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70200001_User_ Manual_PLUS 1 Inverter Family

1. Based on some physical limitations it s not possible to detect every short circuit Dependent on the length of the cable cable wire size and cable routing a short circuit at the end of a cable can exhibit the same electrical behavior as a connected motor 7020001 31 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 8 Protection 8 2 Runtime Protection Functions 8 2 1 Power Stage Protection PLUS 1 Inverters provide a number of protection functions with error warning and status messages Most of the messages are reported via the API to the application software which must be programmed to take the necessary response The system software reacts only to those errors which would destroy the power stage hardware e Over voltage e Over current e Over temperature and temperature sensor error If one of these errors occurs e The power stage will be disabled PowerStage EnableStatus 0 e The API variable PowerStage Status displays the error in bitwise representation Bit 1 Over temperature Bit 1 Sensor error Bit3 1 Over voltage Bit4 1 Over current e The error will be displayed in the error history memory e For each of these errors there is a counter which counts the total number of detected errors over the lifetime of the inverter Writing a 1 0 sequence to PowerStage Enab ewill clear the errors which are no longer present 8 2 1 1 Over Voltage The DC Link
2. 3x0 16 Dimensions mm W 140 140 140 H 200 200 200 D5 90 110 91 111 98 118 Weight kg gt 2 5 2 7 2 8 3 0 3 5 3 7 Power connectors M6 M8 M10 Type Mixx S 48 180 48 300 48 400 Size MI03 MI04 MI06 Nominal voltage VDC 36 48 Input voltage range VDC 18 62 Nominal current 3 Arms 100 150 200 Maximum current 3 Arms 180 300 400 Boost current 3 Arms 200 330 420 Output voltage 3 Vrms 3x0 240r3x0 32 Dimensions mm W 140 140 140 H 200 200 200 D5 90 110 91 111 98 118 Weight kg gt 2 5 2 7 2 8 3 0 3 5 3 7 Power connectors M6 M8 M10 Type MI20 S 80 650 Size MI20 Nominal voltage VDC 80 Input voltage range VDC 40 105 Nominal current 3 Arms 325 Maximum current 3 Arms 650 Boost current 3 Arms 715 Output voltage 3 Vrms 3x0 53 Dimensions mm W 280 H 280 D5 101 143 Weight kg 9 10 5 Power connectors M10 1 8kHz switching frequency 2 2 2min 3 for 10 seconds 4 input voltage nominal voltage 5 plate version finned version 7020001 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 6 1 Input Output Types 12 User Manual 6 Input Output Types and Specification PLUS 1 Inverters perform two functions gt Motor Control gt Application Control The corresponding hardware sections have separate power supply pins which may be supplied by different voltages The Motor Control section is typically powered by the vehicle s main supply volt
3. The integral gain MotorControl Speedk is expressed in Nm rpm s amount the torque set value should increase in one second per rpm deviation These control parameters can be optimized at the time of final vehicle performance testing A standard rule for speed control tuning is gt Switch off the integral part by setting MotorControl Speedk O gt Increase the proportional gain until the control starts to oscillate consider the complete speed range gt Reduce to proportional gain to 70 of the former value gt Keep this proportional gain and follow the same procedure to tune the integral gain 11 1 3 Speed Feedback The field oriented motor control requires a speed feedback value The quality of the speed feedback signal is very important for the performance of the speed control Inadequate encoder signals or encoder quality may result in oscillations and insufficient control behavior PLUS 1 Inverters require a quadrature encoder with a resolution in the range of 32 to 1024 pulses per revolution mounted directly to the motor shaft The output of the encoder can be open collector or push pull It is very important to provide the API variable Motor EncPulses with the resolution of the encoder used in the application PLUS 1 Motor Compliance Blocks provide this data The encoder signals have to be aligned with the rotation direction of the motor If the phase order of the motor current is U V W the phase of the encoder signal A has
4. ccccccsssssssssesssssssssssssssssssssesessssssssssssssssssessssessssssssssessssssesssscsssesesessessscsesssaeesees 40 10 4 NVRamiser Datassist naa eree E shasscsisisnasiacatcasvisearesete 40 11 Motor Control 41 11 1 Control STrUCTULE eceecesesessssessssssssessssessssessssessssssssessssesssscsesscsescssscsseseessaesssesesssseseessseesess 41 11 1 1 Field Oriented Motor Control ss ireereeerereereasereremrenenserereareneaserensereaseses 41 11 1 2 Speed Controller ecessssssscsscssecsecsecsecsscssecsccsscssecsecsccsscssccsecsceseessecsecscesecesccuceseessess 42 TRES Speed FECADACK vecisssssscsessrsicsassessscnesnscossvessdsosesrsonssceanetseiduesevessieotas sduanseastscvsessaazvasesd 42 11 1 4 Torque Feed Forward ssscssssssssecsscssscsssecsccsscssscscssssscescsucsacessesscsuceusesceaseeueeacensess 42 11 1 5 Torque Limitation 11 1 6 Current Limitation 11 1 7 Speed Control Versus Torque Control cssssssssscseccsecsecssessccsececssessececseeseensees 43 11 2 Motor DETIMILION ssccsscisessessaesossscuserassicsssncsxssevsssessscsssucsducndetshasesuinnsstevnes uonseeea aisancssnsisnevsitessee 11 2 1 Electric Motor Compliance Blocks 11 2 2 Open Electric Motor Data Function BIOCK 44 11 2 3 Electric Motor Data Download Block e 44 11 2 4 Re Initialization of Motor Data erre reeseereeeaneaas 45 11 3 Temperature Compensation sssee
5. 468k 12V I O supply voltage A higher resistance works but will be detected as output disconnected Open circuit detection Fault indication provided If the voltage at the output pin in OFF state is less than 9V the Pin status Output disconnected will be reported Considering the internal resistance of 136kOhm the load resistance should be maximum 45kOhm at 12V I O supply voltage For higher O supply voltages the maximum load resistance can be calculated with the formula Ru 1 136K0 9V With Vio O supply voltage Max resistance ON state 0 2 0 2 0 25 Roson 92 25 C Damage to the application control section of the inverter may occur If voltage is applied to the main contactor output the application control section of the inverter will be powered up If significant current is driven through the main contactor output the module will be demaged 70200001 PLUS 1 Inverter Family User Manual 6 Input Output Types and Specification N SCHWARZMULLER INVERTER 6 5 Inputs Outputs continued 6 5 4 Output with Enhanced Safety DOUT safety PWMOUT safety POUT safety Output pins which are marked with the extension safety are equipped with a redundant safety transistor The safety transistor is connected in series to the standard output transistor In case of an unintended activation of the output caused by a transistor fault the second transistor will
6. C1p01 power supply The pre charge circuit for the power stage capacitors which is supplied by the same pin causes an inrush current significantly higher than the nominal supply current Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Power supply Power supply input for internal power supplies of control circuits Input voltage range VDC 16 36 18 62 40 105 Supply current typ 0 24 0 13 0 1 nominal voltage A Inrush current A lt 100ms 24 10 12 Power supply Ground Power supply and signal ground Internal structure Connection with minus power supply 7 2 Auxiliary Power Supplies 7 2 1 Sensor Power Supply PLUS 1 inverters provide a sensor power supply pin with a programmable output voltage of 5V 10V or 12V Typically this power supply is used for throttles foot pedals or mini levers A feedback value C7p23 Vo tis available to factor the actual voltage into the calculation of the set value out of the sensor signal A voltage higher than 15V will be reported as 15V C723 Vo t 15000 and the status feedback value out of range will be reported C7p23 PinStatus 1 If the output value of a sensor depends proportionally on its supply voltage potentiometer then it is highly recommended to use the feedback value C7p23 Volt to monitor the actual voltage and to react in application software if the voltage drops due to a short circuit or overloa
7. N SCHWARZMULLER INVERTER MEMBER OF THE SAUER DANFOSS GROUP PLUS 1 Inverter Family User Manual 70200001 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual Revisions Version History Table of Versions Description First edition 14 09 2010 18 10 2011 06 02 2012 Document CAN Bus wiring hints mentioned recommendation fuse added Version 1 2 Schwarzmiller Inverter welcomes suggestions to improve our documentation If you have suggestions for improving this document please contact Schwarzmiller Inverter at info schwarzmueller inverter com 2010 Schwarzmiiller Inverter Schwarzmiller Inverter can accept no responsibility for possible errors in catalogs brochures and other printed material Schwarzmiller Inverter reserves the right to alter its products without prior notice This also applies to products already ordered provides that such alterations can be made without affecting agreed specifications All trademarks in this material are properties of the respective owners Sauer Danfoss the Sauer Danfoss logotype the Sauer Danfoss S icon PLUS 1 what really matters is inside and Know How in Motion are trademarks of the Sauer Danfoss Group 70200001 ean PLUS 1 Inverter Family INVERTER 10 User Manual Contents Introduction About this Manual 1 1 PLUS 1 Inverter Family Technical Infor
8. PWM output PWMOUT MC The output configuration is an open collector sinking output with overload and open circuit detection If the output is programmed as PWM output the output signal is pulse width modulated with a constant duty cycle The PWM frequency is constant 100Hz and the duty cycle has a resolution of 10 and is defined by software The PWMOUT mode is intended to be used only for simple voltage control The main contactor output may be locked C7p24 ocked 1 if a failure was detected at the DC Link test at power up If the main contactor output pin is used for a purpose other than to drive a main contactor the load has to be supplied in parallel to Power supply Nominal Voltage V 24 36 48 72 80 Inverter Type MIxx S 24 xxx 48 xxx 80 xxx DOUT MC PWMOUT MC Digital output for main contactor Internal structure Low side switch with free wheeling diode Cathode of free wheeling Power supply diode connected to Signal condition Reactions time minimum 1ms dependent on application DOUT MC SW loop time Signal condition Programmable PWM signal from 0 to 100 with 10 PWMOUT MC step PWM frequency 100Hz Nominal current A 2 0 Maximum current A 9 3 0 Over load protection Non damage current thermal limit status indication at ON state automatic latch off resume Resistance to minus power 136k supply Ohm in OFF state Max load resistance Q 45k 266k
