Home

UMOC Service Manual

1. Note that this is yet another safety interlock system intended to prevent unwanted or unintended operation of the drive system AA Dual Drive Systems with Direction Switch Error For vehicles containing two separate drive systems and a control console user intervention is required before the vehicle can be driven on one controller only If powet is shut off to one drive system only or if an internal malfunction in one drive system causes of total loss of power to that drive the vehicle will drive in reverse but not in forwatd This prevents possible drive system damage SOLECTRIA Fault Diagnosis resulting from torque imbalance that is caused by driving the vehicle with one system only Use the following procedures if it is necessary to drive the vehicle on one system only for example to return the vehicle to a repait depot where it may be serviced 1 First check and reset all circuit breakers supplying power to the drive systems as an effort to restore normal operation If full power cannot be restored it will be necessary to determine which drive system has malfunctioned If the console is equipped with drive status lights turn off the ignition key to the vehicle and wait 30 seconds Turn the key to the on position and observe the status lights They should come on briefly during the power on self test interval If one of the two status lights does not come on or stays on that is the malfunctionin
2. 105 SOLECTRIA Fault Diagnosis DANGER Units subjected to severe ovet voltage from hybrid generating equipment will rupture the UMOC s outer case and expel hot gases DESAT IPM Error This is a serious error which is caused either by a damaged power stage or by a motor with a short circuited winding To avoid damage to a replacement unit be sure to test the motor thoroughly before swapping out the unit with another motor controller If the error continues return the unit for service This error is not related to changes in parameter settings e Special Note Regarding Motor Short Circuits The UMOC 225 is a unique design offering higher electrical efficiency lighter weight and the lowest cost of any UMOC It does not however incorporate output short circuit protection If a model 225 is connected to a short circuited motor damage may result In this case the unit must be returned for service All other UMOC models built after June 30 1998 have output short circuit protection and can withstand connection to a short circuited motor without damage Over current error Engineering improvements and better software control have eliminated the over current errors that were somewhat commonplace in very early UMOC designs It is still possible for a bad motor speed sensor to cause an over current error Conflicting speed data results in a difference between rotor and stator rpm The resulting high slip value c
3. 1998 SOLECTRIA CORPORATION WILMINGTON MA USA IDUTPUT CAN NOT BE PROGRAMME IOP TIONAL CUSTOM D AFTER THE UMOC HAS j BEEN BUILT 1 Su BRAKE 4M B E 12 12 ge VELIS WEISS VOLTS 134 SOLECTRIA Appendices Appendix E Appendix E is the HyperTerminal Manual and is supplied Separately 135 SOLECTRIA Appendices Appendix F Field Testing Procedure for Potentiometer Box The potentiometer box pot box internal connections are as follows 10 pin ribbon cable 1 NC NC Max Pedal Moving Contact wiper Moving Contact wiper Min Pedal Resetved Resetved NC NC 0 1 uU BW P2 Note Pins 4 and 5 are connected together electrically To test the pot box in the field proceed as follows 1 Make sure pot box arm is at full rest position 2 Disconnect the pot box cable from the box where it terminates early models at controller later models at ignition box 3 Connect analog ohmmeter between pins 3 and 4 Reading should be 5000 ohms 20 9 4 Connect ohmmeter between pins 5 and 6 Reading should be between 0 and 100 ohms 5 Slowly press down the accelerator pedal The ohmmeter reading should smoothly increase to a high value 136 SOLECTRIA Appendices Conditions a There must be no continuity between chassis ground and pins 3 4 5 b The lowest reading in step 4 should
4. 50 0 10 C 20 C 30 C 40 C 50 C 65 C 70 75 HEATSINK TEMP Torque Decrease VS Heatsink Temp For UMOC640 100 50 0 10 C 20 30 C 40 50 65 70 75 80 HEATSINK TEMP 130 3 SOLECTRIA Appendices Appendix C Appendix C1 0 O 2 Ab r fa mi 55 0 t e b r IGNITION BOX Appendix C 1 Ignition Box Drawing DRAWING OF IGNITION BOX ACCELERATOR SIGNALS CHARGER INTERLOCK ma CONTROLLER DISABLE Qro SOLECTRIA CORPORATION VILMINGTON USA 131 SOLECTRIA Appendices Appendix C2A Driver s Console The drivers console is made up of the Tri selector switch the regen brake disable switch an accessory switch and the ignition box which is located on the bottom of the console The Tri selector switch provides 3 forward power levels neutral and reverse positions The regen brake disable switch allows the driver to turn off the regen braking this is advantageous during slippery road conditions The accessory switch is rated for 12 A at 12VDC and is used in other Solectria vehicles as the heater switch but it can be used for other 12V applications The ignition box has inputs from the Tri selector switch the regen disable switch the throttle pedal charger ignition disable and keyed 12V DC It sends signals to the reverse light and to the UM
5. If external capacitors are being used the system must allow for allow five minutes to pass between the capacitor opening and closing again Units supplied with gray plastic battery connectors can be safely exposed to battery voltages as high as 400 volts Units supplied with orange battery connectors must not be exposed to input voltages higher than 200 volts Always check the nameplate to determine the voltage rating of a particular unit On the top of the UMOC is a Solectria logo sticker The absolute maximum voltage rating can be determined by the color of the sticker SOLECTRIA Installation Table 4 UMOC Voltage Logo Color maximum foreground voltage 200 Serial Data Port The serial data port is used for communication between the UMOC and a personal computer that uses Windows Macintosh or DOS operating systems A 9 pin shielded straight through cable can be connected and run to the passenger compartment of the vehicle The Serial Data cable can be left connected for the monitoring or logging of Port data It is also possible to fine tune the settings of your Connector UMOC while driving using a laptop computer connected to the serial data port Serial Data Port Protector Cap The serial data port connector is protected from dirt and moisture by a red plastic cap Always replace the cap when the serial port is not in use to prevent electrostatic discharge ESD dirt or dust from entering the serial port A
6. SOLECTRIA Fault Diagnosis Some people may find it very difficult to distinguish one smell from another This ability comes from experience When evaluating motor damage it is necessaty to rely on smell visual clues and experience The effects of heat damage are quite evident Note Regarding Monitoring Motor Temperature A good way to monitor motor temperature and function of motor cooling is to attach a small thermal disc snap switch to one of the motor cooling fins A good temperature value would be 190 to 210 F 95 to 100 C The snap switch can then be wired to a dashboard indicator light Snap switches are available from Solectria ot from Selco Error PAL Introduction To help distinguish between the various conditions that can lead to a powet stage fault the UMOC contains an error detection system A short history of detected faults is displayed by the microprocessor after interrogating part of the system known as the Error PAL The Error PAL system is external to the microprocessor This way errors that stem from the microprocessor itself can also be detected On the user data screen the contents of the Error PAL and the type of the last error are displayed in the Status column 104 SOLECTRIA Fault Diagnosis Types of Errors The types of errors that can be displayed by the Error PAL vary accotding to model and software version of the UMOC Not all errors are displayed by all models LED Power Erto
7. UMOC Motor Connector Connecting Your Motor to Your UMOC Now that you have made sure that your UMOC is located in a safe and dry place receives sufficient airflow and has been securely mounted you must now make the connections between the unit and the motor First use the guidelines given regarding the cooling requirements of your motor You will also be given information on the grounding and phasing of your motor as well as instructions on how to properly splice your motor wires should it be necessary to extend their length Making the actual connection between your motor and your UMOC is as simple as pushing together the three phase plugs from each unit Motor Cooling Requirements Depending on class of duty it may be necessary to cool the motor s with forced air except for motors that are water cooled Suitable blowers or fans can be purchased from Solectria For water cooled motors refer to the documentation supplied with your motor Airflow Air velocity of 40 ft sec over the motor cooling fins is required At lower rates the available duty cycle is reduced This may be acceptable in air over situations where adequate cooling is provided by vehicle ram air A good example is a traction motor mounted in an exposed underbody position combined with a light to medium duty cycle such as the Solectria Citivan delivery van SOLECTRIA Installation Table 3 Motor Cooling Recommendations Type of Service Recomm
8. SOLECTRIA Service Manual for Universal Motor Controllers UMOCs Second Edition 3 SOLECTRIA Addendum to Umoc Service Manual As an addendum to the service manual for the Solectria Universal Motor Controller UMOC the following procedure should be followed in regards to the use of connector grease on all Anderson and 9 and 25 pin D sub connectors Before making any Anderson or D sub connection always apply Nyogel Grease Part 760G GM Connector Grease Part 12345579 or other dielectric grease for protection against corrosion or electrical tracking at connector pins and cable shells e For9 and 25 pin D sub connectors Apply grease sparingly to the connector pins and to the connectors cable collar of both the male and female ends Note Excessive grease will attract dirt particles that can interfere with pin contacts when you disconnect and reconnect your cables e For Anderson connectors Apply grease to the pin contacts and back fill the pin casings with grease Do not apply grease to your Deutsch or Packard connectors If you have any questions regarding the proper use of connector grease on your D sub or Anderson connectors please call the Solectria Customer Service Department for details ii 3 SOLECTRIA Foreword Caution The information provided in this manual is intended for use by persons with appropriate technical skills Any effort to perform repairs to or service your unit
9. 89 91 112 113 114 accelerator pedal 14 15 41 67 87 88 89 96 97 114 accessory kit 14 20 39 Airflow 22 e Appendices 127 auto programming 56 Back up Lights 39 Banner is garbled 86 banner line 55 56 73 77 79 85 86 battery box 45 Battery cables 45 Battery Capacity 47 Battery full 100 112 Battery Indicators 63 battery plug 46 61 65 battery terminals 45 49 50 battery voltage 36 41 42 47 49 60 61 66 76 82 87 96 97 98 99 Battery Voltage 61 66 82 Battery voltages 47 Battery Voltages 49 51 brake lights 39 40 41 65 85 109 Brake Lights 41 Brake lights cycle 65 Brake lights stay on all the time 109 Brownouts 37 build date 55 79 85 Cable adapters 60 Cable Types 53 Cable Loop Back Test 72 capacitors 65 66 Capacitors Pre Charge is Complete 65 Caps Lock 76 CAPS LOCK See See Charger disable 92 Checking condition of cables and plugs 124 Checking the pedal pot 110 Choosing Parameters 75 cleaning 101 124 Cleaning 124 Closing the UMOC s Contact 66 Color 52 103 Communications Software 54 Comparing Parameter files 56 150 3 SOLECTRIA configuration number 56 57 74 79 85 Configuration Number Equals Zero 74 Connecting a Test Box See Connecting Your Battery Pack to Your UMOC 41 Connecting your computer 72 Connecting Your Motor to Your UMOC 22 Connecting Your UMOC to Your Motor 2
10. DANGER For systems with battery voltages of 250 and higher battery plugs must be in a dry location and must not be wrapped If the connector is in a poorly chosen location and becomes enctusted with road salt residues upon exposure to water the connector may burst into flame Maintenance Cleaning Requirements and provisions for cleaning were described in the installation section Provided the needed access is available simply remove any insects and debris from the cooling fins Also remove any visible road salt residue by wiping with a damp cloth If allowed to remain on the unit corrosion and connector damage may result from the presence of salt residues Maintenance of cables and plugs Battery and motor plugs Check motor and battery plugs for signs of overheating and melting Plugs should be removable but not too easily Always be sure plugs are inserted completely Subminiature 9 pin connectors Check for signs of water damage and corrosion The 9 pin connector should have insulating loom around it and should not touch metal objects 124 SOLECTRIA Maintenance Waterproofing for your connectors If your UMOC does not have waterproof connectors and will be exposed to a moist or corrosive environment Solectria suggests you apply Nyogel part 760G or GM Connector Grease part 12345579 or other dielectric grease for protection against corrosion or electrical tracking at connecto
11. If this is not the case check to see whether the 12 Volt plugs have been reversed If the keyed 12 Volts is plugged into the fans the fans will run continuously but the unit will be dead If the fans are connected properly on a cold unit but continue to run constantly the processor has malfunctioned Connecting a unit with a microprocessor problem to the main battery may damage the unit Processor Fault If cooling fans brake lights battery indicator lights or other accessories remain on continuously and the unit does not drive the motor the microprocessor has failed Do not attempt to repair or operate the unit in this condition If you suspect trouble with the processor try to recycle the unit by disconnecting the keyed 12 Volts from the UMOC 2 pin 12 volt connector for 30 seconds If normal operation cannot be restored after following the tests listed above return the unit for service Do not reconnect the unit to the main battery No Communications Each time the unit is turned on it sends information to the serial port These include model number build date and configuration number This is called the banner line 3 SOLECTRIA CAUTION If command processing proceeds other than expected and the caps lock indicator is illuminated switch off or reboot the UMOC at once Do not write the long term memory Doing so will reconfigure the unit Switch off the power for 30 seconds then powet up the
