5 ZebraMonitor configuration Data concerning Zebra batteries can be acquired and stored to memory ZEBRAmonitor v2 52 Int Rev date 25 10 05 s n 11137 sw 3 0 21 06 2005 Battery ID 30 Q AIBMIs Data acquisitio amp kg xX AH 9X9 04 ug B g 1 0 Testing 2 Battery real time a Battery setup Battery lifedata qu Battery parametrization Monitoring 1 0 Testing Diagnostic faults Diagnostic values EE Last 20 errors detected Fantest E Manual switch off error System Options Windows Help E x ET 8 Diagnostic values 3 Last 20 errors detected s 1 Battery real time 2 Battery setup 3 Battery lifedata mq 4 Battery parametrization Temp sensor 1 Temp sensor 2 Temp BMI Battery current Battery voltage Smoothcap voltage Soc DOD I isolation Test BMI 2 By ALL lt Data acquisition 10 Actual battery capacity Reset BMIs 11 Capacity fullcharged ci WN System Enable 12 Nameplate capacity 13 Energy in precharge r 14 Regen braking exceede Print Update Multi 250K CAN LISB AccesslevelO 26 01 2006 180 Figure 6 Zeb
7. 4 1 eet 15 3 4 2 16 3 4 3 Speed REFERENCE 16 3 4 4 Torgue LIMIT OCS 4 E 16 3 4 5 Configuration of the COMMAND Source Parameters the Sinus Penta Traction Application 7 RP 18 222 1 18 3 5 2 0 18 3 9 9 Configuration of DIGITAL Input Parameters in the Sinus Penta Traction Application 18 3 6 Digtal Inputs mmc 19 3 6 1 TT 19 3 0 2 START Terminal T4 MDIT 19 3 6 3 ENABLE Terminal MDIZ M 20 3 6 4 Mes aane dub MT 21 3 6 5 REVERSE GEAR Terminal M E UM 21 3 6 6 ACCELERATOR CONTACT Terminal 18 eU Y rio Utd E 21 3 6 7 BRAKE CONTACT Terminal 1 92 MIDI 21 3 6 8 Configuration of the DIGITAL Input Parameters in the Sinus Penta Traction Application 22 TFadionApplicalon Meli etie pisces oM epulis teu mi a a Meer EPI im Fede UR ppt 23 S l Bree EO OE 23 3 7 2 stot Paromelers P359 19 302
8. installed on the inverter CNIOA CANL CAN ground CN10 C CAN V External power supply if any CN10 D 3 1 3 CONTROL OF THE MOTOR TORQUE FOC Field Oriented Control is the implemented control algorithm This is a closed chain control requiring a speed transducer to detect the position of the motor shaft instant by instant Where the speed reference and torque accelerator are used it is used as the torque limit The position of the accelerator is directly proportional to the torque generated by the motor Nevertheless limitations exist to avoid exceeding the limits set by the electric and mechanical features of the equipment components and to obtain the best driving comfort The torque limit produced by the inverter never exceeds a certain limit torque model based on rpm as shown in the figure below The maximum value of the torque limit is equal to parameter C048 percentage with respect to the motor rated torque Torque P00059 7 O Figure 3 Max torque pattern based on rpm When you release the accelerator a decelerating torque P355 is automatically produced which is equal to a percentage of the rated torque allowing the battery to recover the kinetic energy of the vehicle If you press the brake pedal the torque attains a higher value with respect to the decelerating torque equal to parameter P356 computed as a percentage of the motor rated torque 11 35 SINUS PENTA USER MAN
9. the cause responsible for the alarm has been removed DANGER Electrical shock hazard exists on output terminals U V W and resistive braking module terminals B even when the inverter is locked 3 6 5 REVERSE GEAR TERMINAL 17 4 This input only sets the REVERSE GEAR of the vehicle the reverse gear is not enabled It cannot be activated when the START FORWARD GEAR input is active If both inputs are active REVERSE GEAR and START FORWARD GEAR the vehicle RUN is disabled 3 6 6 ACCELERATOR CONTACT TERMINAL 18 MDI5 This input activates the accelerator pressed signal If this signal is active when the BRAKE CONTACT is active the ACCELERATOR CONTACT signal is ignored and the BRAKE CONTACT signal has priority it stops the vehicle through a torque controlled stop When RUNNING the deactivation of this signal stops the vehicle through a controlled stop of the system following the deceleration characteristic Figure 4 3 6 7 BRAKE CONTACT TERMINAL 19 MDI6 This input activates the brake pedal pressed signal When RUNNING the deactivation of this signal stops the vehicle through a controlled stop of the system following the deceleration characteristic Figure 4 If the BRAKE CONTACT signal is active when the ACCELERATOR CONTACT signal is active the BRAKE CONTACT has priority and stops the vehicle through a torque controlled stop 21 35 SINUS PENTA USER MANUAL FOR O TRACTION APPLICATION A E
10. 0 Full scale Value for Max Water Temperature TENE 300 0 300 C Default 200 C ENGINEERING Address Function Upper full scale value for the temperature of the motor cooling water P361 Full scale Value for Min Water Temperature Range 100 300 C Default Level Address Function P362 Full scale Value for Battery Current 0 500 0 500A Default 400 A ENGINEERING Address 962 Function Full scale value for the battery current 25 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION Z ELETTRONICASANTERNO 3 8 Battery Application Menu 3 8 1 DESCRIPTION This menu contains the programming parameters for smart ZEBRA batteries More details about Zebra batteries are given in the relevant User Manual 3 8 2 LisT OF PARAMETERS P363 P374 PARAMETER DESCRIPTION Table 7 List of parameters P363 to P374 344 Battery dynamic control ENGINEERING P366 Power reduction with one battery ENGINEERING 966 40 Rated value for max charge current ENGINEERING P369 Rated value for max discharge current ENGINEERING 969 224A CAN communication timeout ENGINEERING P375 Battery failure handling ADVANCED 975 OAam P363 Zebra Battery Installed 0 No Range Default Level ENGINEERING Address Function This parameter indicates that Zebra batteries are installed P364 Battery Dynamic Control