9. as a USB slave In this configuration all required electrical power is supplied by the upstream PC host No other power source is required Refer to 70100012 CAN Bus wiring hints for detailled information how to connect the CG150 to the bus Refer to the PLUS 7 GUIDE Software User Manual 10100824 for gateway set up information Refer to the CG750 USB CAN Gateway Data Sheet 520L0945 for electrical specifications and connector pin details 70200001 anc PLUS 1 Inverter Family INVERTER User Manual 14 Product Installation and Start Up 14 6 Start Up and Recommended Installation Instructions Working with electric systems can be potentially dangerous All testing fault finding and adjustment should be carried out by competent personnel only The vehicle s drive wheels should be jacked off the floor and free to rotate during the ensuing procedures The battery must be disconnected before PLUS 1 Inverters are being replaced or repaired Before working on the controls it is recommended to disconnect the battery and connect the B and B inverter terminals via a 10 Ohm 25 watt resistor to discharge the internal capacitors Avoid connecting the inverter to a battery with its vent caps removed as due to the inverter s internal capacitance an arc is likely to occur when it is first connected Always wear approved protective equipment If the inverter is connected to the battery while charging the voltage must not exceed the spec
10. drop out times should be investigated to ensure compatible operation If the main contactor coil is not wired to C1p24 Main Contactor Output the PLUS 1 Inverter will not be able to open the main contactor in serious fault conditions and the inverter will not be protected against reverse battery polarity 14 2 2 2 Recommended Main Fuse The main battery cable should be fused with a suitable air break fuse The fuse must be sized in relation to protect the motor and cabling For exact determination consider applicable technical regulations For Safety reasons the use of protected fuses is recommended in order to prevent the spread of fuse particles should the fuse blow 7020001 53 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 14 Product Installation and Start Up 14 3 PLUS 1 Recommended Machine Wiring Guidelines e All wires must be protected from mechanical abuse Wires should be ran in flexible metal or plastic conduits e Use 85 C 185 F wire with abrasion resistant insulation 105 C 221 F wire should be considered near hot surfaces e Usea wire size that is appropriate for the inverter connector e The cables to the battery should be ran side by side and be as short as possible e Separate high current wires from sensor and other noise sensitive input wires e Run wires along the inside of or close to metal machine surfaces where possible This simulates a shield which will minimize the effe
11. i Les DIN DINPU sav encoder t co DIN DIN PU ov i T a DIN 18 gt ATUM DIN w BIETE mm DIN i Em lt DIN i DIN emergency i di DIN stop parallel to first sensor bearing al Power supply lt x x y a ft al DOUT MC t lt gt L a DGA SE elo a O supply input Po Iron ot on mm supply output DC H optional converter e 10 supply output 1 PH a of I s DOUT safety s 4 DN 4 o LH Loe l o I 4 i sit a l a DOUT 5 4 DIN o p l Ha 1 t I i DOUT u4 DN o k DS t I loo I 2 DOUT gt DIN Of I m I Lo I ei DOUT 15 gt DIN or LL i R I EAR x al t o POUT safety DOUT safety ory DIN ENE jH o Hi i I I wl H Sm POUT DOUT w gt DN ol JW i paeem en 413V encoder l a ov A 81 FL al alla i s F Era nE ap N Power Stage T ER O 2 Ss TTT TTT Vy yy fy Ls e optional 1 I Va a 7020001 15 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 6 Input Output Types and Specification 6 3 Input Output Supply Voltage 6 4 Inputs 16 PLUS 1 Inverters have a separate input pin and output pin for the power supply to external components such as relays valves vehicle brake switches The external I O compon
12. limited operation possible 8 Watchdog error operation impossible 9 Power Stage error short circuit to V_DC_Link 10 Power Stage error short circuit to V_DC_Link 11 Error in motor wiring or power stage 12 Shorted power output 13 wrong production data in EEPROM detected 14 current sensor error 15 Undervoltage 16 PCB over temperature 17 PCB temperature sensor error The second part of the Error History Memory consists of 4 API variables to count the absolute numbers of detected power stage protection errors during lifetime of the inverter e ErrorHistory AbsOTErrors Shows absolute number of detected over temperature errors while lifetime of the inverter e ErrorHistory AbsOVErrors Shows absolute number of detected over voltage errors while lifetime of the inverter e ErrorHistory AbsOCErrors Shows absolute number of detected over current errors while lifetime of the inverter e ErrorHistory AbsTSensErrors Shows absolute number of detected temperature sensor errors while lifetime of the inverter e ErrorHistory AbsPCBOTErrors Shows absolute number of detected PCB overtemperature errors while lifetime of the inverter e ErrorHistory AbsPCBTSensErrors Shows absolute number of detected PCB temperature sensor errors while lifetime of the inverter 70200001 A SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 10 Service Function 10 1 Error History continued The lis
13. width programmable 0 to 100 with a resolution of 10 Current controlled output superposed with dither signal low side switch with free wheeling diode Same properties as DOUT but with a free wheeling diode to main power supply C1 P2 Same properties as DOUT MC but in PWM mode similar to PWMOUT Same properties as DOUT but with additional safety transistor Motor temperature sensor Must be used for motor speed feedback encoder Driver for external components like electromagnetic brakes on off valves contactors Simple PWM control of external inductive loads with on off functionality electromagnetic brakes on off valves contactors in order to reduce power consumption and heat Driver for proportional valves Driver for main contactor This output provides a reverse polarity protection for the inverter in combination with the main contactor see further description at 6 5 3 Driver for main contactor This output provides a reverse polarity protection for the inverter in combination with the main contactor see further description at 6 5 3 Driver for safety critical on off component like electromagnetic brake or lowering valve PWMOUT safety POUT safety Same properties as PWMOUT but with additional safety transistor Same properties as POUT but with additional safety transistor Driver for safety critical on off component like electromagnetic brake or lowering valve in PWM m
14. 2 2 Encoder Power SUPPLY sesssissssescssacnsssisssseseasonssconsensssbsacsvaenbecabenssosadonssedasesaseodscndeennssoas 26 7 3 Power Stage SUPpIy scssssascasseesascxesenvaisneaniosszonvosescvonstnesddanonoschiesnnsslusasasescvaneuenievsacevecdssages uboes 26 7 31 Precharging of CapAacitOrs ssssscsescseesseecseessecsseessecssecsssesseessecseeesecusenueesneseseeeee 28 Protection 8 1 Self Test at Power Up ucssssssssscessssecsescseesseesssesssenssesssenseeses 8 1 1 EEPROM CRC Check SLX IDG Link Testorn A 8 1 3 Hardware Watchdog 8 1 4 Power Stage Test 8 2 Runtime Protection Functions s o 8 2 1 Power Stage Protection sicssccsscisisienscasssissesccecaoseisinsenscsoseserssccessosousiescasassieastnatosiecicaecse B22 Unprotected Mode siscsivscasssissicesavesscsssscaavsiisessssecsacasisvvacuetesssasstsscbarsedsstssctateaneetsanas Power Stage 9 1 Eriabley Disa ble siasscvsccsitsicecescccussstttvsesccuntensdestamenza eai eae andaram 9 2 PWM Frequency ssccassscaicesaicssesssascassedcssouscess ssussesssesseevsscsznzasscstussatascuscdssaserarasussbtssecasisdierdvsaetses 9 3 DiaghOStCS E EE T Service Function 10 1 Error iSto sesssesscsssscascisssseccessdsssecietensdavsstsencsccedennnctoscensscbestasesosssssscseecd vsaustotsessetsscessteasedeseevses 10 2 Hour Counter annonserer AEAEE EE ai 7020001 3 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 10 3 Device Inf
15. For the finned type heat sink version it is recommended to ensure 3m s air speed through the entire heat sink 14 2 2 Wiring the Power Stage The power stage is connected using screws labeled and U V W An additional screw not MIO3 type allows the assembly of a power fuse on top of the inverter housing Power connections should be made with flexible heat resisting cables of suitable cross sectional area allowing the current to be carried These should be terminated in crimped cable shoes The inverter is equipped with steel screw assemblies Don t use additional washers Make sure that the cable shoes lay directly on the brass sleeves of the inverter Fixing torque for power connectors Screw size Inverter type Fixing torque M6 MIO3 6 Nm M8 MI04 9 Nm M10 MI06 MI20 17Nm 70200001 sal leith IS PLUS 1 Inverter Family INVERTER User Manual 14 Product Installation and Start Up 14 2 PLUS 1 Inverter Installation Guidelines continued 14 2 2 1 Recommended Main Contactor A single pole single throw contactor with silver alloy tips contactor such as the SW range from Albright International Ltd is recommended to be fitted For currents up to 250A SW 80 For currents up to 400A SW 180 For currents above 400A SW 200 The contactor coil recommended should be specified for continuous operation When alternative manufacturer s products are used the coil currents pull in and
16. OK 1 Overvoltage Bit4 0 OK 1 Overcurrent Bit5 0 Unprotected Mode inactive 1 Unprotected Mode active Bit6 0 OK 1 Power Stage permanently locked because of wrong motor data Bit7 0 OK 1 Power Stage permanently locked because of HW watchdog error Bit8 0 OK 1 Power Stage permanently locked because of current sensor error Bit9 0 OK 1 Power Stage permanently locked because of undervoltage Bit10 0 OK 1 PCB overtemperature Bit11 0 OK 1 PCB temperature sensor error 7020001 37 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 10 1 Error History 38 User Manual 10 Service Function PLUS 1 Inverters provide an Error History Memory which tracks all power stage protection errors and self test errors as integral function of the system software The application software might provide another error history memory for application errors The first part of the Error History Memory consists of 3 API data arrays e ErrorHistory Number 0 7 Error numbers e ErrorHistory Counter 0 7 Number of the same errors in a row e ErrorHistory Hourl0 7 Value of HourCounter nverter when the latest of the same errors in a row occurred Each data array has 8 elements Element O shows the latest error Element 7 shows the oldest error Error numbers 1 Overtemperature 2 Overvoltage 3 Overcurrent 4 Temperature sensor error 5 Unprotected Mode 6 DC_Link error 7 Watchdog error
17. age The application control section is independent It may be connected to the vehicle main power supply or to any other power supply e g DC DC converter within the specified voltage range The Application Control section of each PLUS 1 Inverter hardware device MIxx has interface pins that support multiple functions as well as pins that support fixed functions Pins that support multiple input or output functions are user configurable via the API variable PinConfig using PLUS 1 GUIDE software Refer to product data sheets for the input output I O content of individual devices This portion of the technical information manual provides specifications for each PLUS 1 Inverter I O type AMPSEAL 35 Pin Connector Power supply Ground C1p01 Power supply C1po2 CAN High C1p03 CAN Low C1p04 Power supply Ground C1p05 CAN High C1p06 CAN Low C1p07 I O supply input C1p08 1 O supply output C1p09 AIN unipolar C1p10 AIN bipolar C1p11 Power supply Ground C1p12 DOUT safety PWMOUT safety DIN C1p13 DOUT PWMOUT DIN C1p14 DOUT PWMOUT DIN Cipis POUT DOUT PWMOUT DIN C1p16 Encoder channel A C1p17 DIN DIN PU C1p18 DIN C1p19 DIN C1p20 DIN C1p21 AIN bipolar C1p22 Sensor supply C1p23 DOUT MC PWMOUT MC C1p24 DOUT PWMOUT DIN C1p25 DOUT PWMOUT DIN C1p26 POUT safety DOUT safety PWMOUT safety DIN C1p27 En
