Pedal Controlled Application User Manual For Azure Dynamics
Contents
1. reverse NoBrakeSpeed Speed FullBrakeSpeed FullBrakeSpeed NoBrakeSpeed forward Figure 6 Speed Ramps When Braking MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 9 of 28 In order to avoid oscillations around the EEXNoBrakeSpeed point a hysteretic loop is imple mented as shown in Figure 7 The parameters are listed in Table 5 As the vehicle slows down under regenerative braking past EEXFullBrakeSpeed the torque is reduced linearly with speed Once the vehicle speed drops below EEXNoBrakeSpeed regenerative braking is completely disabled until the vehicle re accelerates past EEXRegenOnSpeed This method has proven to be successful in avoiding brake torque oscillations at very low speeds The regen state variable FRC RegenState takes the values in Table 6 and can be viewed with ccShell Table 5 Regen Parameters Parameter Description EEXFullBrakeSpeed Motor speed both positive and negative above which full braking torque EEXMaxBrakeTorque is applied EEXNoBrakeSpeed Motor speed both positive and negative below which regen braking is completely disabled EEXRegenOnSpeed Motor speed both positive and negative above which regen braking is re enabled 3 a a Brake Torque SO c 2 9 2 c Speed forward Figure 7 Hysteretic Loop around EEXNoBrakeSpeed Table 6 Regen State Values Variable FRC RegenState fo2. 22 Foundation aia 23 Lamp ABE 24 Troubleshooting and More Details 25 Minimum Connections for Operation ea 25 Speedometer TaAChOMete AAA 25 Regenerative Braking on Brake Pedal Instead of Accelerator 26 Fault Clearing 26 DMOC Variable Capture with ccShell for 26 MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 2 of 28 Forward Caution The information provided in this manual is intended for use by persons with appropriate tech nical skills Any effort to perform repairs to or service your unit without the proper tools or knowledge required for the work can result in personal injury and product damage and will void your warranty Contact Information Please feel free to call with any suggestions that you may have regarding the content of your manual If additional service information is needed or to order replacement parts please call Monday Friday 8 30am 5 30pm USA Eastern Time T 781 932 9009 F 781 932 9219 E productsupport azuredynamics com How to Report Errors If while reading through this manual you discover an error in the technical information pro vided Azure Dynamics asks that you notify its Product Support Department Please be pre pared to provide the following information You
3. Switch SW3 Power Saver Switch 3 Position SW4 Forward Reverse Switch 3 Position NOTE Splice directly to the wires or add a connector of your choice 5 5 Regen Disable Switch SW6 Drive Enable Switch R1 Accelerator Pedal Potentiometer 5K R2 Resistor 2 2K R3 Resistor 1 8K B1 12VDC Battery Figure 12 Suggested DMOC Customer Interface I O MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 20 of 28 DMCC Interface Kit The Azure Dynamics DMOC Interface Kit consists of the following items Accelerator Brake Controller ABC Tri Power Switch Foundation Harness Tail Lamp Harness note older versions include only the Regen Brake Harness Note the accelerator pedal is NOT included Any pedal that works with a 5kQ pot is acceptable Accelerator Brake Controller The DMOC is designed for a 5kQ linear pedal pot which is part of the Accelerator Brake Controller in the Azure Dynamics DMOC Interface Kit please see Figure 13 A pot with a differ ent range can be used but it needs to be calibrated using the pedal map please see Figure 3 and Figure 4 The 5kQ linear pot is a variable resistor being used as a voltage divider All pots including this one have three wires but sometimes all three aren t used In the Azure Dynamics pot Pin 3 is the wiper Pin 28 is Pedal High and Pin 6 is Pedal Low Azure specifies a 5 pot and does recommend
4. harness and use custom controls Note that all GND connections are at a common potential For noise immunity they should not be tied to vehicle ground i e external to the DMOC The exception to this is pin 13 on the DMOC 35 pin connector which should be connected to 12V chassis ground Both the backup light and brake light signals are isolated from the DMOC GND and vehicle ground They should be used in conjunction with a voltage source that is referenced to vehicle ground for example the vehicle 12V battery The signals are capable of sinking sourcing 5A and should be fused externally with a 5A fuse If more current is needed then external relays with built in free wheeling diodes should be used Such relays can be purchased from Panasonic or Bosch The power saver internal circuitry is pulled up to 3 3V through a 4 99kQ resistor The internal circuitry for forward and for reverse is pulled up to 3 3V through a resistor Please see Figure 11 for the Azure Dynamics DMOC Foundation Harness part of the Azure Dynamics DMOC Interface Kit mates to 35 pin connector wiring diagram Figure 12 shows a suggested customer interface Please note some existing versions of the DMOC Foundation Harness may not have pins 30 and pins 23 and 12 populated on the mating DMOC 35 pin connector Also existing versions of the Foundation Harness do not include the back up light relay If you need assistance please ask your Azure Dynamics or distrib