12. fuse sizes for UMOC 12 volt output circuits must not exceed four amps For custom installations Solectria can supply properly rated fuses fuse holders and fuse holder mounting boxes at competitive prices SOLECTRIA Installation Testing Regen Brake Lights It is very important to test the regen brake lights after installation With someone following behind you drive your vehicle up to 30 mph and then release the accelerator pedal The brake lights should come on and remain on until the wheels come to a stop If the brake lights stay on all the time even when the UMOC is off reverse the two wires going to the regen brake light output circuit Connecting Your Battery Pack to Your UMOC Battery Pack Once the motor connections have been made you can now Connector proceed to connect your battery pack to your UMOC unit Follow all of the instructions regarding safety Read all section text before attempting any of the procedures desctibed Voltage Ratings Units leaving the factory ate programmed for a designated battery voltage All units have both minimum and maximum voltage settings that can within certain limits be changed by the customer Before changing any settings consult the factory to review possible effects of changes HIGH VOLTAGE 3 SOLECTRIA Installation To assure good operation during all states of charge and for good battery protection battery voltage settings must match the actu
13. soldered connections to unsupported leads 5 Inserting Contact into Housing Contacts should never be forced into housing If the contact does not fit easily check the contact barrel for distortion Replace the barrel if it is distorted or shows signs of wear or damage 145 SOLECTRIA Appendices Appendix M Cooling Fans 41 2 or 6 Heat Sink Finns Mounting Motor Wires Bracket Red Black Battery Wires UMOC 440TF 146 SOLECTRIA Appendices Appendix N PART NAME UMOC 440 amp 440TF 4 5 FANS PART ux SHEET 1 OF 4 SOLECTRIA Notes TOL 0 222 0 005 0 0 010 0 3 0 030 PROJECT DATE 9 20 99 REV 0 FINISH FILE UMOC440TF DRAWN BY V BORBONE DESIGN BY QC CHECK MAT L 147 3 SOLECTRIA indie 1 PART NAME UMOC 640 ult PART amp 22 9 SHEET 1 OF 1 Notes TOL 0 XXX 0 005 0 XX 0 010 0 4 0 030 PROJECT DATE 9 20 99 REV 0 FINISH FILE UMOC 640 DRAWN BY V BORBONE DESIGN BY CHECK MATE 148 3 SOLECTRIA Li Index 149 3 SOLECTRIA Index Index low battery light 98 PEDAL ERROR 87 PEDAL FAULT 87 12 Volt power 34 82 84 12 Volt Power 34 35 36 82 83 24 volt electrical systems 36 25 pin cable 31 32 34 35 64 84 86 90 91 92 25 Pin Ignition Box and Driver Console Connections 31 9 pin 52 124 A D value 89 acceleration 23 48 78 88
14. Brake Lights Cycle The regen brake lights will come on briefly and then go out e Tests complete After about 1 second the status light fans and brake lights will turn off The banner line of text giving model number software version and drive configuration will appear on the laptop screen if connected e Capacitors Pre Charge is Complete After the capacitors pre charge delay or if the unit has been connected to the battery long enough the battery high and low indicators when equipped will go out If the battery has been recently fully charged the battery full indicator light when equipped may remain lighted 3 SOLECTRIA Systems Check CAUTION Drive wheels must be safely off the ground unless you are seated in the operator s position and have made all preparations for vehicle motion to take place Before driving a newly designed vehicle for the first time it is best to test the drive system with the drive wheels jacked up Closing the UMOC s Contactor When pre charge is complete the main contactor can be closed to begin operation The contact will close when the voltage reading on the user data screen Battery Voltage or Batt V increases to within 3 to 5 volts of the actual battery voltage In your vehicle shift to Neutral or to enable the contact If you are using a test box turning the power switch to On will close the contact Note Units built after D
15. CAUTION For motots with integral gear box increasing motor cutrent above the factory setting or recommended limit voids the gear box watranty and may damage the gear box SOLECTRIA Installation being used Battery type and size also determine the maximum battery currents allowable Both maximum battery current and maximum regeneration current may be adjusted using the parameter screen See appendix E For some battery types including lead acid reducing the maximum battery current will increase the vehicle range at the expense of acceleration This 1s the function of the Tri Power selector or power saver when equipped Note Regeneration battery current effects the strength of regeneration mostly at higher rpm Motor currents Note Regeneration motor current effects the strength of regeneration mostly at low rpm Both available torque and motor heating can be controlled by adjusting the maximum motor current It s a good idea not to increase the maximum motor current above the setting supplied by the factory This will result in rapid heating of the motor and possible loss of vehicle performance at high motor temperatures Please note all cautions and remember that motor damage caused by overheating is not covered under warranty In some cases it is possible to reduce motor heating considerably without affecting vehicle performance by reducing the maximum motor current Checking UMOC Battery Polar
16. Damage If one ot more of the power stage components have become damaged this will result in an over current DESAT or IPM fault and no operation The yellow status light will be illuminated when equipped For an explanation of DESAT and IPM faults see the section entitled Error PAL Motor Short Circuited The three types of faults mentioned above could also be the result of motor damage Testing the Motor The most likely location of a motor short circuit is in the wiring and junction box connected to the motor Proceed as follows 1 Disconnect the battery and motor and inspect the wiring thoroughly 2 Open the junction box and look for metal wires touching the case of the motor or junction box or touching each other This problem is more common in Wye connected motots 3 Look for evidence of sparking melting or overheating of plastic insulation and note any unusual or burning smells 102 3 SOLECTRIA 4 Motor winding resistance may be checked if a milli ohm meter is available Motor winding inductance can be compared to the expected value using an inductance meter Compare each winding in the motor to the others A to B B to C and C to A When you ate satisfied the motor wiring is in good condition install the junction box covet 5 Next perform a ground test Grounded Stator Sometimes a damaged motor will develop electrical continuity between the stator windings and the frame or shel
17. Rotor supplies 5V to turn LED on Led battery Low supplies 5V to turn LED on b Led Motion supplies 5V to turn LED on Led Malfunction supplies 5V to turn LED on b Digital GND Driving Current disable switch to GND disables drive but not regen Accelerator analog input 0 5V low brake high accel 5V analog Not all options are available on all models 141 3 SOLECTRIA Appendix K Appendices The list below gives you the translation of abbreviations used for the parameters that appear on your user data screen As Seen on Your Screen 0 Max Bat Volts 1 Max Fwd Speed 2 Min Bat Volts 3 Max Rev Speed 4 Max Pwr Mtr I 5 Brake Min Spd 6 Max Reg Mtr I 7 Brake Lt Curr comes on 8 Power Svr Pot potentiometer 9 Pedal MaxBrake Maximum Brake 10 Power Svr Min 11 Pedal Brake Brake 12 Power Svr Max 13 Pedal Accel Acceleration 14 Regen Bat Max 15 Pedal MaxAccel Max Acceleration 16 Shaft Dir clockwise 17 Speed Limiting 18 Bat Limiting 19 Brake Limiting Translation Maximum Battery Volt Maximum Forward Speed Minimum Battery Volts Maximum Reverse Speed Maximum Motor Current Brake Minimum Speed Maximum Regen Current Brake Lamp Current Power Saver Potentiometer Maximum Brake Power Saver Minimum Brake Power Saver Maximum Acceleration Regen Maximum Maximum Acceleration Shaft Direction Speed Limiting Battery Limiting Margin Br
18. The customer shall pay for the shipping cost UPS ground to return the unit s to Solectria For warranty repairs and replacements Solectria will pay the shipping costs UPS ground of returning the unit to the customer Solectria will not pay for the cost of rush delivery For the purpose of this warranty components include but are not limited to motors motor controllers DC DC converters battery chargers amp hour counters etc This warranty does not cover 1 Products that have been opened tampered with or modified in any way 2 Items defined as routine maintenance 3 Damage caused by misuse accident alteration lack of maintenance inadequate packaging or use of incorrect lubricants 4 Damage or corrosion caused by exposure to after market products the environment or chemical treatments and 5 Wear items including but not limited to extension cords plugs connectors cables and enclosures 6 Damage caused by improper parameter settings 120 SOLECTRIA Warranty In the event that it becomes necessary to return a product to us for setvice call ahead for a Return of Merchandise Authorization Number to help expedite the repair Any item being returned should be wrapped securely in the original or similar packaging to prevent damage in transit Use the following guidelines for packing your unit for return shipment Keep your shipping carton Your carton is specially designed to prevent shipping damage to
19. This may be seen in the limits to torque column If the battery voltage increases still further an over voltage fault will occur This will be noted in the status column If you see over voltage faults battery voltage has become dangerously high Total destruction of the power electronics section of your unit is possible If you are experiencing over voltage faults look into the cause immediately and have it corrected This caution applies especially to hybrid vehicles that contain other systems capable of charging or raising the battery voltage Initial Driving For high power systems typically those found on transit buses the batteries are charged to a very high voltage This improves overall electrical efficiency When the ignition key is first turned on and the accelerator pedal is depressed the drive system will start at reduced totque This causes battery cutrent to flow which quickly reduces the battery voltage Then full torque is applied The whole process takes about five seconds This action occurs only immediately after charging and does not happen during normal driving SOLECTRIA Fault Diagnosis Under voltage During driving the battery becomes depleted and battery voltage continues to drop This is true for all batteries A point is reached at which further discharge is likely to damage the battery or interfere with safe vehicle operation In accordance with battery manufacturers specifications battery
20. develop Be sure battery limiting is not set too low Typically it should not be set to less than 15V In this case the problem would tend to disappear after driving for a few miles If the oscillation occurs in one direction only say in reverse but not in forward suspect a speed sensor problem Other Causes During acceleration or regeneration the drive train of the vehicle will wind up to a certain extent Twisting of drive shafts flexing of motor mounts and tire side walls all contribute to the effect Suspension also contributes through reaction to drive shaft torque Due to this winding up effect a sudden change in torque can result in a sudden change of instantaneous rpm Symptoms of this effect are noted when regenerating to a stop and when accelerating at full power and moderate rpm When regeneration stops however the loss of regen torque allows the drive train to quickly unwind If enough play exists in the drive train motor rpm without regen which was s owing the motor will suddenly exceed brake minimum speed Thus regen will turn on once again The result is a slight shuddering which lasts about one second If objectionable brake minimum speed can be adjusted up or down slightly until the shuddering stops Before doing so check your tire pressure 112 SOLECTRIA Fault Diagnosis Regeneration at Low rpm When regenerating to a standstill rpm decreases until a point is reached at which the same amount of
21. drives the motor regenerative braking function Error detection citcuitry forward reverse selector position and pedal circuit supervisory status Pedal Error The UMOC s accelerator pedal circuit is fully supervised by the microprocessor This means if a malfunction or bad connection develops anywhere in the pedal circuit the microprocessor acts to prevent any further operation of the drive system If the drive system fails to operate and you see the words PEDAL ERROR or PEDAL FAULT displayed in the status column this means a wite has broken or short citcuited somewhere in the pedal circuit Do not operate the vehicle until the cause is discovered SOLECTRIA Fault Diagnosis Use the following guidelines to prevent an accident from occurring and to avoid compromising safety systems Investigate and repair all pedal error faults at once Do not connect unapproved third party pedals to the system Always shift to neutral before leaving the operators position Service or parking brakes must be applied in order for the vehicle to remain motionless Under no circumstances shall the hill hold function when equipped be used for vehicle braking or hill holding unless the driver is seated in the operator s position If erratic or undesired acceleration is detected discontinue operation at once and determine the cause Electrical If a pedal error 1s discovered look at the left most value on the