18. bly 58529 1 Connector plug PBT Black 776164 1 Contacts 770854 1 0 5 1 4 mm 20 16 AWG Sealing plugs 770678 1 Strip length 4 7to5 5mm 0 185 to 0 215 in Insulation diameter range 1 7 to 2 7 mm 0 067 to 0 106 in 7020001 51 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 14 Product Installation and Start Up 14 2 PLUS 1 Inverter Installation Guidelines 52 14 2 1 Mounting the Inverter While the PLUS 1 Inverters can be mounted in the vehicle in any position a careful approach should be adopted when selecting the location in the vehicle for mounting the inverter In choosing the inverter s position ensure the built in two PLUS 1 Inverter LEDs are visible In each case care must be taken to insure that the PLUS 1 Inverter connector is positioned so that moisture drains away from the inverter If the inverter is mounted vertically the connector should be on the bottom Strain relief for mating connector wires should be provided For the plate type heat sink version it is recommended that the inverter is assembled to a flat free of paint surface preferably lightly coated with a thermal transfer compound using the 4 holes provided It is a requirement for the vehicle mounting surface to be a substantial metal part of the truck for the full PLUS 1 Inverter current ratings to be achieved The mounting surface shall meet the requirements Planarity 0 1mm 7 0 1 Surface roughness R2 40um
19. coder supply C1p28 Encoder channel B C1p29 DIN DIN PU C1p30 DIN C1p31 DIN C1p32 DIN C1p33 Rheo C1p34 Power supply Ground C1p35 70200001 aitai PLUS 1 Inverter Family INVERTER User Manual 6 Input Output Types and Specification 6 1 Input Output Types continued 1 12 el E 8 8 G6 86 G6 G6 G6 E 13 eoeoeoee e edses oooooooaooaoq o o DOUT MC PWMOUT MC f Power supply Ground DOUT s PWMOUT s DIN lt 3 DOUT PWMOUT DIN 6 Power supply DOUT PWMOUT DIN d DOUT PWMOUT DIN CANH DOUT PWMOUT DIN POUT s DOUT s PWMOUT s DIN CANL l _ _POUT DOUT PWMOUT DIN 22L LLL LLL Power supply encoder Power supply Ground Encoder channel A 4 o Encoder channel B __ CANH DIN DINPU DIN DIN PU CANL DIN DIN IO supply input DIN DIN O supply output DIN 4 os Cs DIN AIN unipolar TS AIN bipolar Rheo AIN bipolar _ Sensor supply Power supply Ground Power supply Ground En EM eS ee nda ee ea ae e ee n EE MEGa qa CE eea ee ee US s safety A Warnings The functionality and the specificatio
20. cs PLUS 1 Motor Compliance Blocks for specific motors can be supported by Schwarzm ller Inverter motor characterization A motor data setup for Individual motors can be configured based on IEEE standard values see Section 11 2 Motor Definition 11 1 1 Field Oriented Motor Control Motor data MotorControl UserTorqueLimit Motor TorqueMa otorControl SpeedKP MotorControl SpeedKI MotorControl ActSpeed_rpm10 The main part of the Mixx motor control strategy is the field oriented motor control This control requires a set of motor data If the motor data are well defined for Schwarzmiller Inverter tested motors the data are available in PLUS 1 Compliance blocks the torque at the motor shaft follows the torque set value with a maximum delay of 10ms This allows optimization of the vehicle drive system to be independent of the motor torque control and no further tuning of motor data is required to optimize vehicle performance Only the speed controller has to be adapted to the application 7020001 41 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 11 1 42 User Manual 11 Motor Control Control Structure continued 11 1 2 Speed Controller The speed controller has a Pl configuration with anti windup The output of the speed controller is the torque set value The proportional gain MotorControl SpeedkPis expressed in Nm rpm amount of torque the motor has to provide per rpm deviation from set point
21. ctTemp In this case a lower control performance could be experienced Plug amp Perform The needed calculations for temperature compensation are already included in the Motor Compliance Blocks and the Open Motor Data Block The motor control system software provides a number of data for diagnostic purposes 11 4 1 Encoder Diagnostics API variable Description Motor EncA Actual state of the hardware input pin of encoder line A High True Motor EncB Actual state of the hardware input pin of encoder line B High True A simple diagnostic test of the motor encoder can be done by watching the API variables Motor EncA and Motor EncB using the PLUS 1 Service Tool while turning the motor very slowly Both variables have to change status while turning the motor This test provides information about the wiring of the encoder In the event of motor control instability the quality of the encoder signals should also be checked 11 4 2 Diagnostics of Motor Data If the motor data provided to the API are invalid the variable Motor Status will show the status in bitwise pattern 70200001 PLUS 1 Inverter Family User Manual 11 Motor Control N SCHWARZMULLER INVERTER 11 4 Diagnostics continued 11 4 3 Diagnostics of Motor Control API variable MotorControl ActSpeed MotorControl ActStatFreq MotorControl ActSlipFreq MotorControl ActTorque Description Actual motor speed Actual stator frequ
22. cts of EMI RFI radiation e Do not run wires near sharp metal corners Consider running wires through a grommet when rounding a corner e Donotrun wires near hot machine members e Provide strain relief for all wires e Avoid running wires near moving or vibrating components e Avoid long unsupported wire spans e All analog sensors should be powered by the sensor supply from the PLUS 1 Inverter and ground returned to the power supply pin on the PLUS 1 Inverter Sensor lines should be twisted about one turn every 10 cm 4 in e It is better to use wire harness anchors that will allow wires to float with respect to the machine rather than rigid anchors 14 4 Welding on a Machine Equipped with PLUS 1 Modules The following procedures are recommended when welding on a machine equipped with PLUS 1 modules e The engine should be off e Disconnect the battery cables from the battery e Do not use electrical components to ground the welder Clamp the ground cable for the welder to the component that will be welded as close a possible to the weld 14 5 PLUS 1 USB CAN Gateway 54 Communication software uploads and downloads and service and diagnostic tool interaction between PLUS 1 devices and a personal computer PC is accomplished using the vehicle s PLUS 1 CAN network The PLUS 1 CG150 USB CAN gateway provides the communication interface between a PC USB port and the vehicle CAN bus When connected to a PC the gateway acts
23. d Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Sensor supply Power supply for external sensors Programmable output 5 10 12 voltage VDC Tolerance 5 Max output current A 0 1 Over current short circuit Current limitation at 0 1A 7020001 25 SCHWARZMULLER INVERTER PLUS 1 Inverter Family MEMBER OF THE SAUER DANFO User Manual 7 Power Supply 7 2 Auxiliary Power Supplies continued 7 3 Power Stage Supply 7 2 2 Encoder Power Supply PLUS 1 inverters provide another auxiliary power supply with a fixed voltage and a current feedback C7p28 Feedback Value typically used for encoder supply A current higher than 100mA will be reported as 100mA C7p28 FeedbackValue 1000 and the status value out of range will be reported C7p28 PinStatus 1 Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Encoder supply Power supply for encoder e g sensor bearing Supply voltage VDC 13V 10 Ri 30 Q Over current short circuit Current limitation at 0 1A The power stage supply is connected using screws labeled and For each inverter a fuse shall be installed whenever possible near the energy source battery An additional screw also allows the assembly of a power fuse on top of the inverter housing The inverter is equipped with steel screw assemblies Do
24. e API document contains the following information e Variable Name with short description e Variable Type e Variable Function amp Scaling 1 6 PLUS 1 Library Sauer Danfoss provides a library of defined Software function and applications that can be used in PLUS 1 products This library contains Compliance Blocks for PLUS 1 products and Function Blocks for defined functions that can be used to create an individual application Software in PLUS 1 GUIDE Additionally fully approved application software for standard applications is available and will be continuously enlarged The PLUS 1 Library is part of the PLUS 1 GUIDE software tool and also available on the website www sauer danfoss plus1 com Additional secondary information such as Tech Notes and other application notes are also available on website PLUS 1 Inverter product literature is on line at www schwarzmueller inverter com 6 70200001 eee PLUS 1 Inverter Family INVERTER EDER Se User Manual 2 PLUS 1 Inverter Family EMBER O 2 1 PLUS 1 Inverter Family PLUS 1 Inverter MIOS PLUS 1 Inverter M 04 PLUS 1 Inverter M I06 PLUS 1 Inverter M 20 7020001 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 2 PLUS 1 Inverter Family 2 2 Inverter Typical Applications PLUS 1 Inverters is a unique family of inverters as well as machine controllers in one enclosure They are designed to control AC induction motors used in a variety of bat
25. emperature range 40 C 50 C 40 F 122 F 104 F Maximum heat sink temperature 85 C 185 F full current Heat sink switch off temperature 85 C 185 F Relative humidity 100 condensation is allowed Operation signal 2 built in LEDs red and green Signal line connectors AMP Seal 35 pins IP protection IP67 with membrane EMC ESD EN 12895 EN 61000 6 2 EN 61000 6 3 EN 61000 4 2 ISO 7637 1 3 Safety of industrial trucks electrical EN 1175 requirements Vibration broad band random resonance EN 60068 2 64 EN 60068 2 28 Shock EN 60068 2 27 Bump EN 60068 2 29 Cold EN 60068 2 1 Heat EN 60068 2 2 Change of temperature EN 60068 2 14 Damp heat cyclic EN 60068 2 30 UL UL583 listing pending Chemical resistance ISO 16750 5 All PLUS 1 Inverters are CE compliant 70200001 ance PLUS 1 Inverter Family INVERTER User Manual 14 Product Installation and Start Up 14 1 Mating Connectors PLUS 1 Inverters use AMPSEAL connectors Schwarzmiller Inverter has assembled a mating connector kit referred to as a bag assembly Part No information Part Number Component 10107896 35 pin AMPSEAL Mating Connector Bag Assembly 10107897 AMPSEAL Connector Crimping Tool 58529 1 AMPSEAL Mating Connector Part Information Description AMPSEAL reference Crimp tool AMP PRO CRIMPER II Hand Tool Assem
26. ency Actual slip frequency Actual torque set value MotorControl ActQCurrent MotorControl ActDCurrent MotorControl ActCurrent MotorControl ActVoltage MotorControl ActTorqueLimit Actual Q axis current This is the current vector to provide torque Actual D axis current This is the current vector to provide magnetization Actual motor current This is the current that can be measured at the motor cables Actual motor voltage line to line Because the motor voltage is PWM modulated you can only measure it with a low pass filter Actual valid torque limit This is the minimum of calculated physical maximum torque based on the current limit user torque limit and motor torque limit MotorControl ActCurrLimit MotorControl Gen_Mode 7020001 Actual current limit This is the minimum of hardware current limit user current limit and motor current limit Motor operation mode O motor mode Speed and torque are in the same direction Energy flows from inverter to the motor 1 generator mode Speed and torque are in opposite direction Energy flows from motor to the inverter 47 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 12 Controller Area Networks Specifications 12 1 CAN Controller Area Networks Ports 48 The PLUS 1 Inverters have CAN ports conforming to CAN 2 0B The 2 0B version of CAN is meant for 29 bit identifiers The significance of the 2 0B version is that thi
