Datasheet v4
Contents
1. 9 The WaveSculptor provides isolated voltage supplies to operate the motor 10 11 12 13 14 position sensors and motor temperature sensor These supplies are a regulated 5V and a regulated 12V output Please check with your motor supplier for the acceptable operating voltage of the position sensors used in your motor The sensor output supply position inputs and temperature input have an isolation barrier between them and both the DC bus and the CAN bus voltages Motor position sensors are only required when driving a AC Permanent Magnet motor Motor position sensors should be aligned such that the phase angle offset between each sensor s output changing state and the zero crossing point of it s approprate motor phase is no more than the specified maximum This implies that the sensors are 120 offset electrically per motor pole from each other under ideal conditions The polarity and arrangement of the position input signals does not matter The WaveSculptor detects relative alignment of position signals to motor phases as well as the polarity of each input when the Phasorsense algorithm is run during motor controller configuration and setup The WaveSculptor can store this information for multiple motors thus allowing motor changes in your vehicle without having to re run the configuration program Please refer to the communications and programming Appendix in the User s Manual for more information The moto2. 7 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 300 ee 250 EN PASS E 150 K Rie 100 KS E l 50 K i Jl TE 0 20 40 60 80 100 120 140 Output voltage line to line Vrms Illustration 2 Predicted efficiency map of the WaveSculptor controller with a 200V DC bus These efficiency maps were generated using an accurate mathematical model of the WaveSculptor s power stage with individual loss components confirmed using laboratory testing 8 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 OPERATING POWER amp COOLING The maximum instantaneous output power from the WaveSculptor is limited by internal hardware restrictions as detailed in previous sections However the continuous power capability of the controller is limited by thermal performance and is therefore affected by conditions external to the controller such as ambient temperature and cooling system performance The WaveSculptor 200 is water cooled and uses an external radiator with fans to provide cooling for the system Careful consideration should be paid to the position and ventilation of the radiator in your vehicle Maximum instantaneous power output 165 kVA Note 15 Maximum continuous power output at 30 C ambient 107 kVA Note 16 Maximum continuou
3. the device for even a short interval will result in catastrophic failure of the motor controller The WaveSculptor contains sufficient internal capacitance and sufficiently rapid detection circuitry such that it can protect itself against a self imposed worst case situation during normal operation This situation is regenerative braking at full current at maximum continuous bus voltage and having the DC bus connection broken or removed This situation can occur as a result of the DC bus protection contactor opening the battery fuse blowing or a loose connection in the vehicle wiring Operating with higher DC bus voltages than the continuous voltage maximum could result in this self protection mechanism failing to shut down the controller in time resulting in the destruction of the controller The instantaneous current rating of the DC bus is related to the highest power drive situation which is driving at full motor current and full speed In this case the bus current will be V3 V2 RMS motor current maximum 300A giving a current of 368A DC The equivalent factors apply for regenerative braking Although the controller is capable of processing this bus current the motor impedance power factor will limit the current at high speed therefore limiting the bus current Modelling of your motor impedance in the drive system should be performed to calculate peak power The maximum DC bus current can be limited by the WaveSculptor under soft
4. DATASHEET TRI74 015 ver 4 31 August 2015 WaveSculptor 200 Motor Drive Datasheet 31 August 2015 2015 Tritium Pty Ltd Brisbane Australia http www tritium com au 1 of 12 1 2 3 4 5 6 7 8 9 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 TABLE OF CONTENTS Introductton iiias cece ence ee eriin NEEREE ERR ER RENE RENE E KREE EEN E NEE EN 3 DC BUS ek KREE E KEN KENNEN NEES NEE ees at NENNEN KEN ENEE VENEKEEK NEE SN NS ENER 4 Motor Output cccceeesccceeeenceeeeeseoeeeessaeeeeeanoeeeesaeeeseeaaeaeeeagaeeeeeggeaaeanegs 5 Motor Gense KEEN REE KEREN EE ERR RE RER RRE R KENE E RER RRE E NEE E KEE EEEEEEEEEEEE RR EEE En 6 L n eg lah TEE 7 Operating Power amp CoOolimg cccsceceseeeeeeeeeeeeeseeeeaeeeeeeeeeaeeeaaeueaeeueeaaoooues 9 Control amp Telemetry Interface ER RRENRRRER NEE essen ENKER ERR ER ANEN ERKENNEN 10 WIIdEIILC IDETTE 11 Environment al cccccececceeeeceeeneeeeeeeeeeeeeseeeeaeeeeaeeeeneeeaeeueaoeeeaeeeeeoeesaeneaes 12 REVISION RECOM ccceceeeeceeeeeeeeeeeeeeeeeeeeeeeseeeeaeeeeaaeeeeeeeaeneeeeeeaaaeeeeeeaaes 12 2 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 1 INTRODUCTION This document describes the specifications performance and properties of the Tritium WaveSculptor 200 Motor Controller For more details on communications mechanical positioning and mounting wiring and precharge co
