Anvil Controller Service Manual Optimized_0
Contents
1. DISPLAY AND BACKUP ALARM BEEPER TOMBERLIN ANVIL DISPLAY J12 6 52 B CONTROLLER CONNECTIONS 410 Q O 9 Y O 9 8 16 53 9 1 2 3 5 15 SPD SEN A WHITE DRAIN SHIELD BARE SPD SEN V _ RED2. Install Cancel It may indicate that drivers are already installed if so click OK These drivers are already current and up to date to remove these go to Add Remove Programs in the Control Panel After the USB drivers are installed the following screen may appear i wDriverdcall UM presslostaller axe Install HOST Tomberlin aU TO 1 MM RT _Eotuptcall setup To continue the installation of the other three programs may have click on the setup exe box that may be flashing at the bottom of the computer 19 The installation will now continue with similar screens click Allow Click OK below a KC_Host_TOMBERLIM Setup p Welcome to the Host TOMBERLIM installation program Setup cannot install system Files or update shared Files iF they are in use Before proceeding we recommend that you close any applications you may be running Exit Setup Click the box high lighted in RED below 20 Click Continue below Two or more of the following screens may show up click yes on all of them this will use the latest file available files 21 The following screen indicates the first of the three programs has installed successfully click OK to proceed with two more installations Continue to click boxes as before KC Download_AC and KC Logger_USB should both download
3. 37 40 43 51 51 Speedometer This display will function as a speedometer a guide to programming certain performance parameters a diagnostic display and an error code display Key Switch ON Display When the Key Switch is turned ON the speedometer will sweep from 0 MPH to 25 MPH and then back to O MPH This is a simple diagnostic to indicate the key switch or RUN TOW switch has been cycled and that the controller is communicating to the speedometer For the vehicle to operate the Direction Switch must be placed in Neutral center position and the accelerator pedal released When these two conditions have been met a click will be heard indicating that the main power contactor has closed On vehicles so equipped a red Thermal Light will remain lit until the main power contactor has closed A direction can now be selected and the accelerator pressed for speed parking brake must be released In reverse an alarm will sound Themal Light Viewing Error Codes In the unlikely event that there is a vehicle or control malfunction error codes will be displayed on the speedometer The error code will be indicated on the soeedometer only when the directional switch is placed in neutral However all error codes are saved in memory and can be viewed by entering the error viewing mode at anytime To enter the mode to view the stored error codes the key switch needs to be initially turned to the OFF position Next the key
4. Controller Temperature Warning 110 C 230 F Forward and Reverse requested simultaneously High Priority Line Contactor disabled error code will be saved in memory 9 mph 10 mph 12 mph 14 mph 15 mph 16 mph 17 mph 18 mph 19 mph 20 mph 21 mph 22 mph 26 mph 28 mph 30 mph 32 mph 0 long 6 short Phase over current fault too much phase current 0 long 7 short 0 long 9 short 1 long 1 short 1 long 2 short 1 long 3 short 1 long 4 short 1 long 5 short 1 long 6 short 1 long 7 short 1 long 8 short 1 long 9 short 2 long 1 short 2 long 2 short 2 long 3 short 2 long 4 short Battery fault battery voltage too high over 100 volts Phase Error phase not turning on Fault Latch Failed 1 multiple failures Pre charge Failure1 if Capacitors haven t reached 2 Volts after 20 milliseconds of pre charge Pre charge Failure2 if Capacitors haven t reached the pre charge lower limit voltage after 1 second of pre charge Low Battery voltage while running Motor overheated 135 C 275 F Controller overheated 120 C 248 F Throttle Fault Start switch and or potentiometer not in sequence Software Version incorrect Over Current Fault on controller output EEPROM Internal Memory Failure Speed Sensor channel A failed Speed Sensor channel B failed Speed Sensor channel A amp B failed Troubleshooting Error Codes Error codes will only occur under certain conditions Items like no forward or no mov
5. 0011 aga 8811 0011 aga As stated earlier this file needs to be sent back to Kinetek Controls for detailed analysis 39 Un installing KC Host If KC Host has already been installed onto your computer and you are doing an upgrade to the USB Drivers or upgrading KC Host it is suggested that you un install KC Host and other associated programs To un install any of these programs click Control Panel On your desk top and look for an icon or program called Programs and Features and double click 40 Look for KC or Kinetek Controls and double click on each of the three programs in red box and follow the instructions Kel KC Download AC Size 0 34MB Kel FC Host _TOMBERLIN Size 48MEB Kel KC Loager 5 Size 0 04 Evaser Lanking Size 2 7 TMB Kvaser CANLIB SDK Size 19 92 Microsoft Framework 2 0 Service Pack 2 Size 185 00MB Plus the driver needs to be removed as well in red box tis Signum Systems Code Composer ITAGjet Size 657 00MB Drivers For CCS 3 3 i Silicon Laboratories LISBxpress Device Driver Removal XT Sonic Express Labeler Size 13 53MB Follow the instructions for removal Click Continue above 41 Click on Yes above Click OK above You will need to do this for a total of four times once for each program If you cannot find Kinetek Controls USB Adapter Driver Set skip it and just delete the other three programs After
6. accomplishing this you should also right click on the three Icons that may already be on your desktop and delete these icons KC Downlo KC KC Logget You are now ready to re install KC Host and the associated programs 42 Controller Installation Make sure aluminum mounting plate is clean and free of any debris Note that there are three phase cables from the motor one battery positive cable and one battery negative cable There is additional a small ring terminal and a main harness with three connectors These all should be pushed aside to allow the controller to be placed flat against the aluminum mounting plate Place two mounting screws lock washer and flat washers as shown 43 Slide controller s slots into two mounting screws on left Install two additional screws lock washer and flat washer on right of controller passenger side of vehicle 44 Tighten four screws two per side of controller Torque to 75 inch pounds Note U V and W phase cables These need to be attached to the appropriate U V and W connections on the controller The copper busbar at the bottom is battery positive The top most connection to the controller is battery negative 45 Note the positions of U V and W ensure that the cables are matched to the correct terminals Each cable should be secured with a bolt and a flat washer locking washer and nut on the opposite side 46 Batte