11. ETTRONICA SANTERNO Elettronica Santerno S p A Via G Di Vittorio 3 40020 Casalfiumanese BO Italy Tel 39 0542 668611 Fax 39 0542 668622 www elettronicasanterno it sales elettronicasanterno it USER MANUAL FOR TRACTION APPLICATION Z 0 1 2 3 SINUS PENTA ELETTRONICASANTERNO 0 TABLE OF CONTENTS 2 FIU 25091 E 3 see aa E 3 eis 4 SOFTWARE DOWNLOAD FOR APPLICATION 4 1 6 0 000000 00000000 000000 5 2 1 Firmware Upgrade for SINUS PENTA 0 0000000000000000000000000000 0 6 elei HON onm 221 UPA OMEN OM RETE 7 Seles IN m 8 3 1 2 oie ES NET nnn een ae OO omm 9 3 1 3 Control otihe Motor oe ee ee 11 52 2 Measures MENY 13 22221 BSG OMCs 13 Molor Conirol uU Esas A 14 3 9 T 9 79 ects cra T OT TX 14 Control Method Menu TEE 15 3
12. LETTRONICASANTERNO 3 6 8 CONFIGURATION OF THE DIGITAL INPUT PARAMETERS IN THE SINUS PENTA TRACTION APPLICATION Make sure that the digital parameters are set up as follows Table 5 List of parameters C150 to C187 C150 STOP input ADVANCED 1150 0 None C151 REVERSE input ADVANCED 1151 0 None 0 None 0 None Disable alarm RESET in MDI3 0 No 0 None C157 MULTISPEED 2 input ADVANCED 1157 0 None C163 RESET UP DOWN input ADVANCED 1163 0 None C165a External alarm 2 activation delay ADVANCED 1306 Instantaneous C187 Input for torque limit reference source disable ADVANCED 1187 0 None CAUTION DO NOT change parameters C150 to C187 for the Traction application 22 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 7 Traction Application Menu 3 7 1 DESCRIPTION The Traction menu contains user defined parameters concerning the max speed of the vehicle the traction torque pattern and the braking torque pattern the wheel ratio the full scale values for temperature and current measures 3 7 2 LIST OF PARAMETERS P350 P362 PARAMETER DESCRIPTION Table 6 List of parameters P350 to P362 7353 Eneo deereese speed for broking torve ADVANCED 953 P354 Null braking torque speed ADVANCED 100rpm P355 Limit Torque while deccleraing ADVANCED 985 10k P356 Limit torque while braking ADVANCED 956 2096 P357 Forward gear speed setp
13. NO contis do ded ededsandsd ens t etiani essetis eur 30 Figure 6 ZebraMonitor enne hee hse ene eee ese es tes tee ise 30 Figure 7 Monhoring MEU 31 PICS Testing MENU m 31 Figure 9 RemoteDrive control 5 pa 33 0 2 Tables Table 1 Description of the motor parameters and values to be set for the Traction application 14 Table 2 List of parameters C140 to C148 to be selected for the Sinus Penta Traction 17 Table 3 Description of parameter C048 2 2 2 2 000006000000000000000000 es ten see ree tree sree tees tee rese tenere es 18 Table 4 Sinus Penta Traction functions for digital inputs 1 1 000000000000000000 19 Table 5 List of parameters C 150 to C187 umb sepa e pas Le dele 22 Table r Listoi parameters Fo 900 D 302 M UMEN d MEN E MU 23 Table 7 List Gr parameters P363 To P 3 4 css esie ae SN EYES UE e Stau Es a ute cO 26 Table 8 List ot the Traction application alarms assu Ep rM te
14. OF THE COMMAND SouRcE PARAMETERS IN THE SiNUS PENTA TRACTION APPLICATION Table 2 List of parameters C140 to C148 to be selected for the Sinus Penta Traction setting C140 Command digital input n 1 ADVANCED 1140 C141 Command digital input n 2 ADVANCED 1141 2 Serial link C142 digital input n ENGINEERING 1142 0 Disable C145 Reference input n 3 ENGINEERING 1145 0 Disable C147 limit input ENGINEERING 1147 9 Traction C148 Remote control to Local control ENGINEERING 1148 0 StandBy or Flux weakening CAUTION DO NOT change parameters C140 to C148 for the Traction application 17 35 SINUS PENTA TRACTION APPLICATION USER MANUAL FOR 9 ELETTRONICASANTERNO 3 5 Limits Menu 3 5 1 DESCRIPTION The parameters included in the Limits menu for the standard SINUS PENTA series set the maximum torque pattern that can be obtained from the vehicle unless reducers are installed and they limit both traction pattern and braking pattern 3 5 2 PARAMETER 048 PARAMETER DESCRIPTION Parameter C048 15 used for control purposes in the Sinus Penta Traction application C048 Maximum Torque Limit 72 5000 5000 _500 0 500 096 Default 1200 120 0 Level ADVANCED Address 1048 VIC and FOC This parameter sets the maximum limit of the torque demand It is expressed as a percentage of the rated torque of the connected motor The traction torque p