22. e While unplugging or fastening the connector use both hands Grasp the connector shells by the plastic cable strain relief at its base and not by the metal housing Speed sensor cable extensions must be completely shielded Cable shields must have good overall continuity Sensor cable plugs must not touch motor wire braid at any point SOLECTRIA Installation Once the9 pin encoder connection has been made between your motor and your UMOC you can then move onto connecting the 25 pin cable of your unit to your ignition box ot driver s console SOLECTRIA Installation 25 Pin Ignition Box and Driver Console Connections Now that you have mounted your UMOC and connected the unit to your motot you can next make the connection Ignition Box between your UMOC and your ignition box single drive and Console vehicles or driver console used in dual drive vehicles using the 25 pin cable link The UMOC was designed to operate with a Solectria ignition box or driver console only Do not attempt to remove any of the safety feature interfaces Follow all instructions and guidelines regarding the installation of your ignition box or driver console For those with dual drive systems read all of the information regarding issues specific to your requirements 3 SOLECTRIA Installation Single Drive Ignition Box Systems Your ignition or interface box should be located in a protected area such as underne
23. information 4 Write down the build date listed on the computer screen s banner line The build date refers to the release date of the software not to the date on which the unit was physically built AA The replacement unit should have the same build date if it is dual drive system AA Dual drive systems should not be operated with different software versions different banner build dates Premature wear of drive system components may result Installation CAUTION Once the unit is removed from the vehicle and disconnected from the battery it will impossible to read the software settings SOLECTRIA Installation AA For dual drive systems model software version build dates and parameter settings or configuration number must match otherwise the units will not share well Two like units with matching build dates and configuration numbers will give ideal performance For all other systems a matching date is preferred but not required Note Units built after March 31 1999 clearly state the software version number in the banner line Copying Parameters For two UMOC s with the same version softwate saved settings from one of the older units can be transferred to the replacement unit Follow the instructions in Appendix B and save a copy of the older unit s parameter screen settings to your computer Pefore installing the replacement unit Print a copy of the saved settings This way if the
24. on the mounting brackets The direction of rotation of motor shaft 1s set at the factory as a software parameter based on the customer order All units are set to clockwise or counter clockwise based on customer request When vehicle construction is completed it is quite often discovered that the opposite direction of rotation would be appropriate Shaft direction is easily changed with the user data screen Check your warranty before charging Use a computer with the HyperTerminal communications software and the information provided in appendix E Solectria recommends that you return the unit to the factory to have the shaft direction reversed Be sure to pack the unit properly to avoid shipping damage Grounding Your Motor and UMOC must not be removed ot loosened To minimize the introduction of noise resulting from poor grounds ground the motor and the UMOC to the vehicle frame See appendix I for grounding your UMOC SOLECTRIA Installation HIGH VOLTAGE WARNING READ ALL WARNINGS REGARDING THE ENCODER CONNECTOR The motor housing may be connected to the vehicle frame using a bonding jumper connected to a good grounding point on the motor frame You can ground your UMOC by placing a ring terminal under one of the four mounting screws Vibration mounts on the UMOC insulate the UMOC case from possible grounding To ground the case install a bonding wire from one of the UMOC mounting bolts to the ve
25. point where the low battery light illuminates may shorten battery life SOLECTRIA Fault Diagnosis Try to limit driving in such a way that the low battery light does not illuminate Reducing the setting of the power saver control when equipped or the Tri Power Selector will assist in preventing the low battery light from coming on Parameters For certain battery types including nickel metal hydride high battery current will cause battery voltage to drop quite a bit The result will be reduced performance even when the battery is not depleted This will be indicated by the illumination of the low battery light and will be indicated on the user data screen as a limit to torque based on battery voltage This condition may be improved by lowering the minimum battery voltage setting in the parameter screen Be sure not to exceed the manufacturers recommended limits Battery damage may result If a further improvement is needed the battery limiting parameter can be reduced slightly Use care when reducing the setting of the battery limiting parameter As battery limiting is reduced overall drive instability will increase Low values of battery limiting while increasing performance for some types of batteries will introduce shakes or shudders into vehicle operation especially during regeneration Systems that have a nominal battery voltage of 276 or greater use 20 volts or more of battery limiting Systems with nomi
26. prices Battery Interconnects Battery interconnects must be rated to carry the current listed in the table 1 Use the following guidelines when working with battery interconnects Note Always clean battery terminals before installing For lead battery terminals use a wite brush and No Ox grease and brush them until they shine No Ox grease will prevent oxidation after the terminals are brushed and will not interfere with electrical conductivity Installation CAUTION Avoid fuses with only an AC and not a DC rating WARNING The bolts of all cables carrying battery current must be torque tightened to the battery manufacturers specifications Failure to do so can result in the catastrophic failure of your system Also be sure to use lock washers at all such connections SOLECTRIA Installation Nye 9 Grease may also be used For terminal types other than lead follow the directions of the manufacturer If battery terminals are not cleaned prior to installation the oxide and any dirt on the surface will prevent a good connection Heating will result followed by more oxidation The terminal will then overheat and damage the battery Battery interconnect lugs must lie flat against the terminal Do not file or wire brush battery interconnect lugs Do not use washers in between the interconnect lugs and the terminal Use stainless steel bolts only Brass or copper bolts are too soft Follo
27. signs and signals will make diagnosis easy should a problem develop later Note For units shipped before June 30 1998 observable diagnostics may differ slightly SOLECTRIA Systems Check Figure 3 Photo of test box Connecting a Test Box WARNING Test Box Status light and Battery Indicators Ifa test box isto be used drive wheels Note Some customer units do not have battery indicators must be jacked up off ot have only a red battery low light and not a green the floor battery full light Observe all safety precautions 3 SOLECTRIA WARNING Never use a test box to operate a vehicle Using the test box defeats important safety features which WARNING Do not connect a test box if the drive wheels are touching the ground The drive may start suddenly and unexpectedly depending on test box switch settings WARNING Do not free spin any motor and drive train system faster than the Systems Check The status light on the test box normally colored yellow comes on at the following times During the self test After a malfunction Before the error detection circuitry is reset by the operating system The battery indicator lights low and high or full come on during the self test and remain on during the first part of the pre charge delay If a power bus malfunction has occurred such as a capacitor or IGBT failure that prevents completion of pre charge hi
28. size you may want to limit capture time to 15 or 20 minutes due to the high data rate File sizes will grow to several megabytes If you need to save your capture files to a floppy disk compression software is very effective Capture files can be compressed by a factor of 10 or more Emailed files that are sent to Solectria must be no more than two megabytes in size and compressed into a zip file 3 SOLECTRIA Test Drive 3 SOLECTRIA Test Drive It s best to do the initial driving tests with a laptop computer connected to the serial data port especially on a first of a kind platform Connecting Your Computer to Your UMOC Checking Cable Loop Back Test Serial Data Port If you know your communications software is working properly you can test your serial port and cable using the following method 1 Unplug the serial cable from the UMOC leaving the serial cable connected to the computer 2 Look at the free end of the cable you just disconnected You should see very small numbers inside the plug identifying the pin numbers 3 Connect a small jumper wire between pin numbers two and three of the serial cable connected to the computer 4 Try typing a few letters on the keyboard Each letter you type should appear on your computer screen If not your cable is bad or there is a problem with the serial port at your computer 5 Make sure the software is configured to use the correct serial port M
29. systems may not be tested with a test box unless the test box has first been modified to include the drive disable function While the drive disable function prevents motor operation it does not prevent the main contactor from closing Refer to the ignition box and console wiring diagrams in appendix C SOLECTRIA Fault Diagnosis Faults Related to Speed Sensor Cable The nine pin speed sensor cable connects the motor to the UMOC motor controller Motor speed direction and temperature values are reported to the microprocessor If the speed sensor plug is disconnected entirely or if one of the wires inside the cable becomes broken the motor will continue to operate at very low rpm If the motor spins very slowly or if vehicle speed will not exceed one mile per hour check the motor speed sensor cable and observable diagnostics as follows RPM Indication 9 Pin Encoder Speed Sensor Cable CAUTION Use the following procedures to determine if the motor speed sensor has stopped functioning Loose hair or clothing can become entangled in 1 Jack up the drive wheels and place the selector switch in rotating parts Also be the off or neutral position sure to keep control cables away from rotating parts 2 Look at the INFO column of the user data screen At or driveshafts Drive shaft the bottom you will see rotor 0 rpm parts can snag on loose cables causing severe damage 3 Turn the drive
30. the AA symbols at the left hand side of the page To test your dual drive system you can skip to the section titled Testing Your Dual Drive System SOLECTRIA How to Use This Manual Safety Your UMOC when attached to a power source contains voltages sufficient to cause severe personal injury Always use caution when operating near sources of high voltage Warning Labels Labels will be located on the right hand side of the page to indicate areas in a procedure where you should be taking appropriate precautions Labels include Safety Symbols CAUTION DANGER WARNING Indicates the risk of Indicates the risk of Indicates the risk of injury or causing being killed being killed or damage to your unit seriously injured Always use caution when working on or around any electrical equipment Wear eye protection at all times The following symbols will be located in the right hand margin of your manual to indicate sections in a procedure where extra caution and or safety equipment is required Hearing Protection Requited Eye Protection Required SOLECTRIA How to Use This Manual Risk of Electrical Shock Risk of Burns from Battery Acids CORROSIVE HIGH VOLTAGE 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 your Solectria Customer Service representative at the phone number
31. the interface box with a direct connection of customer equipment is not covered under warranty CAUTION the interface box or console Shipping Carton Keep your shipping carton Your carton is specially designed to prevent shipping damage to the metal case and cable connectors of your UMOC If the carton is lost Solectria will supply a replacement carton for a fee If the unit must be shipped immediately you must triple wtap it with large cell bubble pack and place it securely in a double walled corrugated carton for shipment back to Solectria Any repair costs for the unit that are associated with case damage due to improper shipment will be borne by the carrier or the customer and will affect your warranty SOLECTRIA Installation Tools Whether installing a new unit ot swapping out an old one you will need certain tools in order to install and test your UMOC These include e A laptop computer or computer with screen Microsoft HyperTerminal communications software A 7 16 socket wrench with extension A small flat head screwdriver Electric drill with a metal drill bit Use all safety precautions when using metal tools neat a source of electricity or making electrical connections and as always wear eye protection SOLECTRIA Installation Before You Mount Your UMOC Listed is a set comprehensive installation requirements for your UMOC When planning a new installation please consider all