7. successfully After all these have installed one should be able to find them within C Programs Files Right click on each of these programs and Copy then go to your desktop and right click and choose Paste Shortcut This will generate the following three Icons onto your desk top 22 KC Host T KC Downlo The last step in this process is to attach the USB communicator to allow Windows to enumerate recognize that the communicator is attached After attaching on the bottom right of the Windows tool bar a message will pop up saying windows has found new hardware let this process complete When finished another message will pop up saying your new hardware is ready to use This can also be verified by launching Control Panel System Hardware Device Manager Universal Serial Bus Controllers and look for the entry entitled USB Express Device or Silicon Laboratories this name may vary between windows XP Vista or 7 23 Changing Setup Parameters and Retrieving Error Codes using KC Tomberlin Host To communicate to the controller you will need a communication cable and the correct wire adapter harness See above All Tomberlin cables should be version EA61 This will allow a laptop to talk with the controller The black box isolates the laptop from the controller and adjusts the voltages from the controller voltages to the USB voltages One harness KC Host Adapter is used to chang
8. BO button will increment from the speedometer from 10 MPH to 20 MPH If REVERSE is selected regardless of the Performance switch setting 10 MPH default will be displayed Depressing the TURBO button will decrease to 5 MPH and will increment towards 10 MPH with each depression of the TURBO switch Note that in Reverse the back up alarm will sound The following table shows possible speed settings Switch Position Default Setting MPH Speed Range MPH Forward Economy 10 to 20 Forward High Performance 20 to 25 Reverse alarm will sound Acceleration Adjustment Place the Direction switch to NEUTRAL the speedometer should return to zero Press the accelerator all the way to the floor soeedometer should approach 35 but then fall back to display 10 15 20 or 25 MPH This indicates that the potentiometer and start switch in the accelerator are functioning correctly and that the level of MPH displayed is the acceleration rate The higher the MPH number the quicker the acceleration will be Rapid accelerations will reduce battery charge life and distance of travel By pressing the TURBO button the level of acceleration will change keep pressing until the desired level is reached If you do not see the accelerator go above 25 MPH it may be indicative that the accelerator potentiometer is not reaching full voltage which may limit top travel speed Electrical Braking Adjustment Place the Direction switch in NEUTRAL and release the Accelerat
9. For setup and monitoring Publisher Kinebek Controle Location C Program FilesKC 4 Host TOMBERLIM exe Reinstall using recommended settings b This program installed correctly Cancel What settings are applied Simply hit this program installed correctly or cancel 30 Programming New Software into Controller Prior to programming new software into the controller the new program files SINGDSP Ver 2 44 HEX or SINGDSP Ver 3 44 HEX for example need to be loaded into your laptop IMPORTANT Files that are version 2 SINGDSP Ver 2 44 HEX for example are designed for controllers that ARE NOT equipped with the thermal light control Files that are version 3 SINGDSP Ver 3 44 HEX for example are designed for controllers that ARE equipped with the thermal light control e Copy the desired HEX file to o C Program 5 Download e Or in some cases on Windows Vista Windows 7 this location might be o C Program Files 86 Download These directories can also be found by highlighting the KC Download AC icon on your desktop right click and refer to the Target field this will contain either of the above directory paths NOTE When loading a file into the above location s it generally has to be stored in a directory first and cannot be taken directly from an e mail Store the HEX file in a temporary location first and then copy or drag into the above directories Gen
10. HES BATTERY VOLTAGE ogsHynl 5 91 paws Rio NE emo4u MoT iod 10 wa S ZL w 3 E B 35 JONYWYOdYJd 8 zin HOJIIMSA39 318VN3 3 v48 MOIDVINOO 11 21 217 Fd QL Io qe 6 66 6o lololo 00099906 ZI 5 3 E 917 Sooc C Je fo x x EMI bi 2 Lj O 4 m gt 51 12 12V MOTOR amp CONTROLLER cae 2 760 c O c 0 oo E amp SUCK LLLI BO B oo 5 pp BACK H a RRt lt 5 sew 8 3 Q0 8 SEM Vi SPD SEN V RED OO 8 lt a 2 CABLE GAUGE alie TO CONTROLLER 5 518 L M1 s 112 416 18 g L j 4 Red Black Wire Black Wire ANVIL PARK BRAKE SWITCH GND 3 PHASE MOTOR CABLE GAUGE 2 AWG min JM4A JM4B N U Toe 4 Sei D A a 1 10 wm e z eos A ums T3 5 5 V S me EE mH j MOTOR MOTOR TEMP A BLACK MOTOR TEMP ORANG JM2A JM2B 2 614 0 3 DRAIN SHIELD BARE MOTOR TEMP A BLACK MOTOR TEMP B RED
11. Key switch does NOT kill the power to the controller With the power OFF connect KC Program Adapter five wires and two loops into J11 the ten pin connector that is blank on the controller The connector will only fit one way note the locking ramp s position Connect the other end into the USB port in your laptop that has already been powered up and running Look for the ICON that says KC Download AC and double click and say yes and OK to all the Microsoft questions until the following screen appears Sometimes one has to right click and run as Administrator 33 CONFIRM CONTROLLER 15 READY 3 Press OK when Controller is connected 4nd powered up Place the RUN TOW switch to the RUN or ON position and then click on OK The following screen should appear AC Firnnvare Upgrade Press UPGRADE button when File Selected Elapsed Time CHOOSE FILE FOR UPGRADE inn war SIS PD Drag your mouse to the up and down arrows on the right high light the program that you want There may be multiple choices dependent on vehicle configurations For example when a more updated PCB will be able to flash thermal light on the dash the equivalent software will be VERSION 3 39 After highlighting the version you want to download one can click on the UPGRADE FIRMWEAR box 34 Fel AC Upgrade V 1 01 Kinetek Controls A Kinetek Company AC Firmware Upgrade Press UPGRADE button when File Selected Elapsed Tim