15. Ref rpm 0 99 rpm 0 01 it E E3 F E m E El H E E RIT Auto 002 2 Speed Ramp Output E rom Acq Mode Local Dew U5B R5232 Figure 9 RemoteDrive control screen e To activate the ignition key click MDI2 KEY signal to set it it turns to light green e Put the FORWARD or REVERSE gear e Activate the ACCELERATOR contact digital signal Adjust the potentiometer ACCELERATOR e Remove the ACCELERATOR contact digital signal to decelerate e Remove the ACCELERATOR contact digital signal to brake and activate the BRAKE contact e You can also send the FORWARD REVERSE ACCELERATOR BRAKE signals via RemoteDrive do not change the sequence above e The torque reference cannot be sent via RemoteDrive e f inverter alarms trip they are detected by 090 press the RESET button or reset the alarms tripped via RemoteDrive by clicking the MDI3 RESET button twice this button turns to light green if clicked once then it returns dark green if clicked twice 33 35 USER MANUAL FOR TRACTION APPLICATION NOTE NOTE NOTE NOTE gt gt gt 34 35 O SINUS PENTA ELETTRONICASANTERNO If the vehicle is in gear and or the accelerator is pressed before the ignition key is fitted the vehicle will not start If both the ACCELERATOR contact digital signal and the BRAKE contact are active the equipment acts as if the BRAKE was pre
16. TTERIES Do the following to charge the vehicle batteries e Deactivate Sinus Penta drive e Remove the COMMAND ACTIVATION key e Change the operating mode from DISCHARGE to CHARGE 3 8 5 BATTERY DISCHARGE Do the following to charge the vehicle batteries e Remove the COMMAND ACTIVATION key the PARK MODE activates e Change the operating mode from CHARGE to DISCHARGE Fit the COMMAND ACTIVATION key to enter the discharge mode Before fitting the key remove voltage from the vehicle discharge mode and wait at least 10 seconds 29 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION Z ELETTRONICASANTERNO 3 8 6 CAN BATTERY COMMUNICATION A BMI Battery Management with Interface is supplied with ZEBRA batteries The BMI allows communication concerning the battery diagnostics while the ZEBRAmonitor software allows to monitor the battery status see the relevant installation manual Connect the CAN cable via USB and launch the ZEBRAmonitor software if active batteries are automatically detected and the system configures as follows ZEBRAmonitor v2 52 Int Rev date 25 10 05 File BME AlBMIs Data acquisition System Gp Windows Help s E 59 6 4 gu BMI 2 ALL BMIs System configuration Data acquisition Interface type ZEBRA system type SD Reset BMls C Mector CANpari Single System Enable Vector Multi BMls
17. UAL FOR O TRACTION APPLICATION A ELETTRONICASANTERNO Torque P355 P350 P000597 O Figure 4 Limit pattern of the braking torque based on rpm If the braking torque drops below the value set in parameter P353 it is proportional to rpm In case of even lower rpm P354 the braking torque is reset to avoid reversing the direction of rotation of the motor Torque variations should be adjusted through special ramps as they avoid uneven operation of the motor due to sudden variations of the torque delivered to the motor Parameter P026 allows to set the time the acceleration ramp takes to change the reference from O to its max value Parameter P027 allows to set the time the deceleration ramp takes to change the reference from its max value to zero For the systems provided with smart ZEBRA batteries which detecting the internal status of the equipment and send signals about operation limits parameter P364 allows to dynamically adjust the activation thresholds of the control system The following parameters can be used e P368 Maximum recovery current of the batteries P369 Maximum discharge current of the batteries e P370 Voltage value for the traction torque decrease e P371 Voltage value for the traction torque neutralisation The max current for discharge and recovery is limited from the values sent from the battery diagnostics The maximum limit for recovery voltage is the limit which is dynamically set fr
18. al boards It includes 10 signals with two additional signals with respect to the local hardware terminal board Inputs to MDI8 are obtained with the logic OR of the input signals for all active terminal boards e The ENABLE input is obtained with the logic AND of the input signals for terminal MDI2 in all active terminal boards Measure 031 is similar to M032 but it displays the status of the terminal board obtained after delaying input signals M032 where required through special timers The inverter uses this terminal board to acquire digital commands Some functions cannot be programmed but they are assigned to special terminals Table 4 Sinus Penta Traction functions for digital inputs FORWARD GEAR START MDI2 RESET MDI3 3 6 2 START TERMINAL 14 MDI1 This input only sets the FORWARD GEAR of the vehicle the forward gear is not enabled It cannot be activated when the REVERSE GEAR input is active If both inputs are active REVERSE GEAR and START FORWARD GEAR the vehicle RUN is disabled 19 35 SINUS PENTA USER MANUAL FOR O TRACTION APPLICATION A ELETTRONICASANTERNO 3 6 3 ENABLE TERMINAL 15 MDI2 If the ENABLE input signal is disabled for one of the active terminals the inverter CAUTION is instantly disabled and the motor starts idling The mechanical load could then accelerate brake the motor in an uncontrolled way CAUTION protection alarm