5. in a pro cedure where extra caution and or safety equipment is required HEARING PROTECTION EYE PROTECTION REQUIRED REQUIRED Always follow any safety instructions that are given at the beginning of a procedure If you are uncertain as to the safe and proper handling of your equipment contact Azure Dynamics Product Support MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 4 of 28 Overview The Azure Dynamics Digital Motor Controller DMOC445 or DMOC645 is a rugged traction inverter for controlling three phase AC motors and generators Flexible software architecture allows for application specific customization by loading software application modules These application modules communicate with the motor control core and implement the interface to the higher level controls or directly to the driver inputs and outputs This manual discusses the Pedal Controlled application layer which configures the DMOC to function as a stand alone traction controller for vehicular applications In combination with a DMOC Interface Kit this application module offers all the functionality for implementing a complete electric vehicle drive Features include Accelerator pedal mapping with detection of short or disconnected wire Electrical braking with anti reverse disable switch battery protections brake light control Forward reverse neutral gear selection Three level power selection Status r
6. in coast zone 1 ACCEL Vehicle is in FWD or REV and pedal position is in accel zone 2 BRAKE Vehicle is in FWD or REV and pedal position is in brake zone 3 reserved 4 LOW ERROR Pedal is shorted to GND 5 HIGH ERROR Pedal is shorted to Vcc In some vehicles a strong feedback between the vehicle s motion and the driver s foot exists It can lead to unwanted oscillations and may cause serious drivability problems An effective method to break the resonance is to add a dead band to the position sensing this is illustrated in Figure 2 If the driver s foot oscillates within the dead band no change in the measured pedal position is made and the drive torque remains constant The position of the pedal can be viewed by means of the variable FRC PedalS The pedal position FRC PedalS is a normalized variable 0 1 derived from the voltage of the 5kQ pedal potentiometer The pedal map parameters are listed in Table 3 Table 3 Pedal Map Parameters Parameter Description EEXMaxAccelTorque Maximum acceleration torque when pedal is fully depressed EEXMaxBrakeTorque Maximum braking torque when pedal is fully released EEXPedBrake Pedal value below which braking torque begins to be applied EEXPedZero Pedal value below which max braking torque EEXMaxBrakeTorque is applied EEXPedAccel Pedal value above which acceleration torque begins to be applied EEXPedMax Pedal value above which max acceleration torque EEXMaxAccelTorque is
7. power limit for acceleration is selectable by means of the Tri Power Switch part of the optional DMOC Interface Kit which is connected to the Power Saver input The Power Saver is an analog input mapped into three zones as depicted in Figure 9 The power level is determined based on the user input resistance Rp and the threshold values R1 and R2 discussed further below Note that the resistance with key off for Econ max range must be less than the resistance with key off for Normal which must be less than the resistance with key off for Power max power In most circumstances especially if the customer is using Azure s DMOC interface kit no adjustment will be necessary Power Limit Max Range or Economy Normal Max Power EEXMaxAccelPower EEXNormAccelPower EEXMinAccelPower Resistance Rp Position 0 1 Pos Pos2 Figure 9 Power Saver Zones based on power saver resistance input MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 11 of 28 The Power level is determined by the resistance provided across the power saver input as shown in Figure 10 The equation for the voltage divider circuit for the power saver potentiometer is Rp Rp 5KQ where Rp is the resistance across the power saver switch i e the user input across pins 15 and 16 of the DMOC 35 pin connector Position 0 1 normalized 5kQ Powersaver Ede below voltage divider Gnd l
8. AVAD AZURE DYNAMICS Pedal Controlled Application User Manual For Azure Dynamics DMOC Motor Controller MAN 080002 001 DECEMBER 2009 AZURE DYNAMICS INC An ISO 9001 2000 Certified Company 9 Forbes Road Woburn MA USA 01801 T 781 932 9009 F 781 932 9219 productsupport azuredynamics com WWW azuredynamics com Table of Contents ROLE e aa CAUTION 3 Contact 3 HOW to Report eL 3 ctp la ee a Warning LAD GIS er E 4 Safety SYMDOlS 4 BREA Application SoftWare M Pedal ABUSE 6 Applications That Do Not Use 5kQ Pedal 8 Speed RAMPS eba abako aaa eraketara 9 Torque Slew AAA 10 AAL Ae eia ea 11 Safety amp InterlOCKs AAE 13 Principal Application Matia 14 CAN Status EAE 15 Application Parameters toos toes eee Earra aaa 17 Electrical Interface EEK TES Interface A AAA 21 Accelerator Brake COntroll r Eran 21 Tri Power
9. Ox241 in hex Application Parameters Table 15 summarizes the most frequently used application parameters Please refer to the DMOC445 and DMOC645 User Manual for information about other important DMOC parameters Table 15 Frequently Used Pedal Control Application Parameters Variable Description EEXMinAccelPower Acceleration power limit Max Range setting on tri power switch EEXNormAccelPower Acceleration power limit Normal setting on tri power switch EEXMaxAccelPower Acceleration power limit Max Power setting on tri power switch EEXMaxRegenPower Regen power limit EEXNolgnSwitch Can be used to force drive enable EEXPedAccel Acceleration begins above this pedal position EEXPedBrake Regen begins below this pedal position EEXPedHyst Pedal dead band EEXPedMax Full acceleration torque above this pedal position EEXPedZero Full regen torque below this pedal position EEXRegenOnSpeed Speed above which regen is enabled EEXFullBrakeSpeed Speed above which full regen is possible EEXNoBrakeSpeed Speed below which no regen is possible EEXAccelMaxTorque Maximum allowable acceleration torque EEXBrakeMaxTorque Maximum allowable brake torque EEXBrakeTorqueSlew Slew rate limit to brake torque EEXInterlockSpeedHigh Speed above which shifting is disabled except for going to neutral EEXInterlockSpeedLow Speed below which shifting is interlocked with zero accelerat