32. the points below Your design will be a success if these installation and operation guidelines are followed Do not loosen any screws or hardware on the outside of the UMOC case Each fastener and grommet is carefully tightened with sealant during construction If fasteners are loosened or removed the factory seal will be lost Units received for repairs that have been opened by the customer will be ineligible for warranty coverage Do not drill holes into the case of your UMOC Use only the mounting holes provided Never remove the mounting brackets from the unit for any reason If the mounting brackets have been removed reinstall them with 8 32 stainless steel screws only Before installing holes must be covered with sealant Use only GE silicone type II sealant Do not use type I sealant Type I sealant emits corrosive vapors which are harmful to electronic components If ductwork must be attached to the air intake grills on top of the unit adhesive strips of Velcro may be applied to the fan housing The ductwork must be easily removable in order for the UMOC to be serviced Do not attach other vehicle accessories to the top of the vibration mounts The vibration mounts supplied with the UMOC are matched to the weight of the unit Besides transmission of unwanted vibrations attaching objects to the UMOC mounting bolts will make removal and installation difficult SOLECTRIA Installation When carrying installing or rem
33. to the 12 volt power supply Connecting 12 Volt Power to Your UMOC The signal that tells your UMOC to begin and cease operations is referred to as the keyed 12 volts This 12 Volt signal supplied when the ignition key of your vehicle is turned to the on position also serves as a 12 volt power source to your UMOC 12 Volt Power Connnector Cooling Fan 12 Volt Power Power for the UMOC cooling fan motors is derived from the keyed 12 volt input The keyed 12 volt circuit should be capable of supplying the maximum fan current anticipated CAUTION See the fan current table in the Specifications section heed 12 volt power to rise above 16 volts Doing so may damage the cooling fans 3 SOLECTRIA CAUTION Never connect any part of the main battery circuit to the vehicle frame or ground the main battery in any way Doing so will damage the internal filters of the UMCC and will blow internal fuse Voltage Range for 12 volt Power The range for the keyed 12 volt power is 11 16 volts At any voltage below 12 0 cooling fan power is reduced For an additional charge Solectria can supply UMOC s for vehicles with 24 volt electrical systems as a special order except certain models please contact the factory This refers to the vehicle s lighting and auxiliary power circuit and vot the main battery voltage of an electric vehicle Important Note Regarding Keyed 12 Volt Power The neg
34. type the number of the parameter you wish to change and press the enter key You will be prompted at the bottom of the screen to enter a new value There are limits to the numbers you can enter If the number you enter is outside of the limits you will be prompted again After entering the number the parameter list will reappear with the new value listed Parameters may be changed while driving This is a good way to fine tune a drive system All Solectria UMOC s ate set to a standard configuration What remains is to confirm that the configuration number of your unit matches the application Changing any parameters will change your configuration number to 0 and will void your warranty If you do not know your configuration number or if you want to change your patameters you may call the Solectria Customer Service Department Pre approved parameter configurations are available for auto downloading Have your serial number in hand before calling Special Note Regarding Configuration Number Equals Zero A unit where the configuration number equals zero is a custom configuration One of a kind units are often shipped with a unique parameter set not corresponding to any current standard configuration The drive parameters are carefully set manually and recorded to a log file for as built records Note If the customer changes any of the UMOC s parameters the configuration number is automatically set to zero at that time Onc
35. very short period the sensing the instability will shut down completely After such an interruption it will take approximately one second or more for the dtive to come back online This type of response is required in order to provide the fail safe function Fail Safe Function The keyed 12 volt signal provides the capability for rapid shutdown In an emergency situation driving signals to the motor may be completely interrupted by removing the keyed 12 volt signal When the keyed 12 volt signal is present all of the internal power supplies of your UMOC are operating Power supplies shut down when the 12 volt signal is not present In this way it is possible to safely remove all power and possibility of unwanted operation by removing the keyed 12 volt power from the 2 pin 12 volt power connector of yout UMOC To do this either turn off the key add an emergency stop switch and or other safety device to the keyed 12 volt power input line SOLECTRIA Installation Optional Internal DC DC Converter If vehicle supplied 12 volt power is not available the UMOC may be equipped with an internal 12 volt DC DC converter as an option The internal DC DC converter is capable of supplying modest electrical loads to typical automotive accessories such as head lamps and radios It also supplies power to the UMOC cooling fans Internal DC DC converters are only available on UMOC models series 340 and 440 The output curren
36. wheels or the motor shaft slowly by hand If both drive wheels are off the floor make sure only one drive wheel turns As the motor shaft begins to rotate the rpm display will change from 0 to nonzero rpm If the motor shaft is rotating and the rpm indication remains at zero the speed sensor has malfunctioned 4 Check the sensor cable for loose connections or damage SOLECTRIA Fault Diagnosis WARNING Do not the connector with tape This will trap moisture inside the connector if it becomes wet Improper speed sensor adjustment will cause one or more of the following e poor operation e drive instability e differences in operation between forward and reverse operation limited to a certain rpm e over current faults Some types of speed sensors require special tools to adjust It s best not to attempt adjustment of the speed sensor unless correct procedures can be followed Contact the Solectria Customer Service Department for assistance with speed sensor adjustments Motor Temperature Sensor If a problem develops in the motor temperature sensor circuit of the cable this will be displayed on the user data screen in the Limits to Torque column as Motor Temp 0 1 or Motor Temp 0 01 A motor with an open circuit or short circuit in the temperature sensor wires will have very little or no power See the section titled Faults Related to Temperature for more information Groundi
37. with a test box Never connect the test box unless the wheels are jacked up Switch on the keyed 12 Volt power with the test box connected If the test box lights come on briefly the microprocessor is running If the unit runs properly with the test box but does not wotk when connected to the ignition box the problem is in the ignition box cable the ignition box the direction selector switch or the pedal box Test the 25 pin cable from the UMOC to the ignition box or console Unplug the 25 pin connector at the ignition box or console and connect the test box at that point Remember be sure the wheels are free to rotate safely If the drive operates properly with the test box connected this way the 25 pin cable is most likely good A mote thorough test of the 25 pin cable is to perform a continuity check on each pin of the cable using a continuity tester cable tester or ohmmeter Note Systems with consoles do not have all 25 pins of the connector installed There will be no continuity on those pins that are omitted SOLECTRIA Fault Diagnosis Fans run Constantly For ambient temperatures above 30 degrees Centigrade the fans will run constantly This is a normal condition which provides maximum cooling at all times However if you know the unit is cold and the fans run constantly investigate further rude exenanged Some units designed for hot climates have the fans connected so that they will run continuously
38. 10 55 56 106 Replacement Unit 54 Rpm 115 RPM indication 93 RS 232 54 RS 485 54 safety 6 11 12 16 37 41 44 48 50 67 88 89 90 100 101 107 Safety Precautions 44 Saving and rebooting 56 Sequence of Power Up 65 153 3 SOLECTRIA serial data port 52 72 76 79 86 Serial Data Port 52 Serial Port Cable 53 Shaft direction 25 67 Shaft Direction 25 Shielding 53 Shipping Carton 15 silver plating 28 51 Single Drive Ignition Box Systems 32 Smell 103 Smoothness 78 Software Parameters 55 Software settings 73 Soldering 28 51 solid state relays 39 40 speed sensor cable 93 94 speedometer 6 78 Speedometer Calibration 78 Splicing Wires 27 Status light 63 Subminiature D connectors 124 Symptoms 83 112 System Requirements 14 Systems Check 10 59 test box 34 61 62 63 64 66 67 84 86 90 92 Test box 84 Test Box Switch Settings 64 Test Drive Index test light 82 83 Testing Dual drive systems 69 Tests complete 65 the user data screen 25 61 66 67 68 70 73 76 77 78 79 80 86 87 89 93 94 95 96 98 99 100 101 104 108 Tire pressure 113 Tools 16 Tri Power selector 48 Types of batteries 47 Types of Errors 105 Under voltage 98 user data screen 73 76 77 86 107 User Data screen 73 vibration mounts 17 19 20 Vibration mounts 26 Vibration Mounts 19 Vibrations 111
39. 2223 B z 920550550546 AE S seas 22 8813 88 e ss ets cen eese UMOC225 Discontinued 144V 140A 20 car 27 UMOC320T Discontinued 144V 240A 34 car 27 UMOC340 Discontinued 312V 210A 65 car 26 400V 180A 4 1 9A UMOC440 UMOC440F Discontinued 312V 325 240 40 26 UMOC425T 120 492y 90V 240V240A 45 car 28 250 UMOC440T 216V 312y160V870V559A 78 car 28 400V UMOC440TF 216V342 160V370V 250A 78 van 35 400V 250A 2 4 4A UMOC640 156V 312V 120V370V 400A 100 bus 55 400V 425A 2 4 4A UMOC645 156V338 120V370V420A 110 bus 55 450V UMOC340A gt UMOCA40T A Special 312V 180A 56 inverter 26 400V UMOC425T S Special 192V 180A 34 inverter 26 250V UMOC340S gt UMOC440T S _ Special 312V 180A 56 linverter 26 400V 250A 2 4 4A weight does not include cooling fans Available first quarter 2000 Motor Model AC10 ACgtx20 AC21 25 42 50 AC55 AC60 AC90 Peak Torque Nm 50 70 90 140 160 145 240 290 630 Max current A rms 200A 240A 280A 225A 240A 240A 250A 400A 400A Continuous Torque Nm 10 20 21 25 42 50 55 60 90 Continuous Power kW 5kw 12kW 13kW 16kW 21kW 30kW 34kW 36kW 57kW Peak Efficiency 88 90 9296 9196 9396 9396 9396 9396 9396 Motor controller UMOC425T AC325 UMOC425T UMOC425T UMOC440T UMOC440TF UMOC440TF UMOC640 UMOC645 Peak Electrical Power 17kW 34kW 37kW 30kW 75kW 78kW 78kW 100kW 110kW at voltage of 144V 144V 144V 144V 312V
40. 312V 312V 312V 336V Nominal Speed krpm 2 4 3 1 2 4 4 2 5 3 2 Max Speed krpm 12 12 12 12 10 10 10 10 6 Weight Ibs 40 70 86 104 133 198 234 248 440 Diameter in 7 6 8 5 9 75 9 75 9 75 13 5 13 5 13 5 15 5 Length in 10 11 5 12 13 13 14 5 16 17 17 18 18 5 22 Depending on end bells and options Table 2 3 SOLECTRIA Specifications The charts on the previous page show the size and capacities of currently available Solectria UMOCs In addition the chart also gives examples of the more common applications for individual units Features Your UMOC unit has been specially designed for maximum performance and reliability Other features of your unit include Self contained operation A high speed microprocessor Multilevel safety systems for user protection Unit swap out time of five minutes Programmable with ordinary laptop by user Self diagnostics monitor operation continuously Output short circuit protection except model 225 Air cooling which reduces the cost and complexity of your system Lightweight all aluminum construction Built in battery protection feature extends battery life A ratio metric speedometer pulse output signal that drives your electronic speedometer and includes an instant calibration feature Optional 3 SOLECTRIA Specifications Also included with your UMOC is an interface kit Please check with your Solectria Sales or Customer Service representat
41. 4 pin connector of the other UMOC If regen brake light function is restored continue to drive the vehicle this way Tag the first unit as defective with a repair tag and swap out the defective unit at a later time Operation is not Smooth This can be divided into two categories The first would be poor response to changes in pedal position The second would be drive instabilities related to certain operating conditions such as vehicle speed 109 SOLECTRIA Fault Diagnosis Figure 5 Pedal pot box Checking the Pedal Pot Pedal potentiometers Pedal Pots sometimes exhibit problems While a good potentiometer may last a lifetime poor quality units often fail at around 20 000 miles Use an analog ohm meter such as a Simpson 260 or a Solectria pedal potentiometer tester specialized equipment for sale or lease Contact Customer Service for details Unplug the pedal connector from the ignition box and measure the resistance as you vaty pedal position See Appendix F for instructions on how to connect an ohmmeter to the pedal connector The resistance should change smoothly Be sure to measure both sides of the potentiometer Change in pedal resistance either up or down must be consistent with the direction that you ate moving the pedal throughout the entire range If not or if the resistance change is not smooth replace the potentiometer 110 SOLECTRIA Fault Diagnosis Be sure to use the same type of potent
42. 8 connections 10 14 16 22 27 35 41 44 46 49 51 53 67 88 93 107 Connector Tips 27 51 console 15 28 31 34 35 66 69 82 84 90 91 92 100 Contact Does Not Close 66 contactor will not close 90 Control loop 113 Controller v 95 Cooling air 20 Cooling fan 83 Cooling Fan Operation 80 Copying Parameters 56 crimping connector tips 27 Current capacity 39 Current Shunts 51 Damage 21 48 64 100 Data Logging 70 79 delta wye 92 DESAT 102 106 Diagnosing Faults 77 Direct Connection 40 Direction Labels 67 Index direction selector 66 84 89 107 Direction switch 90 Discharging a battery 98 Drive System Performance 57 Drive disable function 92 Dual cables 69 Dual Drive Systems with Console 33 Dual Serial Ports 69 Dual Windows 69 Dual drive systems with direction switch error 90 Ductwork 21 Electrical 12 88 Encoder 26 67 encoder cable 26 36 encoder connections 67 Environmental 18 Error PAL 102 104 105 107 Error PAL OK 107 Excessive cycling of relay 101 External Fans and Blowers 21 Fail Safe function 37 fail safe function 37 100 Fan power cycle 65 Fans Not Running 82 Fans run constantly 85 fault diagnosis 25 60 77 86 151 3 SOLECTRIA Fault Diagnosis 81 Faults related to speed sensor cable 93 Faults Related to Temperature 95 Fuses 40 Fusing 49 G force limit 101 ground test 103 Gro