19. arning Threshold for Battery Endurance Range Default Level ADVANCED Address 972 This parameter sets the threshold for battery endurance The Function BATTERY EMERGENCY warning is displayed measure M116 in the Traction Measures Menu P373 Battery Charge Full scale Value Range Default 76 76 Ah Level Address Function Battery rated capacity P374 CAN Communication Timeout Range Default Level Address Timeout in CAN communication between the batteries and the inverter If communication is suspended the CAN KO BATTERY warning measure M116 in the Traction Measures Menu is displayed For safety reasons regeneration current is decreased by 5096 of the rated value In the traction stage the last acquired values are considered If communication stops for more than timeout seconds alarm A106 CAN Communication KO trips Function P375 Battery Failure Handling 0 Set Alarm Default 0 Set Alarm Level ADVANCED Address This parameter handles battery failures switch off delay switch off either as warnings or as alarms Function 28 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 8 3 ADVICE FOR ZEBRA BATTERY MAINTENANCE Zebra batteries must be recharged frequently and completely They re almost discharged when their charge current drops below 0 5 A and their SOC is 100 AY NOTE Frequently recharge Zebra batteries 3 8 4 How TO CHARGE BA
20. attern see Figure 3 is defined based on parameter 048 It also sets the maximum allowable value required while braking The max value depends on the inverter size 3 5 3 CONFIGURATION OF DIGITAL INPUT PARAMETERS IN THE SINUS PENTA TRACTION APPLICATION Table 3 Description of parameter C048 CO48 Maximum torque 1048 200 0 18 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 6 Digital Inputs Menu 3 6 1 DESCRIPTION NOTE Refer to Sinus Penta s Installation Instructions manual for the hardware description of the digital inputs The parameters contained in this menu assign particular digital control functions to each digital input on the terminal board Each parameter has a particular function which is assigned to a given terminal on the terminal board The full processing of the digital inputs also includes the selection of other remote virtual terminal boards see The Control Method Menu on the standard Programming Instruction Manual and the possibility of delaying input digital signal enable disable by means of software timers see The Timers Menu on the standard Programming Instruction Manual The input status is displayed in M031 M032 M033 Measure 033 indicates the current status of the 8 inputs in the local hardware terminal board Measure 2 shows the current status of the virtual terminal board obtained by processing all active termin
21. ed of this value percent which is computed based on the max torque of the motor P368 Rated Value for Max Charge Current Range Default Level Address Reference value of the max charge current that batteries can absorb when the Function equipment is braking This parameter is used for computing battery dynamic control while braking P369 Rated Value for Max Charge Current Range Default Level Address EX o Reference value of the max discharge current that batteries can produce in the Function traction stage This parameter is used for computing battery dynamic control in the traction stage P370 Torque Reduction Voltage Range Default Level Address When the voltage threshold set in this parameter is attained the traction torque begins to be reduced in a linear way due to limitation depending on bus voltage reduction If parameter P365 is set to Yes the torque reduction is determined by the min value obtained from the computing of the current limit P365 and the voltage limit Limitation for voltage limit can be disabled by setting a lower value than the value set in parameter P371 Function 2 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION Z ELETTRONICASANTERNO P371 Null Torque Voltage Range 0 500 0 500 V Default 380 380 V Level ENGINEERING Address 971 Voltage neutralizing the traction torque due to limitation depending on bus Function voltage reduction P372 W
22. for the keypad interface Both files use hexadecimal files with the MOT format The filenames ending with FO relate to the firmware the filenames ending with F1 relate to the MMI table 9 35 USER MANUAL FOR TRACTION APPLICATION Z ELETTRONICASANTERNO SINUS PENTA 2 1 Firmware Upgrade for SINUS PENTA Inverters This section covers firmware upgrade and application download In case of multidrop connection RS485 only the equipment to be upgraded shall be connected to the network Launch Remote Drive Select the dialog language click a flag and press Next 3 In the Connection Parameters window select the Local mode In the Serial Configuration Parameters window set the interface device the COM being used and the baud rate 38400bps click Connect then click the Next button In the example below USB RS485 converter is used a File Chat Config Aiuto Scelta tipo di connessione Parametr di connessione Parametri configurazione seriale Modalit Porta dispositivo USB RS485 2 wires Y Tipo di collegamento cient Porta PC v Baud rate bps 13400 Host rem Parit pNone v Ritinterm ms 50 Porta TCP IP 71 TimeOut ms 500 ScanTimeOut ms 300 Rem TimeOut s 20 Farametr apparecchiatura Tipo apparecchiatura Indirizzo 1 Click Browse to select the PxxxxFl mot file then click SendTab Once this file i