12. TOMBERLIN CONSUMER DISCLAIMER Tomberlin reserves the right to change the suggestions gained in this consumer support site It is intended primarily for educational purposes only Some experienced consumers prefer to do the maintenance and service themselves for the Do It Yourself owners Tomberlin strongly encourages interaction with your local dealer first and to never attempt a procedure you are unfamiliar with safely performing An electric vehicle has a significant voltage that can result in shock fire and injury if not performed by a professional Damage to the vehicle can also occur Some procedures require specific torque settings that when not followed can result in dangerous possibly life threatening situations Many errors will not surface immediately The information herein has generally proven to enhance the life cycle safety and overall ownership experience when properly followed Tomberlin assumes no liability for the content provided in this consumer educational section and it is possible that an error with regard to spelling grammar nomenclature and translation is present Note that the information provided should be treated as live documents meaning they are always in a state of refinement correction and improvement Check back often and if printed check back prior to reliance to assure they remain current Never attempt to manipulate the vehicle to exceed the speed as required by regulations The highest speed range for Tomber
13. TT POSITIVE greater than 100 000 ohms W and BATT POSITIVE greater than 100 000 ohms Catastrophic failure usually results in one or more of the above reading in a very low resistance less than 100 ohms 17 Installing KC Host AC Downloader and Logger Insert the disc that has been provided it should start an auto install If it doesn t auto install open up the disc drive generally Drive E and click on the setup file as shown below DRIVER 21612010 1 03 PM File Folder k Host Setup 21612010 1 03 File Folder k Logger Setup 21612010 1 03 PM File Folder s AUTORUN 8128712007 3 17 PM Setup Information 1 KB 5 DelDriver2 1125 2010 3 21PM Windows Batch File 2 KB m InstallReadMe 1 25 2010 2 13 PM Text Document 1 KB x setup 1126 2010 2 21PM Windows Batch File 1 KB There is going to be four different programs downloaded and every computer can be slightly different The disc should work with Windows 98 XP 32 and 64 Bit Vista and Window 7 On more recent computers a lot more security questions will be asked continue to click on allow continue yes and OK Click Allow below 18 First the USB Drivers will be installed click Install below A Silicon Laboratories USBXpress Device Driver Installer Silicon Laboratories Silicon Laboratories LISBXpress Device Installation Location Driver Version 3 2 C Program Files Silabs MUUS press Change Install Location
14. and J12 10 11 High Priority Line Contactor disabled and saved in memory 9 mph 0 long 6 short flashes Phase over current fault Under normal circumstances this flash code should not appear over 600 amps in at least one phase of the motor It is possible due severe driving conditions and heavy motor loads this error code may occur If it occurs repeatedly or as soon as the car is moving either the motor or controller may have failed With RUN TOW off perform motor and controller tests with them connected together and separated if necessary See motor and controller tests at the end of fault codes 10 mph 0 long 7 short flashes Battery voltage too high If the voltage at the controller exceeds approximately 100 volts this error will occur With a fully charged battery electrically braking or speed controlling down a steep hill this may occur to prevent catastrophic failure of the controller Ensure that battery charger is not exceeding its charging voltage and end of charge battery voltage should not exceed 98 volts This voltage should diminish to about 85 volts as the battery cools A fully charged battery cannot accept large regen currents without the battery voltage rising After the battery discharges it is unlikely that 100 volts can be achieved Also check for loose connections at BATT and BATT cables at controller and at battery Ensure that no hardware steel washers is between high current carrying conductors Consider reduc
15. ate a speed dependent on how fast the vehicle was pushed and could not determine if speed channel A or speed channel B were not recognized Check voltages at JM4B from the controller JM4B 1 should be 15 volts JM4B 2 amp JM4B 3 should switch between 0 volts and 15 volts JM4B 4 should measure zero volts and if a continuity test is run should be connected to BATTERY NEGATIVE NOTE Complete wiring diagrams and references to J10 JM4B 1 JM4B 2 JM4B 3 and JM4B 4 can be found on page 48 of this manual Error Codes If the vehicle is equipped with a red Thermal Light it will flash a fault codes when they occur count the number of flashes there are short quick flashes and long slow flashes This flash code will also appear on the controller itself and can be read if the plastic cover over the controller area is removed If it is not equipped with this dash light the fault code will be indicated on the speedometer when the forward reverse switch is placed in neutral or can be recalled using 4 key ON cycles and using the Turbo button to scroll through up to 8 stored error codes Low Priority Line Contactor enabled will not disable system and error code will not be saved in memory Speed O mph 4 mph 5 mph 6 mph 7 mph 8 mph Flash Code 0 0 long 1 short 0 long 2 short 0 long 3 short 0 long 4 short 0 long 5 short Description No Fault Low Battery 1 Low Battery 2 Motor Temperature Warning 125 C 257 F