43. DC brush less traction drive and auxiliary drive motors Responding to all input sensors and commands your UMOC provides all the power outputs necessary to operate an over the road vehicle In addition to controlling the main traction motor yout UMOC sends the signals that control the dashboard displays and exterior signal lighting of the vehicle The UMOC is available in many sizes and configurations Size ranges from ultra light models designed for solar power racing cars to large commercial units capable of powering a city transit bus Other configurations supply 60 cycle three phase AC power for driving a standard industrial motor All units except auxiliary drives can use an AC motor as an alternator to generate or recover DC power switching smoothly under power from motor to alternator and back again whenever needed Since Solectria is confident in the craftsmanship of its products and because out components are engineered to work together for maximum efficiency and reliability we highly recommend that you use our motors and components when designing your vehicle s systems With Solectria s guidance you can easily customize your UMOC s parameters to respond to your systems changing requirements Your UMOC was built upon a foundation of experience that has come from over a decade of quality research and development In the unlikely event that you should encounter a problem with your unit or if you simply have a question Solect
44. ECTRIA Fault Diagnosis Pedal and Linkage Design In prototype electric vehicles the quick acceleration of the electric motor will cause the vehicle to accelerate away from the driver the mass of the driver causes them to stay still as the cushioned seat back accelerates toward them As the vehicle accelerates away from the driver the right foot comes off the accelerator pedal and the motor starts to go into regen mode As the vehicle slows the now moving driver continues to move and their foot reapplies pressure to the accelerator pedal starting a cycle of oscillation This pedal feedback is associated with light vehicles and vehicles with a poor accelerator pedal mechanical design This problem is best described as the same drive bucking feeling that one would expetience in a manual transmission internal combustion engine vehicle that occurs when the clutch pedal is released too rapidly Please use the following guidelines when installing and operating your vehicle s pedal potentiometer Be careful of excessive pedal linkage leverage This causes small foot movements to have a great effect on acceleration Avoid pedal locations that require the driver s leg and or foot to be fully extended The more the driver s knee is over their heel the better Pedal linkage kinematics start at the drivers hip and not at the pedal The lighter the vehicle or stronger the drive system the more pedal travel is required to prevent th
45. Motor Connector 25 Pin Ignition Box and Console 9 Pin Encoder Speed Sensor Connector Regen Brake Lights 12V Power Connection Connector Motor Power Wires The three color coded wires red white and blue or other similar colors connect to the motor For correct operation the colors must be matched red to red and so forth If during motor wiring or installation two of the three wires are reversed the motor will not operate This is known as Phasing 24 SOLECTRIA Installation Motor Phasing All UMOC s and Solectria motors have been phased properly and motor wire connectors are color coded before leaving the factory Use the color coded plastic connector housings to identify wires For wires without connectors wires are identified by color bands or by tags reading Blue Red or White for example Unlike standard industrial 3 phase motors the direction of rotation is controlled by the microprocessor and cannot be reversed simply by exchanging wires except for UMOC s without sensors Important to facilitate testing and repair the colors and ordering of the controller wires must not be changed Units received for repair with the colors and or wires out of order will be reset to the original configuration so that they can be tested Make any required changes to the motor wires not to the controller wires Special Note Regarding Motor Shaft Direction The small screws
46. OC drive motor controllers The Tri selector switch and the regen brake disable switch are hard wired to the ignition box contact Solectria if you need to separate either of these from the ignition box The throttle pedal 5 K Ohm is wired to the ignition box using a 10 or 3 Pin Packard connector depending on the accelerator potentiometer used The charger ignition disable is wired to the ignition box using a 4 pin Molex connector Keyed 12V DC is connected to the ignition box using a 2 Pin Packard connector The drive motor UMOC controllers are wired to the ignition box using 25 Pin D connectors The reverse lights are wired to the ignition box using a 2 Pin Deutsch connector The 12VDC accessory switch is wired with standard automotive blade connectors The Drivers console is not user serviceable and any attempt to open or service will void all applicable warranties Mounting of the driver s console is left up to the installer Solectria recommends that any mounting holes be drilled in the aluminum parts CAUTION Be sure to use drill stops to protect wires plugs and switches from aluminum chips drill bits and punches Appendix C2B Driver s Console Dual drive shown 132 XE SOLECTRIA Appendices I to Accelerator Pedalwith 5K Potentiometer 2 Pin Packard 1 Connector to Keyed 12VDC Harness 133 SOLECTRIA Appendices Appendix D Break light Relay Connections APPENDIX D
47. RIA Fault Diagnosis SOLECTRIA Fault Diagnosis Fans Not Running To conserve energy and fan life the fans stop running whenever heat sink temperature is below 30 C If the unit appears to be dead and the fans are not running make the following three checks Battery Voltage Verify that battery voltage is present at the battery connector 12 Volt Power Verify that 12 volt power is present at the 2 pin 12 Volt connector using the procedures directly below Disconnect the two pin connector for the keyed 12 volts at the UMOC and Connect a test light to the vehicle side of the cable Turn on the ignition key The test light will come on if 12 Volts is present at the connector A voltmeter is not a good choice for this job It does not present a load to the keyed 12 Volt circuit A small leakage current will cause the voltmeter to indicate 12 volts when in reality there may not be enough current available to operate the motor controller Use the same technique to also test the 12 Volt power supplied to the ignition box or console SOLECTRIA Fault Diagnosis Using the fan assembly to test the keyed 12 volt CAUTION power If a 12 Volt load or test light is not available the keyed 12 Volts cable can be plugged into the fans to do a test Carefully disconnect the fan power connector on the side of the fan housing most models and plug the keyed 12 Volt correct order before supply directly into the socket on the f
48. Voltage bus error 66 Voltage range for 12 volt power 36 Voltage ratings 41 voltmeter 45 48 61 82 98 warranty v 15 17 18 21 46 48 64 100 Warranty 119 120 water 18 22 45 124 water cooled motors 22 154
49. adapter if possible and proceed as follows Before connecting the serial port cable note the color of the plastic connector body on your UMOC s case If the color is black connect the cable directly If the plug color is white a null modem adapter or null modem cable must be used otherwise no data will be received Black plugs are currently being used in production Therefore no null modem adapter is needed On Charge Voltage When a vehicle is on charge the battery voltage naturally goes up This is true for most batteries Motor controllers are set at the factory to operate over the range of voltages normally expected including voltages experienced immediately after charging However battery voltage while in the process of charging may exceed the maximum voltage allowed during operation This aspect should be a consideration during system design not fault diagnosis Never attempt to operate the motor drive while the battery is being charged The charger disable circuit is provided for this reason It protects the motor control from being exposed to voltages which are dangerously high Some implementations may present excess battery voltage immediately after charging 3 SOLECTRIA Systems Check The microprocessor reading data from the internal precision voltmeter will respond by reducing motor current under the circumstances until the voltage falls within the operating range protecting the controller from damage M
50. ake Limiting 142 Notes upper regen limit RPM x 1000 lower drive limit RPM x 1000 to the motor Amps peak speed at which regen shuts off from motor Current level at which lamp value of power saver of pedal movement for Drive motor Current of pedal movement for Drive motor Current of pedal movement for Drive motor Current of pedal movement for 1 clockwise 1 anti 3 SOLECTRIA 20 Vel Damp tau 21 Low Cur Slip 22 Acc Damp tau 23 Slip 300 pkA 24 Damp viscocity 25 Max Sync Ind 26 Id Slew Limit 27 Max Leak Ind 28 Iq Slew Limit 29 50 Ind Cur 30 Dq Slew Limit 31 Configuration 32 Eff IGBT Res Appendices Acceleration Damp Low Current Motor Slip Drive Viscosity Constant High Current Motor Slip Drive Damping Viscosity Maximum Synchronization Inductance Slew Limit Maximum Leakage Inductance Slew Limit Induction Current Slew Limit Configuration Number Efficient IGBT Resistance 143 SOLECTRIA Appendices Appendix L Crimping Preventive Maintenance Damaged connectors contacts and cables may present hazards resulting in inefficient battery and charger operation To avoid these problems conduct the following maintenance checks at least once annually When you see a problem take corrective action immediately 1 Dirty Connectors When engaged and disengaged the crown contact surfaces of Anderson SB Connectors over wipe thus providi
51. al battery pack in use When the battery becomes depleted during operation motor torque is limited by the UMOC s operating software to prevent battery damage During charging battery voltage may increase beyond the operating limits This is permissible as long as charging voltage does not exceed ratings Please refer to the table in the Specifications section SOLECTRIA Installation SOLECTRIA Installation Safety Precautions There are important guidelines that must be followed when operating on or near batteries or any source of electricity Read all of the following safety precautions before beginning work on your battery pack Use insulated tools and always give electricity the respect it deserves High voltage battery packs can Kill Use an approved face shield when making connections When replacing a connector housing remove and re insert only one pin at a time That way the pins will not come in contact with each other Never connect any terminals of a battery to the vehicle frame as is commonly done with 12 volt vehicle power All exposed metal surfaces carrying battery current such as fuses terminals shunts switches and the like should be placed beneath a protective cover ot inside an insulated box All battery wiring components mentioned directly above must be properly sized and rated to safely carry the maximum current that will flow through them Bare metal surfaces carrying opposite polar
52. an housing Turn on proceeding the ignition key If the fans run 12 volts is present Be sure to put the plugs back in the correct order before proceeding Note On UMOC 200 series 600 series and 800 series units the fan connector plug is not accessible from the outside of the fan housing Use a test light instead Symptoms Itis best to locate and repair any problems with the keyed 12 Volt circuit whenever it is even remotely suspected of being the cause of a problem As mentioned power interruptions as short as a few milliseconds may cause the UMOC to shut down and restart This can result in serious vehicle performance problems Using an Auxiliary Battery to Test the UMOC 12 Volt Power Circuit If you suspect problems with your 12 Volt system the CAUTION UMOC can be tested by connecting it to a 12 Volt battery The minimum recommended size is 12V 7Ah If a short citcuit is The battery must be able to supply the cooling fan current for present UMOC the duration of the test Cooling fan current can be as high as internal wiring will 7 amps Be sure to have an inline fuse size 10 amp in series be damaged ifa with the test battery If a short circuit is present UMOC fuse is not used internal wiring will be damaged if a fuse is not used with the with the test battery test battery SOLECTRIA Fault Diagnosis Test Box If all voltages are present and the unit still appears to be dead try operating the unit
53. any computers have more than one serial port Keep experimenting using this method or try a different computer until you get things working 3 SOLECTRIA Test Drive Note This method will work for either a straight through ot null modem cable Software Settings It won t be possible to see the banner line or communicate with the UMOC unless the communication settings are correct See Appendix E Adjust the communications software to the following settings 38400 N 8 1 or 38400 8 N 1 The User Data Screen After the banner line appears on your computer screen press the Enter key on your laptop The user data screen will appear Some units require a password to see the user data screen Press Enter to clear the password buffer then enter the password Make sure CAPS LOCK is off Your password must be entered exactly If there is no response try again The Parameter Screen If the unit operates but feels weak or performs poorly in some other respect check the parameter screen to make sure the settings are correct Solectria keeps records of parameter settings for each unit that leaves the factory Also there are many standard configurations See appendix E Remember changing your parameters can void your warranty call Solectria s Customer Service Department for details 3 SOLECTRIA Test Drive The parameter screen lists the settings that can be changed by the user To change a parameter