23. he CAN interface via ZEBRA batteries through the MBS This menu is available only if ZEBRA batteries are fitted It is available provided that the ENGINEERING access level is selected e Menu Battery Measures It includes the measures relating to the MBS batteries This menu is available only if ZEBRA batteries are fitted 13 35 SINUS PENTA USER MANUAL FOR 9 TRACTION APPLICATION A ELETTRONICASANTERNO 3 3 Motor Control Menu 3 3 1 DESCRIPTION The control algorithm used for the Sinus Penta Traction application is FOC Field Oriented Control a closed chain control requiring a speed transducer to detect the position of the motor shaft instant by instant with a speed reference The characteristic parameter set for the connected motor is contained in the Motor Control Menu see Sinus Penta s Programming Instructions manual and is set up when tuning the motor Check parameters in Table in particular Table 1 Description of the motor parameters and values to be set for the Traction application C008 BASIC 1008 Regen 2 4 Control algorithm being used BASIC 1010 2 FOC con Type of reference being used ADVANCED 1011 0 Speed speed torque C015 Characteristic electric ratings for the BASIC 1015 1025 25 connected motor ADVANCED C028 Minimum speed to be obtained ADVANCED 1028 6000 C030 Speed for the beginning of flux ENGINEERING 1030 From tuning weakening C031 Max speed alarm thresh
24. inverter must be kept in the open position 3 1 2 CONTROL CONNECTORS NOTE To avoid accidental activation of the round connectors one pole is used as a safety key 3 1 2 1 CN3 MOTOR SIGNAL CONNECTOR 19 pole round connector F is installed on the inverter 3 1 2 2 CN4 KEYPAD AND SERIAL LINK 485 CONNECTION 19 pole round connector F is installed on the inverter 9 35 SINUS PENTA USER MANUAL FOR O TRACTION APPLICATION A ELETTRONICASANTERNO 3 1 2 3 CN5 AUXILIARY ANALOG INPUT CONNECTION 19 pole round connector F is installed on the inverter Spare analog input NSB Speeandoginptt2 Speeandginptt3 1 CNS Spare analog input4 23 CNH S Ground for spare analog input5 CNS Ground for spare analog input Ground for spare analog input7 Safety key ENS 3 1 2 4 CN7 COMMAND CONNECTOR 19 pole round connector F is installed on the inverter Torque reference 0 10V Max torque Accelerator contact Brake contact Coolant PT100 RESET FORWARD REVERSE Ignition KEY Digital input power supply 24Vdc BOBTL Command for power supply internal contactor BOBTL Command for power supply internal contactor External alarm Coolant PT100 Safety key 10 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 1 2 5 CN10 CAN BUS CONNECTOR A 4 pole female connector is
25. l ADVANCED Address 954 Function This parameter sets the speed for a null the braking torque Figure 4 P355 Limit Torque while Decelerating Range 200 Default 0 Level ADVANCED Address 955 Limit torque while decelerating which is applied when the accelerator contact is Function released This is a percentage of the motor rated torque If exceeded the max torque limit is limited to P355 P356 Limit torque while braking Range 0 300 300 Default Level ADVANCED Address Limit torque while braking which is applied when the brake contact is pressed Function after releasing the accelerator contact This is a percentage of the motor rated torque If exceeded the max torque limit is limited to P356 24 35 SINUS PENTA USER MANUAL FOR 2 TRACTION APPLICATION ELETTRONICASANTERNO P357 Forward Gear Speed Setpoint Range 0 8000 0 8000 rpm Default 6000 6000 rom Level ADVANCED Address 957 Setpoint for the forward gear speed reference This is the max speed of the motor UDIN for the forward gear P358 Reverse Gear Speed Setpoint Range Default Level Address Setpoint for the reverse gear speed reference This is the max speed of the motor Function 9 for the reverse gear P359 Wheel Ratio Range 1000 1000 0 001 0 001 Default 0 010 km h rpm Level ENGINEERING Address 959 Function Conversion factor between the motor speed and the vehicle speed P36
26. l the vehicle and to adjust its speed The DC DC converter that recharges the supply batteries for the auxiliary services The wiring block diagram for the connected SINUS PENTA inverter is shown below Battery Vehicle CAN Inverter Figure 1 Block diagram of the traction system NOTE The TRACTION application for SINUS PENTA inverters MUST be activated only after performing the first startup for the FOC motor control 7 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION ELETTRONICASANTERNO 3 1 1 WIRING ONO lt p i x vsl REVERSE A NO 220VAC SUPPLY e pee D Figure 2 Inverter wiring 8 35 SINUS PENTA CAUTION CAUTION CAUTION gt gt CAUTION USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO Connect the main battery to the relevant connector only do not reverse polarities Do not change the sequence of the motor winding phases After connecting the equipment check the following all wires must be properly connected link is missing short circuit is occurring between the terminals and between the terminals and the ground When wiring the equipment the thermal magnetic circuit breaker installed on the