27. ent 6 0 0 0 7 0 0 0 7020001 39 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 10 Service Function 10 1 Error History continued ErrorHistory AbsOTErrors ErrorHistory AbsOVErrors ErrorHistory AbsOCErrors ErrorHistory AbsTSensErrors wow 10 2 Hour Counter PLUS 1 Inverters provide a non resettable hour counter as integral function of the system software The application software may provide another hour counter for application needs API variable Function Remark HourCounter Inverter Hourcounter 0 001h not Counts when the inverter is resettable power supplied at C1p02 HourCounter Power Hour counter 0 001h not Counts when the power resettable stage is enabled 10 3 Device Info The device info variable structure provides device specific information API variable Description Devicelnfo DeadTime Dead time of power stage 0 6400 ns Devicelnfo MinTemp Minimal specified temperature C where the unit will work properly Devicelnfo MinVolt Minimal specified voltage mV where the unit will work properly Devicelnfo MaxVolt Maximal specified voltage mV where the unit will work properly Devicelnfo SeriaINoA First part of the Serial number Devicelnfo SeriaINoB Second part of the Serial number Devicelnfo PartNoO Defines the hardware assembly with software loaded Devicelnfo PartNo1 Is a S D part number and is set when customer speci
28. ent A 3 0 for min 1 second before overload protection activated Over load protection Non damage current thermal limit status indication at ON state automatic latch off resume Resistance to minus power 136k supply Q in OFF state Max load resistance Q 45k 266 k 468 k 12V I O supply voltage A higher resistance works but will be detected as output disconnected Open circuit detection Fault indication provided If the voltage at the output pin in OFF state is less than 9V the Pin status Output disconnected will be reported Considering the internal resistance of 136kOhm the load resistance should be maximum 45kOhm at 12V I O supply voltage For higher O supply voltages the maximum load resistance can be calculated with the formula Ro 2 1 136kQ 9V With Vio I O supply voltage Max resistance ON state 0 2 0 2 0 25 Roson Q 25 C 20 70200001 N SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 6 Input Output Types and Specification Inputs Outputs continued 6 5 2 General Purpose Proportional Inputs Outputs DOUT PWMOUT DIN POUT The characteristics of General Purpose Proportional Input Output pins are GUIDE software controlled A General Purpose Input Output pin can be programmed to work as digital output in binary mode DOUT as PWM output PWMOUT as proportional output closed loop current controlled POUT or as digita
29. ent supply voltage is independent of the vehicle s main power supply It can be connected to the vehicle main power supply or to any other power supply e g DC DC converter in the specified voltage range Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx IO supply input Power supply input for IOs Maximum current ADC 8 0 Voltage range Max input voltage 36 62 105 VDC Min input voltage 12 VDC IO supply output Power supply output for I Os Maximum current ADC 8 0 Output voltage I O supply input A Warnings All output channels contain free wheeling diodes to make wiring as easy as possible Therefore e itis mandatory that the positive poles of all loads are connected to Pin9 of connector 1 e be aware that any voltage to the outputs that is higher than the voltage at pin 9 will destroy the free wheeling diodes e connect Pin8 with the source that has to supply the connected components 6 4 1 Digital DIN Digital inputs connected to PLUS 1 Inverter dedicated DIN pins are debounced in system software with a user configurable time in the range of 0 to 100ms Digital input debounce is defined as an input being in a given state for the configured debounce time before a state change is reported The sample time of digital inputs is 1ms Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 x
30. er and with other intelligent systems over a machine Controller Area Network CAN data bus PLUS 1 hardware products are designed to be equally effective in a distributed CAN system with intelligence in every node or as stand alone control for smaller machine systems PLUS 1 systems are incrementally expandable additional nodes can be added easily to the machine CAN bus to increase system capabilities or computational power 8 70200001 su PLUS 1 Inverter Family INVERTER User Manual 3 PLUS 1 Inverter Naming Convention MEMBER OF Th UER DANFOSS GR 3 1 PLUS 1 Inverter Naming Convention PLUS 1 Inverter Master Model Code Example MI 06 S 48 400 P AM El L L HH Type of heat sink P Mounting Plate FH Finned type with horizontal fins F Finned type with vertical fins Maximum current Arms of Power Stage Nominal Voltage V 24 48 80 Type of Power Stage S single Frame Size 06 Mobile Inverter 7020001 9 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 4 User Liability and Safety Statements 4 1 OEM Responsibility 10 The OEM of a machine or vehicle in which PLUS 1 electronic controls are installed has the full responsibility for all consequences that might occur Schwarzmiller Inverter has no responsibility for any consequences direct or indirect caused by failures or malfunctions Schwarzmiller Inverter has no responsibility for any accidents caused by incorrectly mounted or ma
31. erTorqueLimit must be set to 10000 100 With the variable MotorControl ActTorqueLimitthe valid torque limit in Nm can be read The current limitation see 11 1 6 may prevent achievement of maximum torque 11 1 6 Current Limitation There are three different current limitations Hardware current limit This is the maximum current capability of the power stage hardware Motor current limit This is the current limit for the motor defined at Motor CurrentMax User current limit This is the current limit for the application defined at MotorControl UserCurrLimit as a percentage of the hardware current capability The valid current limit can be read with the API variable MotorControl ActCurrL imit The torque limitation see 11 1 5 may prevent achievement of maximum current 11 1 7 Speed Control Versus Torque Control For most applications the preferred control mode is speed control In some applications torque control may have advantages The speed controller can be used for torque control with following consideration e Provide the absolute torque set value to the torque limit value of the speed controller e Provide a speed limit value to the speed set value of the speed controller e Since the torque limit value accept only absolute values the sign of the torque set value has to transferred to the speed set value Example Values for torque control Values to the speed controller Torque set value 80 M
32. esistor and the values are filtered with a time constant of 500ms The actual temperature is calculated and displayed at PowerStage Tempin the range of 60 C to 170 C If the actual value exceeds the temperature limit stored as production data in EEPROM an over temperature error occurs e Disable the power stage PowerStage EnableStatus 0 e Display the error PowerStage Status Bit1 1 e Increase error counter ErrorHistory AbsOTErrors e Write error history memory In addition to that the inverter types MIO3 and MIO4 have a second internal measurement which monitors the temperature of the power pcb Usually the board temperature is below the temperature of the transistors so the previously mentioned over temperature protection switches off in case of a long overload duration In some special cases very effective forced cooling it can happen that the pcb temperature PowerStage PCBTemp can reach critical values long before the temperature near the transistors is too high In such a case a current derating will take place starting at 115 C with 100 ending at 135 C with 0 of the hardware current limit This derating phase will be indicated at e MotorControl Status Bitl2 1 The very unlikely case of pcb temperature gt 135 C will be indicated at e PowerStage Status Bit10 1 8 2 1 4 Temperature Sensor Error If the result of the power stage temperature calculation or the pcb temperature calculation is out of the sensor range of 60 C t
33. esssssssccsoossssssesesscoosssssssessoeoosossseesscooosssssesssceoososssesssosee 46 114 E DITE e ole E i eE A E E E E E E E A E Toa setansusan s 46 11 4 1 Encoder DiaQnostics esssssssssssecssssssscsseeseesssessssssecssscssscssscsessseesusesseenseesseenseess 46 11 4 2 Diagnostics of Motor Data sessssssssssssecsesssscsescsecssecseesseecssecssssseenseenseeseeesneess 46 11 4 3 Diagnostics of Motor Control 0 essssssescssecssecssscsseessecssecssscssecseecssecseenseenseesseess 47 12 Controller Area Networks Specifications 48 12 1 CAN Controller Area Networks POrts cccsssssssssessssssssesssssssssessssesssssesssssssessssesssseesees 48 12 2 Terminating Resistor sissiscssssdccsdeaseccassectecanttessscsedessdsvsientscasvantincasdsviescaeiedtvcsanieiercentenssecvea 49 12 3 Bus Stubs Wires form Main Bus to the Unit also called Drop 49 12 4 CAN Wiring SUGGESTIONS sessesssessesssscssessssssssssscsssssusesssssessesssesesssesecsnsssssssssessuseseeseeseess 49 12 5 CAN Protocols cicecsazesessccsssvsdscezacescastendstecsssascesantenstesatescedsusteustesentatsssustarqadtesssisieucosenssbistenstdhes 49 13 Product Ratings 50 13 1 ProdictiRatings ssaae east ndia a para assadas acatar ia 50 14 Product Installation and Start Up 51 TA Mating Connectors ccacssecsscsorescsnessisicvessenssoversuensshesnisiovensehessterorsosenesavsievennenurdsssnserbsensaiesoisioase 51 14 2 PLUS 1 Inverter Instal
34. fic software and or parameter settings are loaded from production cell part number that the customer is ordering Devicelnfo nverterFrameSize Inverter frame size 6 for MIO6 20 for MI20 and so on 10 4 NVRam User Data PLUS 1 Inverters provide a non volatile memory area for user data This memory area consists of a RAM area with EEPROM backup In normal operation the memory access for the application software is not different from other RAM areas If power down is detected by the control hardware the NVRam area will be copied immediately to the EEPROM An energy buffer inside the control hardware is capable to supply the voltage for the needed time At power up the data will be restored to the NVRam area before the application software starts 40 70200001 N A SCHWARZMULLER INVERTER 11 1 Control Structure AotorControl RP 2tValue MotorControl TorqueFF PLUS 1 Inverter Family User Manual 11 Motor Control PLUS 1 Inverters control three phase AC induction motors using a field oriented motor control algorithm This technology combined with predefined motor data provided by PLUS 1 Motor Compliance Blocks guarantees optimum motor control performance PLUS 1 Motor Compliance Blocks eliminate the need for detailed knowledge about AC motors and field oriented control for successful installation and set up of the application Basic knowledge about AC induction motors is helpful however for error diagnosti