54. ar plastic face shield or safety goggles Error PAL OK or lt lt none gt gt If this message appeats on your user data screen there are no etrots detected by the Error PAL Motor Turns Very Slowly With the drive system selector in Neutral or Off spin the motor shaft to determine if the motor is free to rotate raise the drive wheels off the ground If the motor cannot be rotated check for a mechanical problem with the drive Also be sure to release the parking pawl or parking brake if equipped Note some systems incorporate a parking brake which is automatically applied when the direction selector is switched to Neutral and possibly in other conditions as well Perform the following tests if the motor is free to rotate but spins very slowly when powered by the drive system 107 SOLECTRIA Fault Diagnosis DANGER Keep loose hair and clothing away from rotating parts No rpm Indication With the drive selector in Neutral spin the motor shaft by hand while watching the rpm display in the info column A constant rpm of 0 indicates a bad motor speed sensor or sensor cable If the rpm display is working proceed to the next test Limits to Torque If available motor torque is very low check the limits to totque on the user data screen Check the pedal torque value in the info column In the parameter screen check the parameter values against ones known to be correct It
55. ath the dash of your vehicle It should also be kept dry at all times When all wires are attached and checked connect the 25 pin cable from the ignition box to the UMOC See appendix C for details SOLECTRIA Installation Drivers Console Back Side d to Accelerator Pedal with SK Potentiometer AA Dual Drive Systems with Console Regan Brake TriSeleetor Dissable Switch witch 33 SOLECTRIA Installation Connect and check all console wiring then choose a good mounting location close to the operator s position such that the console controls may be reached comfortably by the operator Avoid locations where any liquids spilled from a neatby drink holder may enter the console Also avoid areas neat a window which might be left open to admit rain After installation connect the 25 pin cables one to each UMOC motor controller Special Notes for Dual Drive Systems with Consoles AARe Cable Interaction If you are operating a dual drive system and wish to test an individual UMOC motor system separately you must disconnect the 25 pin cable from the system not in use Otherwise if the disabled system is powered down or malfunctioning this will affect the working system through interaction between the two units via the 25 pin cables Operating the console with one system only will also affect pedal position response For any pedal adjustments or repairs be sure both 25 pin cables are connected Connec
56. ative wire of many 12 volt vehicle accessories is often connected to the metallic vehicle frame Conversely many 12 volt accessoties have the negative input wire connected to its own metal case For this reason never use a section of the main vehicle battery of an electric vehicle to supply 12 volts accessory power This will unbalance the main battery causing it to fail In addition it creates a hazardous condition Be sure not to use the motor shell or UMOC case for a grounding point for other electrical accessories For example your motor s cooling blower motor negative return must be connected by a separate wire to your vehicle s frame or to a proper ground point It also must not be connected to the motor case for a ground If this should happen blower motor current or short circuit current can flow through the encoder cable ground conductor This can damage the cable ground circuit or introduce noise into the encoder signal The result will be a malfunction of the drive system In all cases 12 volt accessoties must be grounded separately to a good vehicle ground and not grounded to the drive system Installation SOLECTRIA Installation Brownouts The circuit used to supply keyed 12 volts to the UMOC should be a clean stable source of power Large variations of voltage on the keyed 12 volts signal line will result in erratic operation of the UMOC as follows If the keyed 12 volts signal drops below six volts even for a
57. auses excess current to flow Connecting a UMOC configured for one type of motor to a different type of motor may cause an over current fault If in doubt look at the UMOC nameplate to determine motor type or call Customer Service for assistance The over current faults produced by the two problems above cause the drive to shut down Investigate the cause and solve the problem before continuing 106 SOLECTRIA Fault Diagnosis Over voltage error An ovet voltage ertor is a very rare error caused by connecting the unit to the wrong type of battery system It may also be caused by malfunction in hybrid generating equipment A third possibility would be loose battery connections Whenever regeneration is being used most UMOCS use the regeneration feature it is very important to maintain good connections to the vehicle battery If not this or the other two conditions mentioned here will cause the input voltage to rise to a dangerously high level The cause of this error must be determined and corrected Units subjected to over voltage may be seriously damaged Stay well clear of the UMOC area if you are working on a hybrid vehicle that is a vehicle with on board generating equipment and you are investigating an over voltage situation Disconnect the motor controllers until the problem is corrected As with all high power systems always wear the proper protective gear when working near energized equipment for example a cle
58. cedure is inconvenient see the data logging section below 3 SOLECTRIA Systems Check AA Testing Dual Drive Systems For dual drive systems it is very important to test the operation of each drive separately before testing them together If both drive systems operate perfectly alone but not together it is possible to monitor both user data screens at the same time This occurrence is rare and a problem with the control console should be suspected AADual cables The minimum requirement for monitoring two drives at once is to have two serial cables Plug in the cable of the drive you wish to monitor into the laptop Important Reboot restart the UMOC microprocessor by pressing Shift B before disconnecting the cable This way noise pulses generated when this connecting the cable will not send an arbitrary command to the UMOC AADual Serial Ports It s much better to have two serial ports on the laptop Connect one drive cable to each port AADual Windows It s possible to open two windows of your communications software and configure one window for each serial port You can then see and log data from both drives at the same time 3 SOLECTRIA Systems Check Data Logging If you have trouble giving the user data screen your full attention you may also log setial data to a capture file Configure your communications software to capture the text coming from the serial port Because of restrictions related to file
59. computer file is lost it can still be possible to configure the unit properly using the printed information Comparing Parameter Files Compare the file you have just created to your paper printout of the older unit s settings Check each parameter to make sure there s an exact match Make sure the parameters are numbered the same for each file Once you are certain the two files are the same the auto programming files see appendix E can be used to program one or more UMOCs Saving and Rebooting If everything goes as planned and auto programming is successful be sure to save the new parameter values by wtiting to the memory The procedure for writing values to long term memory is covered in appendix E 3 SOLECTRIA Installation Checking Drive System Performance It is a good idea to test drive the vehicle after downloading new parameters Once you are satisfied with your vehicle s operation save the new parameters to long term memoty Save the current settings to disk and write down the configuration number of your unit 3 SOLECTRIA 3 SOLECTRIA Systems Check Systems Check 3 SOLECTRIA Systems Check CAUTION Never attempt to operate the motor drive while the battery is being charged Cable Adapters UMOCSs with model serial numbers in the low 100 s require a null modem adapter when installing the serial port cable depending on the color of the data port connector Use an insulated
60. current is reduced when voltage approaches the limiting value Finally a battery voltage is reached at which torque and battery current equals zero On the user data screen this can be noted in the limits to torque column Additionally battery voltage is displayed in the info column This is a very accurate measurement The UMOC motor controller incorporates a precision volt metet which is carefully calibrated at the factory and cannot be re calibrated in the field Note A battery voltage calibration check cannot be performed unless the contactor is closed If you can hear the contactor close and an external volt meter is known to be in good calibration disagrees with the voltage reading on the user data screen by more than 3 return the unit for service The internal voltmeter is factory calibrated to within 0 1 volt at operating voltage For systems with a nominal battery voltage of 200 volts or higher if the reading on the user data screen is within 3 to 5 volts of the actual battery voltage as measured at the UMOC s battery connector with the contactor closed and motor a current of zero it should be considered calibrated Low Battery Indication If the low battery indicator light when equipped illuminates the UMOC has begun to limit torque based on battery voltage measurement The result will be reduced performance Return to a charging station and charge the battery as soon as possible Discharging a battery beyond the
61. dditional caps are available from Solectria part DB 9 F dust cap or from Radio Shack SOLECTRIA Installation Cable Types When connecting to the serial port you must use a straight through cable Do not use a null modem cable Nu modem cables have internal connections that may be harmful to the unit and no data will be received If in doubt test the cable with an ohmmeter before using Each pin on one end of the CAUTION cable should connect have continuity to the same numbered pin on the opposite end of the cable Do not use a null Only certain early model UMOC s that have white colored modem cable for your data connector require a null modem adapter or null modem Solectria data port cable connection Shielding Serial Port Cable While not absolutely necessary the serial port cable should be shielded with an internal metal foil or braid All good quality computer serial cables are shielded Do not use homemade cables Operating the unit with an unshielded cable will introduce noise into the serial port connection may cause data errors poor performance and unpredictable response Warning Regarding Grounding the Serial Port Cable When installing and testing a new system for the first time it is best to use a portable computer running off battery power Do not ground the cable at the UMOC The metal jackscrews on your UMOC s case are grounded to the case It is a good idea to use a cable with a p
62. ds on an improperly crimped barrel will be loose and will not have adequate clamping force Test for low pull out force by giving the cable a tug If the cable can be loosened recrimp until it is tight ly Crimped Improperly Crimped Pneumatic Crimp 4 Soldering Contains air pockets The alternative to crimping is to solder all cable strands within the contact barrel The right proportion of solder is essential if this procedure is employed Use a quality 60 40 solder 60 percent tin 40 percent lead in wire form with a rosin flux core Cable strands should be separately fluxed with rosin paste and the contact should be held in a vise with the barrel entrance facing up Apply heat to the outside of the barrel while the solder flows in beside the wire strands Here are some things to avoid when soldering A Don tuse too much solder to the point that it flows out of the contact barrel B Don t allow flux or solder on the outside of the contact This will interfere with contact mounting within the installation or with the contact connection to a mating connector C Don t overheat and cause excessive solder to wick up into the cable an stiffen it This could interfere with contact flexibility when connectors are mated D Don t solder when contact is in the connector housing Solder away from the housing and then insert the contact into the housing NOTE Underwriters Laboratories UL requires the use of a cable clamp for
63. e changes are saved to long term memory it will not be possible to re establish the configuration number even if the parameters are changed back to their original values This is done to prevent the occurrence of standard configurations with any incorrect parameters and can affect your warranty The only way to re establish the configuration number is to auto download a standard parameter file See Appendix E 3 SOLECTRIA Changing Your Parameters Small gradual changes are better than large changes Some parameters may interact slightly It is a good idea to write down before and after values when changing or fine tuning parameters Many parameters are set at the factory to their ideal values and any departure will result in reduced performance Note that the changes you make will disappear once the power is turned off To make the changes permanent it is necessary to write long term memory See Appendix E Remembet the following when changing your UMOC s parameters Once you write long term memoty previous settings are lost Setting incorrect parameters results in poor performance or erratic operation Incorrect parameter settings may damage batteries motors or the unit itself This will affect your warranty Incorrect setting of brake light current may result in a vehicle accident AA Pedal settings affect load sharing on dual drive systems and therefore must be the same on both UMOCs Choosing Pa