16. ccur 2 xx goes into earlier controllers that do not have the ability to light the Thermal Light Version 3 xx goes into later controllers that can light the Thermal Light Restart the download process again with the correct version of software NOTE Prior to doing the original download it is required by the user to run KC Host to see which original version of software is installed 22mph 1 long 9 short flashes Over Current Fault If the contactor coil becomes damaged low resistance the controller may not be able to pull it in but it will protect its internal circuitry If this fault code occurs check coil resistance of contactor nominally it should be 350 ohms Check resistance between harness side of J16 2 and J16 1 should be 350 ohms The error code can also occur if back up alarm fails or if speedometer fails Check wires J16 3 and J16 4 for accidental connection to 12 volt 4 NOTE Check speedometer and backup alarm with diagnostics procedure if this error doesn t occur it eliminates the possibility that J16 3 and J16 4 may be causing this problem 14 26mph 2 long 1 short flash EEPROM Internal Memory Failure After downloading of new software there is a possibility that this error code will appear on power up This signifies that the EEPROM Internal memory has been scanned and an error has occurred Using KC Host to change setup parameters change the FuncBitmap to 65535 and then exit KC Host Cycle the RUN TOW switch a
17. ch will roughly correspond to when the needle of the BATT Gauge Green yellow and red goes into the RED As the battery discharges more and more beeps will occur encouraging the driver to accelerate slowly and head for an electrical outlet ShutDownVolts at 45 volts programmable the controller will shut down with an error code which may be cleared by cycling the key switch More than likely this will continue to happen and the vehicle will be difficult to move Function Bit Map This is an engineer s way enabling and disabling parameters it will be changed in the future The only reason to use this is to enable or disable the alarm for low battery 382 disables the alarm 894 enables the alarm DO NOT ENTER ANY OTHER NUMBERS unless specifically instructed to do so For example some vehicles may have been made without a Parking Brake switch being wired into the controller this function allow you to program around to eliminate the parking brake input NOTE Entering 65535 will clear wipe out all EEProm memory locations This should only be done if the controller is powered up with a EEPROM Internal Memory Failure fault 28 To retrieve the saved error codes select the Setup Transfer option HOST uc TOMBERLIN x EC Host TOMIBERLIN Version 2 01 r Select Setup C Runtime setup Transfer Reprogram mmunication is Established Please Select Mode The following screen wi
18. cuit W and SWITCHED BATT POSITIVE Cable lowest controller cable Open circuit U to unpainted metal surface of the motor high resistance if less than 1000 ohms this could be a start of a problem if less than 100 ohms there is a problem Catastrophic failure of the controller generally results in any one or multiple ones of the above readings measuring very close to zero ohms 16 Isolated Motor Test disconnected from controller Measure resistance between U and V V and W and U and W all should be very low resistance 0 1 ohms Measure resistance between U V or W and an unpainted portion of the frame of the motor resistance should be very high If less than 100 ohms something has shorted to frame If below 1000 ohms it may be a start of something than may result in a short as the motor heats up if higher than 10 000 ohms nothing to worry about Measure resistance between the two pins of the JM2 connector approximately 500 600 ohms at room temperature increasing as motor gets hotter Measure resistance between pins of JM4 connector speed pickup any combination of pins should be high resistance Any low resistance less than 1000 ohms could mean a failure Isolated Controller Test disconnected from motor Measure resistance U and BATT NEGATIVE 25 000 ohms nominal V and BATT NEGATIVE 25 000 ohms nominal W and BATT NEGATIVE 25 000 ohms nominal U and BATT POSITIVE greater than 100 000 ohms V and BA
19. e CHOOSE FILE FOR UPGRADE The following two boxes will ask you are you sure you want to do this this is a complete download not simply for changing parameter the parameters will get set back to their default settings not the end of the world Hit OK twice RECONFIRM FIRMWARE UPGRADE x CONFIRM FIRMWARE UPGRADES RECONMFIRM Controller A FIRMWARE UPGRADE NOT FOR SETUP VvVALIIES Selecting OK will Force FIRMWARE UPGRADE T een The following screen will appear indicating that the programming process has begun You have about four minutes to wait 35 Fal AC Upgrade V 1 01 Kinetek Controls A Kinetek Company Upgrading to SIN GDSP VER 2 36 HEX 1 22 55 Transmiting Upgrade File xi Tamar X Kinetek Controls A Kinetek Company Upgrading to SINGDSPE VER 2 36 HEX Block 2 Total Blocks Section 1 22 25 Transmitting Upgrade File 2X Controller Upgrade Complete FIRMWARE UPGRADED Please Remove Controller Power Fad AC Upgrade V 1 01 gt Kinetek Controls A Kinetek Company SINGDSP VER 2 36 Upgrade Complete ontroller Upgrade Complete PLEASE REMOVE CONTROLLER POWER e programming sequence UCCESSFUL Block 4 otart 1 52 55 PRT End 1 57 26 PMI Transmitting Upgrade File Total Blocks section re pragramming sequence SUCCESSFUL Hit OK and place the RUN TOW switch into th
20. e TOW or OFF position LEDs on controller will turn OFF Now disconnect Program Adapter from J11 and place RUN TOW back to the RUN or ON position Green LED will light on the controller After programming the controller it is recommended that one goes through the diagnostic procedure to ensure that all harness connections are still working and then test drive the vehicle to ensure everything is as it should be Modification of Parameter via KC Host Tomberlin or through the diagnostic procedure may be necessary 36 Running KC Logger The KC Logger program is used for the saving of run time diagnostic data This data can be collected while a vehicle is in the run mode whether it s driving wheels jacked up or just sitting at idle with the key switch ON The logger program will save a data file entitled Piclog pcl This data file will contain run time data of the vehicles performance speeds voltages switch values controller states current fault conditions etc This data file NEEDS to be sent back to Kinetek Controls for detailed analysis Connect the KC Host Adapter harness to the communication cable the same way for KC Host NOTE The Logger application can be attached and run at anytime while the vehicle is running No special combination of Run Tow ON OFF is needed To launch the KC Logger the user MUST highlight the KC Logger USB icon right click and select Run As Administrator this is required by newer v