27. n Test menu allows to test the isolation system The isolation test is normally performed every 10 minutes MBS forces MBI to perform the isolation test Isolation failures can be internal or external to the equipment if contactors are closed isolation failures are external to the equipment if contactors are open isolation failures can be either internal or external If internal isolation failures are detected allow batteries to cool down if two isolation failures are detected a serious failure is occurring The Manual Switch off Error alarm allows to manually set an error to switch off one battery to reset this alarm in menu 7 select the error and click e 5 with three computers Click the first icon to create a ZebraAcquisitionDir file which detects the battery status Click the second icon to create the ZebraDataBase V20 database containing service parameters that are periodically sent out to update the battery status memory parameters should be sent once a month Click the third icon to create a ZebraDataBase file allowing the user to periodically store battery data and create an archive A second vel password is required ALL BMIs This menu allows to simultaneously display all batteries and select the measures to be displayed e Data Acquisition Right click to display a measure list to a text file 32 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 9 Traction Mode Enable Afte
28. ogic function of the inverter for the terminals of all active command sources is as follows e AND for the terminals allocated to the ENABLE External alarms n 1 n 2 n 3 functions for the remaining terminals 3 4 3 SPEED REFERENCE SOURCE The main reference is the speed value to be attained at constant speed MOOO This reference is acquired by the inverter only if the START command and the ENABLE command are active otherwise it is ignored When the main reference is acquired from the inverter the START amp ENABLE commands are active it becomes the input handled by the time ramps that produce the current speed setpoint for the connected motor The speed reference in the Sinus Penta Traction application is sent from 9 Traction traction machine processing TRACTION The source derives from the TRACTION machine processing The machine sets a different speed setpoint that can be user defined based on the preset running direction 3 4 4 TORQUE LIMIT SOURCE Parameter C147 allows to select the source of the Torque Limit value The Torque Limit function is a limit of the absolute value of the torque required from the motor Torque Limit lt torque demand x Torque Limit The reference to be selected for the torque limit in Penta Traction mode is 9 Traction traction machine processing 16 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 4 5 CONFIGURATION
29. oint ADVANCED 957 6000rpm ras Reverse gear speed sepon 1 ADVANCED 2000rem P359 Wheel ratio ENGINEERING 0 01 mem P360 Full scale value for max water temperature ENGINEERING oo 0 P361 Full scale value for min water temperature ENGINEERING P362 Full scale value for battery current ENGINEERING 400A P350 Traction Machine Enable Default Level ENGINEERING Address This parameter enables the traction mode it shall be activated after tuning the Function motor CAUTION to activate the traction mode also set up the parameters in the C14x Control Method menu accordingly 23 35 SINUS PENTA USER MANUAL FOR TRACTION APPLICATION Z ELETTRONICASANTERNO P351 Flux Weakening Enable from Traction Machine 0 No 85 Level ENGINEERING Address 951 Function This parameter enables the flux weakening from the traction machine P352 Reversal of Positive Running Direction 0 No Level ADVANCED Address This parameter allows to reverse the positive running direction Set P352 to 1 Yes Function if the positive running direction of the vehicle does not match with the forward run of the system P353 Linear Decrease Speed for Braking Torque Range Default Level ADVANCED Address 953 This parameter sets the speed for the linear decrease of the braking torque Figure Function 4 P354 Null Braking Torque Speed Range 0 5000 5000 rpm Default 00 rpm Leve
30. old and ADVANCED 1031 6200 enable CAUTION DO NOT change parameters to C012 for the Traction application NOTE can be adjusted based on the speed performance to be obtained For the Traction application parameteres C028 to C031 set the speed limits that Avoid altering parameter 14 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 4 Control Method Menu 3 4 1 DESCRIPTION NOTE Refer to the Installation Instructions manual for the hardware description of the digital inputs COMMANDS and the analog inputs REFERENCES The parameters in the Control Method menu allow to select the following items e The source of the inverter commands digital inputs from three signal sources through parameters C140 C141 C142 which are matched together to obtain MO31 active command set For each of the 3 parameters above you can select the source of the command signals from 5 different sources e The source of the speed reference from 4 different sources that can be selected through parameters C143 C144 C145 C146 They can be summed up e For each of the 4 parameters above you can select the reference source from 9 different sources e The source of the torque limit reference through parameter C147 This parameter allows to select the reference source from 9 different sources In that way you can select and activate different command sources hardware or virtual source