10. applied EEXPedHyst Hysteresis value for pedal input pedal position needs to change by more than EEXPedHyst to be recognized as a valid new position MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Raw Pedal Position Pedal Position Figure 2 Pedal Dead Band Page 7 of 28 Applications That Do Not Use a 5kQ Pedal Pot Figure and Figure 4 below are provided as a reference for applications that do not use a 5kQ pedal pot The circuit schematic in Figure 3 shows the pullup and pulldown resistors inside the DMOC that are associated with the PEDAL HI and PEDAL LOW outputs Note that VCC A is 3 3V The circuit schematic in Figure 4 shows that the ACCEL PEDAL input of the DMOC is pulled down to ground by a 100k9 resistor and the signal then passes through a unity gain buffer Please note though these schematics are accurate as of this writing they are subject to change and therefore should be used for reference only A 3 3V 1 82K PEDAL HI S PEDAL HI 150 PEDAL LO gt PEDAL LO 150 BRAKE LO S BRAKE LO Figure 3 Pullup pulldown resistors inside DMOC associated with PEDAL HI PEDAL LOW outputs 3 3V 3 3V 100nF gt gt ACCEL PEDAL BUE Figure 4 ACCEL PEDAL input of DMOC pulled to ground by 100k resistor then passed through unity gain buffer MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 8 of 28 Speed Ramps Several ramps a
11. could interfere with the operation of the DMOC s internal contactor resulting in excessively long precharge times or damage the DMOC Interlocks At power up the DMOC will remain disabled as long as either the accelerator pedal is depressed or the gear switch is in forward or reverse This is a startup safety interlock you must have zero torque request and be in neutral for the DMOC to power up and enable Startup order of operation sequence Contactor must close Powerstage must advance to READY For these events to occur there are a few application specific interlocks described here which are required in addition to the requirements documented in the DMOC445 and DMOC645 User Manual MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 13 of 28 Contactor Interlock SR2DriveEnabled TRUE or bypass with EEXNolgnSwitch see below and FRC CarDirectionSwitch NEUTRAL Power Stage Interlocks Required for READY indicated by ISR2PowerStageStatelnfo WAITING FOR APPLICATION CODE INTERLOCK Pedal not depressed Pedal position less than EEXPedZero Power Stage Fault acknowledge interlock indicated by ISR2PowerStageStatelnfo FOR FAULT ACKNOWLEDGE Pedal not depressed Pedal position less than EEXPedZero and torque is requested To command torque and spin the motor FRC CarDirectionSwitch FORWARD or REVERSE Pedal depressed Pedal position more than EEXPe
12. dAccel The DMOC also has a drive enable and a drive disable signal digital inputs which are both active low i e need to be pulled to GND to be active For the DMOC to enable drive enable has to be active and drive disable needs to be passive i e not pulled to GND If the drive enable feature is not desired it can be switched off by setting the calibration parameter EEXNolgnSwitch to 1 Grounding drive disable will always result in disabling the DMOC this is often used as a charger interlock Table 11 Drive Enable Disable Parameter Parameter Description EEXNolgnSwitch ISR2DriveEnabled depends on drive enable 1 ISR2DriveEnabled TRUE drive enable ignored Principal Application Variables Table 12 shows the most frequently viewed application variables Refer to the DMOC445 and DMOC645 User Manual for information about other important DMOC variables Table 12 Principal Application Variables Variable Description FRC CarDirectionSwitch Reverse 1 Neutral 0 Forward 1 FRC FinalTorqueDesired Torque command after limits are imposed same as ISR2TorqueDesired FRC Gearlnterlock Interlock based on pedal position and vehicle speed to enable transition between forward and reverse FRC MaxAbsTorqueBySpeed Torque available based on speed 1 no derating fully derated FRC PedalS Pedal Input reading 0 1 replaced ISR2PedalS FRC PedMod
13. distinguished for better readability the EEX parameter prefixes of the parameter names are omitted in Figure 1 Pedal Mode A NEUTRAL HIGH ERROR MaxAccelTorque Torque PedBrake FRC PedalS PedAccel PedHi MaxBrakeTorque Figure 1 Pedal Torque Map Fault Zones The red zones indicate fault zones If the pedal input is shorted high or low zero torque is produced Any pedal values below PedLo hard coded at 0 01 or above PedHi hard coded at 0 9 are consider to be a pedal fault short or open and will result in no torque Brake Zone The first zone of the pedal is used to control regenerative braking It ranges from PedLo fixed to EEXPedBrake Full torque EEXMaxBrakeTorque is applied when the accelerator pedal is not depressed at all As the pedal is depressed past EEXPedZero the brake torque is ramped down linearly Coast or Neutral Zone The torque is zero in the second zone which is delimited by EEXPedBrake and EEXPedAccel Accel Zone Past EEXPedAccel the torque is ramped up as the pedal is depressed The torque reaches its maximum value EEXMaxAccelTorque at EEXPedMax Table 2 summarizes the variable FRC PedMode MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 6 of 28 Table 2 FRC PedMode Variable Variable FRC PedMode State Value Name Description 0 NEUTRAL Vehicle is in neutral or pedal position is