5. Note 22 WaveSculptor enclosure width 172 mm Note 22 WaveSculptor enclosure height 82 mm Note 22 WaveSculptor mass 8 5 kg Note 23 Conduit size for DC and motor cables 40 mm Note 24 Conduit size for CAN bus cables 25 mm Note 24 Tubing size ID for coolant connections 10 mm Note 25 HV electrical terminal thread M8 Note 26 HV electrical fastening torque maximum 12 Nm Note 26 Notes 22 Dimensions do not include attached cabling and connectors 23 24 25 26 Weight includes conduit adapters nuts and washers for high current terminal connections and coolant completely filling the waterblock DC battery and AC motor cabling should be contained in orange flexible conduit CAN bus cabling should be contained in white flexible conduit PVC adapters supplied with the controller are threaded into the front panel of the motor controller and the conduit should be glued into these adapters using standard plumbing type solvent cement to fully waterproof the cable entry points The WaveSculptor is supplied with swivelling nozzles sized for watercooling tubing with a 10mm ID and 13mm OD Refer to the User s Manual for recommended components The WaveSculptor has permanently fitted threaded studs in the connection busbars The correct fastening hardware to use with these busbars is detailed in the User s Manual 11 of 12 D TRITIUM 9 ENVIRONMENTAL DATASHEET WaveSculptor 200 Motor Drive TRI74 015
6. oling and installation please refer to the User s Manual document available on the Tritium website Operating the controller beyond the limits specified in this document will result in the voiding of the controller warranty Tritium accepts no responsibility for events caused as a result of operating the controller beyond the limits specified in this document Note that the specifications in this document are subject to change at any time due to product improvement 3 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 DC BUS The DC bus connection provides power to the controller during normal motoring operation and accepts power from the controller during regenerative braking operation It is expected to be connected to a battery pack through a precharge circuit and a fuse Continuous bus voltage minimum 0 V Note 1 Continuous bus voltage maximum 450 V Instantaneous bus voltage maximum 475 V Note 2 Instantaneous bus current maximum drive 368 A Note 3 4 Instantaneous bus current maximum regen 368 A Note 3 4 DC bus capacitance 800 pF Notes 1 The WaveSculptor control electronics operate from low voltage DC supplied along the CAN bus cable not from the high voltage DC bus Therefore the supply to the main power stage via the DC bus has no operating minimum voltage The WaveSculptor uses 600V IGBTs as the power switching elements Exceeding this voltage across
7. or CAN bus supply voltage minimum 9 V Note 19 CAN bus supply voltage maximum 15 V Note 19 CAN bus supply voltage nominal 13 8 V Note 19 CAN bus supply power maximum 20 W CAN bus data rate maximum 1000 kbps Note 20 CAN bus isolation 1000 V Note 21 Notes 19 Tritium recommends providing the CAN bus supply with 13 8V using a DC DC converter and a backup lead acid battery This arrangement when properly implemented gives a supply that can tolerate failures and still operate the controller successfully for a short period of time 20 The data rate used for CAN bus activity is set during configuration and setup of the controller Factory default for all Tritium devices is 500 kbits per second 21 The CAN bus data connection and power supply are isolated from the high power DC bus to this continuous voltage rating Please refer to the isolation section in the User s Manual regarding recommended earthing and connection practices 10 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 MECHANICAL The WaveSculptor controller is mounted into position using three rubber mounted M6 shoulder bolts All dimensions in this section are with the controller mounted in position on a horizontal surface For full details regarding positioning and fixing of the WaveSculptor please refer to the User s Manual document available on the Tritium website WaveSculptor enclosure length 500 mm
8. r shaft encoder is only required when driving a induction motor The WaveSculptor expects a 100kQ at 25 C NTC thermistor embedded in the motor to detect motor temperature The thermistor B model constants available in the thermistor datasheet can be programmed into the WaveSculptor during configuration setup to exactly match the temperature response of your thermistor 6 of 12 DATASHEET WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 D TRITIUM 5 EFFICIENCY To estimate an operating point efficiency of the WaveSculptor refer to the efficiency maps below These plots are generated for DC bus voltages of 450V and 200V respectively The efficiency in percent is shown using the blue lines and the power being processed by the WaveSculptor in kW using the red lines As an example a vehicle with a 450V DC bus may operating at 250 Vrms output voltage and 150 Arms output current The graph shows that at this point the WaveSculptor will be processing 65 kW of power at just over 98 efficiency 300 Zeil K i Ki Die in 250 40 F T N Q CH E ee Lost a E 150 Ke z N B KA ke 6 3 e 100 w Z tN 50 D O a ee VE 0 50 100 150 200 250 300 Output voltage line to line Vrms Illustration 1 Predicted efficiency map of the WaveSculptor controller with a 450V DC bus