21. e setup parameters speeds acceleration rates braking rates etc while the other adapter Program Adapter is used to download a complete new program As product updates and improvements are made or requests for special items are made new programs can be downloaded into the controller Note the differences in the wires the KC Host Adapter simply has 5 wires the Program Adapter has five wires and two loops 24 Apply the parking brake turn off the Key Switch and turn off the power to the controller by using the RUN TOW switch mounted on the plastic composite cover over the controller Slightly above J11 there are two LEDs a green and a one When the RUN TOW switch is in the OFF or TOW position the green LED will be OFF and will turn ON when the RUN TOW switch is in the ON or RUN position Key switch does NOT kill the power to the controller With the power OFF connect KC Host Adapter five single wires into J11 the ten pin connector that is blank on the controller The connector will only fit one way note the locking ramp s position Connect the other end into the USB port in your laptop that has already been powered up and running Look for the ICON that says KC Host Tomberlin and double click and say yes and OK to all the Microsoft questions until the following screen appears Sometimes one has to right click and run as Administrator 25 TT TW KC Host Version 2 00 Waiting to Communicate cle C
22. ement without an error code may be wiring or a switch failure It is always suggested that for any problem that occurs without an error code that self diagnostics be conducted See Diagnostics and Programming Error Codes 4mph 0 long 1 short flash Low Battery 1 Charge the Battery Controller measures battery voltage at J16 1 after the key switch is turned on but before the line contactor closes If this is less than 63 volts default but programmable this code will occur 63 volts for a 72 volt battery is very low and performance on the car will be severely limited Measure the voltage across the battery terminal If this is significantly higher then troubleshoot and find where the voltage is dropping RUN TOW switch provides voltage to J16 1 with switch in the TOW position battery voltage should be on one side of switch With switch in the RUN position battery voltage will be on both sides of the switch Charge the battery if less than 71 volts The 63 volt level can be increased or decreased using KC Host 5mph long 2 short flashes Low Battery 2 Charge the Battery Same as above but voltage at J16 1 is less than 58 volts Car will most likely not run very well before error code 14 occurs Suggest charging the battery before this error code appears The 58 volt is default level can be changed using KC Host 10 6mph 0 long 3 short flashes Motor Temperature Warning 125 C Let cool Controller continuously monitors temperature
23. erally it will state you need to provide administrator permission click continue and then continue again 31 Kite atrols HII A Kinstek Company MODEL KCCA0068 EA61 SERIAL NO EA1017000317 To communicate to the controller you will need a communication cable and the correct wire adapter harness This will allow a laptop to talk with the controller The black box isolates the laptop from the controller and adjusts the voltages from the controller voltages to the USB voltages For Window s 7 and Vista 64 bit laptops the cable should be marked with EA61 as shown above One harness KC Host Adapter is used to change setup parameters speeds acceleration rates braking rates etc while the other adapter Program Adapter is used to download a complete new program As product updates and improvements are made or requests for special items are made new programs can be downloaded into the controller Note the differences in the wires the KC Host Adapter simply has 5 wires the Program Adapter has five wires and two loops 32 Apply the parking brake turn off the Key Switch and turn off the power to the controller by using the RUN TOW switch mounted on the plastic composite cover over the controller Slightly above J11 there are two LEDs a green and ared one When the RUN TOW switch is in the OFF or TOW position the green LED will be OFF and will turn ON when the RUN TOW switch is in the ON or RUN position
24. ersions of Windows due to KC Logger writing to a data file on the computer The following screen will appear Fad Kinetek USB Data Logger Data Dump Version 1 01 5elect Baud Rate ITOPPEL 2400 19200 9600 38400 Decimal Hex 4 n When ready select the Start button this will start the logging process 37 When logging the screen will appear as follows Fa Kinetek USB Data Logger EC Data Dump Version 1 01 Select Baud Rate z wr TSLARRARRARRARRRRRRRRRRRRNRRRRRNERRRRARARRARRARRARRERRIERR RR 7 2400 19200 C 9600 v 38400 USB Status 0 hU SBDeviee 180 EytesInGQueue 0 Queue Status 0 The data in the center portion of the screen is the data that is saved to the file When finished select the Stop button this will stop the logging of data but not close the application The Start button can be re applied at anytime this will simply keep appending new data to the existing data file When completely finished select the Stop button and close the application To view the data file go to the location where KC Logger USB is installed C Program FilesAKC Logger 05 Or in some cases on Windows Vista Windows 7 this location might be C Program Files 86 Logger 05 Locate the Piclog pcl file double click to open Windows will ask for a program to open this file with It is simply a text file so selecting a te
25. ing Braking Rate to a minimum using Diagnostic and Programming procedure 12mph 0 long 9 short flashes Phase fault U V or W Controller protection circuitry is preventing phase current This can be an internal controller fault or a motor fault or both Test motor and controller isolated from each other See below if both test out OK most likely internal controller fault change out the controller 14mph 1 long 1 short flash Fault Latch Failed 1 A fault has occurred but the internal hardware and software cannot determine which fault it is If it does not reoccur then do nothing If it results in another error code resolve that error code first If condition continues ensure software is latest 2 43 3 43 and if the problem continues replace the controller 12 15mph 1 long 2 short flashes Pre charge Failure Circuitry internal to the controller will pre charge capacitors internal to the controller For the main contactor to pull in the voltage of these capacitors needs to reach a certain point Flash code 1 2 ensures the voltage on the capacitors reaches 2 volts after a very short period of time If the voltage does not increase it most likely is due to a catastrophic failure of the transistors internal to the controller Conduct Motor and Controller test connected as described at the end of the fault codes Also ensure that no auxiliary wiring has been added to the switched side of the main contactor Any additional circuit may pre