31. om the vehicle batteries If voltage ranges between the two limits set via parameters P370 P371 the traction torque is limited with a proportional pattern and it drops to O when the battery voltage value is the same as the value set in parameter P371 If parameter P364 is set up to avoid using dynamic parameters the max discharge current and the max recovery current is computed as stated above When only one battery is operating all variables relating to torque and power i e parameters Tmax Pnom are decreased by a value percent based on the values set in parameters P366 P367 12 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 2 Measures Menu 3 2 1 DESCRIPTION The Measures Menu contains all the variables measured by the inverter In the RemoteDrive software all measures are divided into submenus one for each type of measures The measure submenus are the following Menu General Measures It includes current measures voltage measures power measures the inverter digital inputs the status measures for the digital analog outputs of the inverter the ambient temperature measures and IGBT temperature measures the inverter status measure and the active alarm e Menu Traction Measures It includes measures concerning the traction application currents motor voltage battery voltage unit speed battery warnings Menu CAN Measures It includes the words sent from t
32. r setting parameters in Sinus Penta Traction mode you can start the equipment in Traction mode Do the following e Make sure that the water flow pump switch and the water air exchanger switch are closed e Enter the DISCHARGE mode see relevant section above e Turn on your computer launch RemoteDrive activate the connection and open the project Li RemotelDrive File Parameters Printing Acq Setting Chat Config Graphics Activity Tracker Window Help ee 72719 EnAcg Eng Back 1 163 E m Measure Mas TractionMeasure Maxx TuneMeasure BattMeasure Power Off Measure Fault List 1 Fault List 2 Fault List 3 Fault ey DE EC R Auto M SS Irverter Status Inverter in Alarm Se Te R Auto M SD Alarm Cade INVERTER m en R Auto 052 0 Time DE OCEDU Fh Acq Faul E Auto MO54 Supply Time O0000h Faul m 3 Faul 18 3 Faul m Bu rad Fine Spd 000 38 1 0 2 POO By Proc 2 POO 12 A v vvivjvj vVAA A bhGou sc COD Torque 00 88 CI amp 100 4002 E ES 8 co MDHIAVANTI MDISIRESET MDISIMDIETRO MBISIACC MDIB IFRENU MBIZICIRC RAF Mol ALAM Auto MO00 Reference to Steady RPM 000 Acq Gr E speed
33. raMonitor screen 30 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO The following menus are available e Battery Real time menu e Battery Setup menu Battery Lifedata menu e Battery Parameterization menu Parameter 60 MainsCurrentMaxAvalaible if the mains 15 limited power for each battery can be limited accordingly Parameter 4 in menu 2 if current is limited below 16A and is supplied via AC header input current is limited e Monitoring menu The following measures are particularly important 11 DC supply available PIN 10 12 Emergency voltage PIN 9 13 External Ub voltage PIN10 14 Ub voltage PIN 11 1 Battery real time 2 Battery setup 3 Battery lifedats E A Battery parametrization Eg Mnnilnring R Testing 7 Diagnostic faults Diagnostic values 9 Last 20 enors detected Syotem cnablc from MBS ISO test enable from MBS FALSE 150 test enable trom zebr invalid handle ISO test in progress FALSE ISO measurement verificat FALSE ISO res measured 993 Number of ISO errors remo 0 plugged voltage 0 Mains current max for ch DC supply avallable EMERGENCY voltage pin 9 EXT Ub voltage Pin 10 UB voltage pin 11 On board batt need recharge DC DC request Release DC DC DC DC enahle Release discharge Diochargc cnablc Ambient temperature 0 Hin ambient temperature TC
34. s different speed references hardware or virtual references and you can activate an external torque limit The inverter commands can be sent via e Hardware terminal board terminals in control board ES821 which is logically divided into terminal board A and terminal board B e Virtual remote terminal board through serial link with MODBUS communication protocol Multiple reference sources can be activated at a time up to 3 sources through parameters C140 C141 C142 in that case the inverter will apply OR AND logic functions to the different terminals to obtain the active terminal board The references and the torque limit signal can be sent from e Three analog inputs acquired on the hardware terminal board REF AINT AIN2 e FIN frequency input e Encoder input e Keypad Serial link with MODBUS communication protocol e Field bus for option board e Traction from traction machine processing Up to 4 reference sources can be activated through parameters C143 C144 C145 C146 in that case the inverter will consider the sum of all active references as the main reference 15 35 SINUS PENTA USER MANUAL FOR O TRACTION APPLICATION A ELETTRONICASANTERNO 3 4 2 COMMAND SOURCES For the Sinus Penta Traction application the inverter commands are sent from the following sources 1 Terminals 2 Serial link with MODBUS communication protocol Because multiple command sources are activated at a time the l