35. ge C1p02 The application software has already started and can close the main contactor to shorten the time of charging the DC Link capacitors The only criterion to start the power stage test is the level of the DC Link voltage independent of the status of the main contactor One of the tests requires a correctly connected motor An extensive test of the power stage is performed to detect e Ashorted power transistor e Adamaged power transistor will not switch on This fault can only be detected if a motor is correctly connected e A short circuit of a phase output to V DC Link e A short circuit of a phase output to V DC Link e A Short circuit between two phase outputs short circuit in wiring or motor Errors Error message Meaning Recommended Result afterwards and recovery action conclusion Short circuit to Short circuit between a Switch off power supply Still the same error Inverter V_DC_Link phase output andthe Disconnect phase damaged o or power stage outputs Short circuit to supply or between the Switch on power supply Only error Error in motor wiring V_DC_Link phase outputs again or power stage There is a short Shorted power circuit in the motor or the wiring output Error in motor Motor not connected Test motor wiring If the error occurs with a correct wiring or Motor wiring incorrect Exchange motor wired motor the power stage is power stage Motor winding broken damaged
36. ified input voltage of the inverter 7020001 55 Notes
37. intained equipment Schwarzmiller Inverter does not assume any responsibility for PLUS 1 products being incorrectly applied or the system being programmed in a manner that jeopardizes safety All safety critical systems shall include an emergency stop to switch off the main supply voltage for the outputs of the electronic control system All safety critical components shall be installed in such a way that can be switched off at any time Please note the power stage capacitors will maintain a stored energy of over 100Ws and could therefore supply connected components for some seconds after emergency stop is switched off The emergency stop must be easily seen and must be accessible to the operator 70200001 cabal td Aa PLUS 1 Inverter Family INVERTER User Manual 5 PLUS 1 Inverter Power Stage Specification 5 1 Ratings The PLUS 1 Inverter Family is designed to operate with a nominal voltage supply of 24V 36V 48V and 80V The inverter will operate with full functionality if the supply voltage is in the voltage range specified for each of the types 5 2 Power Data Type Mixx S 24 240 24 300 24 400 Size MIO3 MI04 MI06 Nominal voltage VDC 24 Input voltage range VDC 16 36 Nominal current 3 Arms 120 150 200 Maximum current 3 Arms 240 300 400 Boost current 3 Arms 260 330 420 Output voltage 3 Vrms
38. l input DIN For specification in DOUT PWMOUT and DIN mode refer to General Purpose Input Outputs Section 6 5 1 In POUT mode the output is closed loop current controlled by a hardware two level controller The frequency of the output signal varies between 500Hz and 2kHz The current set value is defined by software A set value of 0 will switch off the output completely A dither signal with a fixed frequency of 62 5Hz can be added with a software defined amplitude up to 250mA The dither amplitude will be limited to the actual current set value dynamically Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx POUT Current controlled output superposed with dither signal Internal structure Low side switch with free wheeling diode Cathode of free wheeling I O supply output diode connected to Current range A 0 04 2 0 Dither signal frequency 62 5 Hz 0 0 25 A amplitude Repeat accuracy from unit lt 10ma for set values 0 to 330mA to unit lt 3 for set values 330mA to 2A Switching frequency Hz 500 2000 Over load protection Non damage current thermal limit automatic latch off resume Resistance to minus power 136k supply Q in OFF state Max load resistance Q O 45k 266 k 468 k 12V O supply voltage A higher resistance works but will be detected as output disconnected Open circuit detection Fault indicatio
39. lation Guidelines 0 ssessssssssscsscssessecccsecssessecesensesseceeseensees 52 14 2 1 MOunting the INverter cccsssssssscsssssscsecsscssccsecsscsscsccsscssescessccsscsccssenscesecsseasessees 52 14 2 2 Wiring the Power Stage ccsssssssecsesssessessscssccsececssesscssesecsecssessessesssessessesseeseensess 52 14 3 PLUS 1 Recommended Machine Wiring Guidelines 54 14 4 Welding on a Machine Equipped with PLUS 1 Modules 54 145 PLUS 1 USB CAN Gateway ciiccccsscssecseassosesssassssesesessseasuoscosetoscsonseseasbecsnsebsessesaiosssoessnessssevees 54 14 6 Start Up and Recommended Installation Instructions 55 4 70200001 User Manual 1 Introduction About this Manual Taitai PLUS 1 Inverter Family INVERTER 1 1 PLUS 1 Inverter Family Technical Information This manual is designed to be a comprehensive PLUS 1 inverter family reference tool for vehicle OEM design engineering and service personnel It is one of five primary sources of the PLUS 1 Inverter product technical information The other four sources are e Individual PLUS 1 Inverter product data sheets e The PLUS 1 Graphical User Interface Development Environment GUIDE Software User Manual e The application interface document e The PLUS 1 library 1 2 What Information is in this Manual This manual describes electrical details that are common to all PLUS 1 Inverters hardware including general specifications basic o
40. lusive encoder and temperature sensor data using the Service Tool Ifthe application software allows changing motor data at run time the Motor Data Download Block has to be installed As this block requires default values a Motor Compliance Block or an Open Motor Data Block has to be installed additionally 70200001 eee PLUS 1 Inverter Family INVERTER Pn Sie User Manual 11 Motor Control 11 2 Motor Definition continued 11 2 4 Re Initialization of Motor Data If motor data are changed during runtime switch between motor data blocks the data will only become valid after a reinitialization This has to be done by writing a 0 1 sequence to Motor Reinit The re initialization will not be performed until the power stage is disabled and the actual speed is lower than 10 rpm Motor Status bit23 is 1 while a reinitialization is pending 7020001 45 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 11 Motor Control 11 3 Temperature Compensation 11 4 Diagnostics 46 For best performance the field oriented motor control includes an adaptation algorithm to consider the influence of the actual motor temperature As the measurement of the motor temperature is dependent on the application the PLUS 1 application software must provide the actual motor temperature to the field oriented control via API variable Motor ActTemp If no temperature sensor is available a constant value of 20 C can be connected to Motor A
41. mation 1 2 What Information is in this Manuall c sssssssssssecsecsscsscssecssssccsscssecsessscssecsecucsacesseseeseesees 1 3 What Information is in Product Data Sheet cssscssscsscessscsscssecsessscnsessecsscesescesecseesees 1 4 What Information is in the PLUS 1 GUIDE Software User Manual 1 5 What Information is in the API esssssssscecsessscssscsecsscsscssecsccuccsscssecuccucsssccucsaceacesseeseesees 1 6 PEST Li AAP Yscicsccsstdeessccdscustsssosstsdevsscacs cdvaazascssastatscthatetes scatesesebeossisssasseasdatsastensesessanessansinionats PLUS 1 Inverter Family 2 1 PEUS 1 Inverter Family sssiscisscsssssssssccassstesssnsieassasstcnssctsssatanssesiessoasivaanstatisadenisnnnnn ceases 2 2 Inverter Typical Applications sesssessssecsssssecssecsecssscssecssecnsscssscssecseesseecssscneeeseeeneeeseesees 2 3 PLUS 1 Inverters fit with other PLUS 1 ProdUucts sessssssscsscssessecsscsecssesecscesecesesseees PLUS 1 Inverter Naming Convention 3 1 PLUS 1 Inverter Naming CONVENTION sssessessessseseesssssesssesssssessesssessssuseseessessssseeseess User Liability and Safety Statements 4 1 OEM Responsibility sssssstsscatancsseussssss ctessaseassoosssensccsstbesssatasspietvsvsensssadssnssdsasisissvasctvsaascuatsasneas PLUS 1 Inverter Power Stage Specification 5 1 RCIA EEEE A E E E E EAE E E E A A 5 2 Power Deh PANA NR GRE APESAR SR CRT RD DO DO PEDE Input Output Types and Specification 6 1 Input Output Ty Pe sisiissisisscscss
42. n t use additional washers Make sure that the cable shoes lay directly on the brass sleeves of the inverter Details for Power Stage wiring see 14 2 2 A Warnings As the currents can be in the range of some hundred Amps a proper electric contact between brass sleeves and cable shoes is essential to avoid hot spots Make sure that the cable shoe directly lies on the brass sleeve 26 70200001 ee PLUS 1 Inverter Family INVERTER User Manual 7 Power Supply MEMBER OF THE SAUER DANFOSS G 7 3 Power Stage Supply continued Connection with a fuse Connection without a fuse 7020001 27 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 7 Power Supply 7 3 Power Stage Supply continued 7 3 1 Pre charging of capacitors The power stage capacitors are pre charged by the control power supply C1p02 via a positive thermal coefficient PTC resistor The inrush current of the power stage supply is dependent on the voltage level of the power stage capacitors at the time of connecting voltage to the power stage The time between switching control power supply and power stage supply is responsible for the peak value of the inrush current In practice a compromise between start up time and inrush current has to be found The easiest way is to switch on the main switch immediately after the start of the application software The PLUS 1 Inverter function block library provides a functi
43. n provided If the voltage at the output pin in OFF state is less than 9V the Pin status Output disconnected will be reported Considering the internal resistance of 136kOhm the load resistance should be maximum 45kOhm at 12V I O supply voltage For higher O supply voltages the maximum load resistance can be calculated with the formula Ra 2 1 1364Q 9V With Vio O supply voltage Max resistance ON state 0 2 0 2 0 25 Roson Q 25 C 7020001 21 SCHWARZMULLER INVERTER PLUS 17 Inverter Family 6 5 22 User Manual 6 Input Output Types and Specification Inputs Outputs continued 6 5 3 Main Contactor Output DOUT MC PWMOUT MC The main contactor output is a special output pin designed to drive the vehicle s main contactor In difference to standard output pins the free wheeling diode is connected to the pin Power supply instead of I O supply output This is because the main contactor is typically supplied in parallel to Power supply with the vehicle s battery voltage via the vehicle s key switch Another diode protects this output against reverse polarity Together with the main contactor this circuit provides the reverse polarity protection for the inverter because the main contactor can only switch the battery to the power stage if the polarity is correct The main contactor output can be programmed to work as digital output in binary mode DOUT MC or as