26. ion of the controller this error will occur Update to latest software 2 43 or 3 43 software Otherwise see flash code 3 above If J10 at the controller is disconnected this error code will occur 19mph 1 long 6 short flashes Controller overheated 120 C See flash code 4 above 13 20mph 1 long 7 short flashes Throttle Fault For the vehicle to operate after the key has been turned on the Direction switch must be placed in NEUTRAL and the accelerator needs to be released If the controller measures the throttle switch to be open but the voltage on the accelerator potentiometer to be out of range this error code will occur Or if the start switch does not close when the accelerator is depressed this code will occur as the accelerator is depressed Measure voltage at J12 13 throttle switch this should be zero volts with the accelerator released and battery voltage 72 volts nominally when the accelerator is depressed Also measure voltage at J12 5 this is the voltage that the controller uses for speed control Low voltage is zero speed increasing voltage is increasing speed When it gets to about 3 5 volts you are at MAXIMUM speed Throttle switch should close before this voltage gets above 1 0 volt 21mph 1 long 8 short flashes Software Version Incorrect Internal to the controller a memory location is set to indicate that it should be version 2 or 3 software If the incorrect software is loaded into the controller this error code will o
27. lin E Merge PTV s and LSV s are factory set at 15 19 mph as a PTV or 22 25 mph as an LSV Consumers should always exercise prudent common sense measures use proper safety gear with tools designed specifically for the task Always utilize insulated tools around electrical connections Never exceed your comfort level and when in doubt stop and call your local dealer Tomberlin Authorized Dealers are always your best resource If you notice an error or have an idea that will improve our efforts here please email your idea to info tomberlin net Kineteke Controller Service Manual For The TOMBERLIN ANVIL E Motion Documentation Rev 1 1 Table of Contents Function of Speedometer Key Switch On Display Viewing Error Codes Diagnostics amp Parameter Programming Speed Adjustment Acceleration Adjustment Electrical Braking Adjustment Motor Speed Sensor Testing Error Codes Troubleshooting Error Codes Checking Motor Speed Sensor Motor amp Controller Test connected Isolated Motor Test disconnected from controller Isolated Controller Test disconnected from motor Installing KC Host AC Download and Logger Changing Setup Parameters or Retrieving Error Codes using KC Host Programming New Software into Controller Running KC Logger Un installing KC Host Controller Installation Controller Connection Definition Various Schematics I OO Ul Ul 10 15 16 17 17 18 24 31
28. ll appear GENERE 4 Host TOMBERLIN Version 2 01 r select Mode Setup Funtime E Repro erartt hoose Operation setup Transfer Mode Choose Operation Copy Read Stored Fault Codes Program Choose Read Stored Fault Codes option the following screen will appear 29 x p Host TOMBERLIN Version 2 01 Auxilary Reads stored Fault Codes 22 Speed Sensor A Failed Clear Errors These can be cleared by selecting the Clear Errors box or can be saved to a file by selecting Save By simply exiting the error codes will remain the same Error codes can also be displayed through the speedometer see Viewing Error Codes section on page 4 Referring back to the Setup section after setting the parameters to the desired values and hitting enter each time the values have been programmed Close out the KC Host screen by clicking on the X in the top right hand corner Turn the RUN TOW switch to the TOW or OFF position and remove the wire adapter harness from J11 On a Vista machine one may get the following message Program Compatibility Assistant X This program might not have installed correctly IF this program didn t install correctly try reinstalling using settings that are compatible with this version of Windows no Program Sends serial commands receives responses to board KC
29. nd the error code should not occur NOTE If this error code continues to occur the controller should be replaced 28mph 2 long and 2 short flashes Speed Sensor Channel A Failure Speed sensor channel A has failed to receive speed pulses from the motor Refer to Checking Motor Speed Sensor section below 30mph 2 long and 3 short flashes Speed Sensor Channel B Failure Speed sensor channel B has failed to receive speed pulses from the motor Refer to Checking Motor Speed Sensor section below 32mph 2 long and 4 short flashes Speed Sensor Channels A amp B Failure Speed sensor channels A amp B have both failed to receive speed pulses from the motor Refer to Checking Motor Speed Sensor section below Checking Motor Speed Sensor Failure of the speed sensor generally results in very slow speed and no speed registration on the speedometer and jerky operation To check the speed sensor in Diagnostics refer to Motor Speed Sensor Test on page 8 15 Motor amp Controller Test still connected together Measure resistance U and BATT NEGATIVE Cable top of controller or at battery 10 000 ohms nominal V and BATT NEGATIVE Cable top of controller or at battery 10 000 ohms nominal W and BATT NEGATIVE Cable top of controller or at battery 10 000 ohms nominal U and SWITCHED BATT POSITIVE Cable lowest controller cable Open circuit V and SWITCHED BATT POSITIVE Cable lowest controller cable Open cir