14. e Pedal zone indicator acceleration neutral or braking FRC PedTorqueDesired Torque request based on pedal position FRC PowerSaverSel Selection of power level FRC RegenState Regenerative braking finite state machine indicator formerly ISR2RegenState FRC SpeedLimit Torque limiting based on speed 0 1 ISR2PedalS Replaced by FRC PedalS ISR1PowerSaver Power saver potentiometer position Azure internal use only ISR2PowerSaverSel Selection of power level replaced by FRC PowerSaverSel ISR2SpeedLimit Torque limiting based on speed 0 1 replaced by FRC SpeedLimit MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 14 of 28 CAN Status Reporting While this application does not receive any command messages over CAN it may be enabled to report status for use in vehicle displays Setting the parameter EEXCANTxEnabled 1 enables sending of all status messages Three status messages are available with the contents defined in Table 13 The CAN ID and transmit rate of each message may be individually configured using the CAN parameters defined in Table 14 General CANbus settings are documented in the DMOC445 and DMOC645 User Manual Table 13 DMOC Status Messages Over CAN Message Temperature Status Message EEXCANTempsStatusID Rate sec 1 EEXCANTempsStatusCycleSec DLC 8 Format standard Direction
15. eporting over CAN new FRC software only For general information regarding the DMOC including important safety instructions and warnings the DMOC445 and DMOC645 User Manual should be consulted which is distributed and revised separately See Table 1 for the list of relevant manuals Azure s PC based diagnostics calibration tool ccShell allows the user to access and modify DMOC calibration parameters and to visualize and capture signals and variables in real time Calibration parameters have EE1 EE2 or EEX prefixes Variables have EE3 ISR or FRC prefixes While the meanings of the most important calibrations and signals of the DMOC core are described in this document the reader is referred to the ccShell User Manual for information on how to install and use this tool Table 1 List of Relevant Manuals Document Name Document Number DMOC445 and DMOC645 User Manual MAN 080001 Pedal Controller Application User Manual MAN 080002 CAN Controlled Application User Manual MAN 080003 ccShell User Manual MAN 080008 Please note this manual is distributed as part of the ccShell software It is available under ccShell s Help menu MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 5 of 28 Application Software Pedal Map The accelerator pedal position is mapped to a desired torque as described here The map itself is configurable by parameter calibration Three valid zones can be
16. er Switch and Pedal Connections Besides the connections to the Tri Power Switch and the accelerator pedal note pedal is not included in Interface Kit shown in Figure 16 the following connections are made Keyed 12 volt Black is ground Red is 12 volts Speedometer Output Optional See Troubleshooting and More Details Charger Interlock Optional This keeps the vehicle from being driven while the charger is connected Closing connecting the white wire to the black wire this interlock will keep the DMOC from driving the motor MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 23 of 28 Table 16 summarizes the wiring of the Azure Dynamics Foundation Harness see also the 35 Pin Connector Pinout information in the DMOC445 and DMOC645 User Manual Table 16 Azure Dynamics Foundation Harness Wiring Signal Source Pin Cable Recommendation Color Stripe Destination Pin Connector Connector REGEN_DISABLE AMP35 7 22AWG 15 cond grey shielded red AMP2F Plug 1 GND D AMP35 35 22AWG 15 cond grey shielded black AMP2F Plug 2 POWER_SAVER AMP35 15 22AWG 15 cond grey shielded green black X AMP3F Plug 3 GND_A AMP35 5 22AWG 15 cond grey shielded green AMP3F Plug 2 FORWARD AMP35 29 22AWG 15 cond grey shielded red white Molex 3M Intl Plug 1 REVERSE AMP35 18 22AWG 15 cond grey shielded green white Molex Intl Plug 3 GND D AMP35 20 22AWG 15 cond gre
17. ights when the DMOC is in regen mode With this modification the regen relay is eliminated and replaced with a similar but normally closed relay to activate the regen function when the brake lights come on A normally closed relay would need to be installed so that when the brake lights come on the relay opens up and lets the regen circuit activate on the DMOC Fault Clearing Most DMOC faults are cleared by releasing the accelerator pedal completely and cycling through neutral See also the sections discussing faults on the DMOC445 and DMOC645 User Manual DMOC Variable Capture with ccShell for Troubleshooting If you cannot communicate with your DMOC using ccShell see the ccShell User Manual and the DMOCA45 and DMOC645 User Manual If you are having problems getting your system running or if the performance is less than expected Azure Dynamics or your distributor will typically ask you to capture some data from the DMOC using your laptop computer and Azure s ccShell Java based shell program You should have received information on how to access and use both this program and the ccs viewer file when your DMOC was shipped to you Please see the ccShell User Manual for more details If your motor will not spin Do you hear the contactor relay close inside the DMOC See the Troubleshooting section of the main DMOC manual the DMOC445 and DMOC645 User Manual See also Minimum Connections Required for Operation above Please sa