9. rated current and at elevated temperatures 7 As long as the minimum inductance per phase requirement is met the WaveSculptor will regulate current and operate successfully into a shorted connection 8 The WaveSculptor can report inductance and resistance present on it s output when running the configuration setup program This will provide a figure for the complete output circuit including motor external inductors if any wiring and connectors This can be used to verify these values meet the datasheet requirements but only for low current operation as the test is performed using a current of approximately 20A 5 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 MOTOR SENSE When driving an AC Permanent Magnet motor the WaveSculptor requires three sensors from the motor to give position feedback at low velocities When driving an induction motor the WaveSculptor requires a motor shaft encoder to give velocity feedback Motor temperature can also be measured for both telemetry data and motor protection if desired Sensor power supply output 1 5 V Note 9 Sensor power supply output 2 12 V Note 9 Sensor power supply current maximum 100 mA Sensor power supply isolation 1000 V Note 10 BLDC motor position sensor input phase offset 10 Note 11 12 Induction motor encoder resolution minimum 64 ppr Note 13 NTC Temperature sensor at 25 C 100 kQ Note 14 Notes
10. s power output at 40 C ambient 91 kVA Note 16 Maximum continuous power output at 50 C ambient 76 kVA Note 16 Acceptable metallic cooling system components Aluminium Note 17 Coolant pressure maximum 0 75 Bar Note 18 Notes 15 Maximum software current limit multiplied by maximum DC bus voltage limit 16 17 18 The controller is thermally limited to maintain the junction temperature of the main silicon devices below 100 C Stated figures are with Tritium specified cooling system components with fan forced airflow Refer to the User s Manual for recommended components To prevent dissimilar metal corrosion problems all items in the liquid cooling loop must be either plastic or aluminium Note specifically that many automotive radiators are copper and must not be used Please use only the components recommended by Tritium as specified in the User s Manual To avoid exceeding this pressure it is recommended to use a pump with a maximum head of less than this value The Koolance PMP 400 pump recommended in the User s Manual meets this requirement 9 of 12 DATASHEET WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 D TRITIUM CONTROL amp TELEMETRY INTERFACE The WaveSculptor receives commands and transmits telemetry values using a CAN bus connection No other interface is provided Low voltage DC power must be provided along the CAN bus cable to operate the control electronics of the WaveSculpt
11. ver 4 31 August 2015 The WaveSculptor controller is environmentally sealed against water and dust ingress when mounted according to the User s Manual To reach the specified IP rating please note that the conduit fittings on the front of the WaveSculptor must be permanently glued to the conduit using a PVC cement Environmental rating conduit glued IP65 Note 27 Environmental rating conduit push fit only IP54 Notes 27 The acceptable mounting positions as detailed in the User s Manual are shown below L al 10 REVISION RECORD REV DATE CHANGE 1 12 April 2010 Document creation JMK MSM 2 10 December 2010 Updated for v2 production hardware JMK 3 26 April 2011 Added bus capacitance number revised max coolant pressure and minimum encoder count JMK 4 31 August 2015 a figures for new waterblock coolant fixture locations 12 of 12
12. ware control and is adjustable dynamically via a command on the CAN bus during operation to anywhere between 0 and 100 of full current This feature can be used to limit the current capability and sizing of battery packs battery wiring battery fusing and contactors 4 of 12 DATASHEET TRITIUM WaveSculptor 200 Motor Drive TRI74 015 ver 4 31 August 2015 MOTOR OUTPUT The motor output connection provides three phase power to the motor during normal motoring operation and receives power during regenerative braking It is expected to be connected to a three phase motor either an induction or BLDC permanent magnet type Instantaneous motor current maximum 300 Ams Note 5 Output voltage maximum at max DC bus 320 Vimstine line Motor phase inductance minimum 50 uH Note 6 8 Motor resistance minimum 0 Q Note 7 8 Notes 5 The motor current limit is software controlled and may be limited to lower values via the configuration setup utility if required 6 The WaveSculptor requires a minimum amount of inductance in each motor phase to properly regulate current Not providing this inductance may result in an out of regulation condition of the motor current control loop possibly resulting in an undesired self protection shutdown or failure of the controller Please ensure that both the motor inductance and any external inductors if used are still providing at least the minimum required inductance even at full
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