35. s downloaded the application download is complete end of the download procedure Click Browse to select the file to be updated PXxxxxFO mot for the firmware and P oxxF1 mot for the MMI table first click Open then click Send or SendTab Confirm flash clearing Procedure is over 2 7 Select Firmware Upgrade from the File drop down menu Enter the path for the PXxxxxFO mot and PXxxxxF 1 files to be downloaded If only one of the firmware files or MMI tables is to be updated go to step 7 If an application shall be downloaded to a PXxxxx select the PXxxxxFO mot file and click the Open button 5 Send the Autodet command to allow Remote Drive to detect the type of equipment Once the product is detected PXxxxx will appear in the Equipment Type window Press the Send button confirmation for the Flash clearing will appear Click Yes to start downloading Once download is over go to step 6 6 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 TRACTION APPLICATION 3 1 Introduction The inverters of the SINUS PENTA series can be used in Traction mode even when handling Zebra batteries The main components forming the traction system of an electric vehicle are the following The battery the energy accumulator of the system The electric motor that converts electric energy into mechanical energy The inverter that delivers energy to the motor and that allows to contro
36. s pressed and the run selector switch is on the vehicle does not start The vehicle run is enabled only if the key is fitted when the run selector switch is NOTE off 20 35 SINUS PENTA USER MANUAL FOR Z TRACTION APPLICATION ELETTRONICASANTERNO 3 6 4 RESET TERMINAL 16 MDI3 The RESET function is assigned to input terminal MDI3 It resets the alarms to unlock the inverter If a protection trips the inverter locks the motor starts idling the motor idles and stops due to friction or the mechanical load and an alarm message is displayed see ALARMS AND WARNINGS Reset procedure To unlock the inverter activate the RESET input for an instant or press the RESET key on the keypad When the inverter unlocks and the cause for the alarm has been removed Inverter OK comes up on the screen otherwise the alarm persists and cannot be reset Factory setting activate and deactivate the ENABLE command see parameter C181 to restart the inverter Factory setting the inverter power off does not reset the alarm tripped which is stored to memory and is displayed at next power on to lock the inverter Perform reset procedure to unlock the inverter The alarms stored may be automatically reset at power on by setting special parameters see Sinus Penta s Programming Instructions manual If an alarm trips refer to the Sinus Penta s Programming Instructions manual CAUTION diagnostics Reset the equipment after
37. ssed If both selectors for FORWARD and REVERSE gear are active the drive stops If the forward and or reverse gear is set when the equipment is running the drive does not stop SINUS PENTA TRACTION APPLICATION O USER MANUAL FOR 3 10 Alarms for Sinus Penta Traction Application 3 10 1 INTRODUCTION This section covers the alarms for the Traction application Different alarms are detailed in Sinus Penta s Programming Instructions Manual 3 10 2 ALARM CODES Table 8 List of the Traction application alarms This alarm trips if the b discharge enable message is sent by the MBS or if the MBS A105 Zebra Battery KO detects an error level higher than the Notice level see Zebra battery user manual when parameter P375 is set to O Alarm A106 CAN Communication This alarm trips if communication is suspended KO for more than timeout seconds P374 35 35
38. trips the inverter deactivates and the motor starts idling NOTE The activation of the ENABLE command enables particular alarms which control the configuration consistency of certain parameters When the ENABLE contact is closed C parameters cannot be altered factory NOTE setting Set POO3 as Standby Fluxing to allow C parameter alteration even when the inverter is enabled but the motor is not running gt gt gt p The ENABLE input function is assigned to terminal MDI2 It enables the inverter operation It cannot be programmed for other terminals although additional functions may be assigned to the ENABLE terminal To enable the inverter operation the ENABLE input is to be always active for all active terminal boards regardless of the control mode being used If the ENABLE input is disabled the inverter output voltage is always cut off so the connected motor starts idling the motor idles and stops due to friction or the mechanical load If the ENABLE command is already active when the inverter is powered on the inverter starts only when terminal MDI2 is opened and closed again If the ENABLE input is disabled when the inverter is controlling the motor it is closed with a delay time depending on the inverter size This ENABLE delay starts from the instant when the input is disabled regardless of the enabling delay if any set through a software timer in MDI2 For safety reasons if the ignition key is fitted when the accelerator i
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