18. inside DMOC outside DMOC Figure 10 Voltage Divider Circuit for Power Saver Potentiometer The Power Saver zones are shown in Table 9 and the power levels can be adjusted by the cali brations there Table 9 Power Saver Zones Variable FRC PowerSaverSel State Name Description 1 MAX_POWER EEXMaxAccelPower is the selected power limit 2 NORM_POWER EEXNormAccelPower is the selected power limit 3 MIN_POWER EEXMinAccelPower is the selected power limit Power Saver Thresholds The zone thresholds R1 and R2 in Figure 9 default 3 8k and 8 15 kQ respectively The resistance across the power saver input pins 15 and 16 on the DMOC 35 pin connector determines the power saver setting as follows Range lt 3 8kQ Normal 3 8kQ lt Rp lt 8 15 kQ Max Power 8 15 kQ Rp These thresholds are not adjustable in software released before April 2008 including 1631 MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 12 of 28 Adjustable Zone Thresholds The adjustable zone thresholds are a new feature implemented in the FRC software release starting in April 2008 The zone thresholds are controlled via calibration of the parameters in Table 10 Calibration instructions are below Table 10 Power Saver Calibration Parameter Description EEXPowerSaverPos1 Below this threshold the PowerSaver mode is MIN POWER EEXPowerSaverPos2 Above this th
19. n MA USA 01801 T 781 932 9009 781 932 9219 4020A Sladeview Crescent Unit 6 Mississauga ON Canada 151 6 1 1 905 607 3486 F 905 607 6391 www azuredynamics com
20. nd 3 0x4e20 indicate zero speed 0x4e20 20000 and 20000 1 20000 RPM Byte 4 shows the PowerStageState at 1 READY Byte 5 shows there are no active errors Byte 6 shows the Status Code of 0x23 hex which corresponds to 00100011 binary which as shown in the DMOC445 and DMOC645 User Manual indicates the contactor is closed power stage is ready more torque and power are available Note that bit 5 the thermal limit active signal is not relevant in the READY state Table 14 Application Specific CAN Parameters Variable Description EEXCANElecStatus1ID Electrical Status Message CAN ID EEXCANElectStatus1CycleSec Transmit rate for Electrical Status Message in seconds EEXCANMechStatus1ID Mechanical Status Message CAN ID EEXCANMechStatus1CycleSec Transmit rate for Mechanical Status Message in seconds EEXCANTempStatusID Temperature Status Message CAN ID EEXCANTempStatusCycleSec Transmit rate for Temperature Status Message in seconds EEXCANTxEnabled Set to 1 to enable status reporting of all messages If set to zero only the mechanical status message will be transmitted at a low frequency to indicate the DMOC is alive MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 16 of 28 All CANIds are displayed as decimal numbers in ccShell Many CAN tools work more naturally in hex so note for example the default Mechanical Status ID of 577 in decimal
21. nnected inside the junction box 12 volts on pin 1 on 35 pin connector ground pin 13 on 35 pin connector to the 12V return connect pins 19 and 29 on 35 pin connector to each other The should power up and spin the motor once the pedal is pressed However pins 19 and 29 cannot be left connected Step 4 provides a forward request This is because the DMOC contactor needs to close and then the DMOC needs to see a neutral signal and then a forward signal each time the DMOC is power cycled Please refer also to the Safety and Interlocks section of this manual Speedometer Tachometer The DMOC has a frequency modulated 12V push pull output open emitter gauge drive that can drive some speedos tachs Azure has had success with the Continental was Siemens VDO Cockpit Series 85mm diameter wired to work with electronic transmissions This output is Pin 25 from the DMOC 35 pin connector marked on the Azure Foundation Harness in the Azure DMOC Interface Kit Speedometer Installation and Operation Instructions Download PDF http usa vdo com generator www us en vdo main products_solutions cars performance_instruments vdo_performance_instru ments instrument_series cockpit speedometers download flc_0515012051programmablespeedometer_en pdf The DMOC parameter called EE1SpeedoDiv can be adjusted for specific speedos tachs However every speedojtach is different and the software isn t designed to work with all
22. of them To calibrate EE1SpeedoDiv Connect speedo output to speedometer Calculate km h corresponding to 2500 rpm at the motor Don t spin the motor during the calibration process Set EE1SpeedoDiv 100 speedometer should move If reading is higher then km h calculate above make the number more negative e g 110 f reading is lower then km h calculate above make the number less negative e g 90 Once speedometer displays the correct speed flip the sign of EEISpeedoDiv make it a positive number Now drive the vehicle and double check speedometer calibration The equation for the speedo is 2 x rpm EE1SpeedoDiv speedo output frequency MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 25 of 28 Regenerative Braking on Brake Pedal Instead of Accelerator Pedal Azure Dynamics system normally has regenerative braking on the accelerator pedal Some customers have expressed interest in moving regen to the brake pedal The regen brake light switch can be tied into the Regen Disable signal using a relay so that regen comes on only when the accelerator pedal has been released and the brake pedal has been pressed This is the reverse of having the controller turn on the brake lights when you release the accelerator This change actually reverses the function of the regen relay In the Azure Dynamics DMOC Interface Kit the regen brake light relay turns on the brake l