44. nput The filter can be bypassed by setting the filter time constant to 0 Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx AIN bipolar Analog input bipolar Resolution 12 bit Input resistance Q 120k Voltage range V 10 10 Recommended resistance 1k 10k range of external Potentiometer Q 6 4 5 Rheo This input has a pull up resistor of 10kQ to 5V The system software calculates the resistance of the connected external sensor in the range of 0 to 12kQ If the resistance is higher than 12kQ the results of the calculation shows 12kQ and an Input out of range status is reported at the API variable PinStatus A first order filter in the system software is available with a configurable filter time constant in the range of 10ms to 2000ms The filter can be bypassed by setting the filter time constant to 0 Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Rheo Measurement of an external resistance to minus power supply e g motor temperature sensor Range of resistance Q 0 12k 70200001 N SCHWARZMULLER INVERTER 6 4 Inputs continued 6 5 Inputs Outputs PLUS 1 Inverter Family User Manual 6 Input Output Types and Specification 6 4 6 Encoder Channel A Encoder Channel B Paired inputs driven from a quadrature encoder The inputs have pull up resistors of 1 1kQ t
45. nput with Unipolar Range AIN Unipolar The sample time for analog inputs is 1ms For each analog input a separate first order filter in the system software is available with a configurable filter time constant in the range of 10ms to 200ms The filter can be bypassed by setting the filter time constant to 0 This analog input provides additional safety functions The input voltage range of 0 to 10V is converted to the range of 10 to 90 of the DSP input range and is provided to two separate DSP channels This allows the detection of any failure on the hardware input circuit as well as the detection of an input voltage out of the specified range A out of range or hardware error will be reported at the corresponding API variable PinStatus Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx AIN unipolar Analog input unipolar Resolution 12 bit Input resistance Q 120k Voltage range V 0 10 Recommended resistance 1k 10k range of external Potentiometer Q 7020001 17 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 18 User Manual 6 Input Output Types and Specification 6 4 Inputs continued 6 4 4 Analog Inputs with Bipolar Range AIN bipolar The sample time for analog inputs is 1ms In the system software a separate first order filter with configurable filter time contstant in the range of 10ms to 200ms is available for each analog i
46. ns of PLUS 1 Inverter inputs and outputs are different from other PLUS 1 controllers and I O expanders 7020001 13 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 6 Input Output Types and Specification 6 1 Input Output Types continued The following table lists Mixx input and output types and typical usage Function DIN DIN PU AIN unipolar Description Digital input high active Digital input with pull up resistor low active Analog input 0 to 10V Typical usage Standard digital inputs Interface input from external components with open collector outputs such as encoders for motor encoder there are separate inputs available Inputs for set value potentiometer throttle minilever AIN bipolar Analog input 10 to 10V Interface input from vehicle master controller providing set value for speed and driving direction 10V to OV backward OV to 10V forward Rheo Encoder channel A channel B DOUT PWMOUT POUT DOUT MC PWMOUT MC DOUT safety Rheostat input Measurement of an external resistance between this pin and minus power supply Paired inputs driven from a quadrature encoder Encoder with open collector or push pull outputs can be used Digital output low side switch with free wheeling diode to I O supply output Digital output with the same properties as DOUT but using pulse width modulated signal with a frequency of 100Hz Pulse
47. o 170 C a temperature sensor error occurs e f Unprotected mode is inactive disable the power stage PowerStage EnableStatus 0 e Display the error PowerStage Status Bit2 1 for power stage PowerStage Status Bit11 1 for pcb e Increase error counter ErrorHistory AbsTSensErrors for power stage ErrorHistory AbsPCBTSensErrors for pcb e Write error history memory 7020001 33 SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 8 Protection 8 2 Runtime Protection Functions continued With the help of Unprotected mode see 8 2 2 a limp home mode can be programmed in GUIDE to allow limited operation in the event of a temperature sensor error 8 2 2 Unprotected Mode The unprotected mode allows the power stage to be enabled even if a temperature sensor error would lock it The unprotected mode is activated when PowerStage Unprotected is changed from O to 1 To avoid an unintended usage of the unprotected mode the APL resets the unprotected mode after 60 seconds Within these 60 seconds the unprotected mode can be inactivated by PowerStage Unprotected 0 but not retriggered In order to recognize the usage of unprotected mode when the machine is serviced usage of unprotected mode is stored in error history memory 34 70200001 N SCHWARZMULLER INVERTER 9 1 Enable Disable PLUS 1 Inverter Family User Manual 9 Power Stage With the variable PowerStage Enable the power stage can be s
48. o encoder supply Encoders with open collector or push pull outputs and 32 to 1024 pulses per revolution can be used A Warnings The field oriented motor control requires the speed feedback value measured with a quadrature encoder Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Encoder channel A Encoder Square wave signal from encoder with 90 phase shift channel B between channel A and channel B Internal structure Internal pull up resistors to power supply encoder Pull up resistor Q 1 1k Maximum frequency kHz 10 open collector Maximum frequency kHz 50 push pull Low level maximum V 1 77 High level minimum V 7 1 A Warnings Single outputs can sink up to 3 Amps However the total output current for the application control section of the device must not exceed 8 amps 6 5 1 General Purpose Input Output DOUT PWMOUT DIN The characteristics of General Purpose Input Output pins are GUIDE software controlled A General Purpose Input Output pin can be programmed to work as digital output in binary mode DOUT as PWM output PWMOUT or as digital input DIN The output configuration is an open collector sinking output with overload and open circuit detection If a General Purpose Input Output pin is programmed as PWM output the output signal is pulse width modulated with a constant duty cycle The PWM frequency is c
49. ode Driver for safety critical proportional valve 14 70200001 Taitai PLUS 1 Inverter Family INVERTER User Manual 6 Input Output Types and Specification 6 1 Input Output Types continued The following ratings apply to all input and output types Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Protection Max input voltage V 36 62 105 Max input voltage spikes 36 72 120 for lt 100ms V 6 2 Input Output Wiring Principle The following diagram shows the wiring principle of the inputs and outputs 1 Connector Type i j j AMP SEAL Standard functions Alternative functions r gt gt E imam CANH is CANL Controller CANH T Power ground L EV or 10V or 12V Dm Potentiometer supply 5V or 10V or 12V e ppi pie a E pf a 7 AIN unipolar ov 10V Sm AIN bipolar 10V OV 10V Power Supplies E a AN bipolar TOVON ION DIN PU suitable gt Power ground keene li rev for encoder inputs cl
50. odulation method is used which provides the double PWM frequency to the motor in most of the applications 8 kHz provides a silent behavior However if the motor noise is too high the PWM frequency can be increased A higher PWM frequency leads to e higher power losses e slightly lower maximum motor voltage less performance in field weakening area gt reduced maximum speed 70200001 N SCHWARZMULLER INVERTER 9 3 Diagnostics PLUS 1 Inverter Family User Manual 9 Power Stage The API provides a number of data for diagnostic purposes of the power stage API variable Description PowerStage EnableStatus Displays the actual status of the power stage The power stage can be disabled because of an error even if PowerStage Enable is true False Power Stage disabled True Power Stage enabled PowerStage Temp Actual temperature at power stage in degree Celsius PowerStage TempLimit The temperature limit of the power stage PowerStage HWCurrLimit Current capability of the power stage Remark The current may be limited by user current limitation PowerStage Locked 0 unlocked okay 1 the power stage is temporarily locked during initialization and self test 2 the power stage is permanently locked because of an error The reason can be found at Se test Error or PowerStage Status PowerStage Status Bito 0 OK 1 wrong value at PWMFreq Bit1 0 OK 1 Overtemperature Bit2 0 OK 1 Temperature sensor error Bit3 0
51. on block main contactor which allows a controlled switching of the main contactor at a defined voltage level Short delay for main contactor control power supply main contactor power stage voltage inrush current Longer delay for main contactor control power supply main contactor power stage Lee voltage inrush current MK 28 70200001 N SCHWARZMULLER INVERTER 8 1 Self Test at Power Up PLUS 1 Inverter Family User Manual 8 Protection At power up a self test routine is performed to detect failures in the hardware of the power stage or external wiring The system software is processing following steps EEPROM CRC check Configuration of the IOs and sensor power supply Test of DC link voltage Test of hardware watchdog Start of PLUS 1 application software Test of power stage The API variable Se ftest displays errors warnings and the status of the self test For details please refer to the API description During the tests the power stage is locked by system software means the application software can not enable the power stage before the tests are passed If one of the tests fails with an error the power stage will be locked permanently If an over voltage error occurs at any time during the execution of the self test routine all test will be skipped and a self test error will be reported Test not passed because of hardware over voltage pr
52. onductors The terminating resistor must be kept within the following specification Description Units Minimum Maximum Nominal Comment Resistance Ohm 110 130 120 Minimum power dissipation 400 mW 12 3 Bus Stubs Wires form Main Bus to the Unit also called Drop Be aware of the length of the stubs drops when used Max length 1Mbps is 30 cm see Figure 9 Bus stubs Lower baud rates allow longer stubs Node 1 Node 30 CAN_L 40m 130 ft 1 Mbps Figure 9 Bus stubs A Warnings The programmer of the PLUS 1 application software has to consider a proper reaction on CAN Bus malfunction dependent on the application requirements 12 4 CAN Wiring Suggestions Although the CAN bus is insensitive to electromagnetic interference it is recommended to use twisted pair with shield Shield must be connected to ground 12 5 CAN Protocols Different protocols will be available through PLUS 1 GUIDE programming in the form of function blocks Contact Schwarzmiller Inverter for further information 7020001 49 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 13 1 Product Ratings 50 User Manual 13 Product Ratings Environmental Switching frequency 8kHz standard adjustable 4 8 12 16 kHz Efficiency about 95 at nominal output Output frequency 0 300 Hz Tolerable supply voltage drop Down to 50 of nominal voltage for max 50ms Ambient t