64. easuring Battery Voltage After connecting the UMOC main battery plug carefully measure the battery voltage using a voltmeter To do this it is often possible to insert the voltmeter test probes into the back of the battery connector If uncertain of proper procedure skip this step Once you have established communication with your UMOC you can read battery voltage by looking at the user data screen on your computer Turning on Your Keyed 12 Vol ts Sys tems Hazardous voltages are present inside the main battery plug The term Keyed 12 volts refers to the current that powers your 12 volt accessories and is started by turning your vehicle s ignition to the ON position Make sure that your ignition switch is in the OFF position Before turning on the keyed 12 volts have either your test box and laptop or other computer connected and in an observable position or have the battery level indicator and or status lights if equipped within view if a computer is not available 3 SOLECTRIA Systems Check Observing Your Vehicles Diagnostics Diagnostic tests require about 2 seconds and may be observed by the operator via your vehicles LED read out lights dash systems or your test box When your keyed 12 volts system is first switched on the UMOC will power up and begin diagnostic tests When all tests are completed motor drive operation can begin Familiarizing yourself with these outward
65. ecember 31 1998 require the direction selector switch to be in Neutral or Off before the contact will close If Contact Does Not Close Please check the following before assuming that there has been an internal malfunction of your UMOC Pre charge the capacitors have not been given time to charge Neutral interlock the direction handle is in forward or reverse Charger is on the contactor won t operate if the charger is connected to AC power 25 pin driver cable cable has become loose or disconnected Keyed 12 volts the keyed 12 volts is not on or fuse is bad Keyed 12 volts no 12 volts at ignition box or console Power switch the test box switch is not on when using a test box Voltage bus error The battery voltage is too high or too low to allow operation 3 SOLECTRIA Motor Spin Test After the contact closes try spinning the motor Lift the drive wheels off the ground and make sure that your vehicle is safely supported Using the selector switch choose forward reverse Depress the accelerator pedal slowly more and more until the motor starts to spin You will need to press it more than halfway Shaft Direction Occasionally due to transmission and differential gearing drive wheels will turn backward when the selector lever is in forward This is no cause for alarm Shaft direction is easily reversed Through software See your warranty or cal
66. ended motor cooling Light duty 200 250 cfm 6 inch diameter brushless fan Example 2500 car with AC21 with 120 F thermal switch fastened to motor motor case Switch type close on rise Medium duty 400 500 cfm blower providing actual airflow Example Truck or bus with of 300 cfm Fan should run continuously In AC42 or AC50 cold climates a thermal switch must be added as above Heavy duty 700 1000 cfm blower with actual airflow of Example Large vehicle with 600 800 cfm Blower should run AC60 motor continuously whenever vehicle is in use Problems with Overcooling Very high airflow rates can allow the motor to operate at full power for a prolonged period This can result in overheating of the rotor In this situation you should consider choosing a larger motor or a supply of cooling air for the internal rotor The internal rotor is not protected electrically from overheating like the stator windings If the stator windings should overheat during prolonged high speed driving or hill climbing temperature sensors embedded within the stator windings will signal the microprocessor to reduce the motor power In many driving situations this will not be noticeable but the installation should be planned to minimize the occurrence Some traffic operations requiring bursts of brisk acceleration may be adversely affected by reduced power SOLECTRIA Installation Anderson Battery Connector 3 Pin
67. energy is being used as is produced Thus it is not desirable to regenerate down to zero rpm Besides wasting powet this would cause the vehicle to stop abruptly A much smoother solution is afforded by setting the brake minimum speed parameter to a comfortable value Typical values range from 200 to 400 rpm Control Loop Under hard acceleration and full power some drive trains exhibit the tendency to wind up to such a degree that the internal damping software is overwhelmed and an oscillation may develop Normally increasing the damping level will smooth out the oscillation It is also possible to increase the damping to a level that makes the problem worse If your Solectria drive system has trouble with oscillations please contact the factory for assistance Tire Pressure An important factor when dealing with oscillations is tire pressure The lower the tite pressure the more the tite side wall will be allowed to flex and the worse instabilities will become Always inflate tires to the maximum pressure listed on the side wall to give maximum vehicle range and avoid problems with oscillations Changing to a different brand of tire may also help Fuel saver tire types are recommended While it s true that heavier side walls may be more resistant to flexing the only way to find out is through trial and experiment Contact Solectria for recommendations about choosing tires likely to yield a satisfactory result 113 SOL
68. er eNote About Limits to Torque All values in the Limits to Torque column represent a multiplier that is used to calculate resultant torque from the desired torque commanded by the operator via the accelerator pedal The lower the multiplier the lower the resulting torque value Values range from 1 0 for full torque to 0 01 or even 0 0 for little or no motor torque Multipliers are compared by the microprocessor and the minimum of the values is used as a multiplier for output motor torque Faults Related to Battery Voltage If the battery voltage is too high or too low the drive system will not operate Because the UMOC motor controller was designed for maximum possible electrical efficiency it s best to operate it within the voltage limits for which it was designed SOLECTRIA Fault Diagnosis Over Voltage Your UMOC will limit torque whenever a battery over voltage condition exists This is most common during regeneration when power directed into the battery tends to raise its voltage This protects the battery from damage Maximum battery voltage is carefully set at the factory and may be adjusted by the user in the parameter screen See your warranty regarding changing parameters Use care when adjusting the maximum battery voltage Refer to battery manufacturers data to determine what voltage level the battery may safely handle In addition your unit will stop operating if the input voltage is too high
69. er demand Please contact the factory for information on customizing your data interface for high volume sales applications if RS 485 or other data interface is needed Swapping your UMOC for a Replacement Unit If a UMOC malfunctions the factory will ship a pre programmed matching unit for direct replacement Installation is as simple as bolting the unit down and connecting the power and sensor plugs 3 SOLECTRIA Use the following procedures to check the parameters of your existing UMOC so that they be compared to those of your replacement unit before installing After installation you can either download the saved parameters from your older unit or go ahead and operate your system if the parameters of the newer unit already match If this 1s a first time installation go to the section titled Mounting Your UMOC in the Installation section of this manual Checking Software Parameters 1 Connect a computer to the serial data port of the unit you are replacing 2 Be sure you are swapping out a like unit model or one that is compatible with your drive system The UMOC s model number and recommended motor type for operation are found on the unit s nameplate In some cases it will not be possible to use a UMOC with a different type motor unless the unit is first returned to the factory for modification 3 Use the directions given in appendix E to hook up your computer to your unit and find the necessary
70. fessionally crimped may be soldered to insure a good connection While soldering position the pins so that solder does not drip down onto the contact area If it does wipe clean with a wet sponge before the solder solidifies After soldering clean any remaining flux residue from the pins using a cloth moistened with alcohol Avoid scraping or brushing the pins with a metallic object because this will remove the silver plating Connecting Your UMOC to Your Motor After following all of the guidelines for setting up your motor and your UMOC you can now connect the two units together To make the connection simply push the three phase red white and blue connector pins from the UMOC to the matching red white and blue connectors of the motor From this point you can connect your ignition box or driver console systems SOLECTRIA Installation 9 Pin Encoder Speed Sensor Connection The 9 Pin encoder or speed sensor connection allows your UMOC to monitor the speed direction and temperature of your motor Warnings Regarding the 9 Pin Encoder Speed Sensor Cable and Grounding Since high voltages can develop on the encoder cable follow 9 Pin Speed these warnings Sensor Connector e Prevent the possibility of electric shock by switching off the motor controller completely before connecting or disconnecting the encoder connector e Do not handle the encoder speed sensor connector while the motor is running
71. from rotating parts or driveshafts Drive shaft parts can snag on loose cables causing severe damage 3 SOLECTRIA Systems Check Phasing If the motor shaft will not spin but wiggles or turns very slowly exchange any two of the motor wires not the controller wires This method applies to induction motors only The need to do this is extremely rare except for motors that have been customer replaced or worked on Complete drive systems ate always shipped from the factory with correct phasing because they are tested for operation before shipment Monitoring the User Data Screen While Driving If a problem occurs while driving enlist the services of a helper who can watch the screen while you drive If a helper is not available and the drive system shuts down use the following procedure If the drive system shuts down while holding the accelerator down continue to press the accelerator to the floor without releasing it If operation doesn t resume keep your foot to the floor and shift into neutral or off Carefully pull over to the side of the road braking with the left foot Apply the hazard warning lamps and parking brake After determining that you are in a safe location study the user data screen As long as you hold the accelerator down fault codes will be saved This is an easy way to diagnose a problem quickly Be sure to choose a lightly traveled road where it is safe to pull over If this pro
72. from prolonged elevated temperatures will be evident This will affect your new product warranty coverage Any ductwork used to supply cooling air to your unit s fan air intake grilles must have a cross sectional size at least as large as the fan intake grille itself For example a single 5 inch fan should be supplied through a ductwotk having a cross section of no smaller than five inches Two 5 inch fans would require a duct of at least seven inch diameter cross section and so forth Because of the changes in ait static pressure resulting from ductwotk airflow is reduced Length of the ductwork should be kept to a minimum Do not restrict airflow by adding louvered grilles unless the louvers are fixed in the full open position External Fans and Blowers Your UMOC controls the power to the cooling fans mounted on the top of the unit When cooling is needed for the unit s heat sink fins the fans are switched on by the unit s internal microprocessor If external fans or blowers are needed these fans must not be connected to the UMOC fan power cable The external fan or blower motors should be connected to the vehicle s 12 volt system directly If you wish to control external fans or dampers with the UMOC fan power signal Solectria can supply a fan relay kit for an additional charge Damage to the unit from the connection of external fans or blowers to fan power outputs are not covered under warranty SOLECTRIA Installation
73. g drive 1 Remove the 25 pin cable from the malfunctioning drive If in doubt or if the console does not have status lights try one and then the other Once the 25 pin cable has been disconnected from the malfunctioning drive it will be possible to operate the vehicle using the remaining working drive only Avoid hard acceleration if possible to reduce stress on the drive system while the vehicle is being driven back for service After the malfunction has been cotrected be sure to reconnect the 25 pin cable SOLECTRIA Fault Diagnosis Charger Disable When the vehicle is being charged a signal is sent to the ignition box or console to prevent operation of the drive system Besides protecting the motor controller from exposure to high charging voltages this prevents the vehicle from being driven away with the charging cord still connected Many vehicle owners unable to get the drive system to operate have later discovered the charging cord connected to the vehicle For this reason it is better to install the charging socket on the same side of the vehicle as the driver s door If this isn t possible then locate the charger status lights in a position observable by the operator Drive Disable Function All vehicles equipped with A Y delta wye switching include a drive disable function Transit buses with electrically operated doors may also include this function This signal is on pin 11 of the 25 pin cable These