23. or Temperature Sensor is designed to protect the motor not provide a actual temperature feedback The temperature reported over CAN is only intended to indi cate if a problem exists therefore only three discrete values are provided 20C if the tempera ture is OK and the motor can operate normally 120C if some thermal derating is taking place and 200C if the motor is over temperature and completely thermal limited Note that ISR2BatVoltageWEF is the filtered battery voltage and is approximately equal to ISR2BatVoltage Note all these messages are Big Endian Format Motorola most significant byte first and all signed values have offsets equal to their maximum negative value To find the desired value in the units you expect take the raw value over CAN multiply by the resolution and add the offset Example of Parsing a Temperature Signal Looking at a temperature signal for example the inverter temperature with a range 40C to 200C with a resolution of 1C and offset of 40C the following table has some example conversions Hex Value Decimal Value Temperature 0x00 0 40C Ox3C 60 20C OxFO 240 200C OxF1 OxFF 241 255 Error invalid data Example of Parsing the Mechanical Status Message For example on startup the Mechanical Status Message content might read as follows 75 30 4e 20 01 00 23 ff Bytes and 1 0x7530 indicate zero torque 0x7530 30000 and 30000 0 1 3000 0 Nm Bytes 2 a
24. or pedal input EEXBrakeLightOffTorque Torque below which the brake lights are turned off EEXBrakeLightOnTorque Torque above which the brake lights are switched on EEXFullAccelPosSpeed Maximum forward speed allowing full acceleration torque EEXFullAccelNegSpeed Maximum reverse speed allowing full acceleration torque EEXTorqueSlew Slew rate limit to torque when accelerating EEXUnloadTorqueSlew Slew rate limit in unload zone MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 17 of 28 Electrical Interface Besides the high voltage connections which are documented in the DMOC445 and DMOC645 User Manual a number of low voltage signals are used for the Pedal Controlled application module The 12V auxiliary supply needs to be able to source 10A of current and must be pro tected by a 15A fuse The auxiliary supply also acts as an enable signal for the internal power supply of the DMOC In other words a DMOC requires 12V to be present in order to operate Three connectors exist on the side of the DMOC 14 pin AMPSeal For the motor speed sensor cable dedicated connector 8 pin AMPSeal For RS 232 and CAN communications 35 pin AMPSeal Application interface connector It is recommended that an Azure Dynamics DMOC Interface Kit be used for the connections of the pedal and control switches however it is also possible to implement a customized inter face
25. r name Name and edition of your manual Page number s where the error s appear Part number and serial number of your unit Information contained in this manual is based on the latest product information available at the time of publication The right is reserved to make changes at any time without notice Copyright 2009 Azure Dynamics Inc All rights reserved No part of this manual may be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying and recording without the prior written permission of Azure Dynamics Inc This applies to all text illustrations tables and charts MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 3 of 28 Safety For your safety and the safety of others please read and understand this entire manual before installing the components you have received from Azure Dynamics If you have ques tions regarding the contents of this manual please call the Azure Dynamics Product Support Department before proceeding Warning Labels Labels indicate areas in a procedure where you should take appropriate precautions Labels include r bo WARNING AND DANGER RISK OF ELECTRIC SHOCK Safety Symbols Always use caution when working on or around any electrical equipment Wear eye protection at all times The following symbols will be located in your manual to indicate sections
26. re implemented to reduce and limit the drive torque corresponding to vehicle speed These ramps prevent the vehicle from over speeding both in reverse for safety and in forward for motor protection The overspeed protection ramps are illustrated in Figure 5 The acceleration parameters are listed in Table 4 During regenerative braking the brake torque must be reduced to zero before the vehicle starts reversing its direction These ramps are illustrated in Figure 6 Similar to the pedal map the speed ramps are configurable by means of parameter calibration the parameters them selves are listed in Table 5 Acceleration Torque forward NoAccelPosSpeed NegSpeed Speed FullAcce PosSpeed reverse NoAccelNegSpeed Figure 5 Speed Ramps under Acceleration Table 4 Acceleration Parameters Parameter Description EEXFullAccelPosSpeed Positive forward motor speed up to which full acceleration torque EEXMaxAccelTorque is allowed EEXNoAccelPosSpeed Positive forward motor speed above which acceleration torque is zero EEXFullAccelNegSpeed Negative reverse motor speed up to which full acceleration torque EEXMaxAccelTorque is allowed EEXNoAccelNegSpeed Negative reverse motor speed above which acceleration torque is zero Note Torque is linearly ramped between EEXFullAccelPosSpeed and EEXNoAccelPosSpeed and between EEXFullAccelNegSpeed and EEXNoAccelNegSpeed Brake Torque