30. oeedometer and the Turbo button It is recommended to initially set the Parking Brake which should light the parking brake light on the instrument cluster When placed in reverse the back up alarm should sound If the instrument cluster is equipped with a Thermal Light the light will flash during Diagnostics and Programming Items like no forward or no movement without an error code may be wiring or a switch failure It is always suggested that for any problem that occurs without an error code that self diagnostics be completed If the results of putting these switches in the positions indicated do not result in a reaction of the speedometer one can hopefully determine which switch is or is not working so that the switch and wiring can be appropriately troubleshot and repaired Speed Adjustment To enter the Diagnostics and Programming mode the key switch needs to be turned on 3 times within 5 seconds and left in the ON position the third time ON OFF ON OFF ON The main power contactor should not pull in no click If it does the vehicle is in the normal driving mode and not in Diagnostics Try cycling the key switch again 3 times in less than 5 seconds The speedometer needle will now register certain switch activations and deactivations The Thermal Light if equipped will flash three times indicating that the vehicle is in Diagnostic and Programming Mode The default display when the speed should indicate zero MPH is Directi
31. of the motor through JM2 and to J10 1 and J10 2 At room temperature resistance within motor is approximately 570 ohms At 100 degree C it is approximately at 1000 ohms Performance of controller will be reduced if temperature continues to raise controller will shut down system with flash 1 long 5 short 18MPH If this connector is corroded or has bad connection or this connector disconnected this error code may occur prematurely Let motor cool or drive at a slower rate Check battery voltage for charged battery ensure brakes are not dragging The motor s two pin thermal connector JM2 is shown below Motor Thermal Connector 7mph long 4 short flashes Heat Sink Temperature Warning 110 C Let cool Internal to the controller the transistor heat sink is monitored Performance will start to reduce and if temperature continues to raise flash code 1 long 6 short 19MPH may occur and the vehicle will shut down Ensure battery is well charged brakes are not dragging and that controller is securely fastened to mounting plate If this occurs with a cool controller the problem is internal to the controller and the controller will need to be replaced 8mph 0 long 5 short flashes Forward and Reverse requested together If the controller sees both the FWD and REV simultaneously it will default to NEUTRAL Directional switch and or wiring need to be repaired Battery voltage has been applied simultaneously to controller connector J12 9
32. onal Switch in center position Neutral Foot off of the accelerator and brake pedal The main controller monitors the Directional switch the Brake Pedal switch the Accelerator Pedal switch and potentiometer the Economy High Performance switch and the Turbo button If the display shows a speed between 5 and 25 MPH at least one of the switches may be activated If zero speed cannot be achieved then one needs to determine which switch is stuck in the ON position By placing the Directional switch in FORWARD the speedometer will display whatever speed that has been 5 programmed for HIGH PERFORMANCE or ECONOMY settings For example if HIGH PERFORMANCE and FORWARD have been requested the display will display 25 MPH default setting If this does not occur it may be indicative of a switch failure On the other hand if ECONOMY and FORWARD are selected the speedometer will display 20 MPH default setting While in FORWARD and ECONOMY or PERFORMANCE pressing the TURBO button will reprogram the speed setting and the speedometer needle will indicate what the speed has changed to For example if in FORWARD and PERFORMANCE pressing the TURBO once will move the needle to 20 MPH pressing again will increment 1 MPH for each TURBO button depression Where ever the speed is left will be the programmed value If FORWARD and ECONOMY are requested pressing the TURBO will move the speedometer needle to 10 MPH and each depression of the TUR
33. ontroller Power gt 28 While this screen is showing the number 28 is incrementing indicating how long it has appeared in seconds you have 255 seconds to connect and it is waiting for power to be applied to the controller Place the RUN TOW switch into the RUN position and the following screen should appear FS HOST USB TOMBERLIN p gt Host i TOMBERLIN Version 2 01 gt Select Mode C Setup C Runtime Setup Transfer C Reprogram mmunication is Established Please Select Mode 26 Use your mouse to select Setup to change parameters or Setup Transfer to view error codes The following screen will appear for Setup Fa KC HOST USB X EC Host 4 lt LI A Version 2 00 select Mode v Setup C Runtime Setup Transfer Reprogram Viewing Setup Variables Page 1 of 1 Total 13 setup Variable Value Units Fast speed MPH Slow speed MPH Rev speed MPH AccelRate Val CoastRate Val BrakingRate Val Min Key On Volts Volts SlowDown Volts Volts Shutdown olts Volts FuncBitmap BMP Screen above shows Factory Defaults NOTE In the above graphic there is the Version level Version 2 39 This is the version that is currently loaded in the controller This will vary dependent on controller revision and software revision To date there are quite a few versions of controller softwa
34. or Pedal the soeedometer should return to zero Push down on the Brake Pedal soeedometer will indicate 10 15 20 or 25 MPH This indicates that the brake pedal switch is working and that the level of MPH displayed is the amount of electrical braking The higher the MPH the shorter the stopping distance when the brake pedal is depressed By pressing the TURBO button the level of electrical braking will change keep pressing until the desired level is reached 25 MPH is aggressive braking while 10 MPH is softer and will require longer distances to stop the vehicle Motor Speed Sensor Test One final diagnostic test is the ability to ensure that the motor s speed sensor is working Make sure that the Directional switch is in NEUTRAL and the speedometer is displaying O MPH Ensure that the car is on flat ground and not in danger of rolling away Release the parking brake and gently push the car either forward or reverse As the controller senses the two signals from the speed sensor the speedometer should display the following O MPH neither channel is registering could be 15 volt or BATT NEGATIVE wire broken 5 MPH Channel A failure check J10 6 and pin 3 of 4 pin connector from motor JM4 10 MPH Channel B failure check J10 3 and pin 2 of 4 pin connector from motor JM4 15 MPH Both channels functioning maybe problem is elsewhere or intermittent NOTE On older software revisions pre 2 44 3 44 the speedometer would indic