53. onstant 100Hz and the duty cycle has a resolution of 10 and is defined by software The purpose of the PWMOUT mode is simple voltage control For closed loop current control use the POUT mode on an appropriate pin 7020001 19 SCHWARZMULLER INVERTER PLUS 17 Inverter Family User Manual 6 Input Output Types and Specification 6 5 Inputs Outputs continued 6 5 1 General Purpose Inputs Outputs DOUT PWMOUT DIN continued If a General Purpose Input Output pin is programmed as digital input the signal is debounced in system software with a user configurable time in the range of 0 to 100ms Digital input debounce is defined as an input being in a given state for the configured debounce time before a state change is reported The sample time of digital inputs is ms The status of the pin can be read in GUIDE software in all configuration modes using the API variable Digin The debouncing is only active in DIN mode Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx DOUT PWMOUT Digital output Internal structure Low side switch with free wheeling diode Cathode of free wheeling I O supply output diode connected to Signal condition DOUT Reactions time minimum 1ms dependent on application SW loop time Signal condition PWMOUT Programmable PWM signal from 0 to 100 with 10 step PWM frequency 100Hz Nominal current A 2 0 Maximum curr
54. otection 8 1 1 EEPROM CRC Check First a CRC check of the EEPROM data will be performed The EEPROM is split into three sections Production data Data stored at production of the device in a protected memory area to adjust software scaling to actual hardware User data Memory area accessible by the user Error History data Memory area where the error history data is stored If the CRC check fails for the production data area an error will be reported Se ftest Error Bit7 1 since wrong data may lead to incorrect behavior The self test routine will be skipped and the power stage and the main contactor output will be locked If the CRC check fails for the user data area only a warning will be reported Appropriated response to this failure should be programmed in the PLUS 1 application software If the CRC check fails for the Error History data area only a warning will be reported The device is functional but error history data might be corrupted 7020001 29 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 8 1 30 User Manual 8 Protection Self Test at Power Up continued 8 1 2 DC Link Test With the DC link test a short circuit in the DC link circuit internal hardware like capacitor board or external wiring can be detected Before the main contactor gets closed the capacitor bank is pre charged via a resistor powered by the power supply voltage C1p02 Test algorithm e WaituntilV DC Link gt Thre
55. otor encoder temperature sensor as well as the calculation of the actual motor temperature the generation of an error signal at over temperature and the surveillance of the minimum and maximum encoder supply current The name of the compliance block is reflecting the part number of the motor package Plug amp Perform All adjustments and calculations related to motor encoder and temperature sensor are done by just installing the appropriate Motor Compliance Block The following error signals are provided by the Motor Compliance Block MotorData Motor MaxTempErr True if actual temperature exceeds maximum motor temperature specified inside the compliance block MotorData Enc MaxCurrErr True if encoder supply current exceeds maximum specified inside the compliance block MotorData Enc MinCurrErr True if encoder supply current is lower than minimum specified inside the compliance block Indicates a disconnection of the encoder a broken encoder wire or any other encoder failure The reaction to these error signals have to be programmed dependent on the application 11 2 2 Open Electric Motor Data Function Block For motors not measured by Schwarzmiller Inverter the data for motor encoder and temperature sensor can be edited in the GUIDE template Required motor data are IEEE values supported by the Motor manufacturer 11 2 3 Electric Motor Data Download Block This function block allows set up of motor data inc
56. otorControl UserTorqueLimit 8000 Speed limit 2000 rpm MotorControl RPMSetPoint 20000 Torque set value 50 MotorControl UserTorqueLimit 5000 Speed limit 2000 rpm MotorControl RPMSetPoint 20000 The PLUS 1 Inverter function block library provides the function block Torque Control which contains the related calculations 7020001 43 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 11 2 Motor Definition 44 User Manual 11 Motor Control The field oriented motor control algorithm requires entry of motor data These are physical data of the motor independent of the application No optimization of motor data at final machine performance testing is required The required motor data have to be provided to the API variable structure Motor xxx Because the motor typically comes in a package with encoder and temperature sensor those data are included in the same structure There are three different ways to provide the motor data With Motor Compliance Blocks and Open Data Blocks the motor parameters are part of the source code and can only be edited in the PLUS 1 GUIDE Working with Download Blocks allows the independent handling of application software and motor parameters by downloading two lhx files with the PLUS 1 Service tool 11 2 1 Electric Motor Compliance Blocks Motors measured by Schwarzmiller Inverter are supported with PLUS 1 Compliance Blocks including all required data for the complete motor package m
57. perating system input and output parameters environmental ratings and installation details 1 3 What Information is in Product Data Sheet Parameters and engineering data that are unique to an individual PLUS 1 Inverter are contained in the respective inverter product data sheet Data sheets contain the following information Numbers and types of inputs and outputs Inverter maximum current and voltage capability Power supply current consumption Inverter installation drawings Inverter weights Product ordering information 1 4 What Information is in the PLUS 1 GUIDE Software User Manual Detailed information regarding the PLUS 1 GUIDE software tool set that is used to build PLUS 1 machine management solutions is contained in the user manual This technical information manual covers the following broad topics e How to use the GUIDE graphical application development tool to create machine applications How to configure input and output parameters How to download GUIDE applications to target PLUS 1 hardware How to upload and download tuning parameters How to use the diagnostic and service tool 7020001 5 SCHWARZMULLER INVERTER PLUS 17 Inverter Family User Manual 1 Introduction About this Manual 1 5 What Information is in the API Detailed information for the Parameter interface between the internal Inverter control Software and the PLUS 1 Application Software created in PLUS 1 GUIDE The Application Layer Interfac
58. rotection activated Resistance to minus power 136k supply Q in OFF state Max load resistance Q 45k 266 k 468 k 7020001 23 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 6 5 24 User Manual 6 Input Output Types and Specification Inputs Outputs continued 6 5 4 Output with Enhanced Safety DOUT safety PWMOUT safety POUT safety continued Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx POUT safety Current controlled output for safety relevant components e g lower valve superposed with dither signal Internal structure Low side switch with additional safety switch in series and free wheeling diode Cathode of free wheeling I O supply output diode connected to Current range A 0 2 0 Dither signal frequency amplitude 62 5Hz 0 0 25 A Repeat accuracy lt 10mA for set values 0 to 330mA lt 3 for set values 330mA to 2A A higher resistance works but will be detected as output disconnected Switching frequency Hz 500 2000 Resistance to minus power 136k supply Q in OFF state Max load resistance Q 45k 266 k 468 k 70200001 User Manual 7 Power Supply ance PLUS 1 Inverter Family INVERTER 7 1 Control Power Supply The main power supply for the application control circuits has to be provided at pin C1p02 power supply and
59. s is a fullCAN which translates into extensive hardware filtering of incoming IDs messages This in turn leads to a lower load of the CPU thus allowing for more calculation capability left for the user customer application itself The inverters have double CAN ports for easy wiring The pins related are as follows Port Pin name Pin The C1p03 and C1p04 are internally connected in parallel with C1p06 and C1p07 See 1 qu CANH D CANL i Figure 7 Double CAN port Comecior Type i AME SEAL Standard functions CE O CS s 48 CANH D ANL I The double CAN port also gives the opportunity to use daisy chain or stub wiring of the bus The advantage of the daisy chaining is that it eliminates connectors in the wiring harness thus providing higher reliability See Figure 8 Be aware of stub length see Figure 9 Bus stubs 3 4 6 7 3 4 6 7 3 4 6 7 Mixx Mixx Mixx 3 4 3 4 3 4 Mixx Mixx Mixx Figure 8 Bus topology 70200001 mes pel ITA PLUS 1 Inverter Family INVERTER rn Sea User Manual 12 Controller Area Networks Specifications 12 2 Terminating Resistor Each end of the CAN bus must be terminated with an appropriate resistance to provide correct termination of the CAN_H and CAN_L c
60. shold voltage 1 6V 3 5V e The test is OK as soon as this condition is fulfilled e If this condition is not fulfilled before 5s after power on the test failed gt Selftest Error BitO 1 Error Link Circuit The main contactor output and the power stage are locked permanently C7p24 Locked 1 PowerStage Locked 2 all following tests will be skipped If this error occurs gt Switch off power supply gt Disconnect the power cables and gt Switch on power supply again If the DC Link test with the power cables disconnected shows no error there is either a short circuit in the wiring of the power cables and or the load in that circuit is too high and pulls down the DC Link voltage If the error still occurs with the disconnected power cables there is a failure in the inverter power stage and the device must be replaced 8 1 3 Hardware Watchdog In addition to the internal DSP watchdog PLUS 1 Inverters have a separate hardware watchdog This watchdog is triggered by a toggle signal generated by system software If the trigger signal is not toggling the hardware watchdog disables the power stage and all interface outputs The hardware watchdog will be checked by the self test routine at power up The result can be a warning or an error PLUS 1 Inverters are designed and produced to a very high quality standard The hardware watchdog is an additional feature which increases the safety of the inver
61. sisissssnsccsccssnacssscesaceseseotecssccessasssesagecsseacousceseassosscaseasscisoaczsazeae 6 2 Input Output Wiring Principle As 6 3 Input Output Supply VOItaGe reessesssecseecseecnsecseecsecsssecseensecsseesseessecssecsscenseenseesseensees 6 4 MI 68 Ls pR ES E ua a ERR RR ER DOR ESP SR ERR RR EE ESGOTO RUE RR RR SR ERRO E O 6 4 2 Multi Function Input DIN DIN PU Freq 6 4 3 Analog Input with Unipolar Range AIN Unipolar 6 4 4 Analog Inputs with Bipolar Range AIN bipolar 6 4 5 RICO iscascavssastcnsisasctssstassusscnsnenvcassstasvenssastorsbastarcsessstucsuonsteess 6 4 6 Encoder Channel A Encoder Channel B 6 5 Inputs OUtputS siccssssscosesecoresnersiereroiessovevesss ntesssensenssiesnicrsoteieseonevesstesenbens E 6 5 1 General Purpose Input Output DOUT PWMOUT DIN 6 5 2 General Purpose Proportional Inputs Outputs DOUT PWMOUT DIN POUT rr eeeeeeerneerseereeerseerseenseenseas 21 6 5 3 Main Contactor Output DOUT MC PWMOUT MO 22 6 5 4 Output with Enhanced Safety DOUT safety PWMOUT safety POUT safety 23 Power Supply 71 Control Power SUPPLY ssssssssssssssassssenswassesssssssssessesnssanssinssiaessaassaenodeseiseteastseceoseadszessenssseensdeieas 72 Auxiliary Power Supplies sesssssssesssesssscssecssecssecsescnsssssecscessssssssssscnsecseessseseeessesneenseesees 7 21 Sensor Power Supply Se 7