27. reshold the PowerSaver mode is MAX POWER Adjusting Tri Power Switch Resistances in FRC Software In FRC software if the default resistances for the tri power switch thresholds are incor rect for your application they can be adjusted in software using ccShell based on position ISR1PowerSaver The two ccShell parameters involved are EEXPowerSaverPos1 and EEXPowerSaverPos2 The default values for EEXPowerSaverPos1 and EEXPowerSaverPos2 are 0 42969 and 0 61914 respectively corresponding to the default resistances specified above Example of correction if the resistances are not within the ranges above for FRC software only Tri power switch Measure key off Calculate Rp Change EEXPowerSaverPos1 Change setting resistance Rp Rp 5kQ EEXPowerSaverPos2 Econ max range 1 56 kQ 0 24 currently 0 42969 needs to Normal 2 29 kQ 0 31 be between 0 24 and 0 31 currently 0 61914 needs to Power max power 5 42 kQ 0 52 be between 0 31 and 0 52 Safety amp Interlocks Shutdown Disconnect For a shutoff it is recommended that the 12V be disconnected Removing the 12V power will immediately disable the DMOC power supply and shut the unit down For additional safety it is recommended that an emergency high voltage disconnect be provided as well however this should be a normally closed switch that is only actuated in emergencies or for maintenance If a contactor is used as a HV disconnect it
28. rmally called ISR2RegenState State Name Description 0 POWERUP Regenerative braking feature not yet initialized 1 DISABLED Regenerative braking feature is disabled 2 ENABLED Regenerative braking feature is enabled 3 FAULT Regenerative braking feature has a problem Torque Slew Rate Limiting To improve drivability it is necessary to limit the rate of change of the motor torque also known as slew rate The application software provides several parameters to tune the slew rates as shown in Table 7 Table 7 Slew Rate Parameters Parameter Description EEXTorqueSlew Slew rate limit on torque set point in acceleration mode EEXBrakeTorqueSlew Slew rate limit on torque set point in braking mode EEXUnloadSlew Slew rate when reducing torque while preserving torque sign MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 10 of 28 Specific positive and negative slew rates are applied based on the torque level divided into four zones as shown in Table 8 Table 8 Torque Slew Rate Parameters Logic Initial Torque Value Increasing Torque Decreasing Torque EEXTorqueSlew EEXUnloadSlew EEXTorqueSlew EEXTorqueSlew EEXBrakeTorqueSlew EEXBrakeTorqueSlew EEXBrakeTorqueSlew EEXUnloadSlew A graphic representation of the torque slew rate limits is shown in Figure 8 EEXPreloadTorque 0 EEXPreloadTorque Figure 8 Torque Slew Rate Limits Power Saver Selector The battery
29. the use of pedals which have a voltage output Figure 13 Accelerator Brake Controller ABC 1 MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 21 of 28 Tri Power Switch The Tri Power Switch implements several functions Fwd Rev Switch Battery Power Selection Max Power Normal Max Range Disable switch for electric braking regen Reverse light control Backup light control Cabin heater control Please see Figure 14 Note that the three wires to the heat switch the one reverse lamp con nector regen disable and the one neutral interlock connector are not needed for DMOC operation Output to Heater Relay 12 Volts When Switch is On d 4 12 Volt Input to Heat Switch T I d Regenerative Braking Disable x Closed for No Regen Heat Switch Ground Lug Neutral Interlock m lt t Not Connected DMOCs Ted Forward and Reverse Output P if d A b Reverse Lamp Output Closed in Reverse IW Power Level Output Figure 14 Tri Power Switch MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 22 of 28 Foundation Harness The Foundation Harness provides the wiring between the connections between the DMOC and the other Interface Kit Components See Figure 15 and Figure 16 The wiring diagram for the Foundation Harness is shown in Figure 11 and Figure 12 Figure 15 Foundation Harness Figure 16 Tri Pow
30. to at least the nominal voltage that your DMOC was programmed for Check that there are no mechanical issues with your vehicle such as a slipping clutch dragging brake pad etc Please save the par file DMOC parameter file from your DMOC and email it to your Azure Dynamics or distributor contact Using ccShell please also capture at least 30 60 seconds worth of data and email the resulting txt file it to your Azure Dynamics or distributor contact Set the ccShell capture interval to one 1 second Start the capture press the accelerator to the floor or until the vehicle reaches its top speed release the pedal and stop the capture The variables to capture will depend on your software revision but the following list of 20 variables is an example 1 FRC PedalS 11 ISR2IsLimit 2 ISR2BatVoltage 12 ISR2MaxPowerOut 3 ISR2EstBatCurrent 13 ISR2MotorLimit 4 ISR2HeatSinkLimit 14 ISR2MotorTorqueLimitCause 5 ISR2Hertz 15 ISR2PSFaultActive 6 ISR2IdF 16 ISR2RealTorque 7 ISR2IdSet 17 ISR2TorqueDesired 8 ISR2IqF 18 ISR2VdF 9 ISR2IqSet 19 ISR2VqF 10 ISR2IsF 20 ISR2VsF MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 27 of 28 AZURE DYNAMICS part of the solution DETROIT 14925 W 11 Mile Road Oak Park MI USA 48237 T 248 298 2403 F 249 298 2410 VANCOUVER 3900 North Fraser Way Burnaby BC Canada V5J 5H6 T 604 224 2421 F 604 419 6392 BOSTON 9 Forbes Road Wobur