35. re in the field 2 36 2 38 2 39 2 44 and 3 36 3 38 3 39 3 44 There are presently 10 programmable boxes moving your mouse into the box and typing a number and hitting enter will change the parameter value Fast Speed this sets that maximum speed in the HP high performance values of 20 to 25 are valid Slow Speed this sets the speed in the Economy mode 10 to 20 are valid Rev Speed this sets the maximum speed in reverse 5 to 10 are valid Accel Rate this set the acceleration rate min 10 max 40 The higher the number lessens the time to maximum speed and will also consume the most battery amps Default 20 Coast Rate this sets the amount of regenerative braking when the accelerator pedal is released 1 would be a coast 13 would slow the vehicle the most Default 2 27 Braking Rate this sets the amount of regenerative braking that occurs when the service brake switch is activated pressing the service brake pedal 4 is the minimum and 16 is the maximum rate The numbers correspond to the same amount of braking that occurs during Coast Rate Default 8 Min Key On Volts this is the minimum voltage required at power on for the line contactor to close 63 to 72 volts is allowed At any of these voltages the car is not going to travel very far SlowDownVolts this is the voltage 53 to 63 volts that will sound the back up alarm as long as you are below this voltage During acceleration one may hear a single beep whi
36. ry negative gets attached to the top terminal of the controller The ring terminal goes on top of the cable NOT between the cable and controller terminal Connect Battery Negative cable to terminal of controller Ring terminal goes between bolt head and cable flat washer lock washer and nut under terminal torques to 180 inch pounds these are heavy current electrical connections and under no circumstances should the cable loosen Battery Positive connection at bottom of the controller copper busbar under controller terminal flat washer and bolt head holding them together lock washer and nut torque to 180 inch pounds Connect V W and U phase wires to corresponding V W and U controller terminals Copper terminal of cable goes between bolt head and terminal steel flat washer lock washer and bolt go under terminal torque to 180 inch pounds 48 Before connecting J10 J12 J16 connectors use automotive dielectric grease into all of the pins Fill cavity space with this grease It will protect from moisture and will allow for better electrical connection Smear dielectric grease as shown 49 Plug in three connectors the top one is J10 and has 6 wires all on one side of the connector J16 is the smaller connector in the middle and J12 is the one nearest the floor Make sure the locking clips circled in red are latched Controller Connection Definition J11 50 VARIOUS SCHEMATICS SWITC
37. switch needs to be turned ON OFF 4 times within 5 seconds and left in the ON position the fourth time ON OFF ON OFF ON OFF ON The main power contactor should not pull in no click If the main power contactor does come in then the vehicle is in the normal driving mode and not in error viewing mode Re try by initially turning to the OFF position and cycling the key switch ON OFF four times within 5 seconds and leaving in the ON position On the fourth ON the speedometer will indicate the most recent error code and each push of the Turbo button will cycle to the next error code When the speedometer goes to 0 MPH it is an indication that all error codes have been seen A total of 8 error codes are saved in memory NOTE If the soeedometer indicates O MPH regardless of how many times the Turbo button has been pressed then there are NO error codes stored The example below is the display indicating 18 MPH which is a motor overheating condition To exit this mode simply turn the key switch to the OFF position Refer to the Error Codes section on page 9 for the error code per speedometer value for full error code details NOTE Error codes will also be flashed on the Thermal Light on the speedometer if equipped in long and short bursts Diagnostics and Programming The Anvil vehicle is set up so that quick troubleshooting of switches and harness connections and some basic programming can be achieved by using the S
38. vent the caps from charging up in the required time and may cause this fault 16mph 1 long 3 short flashes Pre charge Failure 2 Assuming the previous error code has passed the capacitor voltage needs to reach approximately 12 volts less than Battery Positive in a certain time period If it doesn t flash code 1 3 will occur Recycling the key switch may resolve this issue so is a temporary solution If there is voltage remaining in the Capacitors it takes less time to reach the tested voltages With the RUN TOW switch in the RUN position turn the key ON one should see voltage increase on the Batt cable attached at the bottom of the controller This voltage should also stay for a long time after the key switch has been turned off Rapid voltage reduction after the key switch has been turned off indicates something is draining the Capacitors either external or internal to the controller Charge batteries also check voltage at J16 1 this is wire that will charge internal capacitors 17mph 1 long 4 short flashes Low Battery voltage is 55 of 72V 39 6 volts while running Charge the Batteries Battery voltage is very dependent on the state of charge of the battery speed of the vehicle and grade of road If battery voltage ever gets as low as 39 6 volts flash code 1 4 will show Generally the batteries need charging 18mph 1 long 5 short flashes Motor overheated 135 C Let cool If 2 xx or 3 xx software is loaded into the incorrect vers
39. xt editor such as WordPad or Notepad will be just fine 38 The contents of the file will look as follows 33 3 3E3E 3C3C 3 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 5555 5555 5555 5555 5555 5555 5555 5555 B RR 5555 5555 8928 aga gor aga 8928 GICA BBB Bora agi gor aga gor aga gor aua 3E3E 3E 3E 3E 3E3C 3 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E 3E3E 3E 3E 3E 3E3C 3 3E 3E 3E3C 3 3E 3E 2288 ang 2288 0000 2288 HH68 2288 aga 2288 agg 2288 2288 ang 2288 HH68 2288 0000 2288 3E3E 3E 3E 3E 12 11 2818 EHEHEH 2298 AHAB 9600 2298 AHAB 8888 2290 GBBB 2298 AHAB 9600 2290 GBBB 8888 2298 GBBB 9600 2290 GBBB 8888 2290 AHAB 9600 2298 GBBB 8888 2290 GBBB 88188 3E 3E 3 3E 3E 3E 3E 3C 3E 3E 14 38 3E 3 3 3E 3E 3 3 3 0011 8811 66 06 BB11 B6 BH BB11 B6 dB 8811 0 BH 8811 B6 BH 8811 B6 BH BB11 8811 0 00 0011 B6 BH 0011 aga BB11 0011 ama BB11 HHH6 8811 aga 0011 HAGA 8811 ama
Download Pdf Manuals
Related Search