62. switch off the output At each switching cycle the functionality of both transistors is checked by system software If a transistor is damaged and can t switch off anymore the second transistor takes over the full functionality of the output and the API variable SafetyStatus shows a Safety Error Afterwards the output will work like a standard output This feature provides a very high safety on the appropriate outputs These outputs should be reserved to drive components related to safety critical functions like electromagnetic brakes or lowering valves The technical specification is identical to standard outputs of the type DOUT PWMOUT and POUT Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx DOUT safety PWMOUT safety Digital output for safety relevant components e g magnetic brake Internal structure Low side switch with additional safety switch in series and free wheeling diode Cathode of free wheeling diode connected to I O supply output Signal condition Reaction time minimum 1ms dependent on application 12V 1 O supply voltage A higher resistance works but will be detected as output disconnected DOUT safety SW loop time Signal condition Programmable PWM signal from 0 to 100 with 10 PWMOUT safety step PWM frequency 100Hz Nominal current A 2 0 Maximum current A 3 0 for min 1 second before overload p
63. ter beyond the DSP watchdog If the hardware watchdog test results in a warning the functionality of the inverter is limited to the DSP watchdog If this is the only error the inverter is still functional Appropriated actions should be incorporated in the PLUS 1 Application Software dependent on the safety requirements of the application 70200001 N A SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 8 Protection 8 1 Self Test at Power Up continued 8 1 3 Hardware Watchdog continued Selftest Warning BitO 1 Failure in Watchdog circuit limited operation possible The Watchdog can t switch off the power stage and the outputs Selftest Warning Bit1 1 Watchdog not tested because of low DC Link voltage A minimum DC Link voltage is necessary to perform the Watchdog test If this voltage is not reached 5 seconds after start of Watchdog test routine the test will be skipped and this warning will be reported Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx Minimum DC Link voltage 5 2 10 11 to perform Watchdog test V Errors Selftest ErrorBitl 1 Watchdog error operation impossible The power stage and the outputs are always disabled The inverter is not functional Further self tests are discontinued 8 1 4 Power Stage Test The power stage test will be performed as soon the DC Link voltage reaches 90 of the power supply volta
64. tery powered material handling equipment and machinery to provide propel steering and work functionality The unique requirements of electric vehicle control necessitate that the specifications and typical use of PLUS 1 Inverter input output to be different than the input output specifications common to other PLUS 1 devices Typical applications of PLUS 1 Inverters include but are not limited to Walkie rider pallet and various types of low lift warehouse trucks Walk behind stacker lift trucks and order pickers Reach and 4 way warehouse trucks Sweepers scrubbers Side loaders Counterbalanced trucks Tow tractors and airport ground support vehicles Electric platform and neighborhood vehicles Golf cars Turf care equipment and machinery Aerial telescopic boom and scissor lift access equipment 2 3 PLUS 1 Inverters fit with other PLUS 1 Products The PLUS 1 Inverter family represents a major extension to Sauer Danfoss machine management products In addition to the PLUS 1 Inverter family discussed in this manual these also include vehicle microcontrollers graphical display terminals and operator input devices such as joysticks and finger tips The PLUS 1 products provide flexible expandable powerful and cost effective total machine management systems Current users of PLUS 1 should note that the PLUS 1 Inverters inputs and outputs are defined differently from the PLUS 1 microcontrollers These devices communicate with each oth
65. ting of errors in the Error History Memory is managed in the following sequence If the current error is the same as the last entry in ErrorHistory Number 0 Copy the value of HourCounter nverterto ErrorHistory Hour 0 Increment the value of ErrorHistory Counter 0 Increment the value of the related absolute error counter If the current error is different from the last entry in ErrorHistory Number 0 Move all entries of ErrorHistory Number ErrorHistory Hour and ErrorHistory Counterto the next element Write the error number to ErrorHistory Number 0 Copy the value of HourCounter nverterto ErrorHistory Hour 0 Write 1 to ErrorHistory Counter 0 Increment the value of the related absolute error counter Example Errors during live time Error type Value of HourCounter Overcurrent 1000 Overtemperature 2050 Overtemperature 2060 Overtemperature 2065 Overcurrent 3000 Overcurrent 3005 TempSensorError 3100 TempSensorError 3100 TempSensorError 3110 TempSensorError 3120 Unprotected Mode 3300 Unprotected Mode 3310 Unprotected Mode 3316 TempSensorError 3407 TempSensorError 3409 Content of Error History Memory Element ErrorHistory Number ErrorHistory Hour ErrorHistory Counter 0 4 3409 2 TempSensorError 1 5 3316 3 Unprotected Mode 2 4 3120 4 TempSensorError 3 3 3005 2 Overcurrent 4 1 2065 3 Overtemperature 5 3 1000 1 Overcurr
66. to be before B A Warnings A wrong value entered in Motor EncPulses can in the worst case result in uncontrolled acceleration If the encoder signal is missing the motor will run at low speed but can provide full torque Bad encoder signal conditions can result in jerky control behavior 11 1 4 Torque Feed Forward A step change in motor load torque will always result in a speed deviation for a short time The speed deviation will then change the motor torque to the right level to bring the speed back to the set value Typically such a control cycle takes less than 100ms If a very fast speed control is needed and the motor load can be estimated the torque feed forward input MotorControl TorqueFF can be used The estimated motor load torque has to be provided to the feed forward input A load change will directly result in the right motor torque without a speed deviation Even if the estimated load is not very accurate the speed deviation can be minimized 70200001 N SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 11 Motor Control 11 1 Control Structure continued 11 1 5 Torque Limitation The torque limitation for the motor is defined in the motor definition data structure Motor TorqueMax Another torque limitation can be entered at the motor control data structure MotorControl UserTorqueLimit This value is defined as a percentage of MotorTorqueMax If no torque limitation is needed MotorControl Us
67. voltage is compared to the maximum allowed value using a hardware comparator If the actual DC Link voltage exceeds the maximum value e The power stage is disabled by hardware e Aninterrupt at the highest level is triggered e The error handling procedure is performed by software Disable the power stage PowerStage EnableStatus 0 Display the error PowerStage Status Bit3 1 Increase error counter ErrorHistory AbsOVErrors Write error history memory The actual DC Link voltage is also displayed at V DC Link Volt 32 70200001 N SCHWARZMULLER INVERTER PLUS 1 Inverter Family User Manual 8 Protection 8 2 Runtime Protection Functions continued 8 2 1 2 Over Current In normal operation the current is limited by the software current controller In addition the current in each phase is limited by hardware If the actual current exceeds the maximum value the corresponding phase output is switched off for 50 us and a signal is sent to the DSP This signal triggers a software integrator If the integrator exceeds a limit over current signal is active for more than 3 seconds the error handling procedure is performed e Disable the power stage PowerStage EnableStatus 0 e Display the error PowerStage Status Bit4 1 e Increase error counter ErrorHistory AbsOCErrors e Write error history memory 8 2 1 3 Over Temperature The temperature of the power stage the transistors is measured with a PTC r
68. witched on and off Enabling the power stage is only allowed if PowerStage Status Bit1 0 PowerStage Status Bit3 0 PowerStage Status Bit4 0 PowerStage Status Bit10 0 PowerStage Locked 0 PowerStage Status Bit2 1 or PowerStage Status Bit11 1 and PowerStage Unprotected 1 PowerStage Status Bit3 0 PowerStage Status Bit4 0 PowerStage Locked 0 A 1 to O sequence at PowerStage Enable r PowerStage Status Bit7 PowerStage Status Bit2 PowerStage Status Bit PowerStage Status Bit4 PowerStage Status Bit10 PowerStage Status Bit 7 no Overtemperature at power stage no Overvoltage no Overcurrent no Overtemperature at PCB Power stage temperature sensor error PCB temperature sensor error Unprotected mode activated no overvoltage no overcurrent esets the PowerStage status bits Power stage overtemperature Power stage temperature sensor error Overvoltage Overcurrent PCB overtemperature PCB temperature sensor error The power stage can be disabled because of an error even if PowerStage Enable is true Therefore the actual status of the power stage can be read at PowerStage EnableStatus 7020001 35 SCHWARZMULLER INVERTER PLUS 1 Inverter Family 9 2 PWM Frequency 36 User Manual The PWM frequency of the power stage can be varied in 4 steps T 4 kHz 8 kHz default value 12 kHz 16 kHz with the API variable PowerStage PWMFreq Because a center aligned m
69. xx DIN Digital input with pull down Logic High active Input resistance Q 18k 18k 47k Low level V max 3 75 High level V min 9 0 70200001 N SCHWARZMULLER INVERTER 6 4 Inputs continued PLUS 1 Inverter Family User Manual 6 Input Output Types and Specification 6 4 2 Multi Function Input DIN DIN PU Freq The characteristics of Multi Function Input pins are GUIDE software controlled The inputs can be high active with pull down resistors DIN or low active with pull up resistors to 15V DIN PU The inputs can be used as digital inputs single counters or paired to one quadrature counter driven from a quadrature encoder If the inputs are used in counter mode the status of the digital input signals can be read in parallel The digital input signals are debounced in system software with a user configurable time in the range of 0 to 100ms Digital input debounce is defined as an input being in a given state for the configured debounce time before a state change is reported The sample time of digital inputs is 1ms Nominal Voltage V 24 36 48 72 80 Inverter Type Mixx S 24 xxx 48 xxx 80 xxx DIN PU Digital input with pull up resistor to 15V Logic low active Input resistance Q to 15V 1 1k Low level V max 3 75 High level V min 9 0 Maximum frequency in 100 counter mode Hz Quad counter mode counts 4 pulses per encoder period 6 4 3 Analog I

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