31. tx Endian big Byte Signal Name Min Max Res Units Width Offset Details 0 motor stator temperature 40 200 1 C 8 40 based on ISR2MotorLimit see note below 1 inverter temperature 40 200 1 C 8 40 ISR2HeatsinkTemp 2 3 4 5 reserved 6 CAN interface level 0 240 1 8 0 rolling counter 0 255 1 8 0 Value increments with each message to show DMOC is alive Message Mechanical Status Message EEXCANMechStatus1ID Rate sec 0 02 EEXCANMechStatus1CycleSec DLC 8 Format standard Direction tx Endian big Byte Signal Name Min Max Res Units Width Offset Details 0 1 motor torque actual 3000 3000 0 1 Nm 16 3000 SR2RealTorque 2 3 motor speed actual 20000 20000 1 rpm 16 20000 SR2HertzWF 4 powerstage state 0 240 1 8 0 SR2PowerStageState 5 active fault enum 0 240 1 nja 8 0 SR2PSFaultActive see DMOC445 and DMOC645 User Manual 6 status code 0 255 1 n a 8 0 SR2StatusCode see DMOC445 and DMOC645 User Manual 7 reserved Message Electrical Status Message EEXCANElecStatus1ID Rate sec 0 02 EEXCANElecStatus1CycleSec DLC 8 Format standard Direction tx Endian big Byte Signal Name Min Max Res Units Width Offset Details 0 1 DC battery voltage 0 1000 0 1 V 16 0 ISR2BatVoltageWF 2 3 DC current 500 500 0 1 A 16 500 ISR2EstBatCurrent 4 thermal limit cause 0 240 1 n a 8 0 ISR2ThermCurrentLimitCause 5 6 7 reserved MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 15 of 28 Note that the Mot
32. utor contact MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 18 of 28 AMPSEAL 35 PIN BRAKE LIGHTS WEATHERPACK 4M BRAKE_LT_SRC o BRAKE_LT_SINK BRAKE_LT_SRC BRAKE_LT_SINK BAKUP_LT_SRC BAKUP_LT_SINK BAKUP_LT_SRC BAKUP LT SINK WEATHERPACK 2F DRIVI A DN TN ISABLE KEYED 12V SRC Dr WEATHERPACK MOLEX 3M AMP 2F T DIG GND UNTERMINATED BK UNTERMINATED KEYED 12V SRC p KEYED 12V SINK Les Te ACCEL PEDAL e POWER SAVER DO FORWARD Di ND REVERSE DO DISABLE c DIG GND DRIVE ENABLE BK Figure 11 DMOC I O Interface Harness Foundation Harness MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 19 of 28 BRAKE LIGHTS WEATHERPACK 4F WEATHERPACK 2M Tz v WEATHERPACK 1F SPEEDO SPEEDO_OUT S WEATHERPACK 2F Er KEYED 12V SRC KEYED 12V SINK WEATHERPACK 3M ACCEL PEDAL PEDAL_LO ACCEL_PEDAL PEDAL HI POWER SAVER OND MAX RANGE POWER SAVER MAX POWER NORMAL MOLEX 3F FORWARD FORWARD DIG GND NEUTRAL REVERSE REVERSE Legend AMP 2M REGEN DISABLE F1 12VDC Fuse 15A K1 Brake Lights Relay K2 Back up Lights Relay DRIVE ENABLE V SW1 Ignition Key Switch SW2 Drive Disable
33. ve the par file DMOC parameter file from your DMOC and email it to your your Azure Dynamics or distributor contact MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 26 of 28 Please also capture 10 20 seconds worth of ccShell data and email the resulting txt file it to your Azure Dynamics or distributor contact Set the ccShell capture interval to one 1 second Make sure you press the accelerator pedal or engage the throttle pot completely and release it completely during the test The list of variables to capture varies depends on which software revision you have but if you start with the default list that may be sufficient to determine the problem Alternatively here is one possible list of 20 variables 1 FRC CarDirectionSwitch 11 ISR2IsLimit 2 FRC PedalS 12 ISR2MotorPTCVoltage 3 ISR2BatVoltage 13 ISR2MotorTorqueLimitCause 4 ISR2ContactorState 14 ISR2PowerStageState 5 ISR2DriveEnabled 15 ISR2PSFaultActive 6 ISR2EstBatCurrent 16 ISR2RealTorque 7 ISR2HeatsinkTemp 17 ISR2TorqueDesired 8 ISR2Hertz 18 ISR2VdF 9 ISR2IdSet 19 ISR2VqF 10 ISR2IqSet 20 ISR2VsF If your system is operating but you expected better performance Make sure that both your accelerator pedal and the pedal potentiometer have the full range of mechanical travel Make sure you are in Max Power mode see Power Saver Selector section above Check that your battery pack is in good shape and is fully charged
34. y shielded blue Molex Intl Plug 2 SPEEDO BUF AMP35 25 22AWG 15 cond grey shielded white Weatherpack 1M A KEYED 12V 8 AMP35 1 18AWG 2 cond grey red Weatherpack 2M A KEYED 12V SINK AMP35 13 18AWG 2 cond grey black Weatherpack 2M B PEDAL LO AMP35 6 22AWG 15 cond grey shielded blue white Weatherpack 3F A ACCEL PEDAL AMP35 3 22AWG 15 cond grey shielded white Weatherpack 3F B PEDAL HI AMP35 28 22AWG 15 cond grey shielded white black Weatherpack DRIVE DISABLE 5 8 20AWG 2 cond grey shielded white Weatherpack 2F A GND D AMP35 19 20AWG 2 cond grey shielded black Weatherpack 2F B BRAKE LT SRC AMP35 14 18AWG 2 cond grey red Weatherpack 4M C BRAKE LT SINK AMP35 24 18AWG 2 cond grey black Weatherpack 4M D BACKUP LT 58 AMP35 23 18AWG 2 cond grey red Weatherpack 4M A BACKUP LT SINK AMP35 12 18AWG 2 cond grey black Weatherpack 4M B Important None of the GND D and GND pins should be connected to vehicle chassis i e external to the DMOC Tail Lamp Harness The Tail Lamp Harness is illustrated in Figure 17 12 Volt amp Switched Brake 12 Volt Supply 3 Ground Su Se Ground 12 Volt Switched 12 Volt Supply Reverse Figure 17 Tail Lamp Harness MAN 080002 001 DMOC Pedal Controlled Application User Manual December 2009 Page 24 of 28 Troubleshooting and More Details Minimum Connections for Operation The DMOC requires in order high voltage co
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