74. gh and low lights will both remain on Nearing the end of pre charge when internal voltages are within the range of normal operation and at all other times only one or neither will light The purpose of the test box is to troubleshoot a malfunction or verify operation of a new drive Please follow all directions for the use of your test box closely and read all warnings before connecting and operating Test Box Switch Settings Before connecting your test box e Place all switches in the off position Be sure the drive wheels are free to rotate Connect your test box to the 25 pin cable Note Do not use a test box to spin a brush less DC motor unless the vehicle drive train is connected The drive train components provide an inertial braking action that will prevent the motor from over speeding If a brush less DC motor is operated without a load test box settings may cause a sudden increase in rpm at top speed which can destroy the motor Damage of this type is not covered under warranty 3 SOLECTRIA Systems Check Sequence of Power Up Connect the battery plug on the UMOC to the battery pack plug Include an appropriately sized fuse in the battery circuit Power on Self Test When ready turn the key on Self test will begin You may observe the following e Fan Power Cycle Cooling fans will spin very briefly Note with some brands of fans the fans will not spin during self test every time e
75. hicle frame Be sure to use a toothed washer to penetrate the anodized coating on the mounting bracket For vehicles with nonmetallic bodies the motor and controller cases may be bonded to one another with a jumper wire A signal ground is provided through the encoder cable Warnings Regarding the Encoder Connector and Grounding Since high voltages can develop on the encoder cable follow these warnings Do not handle the encoder connector while the motor is running Never unplug the connector without first switching off the power While unplugging or fastening the connector use both hands Grasp the connector shells by the plastic cable strain relief at the base and not by the metal housing Prevent the possibility of electric shock by switching off the motor controller completely before connecting or disconnecting the encoder connector SOLECTRIA Installation Splicing Wires If it becomes necessary to lengthen the motor wires in order to carry out or modify an installation be sure to mark the wires with respect to color Red White and Blue before proceeding Spare connector pins are available at competitive prices from Solectria To prevent splicing specify the length of motor wires desired when ordering your motor Follow these guidelines when splicing extensions onto the connector wires of your motor or UMOC The same wire size gauge as the original wires must be used Wires must be covered with bra
76. iagnosis Regeneration Disable Note All vehicles must be equipped with a regeneration disable switch During periods of ice snow or heavy rain regeneration or regen should be shut off Test the operation of regen to familiarize yourself with its effect For units built prior to January 1 1999 regen may be less noticeable at high speeds Speedometer Calibration For vehicles equipped with the electronic speedometer option test the speedometer and calibrate it using the parameter screen and a vehicle dynamometer or measured mile You can call Solectrias Customer Service Department for mote details Motor Over Heating While test driving be alert to high motor and UMOC temperatures as displayed under Limits to Torque on the user data screen An overheated motor will result in loss of powet especially after going down hills or slowing down with regen on expressway off ramps Be aware that any time the screen shows a limit due to motor temperature available acceleration may be quite low If this happens try to improve motor cooling ot reduce the motor current setting slightly until the problem diminishes 3 SOLECTRIA Test Drive No Communications Each time the unit is turned on it sends information to the serial port These include model number build date and configuration number This is called the banner line If you do not see the banner when switching on the unit either the unit is not commun
77. icating or there s a problem with your communications software serial data port or cable See appendix E Data Logging If you have trouble giving the user data screen your full attention you may also log serial data to a capture file Call Solectria for more information regarding how to create a capture file 3 SOLECTRIA Test Drive Checking Cooling Fan Operation 12V DC for Cooling Fans Mountin Bracke Sensorless 340 Controller Bracket 4 Pin Packard Not Used on w s 2 Pin Packard from Keyed 12V DC ebox Figure 4 UMOC Cooling Fans Drive the vehicle for a few minutes or operate the unit until the user data screen shows a heat sink temperature of 31 degrees Celsius or more The cooling fans should be on Replace defective fans promptly Operating the unit with one ot more dead fans will stress the unit and should be avoided Replacement fans are available from Solectria When checking the cooling fans or if high heat sink temperatures 7 50 to 60 Celsius have been noted check ductwork and installation to make certain the UMOC cooling fans ate not drawing in hot exhaust air from the UMOC heat sink air outlets Fan motors operated at these temperatures have demonstrated a life expectancy of only about one year UMOCs use ball bearing industrial grade fans Fans operated at normal ambient temperatures of 30 Celsius and below should last the life of the vehicle 3 SOLECT
78. id or conduit for EMI teduction All connections must be secure and well insulated Braid must be insulated from wire at all points Braid must have good overall continuity Wire conductors must not touch together during operation Crimping Connector Tips Use the information given in appendix L to help you properly crimp the Anderson connector tips Remember connector tips top and bottom must be free of solder and other residues in order to make a reliable connection Keep these other things in mind regarding crimping connector tips Check the pins after crimping the connector tips to be sure that they have not become bent during the crimping process SOLECTRIA Installation It is best to use a crimping tool that is designed specifically for the pins Pins must be straight to ensure a good connection Insert the pins into the plastic housings until you hear a click Try connecting the motor plug to the UMOC If the pins are in good condition the plug will be somewhat difficult to insert If the plugs slide together easily the connector pins are not exerting sufficient pressure to provide a good connection Disassemble the connector and check for bent pins Do not force the connector if it cannot be mated Disassemble the connector and check for bent pins See appendix L for detailed instructions regarding crimping and soldering connections Soldering Connector Pins As mentioned previously pins that are not pro
79. ill be displayed To reset the unit shut off the power to the UMOC for five minutes When normal operating conditions are restoted the UMOC will function normally Look into the cause of the excessive relay cycling and correct the problem Self Cleaning Feature If the microprocessor detects the presence of dirt or oxidation on the relay contacts it will disable the unit and attempt to clean the relay contacts by cycling them once every 10 seconds Relay fault will be displayed If the relay is unable to clean itself after 10 or 20 cycles or if a relay fault occurs while driving the vehicle return the unit for service Power Stage Fault The final category of operation is the power stage fault This is the most serious category In general a display of power stage fault indicates that serious damage has occurred or is about to occur The Power Stage consists of specialized silicon transistors that operate at extremely high currents Included in the power stage are other electrical components and safety systems that are all designed to ensure that the operating conditions required by the rather unforgiving silicon transistors are not exceeded 101 SOLECTRIA Fault Diagnosis Different types of errors that result in a display of power stage fault are discussed below in the section entitled Error PAL Power stage faults can be divided into two categories those in the controller and those in the motor Internal
80. iometer as was originally installed Standard potentiometers available at electronics supply stores will not work The internal construction differs greatly Replacement potentiometers are available from Solectria for all Solectria products After replacing the potentiometer it will be necessary to calibrate it some models Before reconnecting the pedal pot cable to the ignition box connect an ohmmeter to the pedal cable following the directions in appendix F Loosen the set screw on the lever arm and using a screwdriver inserted into the end of the potentiometer shaft adjust the potentiometer shaft until one half of the potentiometer reads near zero ohms at one of the mechanical stops The other half of the potentiometer must measure close to zero ohms at the other mechanical stop Fine tune the adjustment until it is centered Tighten the set screw securely Note Some potentiometers are factory calibrated and cannot be adjusted Vibrations Various system interactions on any given electric vehicle platform may result in drive system instability These instabilities or vibrations can usually be tuned out by careful parameter selection proper tire pressure good speed sensor function and an understanding of the trade offs involved 111 SOLECTRIA Fault Diagnosis Battery Full When using regeneration on a battery that is not depleted voltage will quickly rise to limiting value In some cases an oscillation may
81. ire a password to be entered from the computer keyboard before user screen data is presented This is done to prevent accidental or unwanted parameter changes If desired the user can disable the password Faults Related to Driver amp Dashboard 25 pin Cable The UMOC motor controller communicates to vehicle controls and displays via the 25 pin cable connected to the side of the unit This is the same cable that is used to connect the test box Ifa malfunction occurs in the 25 pin cable ignition box vehicle control or display systems clues to the malfunction may be found on the user data screen Refer to the sample user data screen 86 SOLECTRIA Fault Diagnosis The first line labeled AD shows the numerical value of analog to digital converter values supplied to the microprocessor Directly below labeled D are the motor current values in binary and the motor current sensor readings in amps A In the center of the user data screen are three columns The first column labeled INFO displays commanded torque and current values rpm unit temperature and battery voltage The second column entitled Limits to Torque provides any information regarding power reductions being caused by user controls equipment temperature battery voltage and rpm The right most column labeled Status shows the operating state of internal systems These are the main contactor system or Relay the high current Power Stage which
82. is feedback Six inches of travel at the driver s toe is a good number to start a design with 114 SOLECTRIA Fault Diagnosis Avoid having the driver s heel off the floor of the vehicle Having the heel on the floor is a must to reduce this type of feedback The driver s seat must be well connected to the vehicle a lose seat or springy seat will greatly aggravate the problem Please contact the Solectria Customer Service Department for instructions if you have a newly designed system and are still WARNING experiencing instabilities such as shuddering jerking or WARNING oscillations even after having gone through all of the above points Do not allow your vehicle to coast downhill There are several remedies that may be applied to various at speeds higher than its customer situations It is possible that some small matter has maximum rated speed been overlooked and an easy change or adjustment will solve Motors damaged by the problem over speeding will be considered a zotal loss Rpm and will not be covered Maximum motor rpm is set at the factory and should not be under warranty changed Induction motors and brush less DC motors can both the damaged by over speeding 115 SOLECTRIA Fault Diagnosis Pedal Settings Pedal settings may be changed slightly to suit the users requirement Note pedal position controls motor orgze not motor speed See appendix G AA Note Regarding Pedal Setting
83. ity Your UMOC is protected against reverse polarity Use a voltmeter and check all battery and connector polarities before connecting your UMOC or any other device to your battery Be sure to follow all safety procedures Damage caused by reverse polarity is not covered under the new product warranty 3 SOLECTRIA Measuring Battery Voltages Before connecting the battery for the first time measure each battery to determine its individual voltage and keep note of individual readings Measure the total voltage Add the individual voltages using a calculator If the readings don t add up check for one or more batteries connected in reverse Any battery modules left connected in reverse will be destroyed once the vehicle is driven for a short time Do not skip this step When finished connecting batteries re check all connections for tightness Loose connections will overheat quickly and may damage batteries or interconnects Battery Fusing Battery packs must be fused with fast acting fuses rated for the DC battery voltage and current from the table These protect the system from inadvertent short circuits of a fully charged battery Because a depleted battery may not produce sufficient short circuit current to open the fuse do not use a current rating higher than in the table AC rated fuses cannot break a DC arc under some conditions Battery fuses for use with UMOC motor controllers are available from Solectria at competitive
84. ity DC battery current positive and negative inside fuse and connection boxes must be separated as much as possible to avoid mutual contact by metal tools or SOLECTRIA Installation other parts We recommend a minimum of six inches Never use a bare metal plate for a battery box cover The vehicle could roll in an accident and the battery terminals fall against the cover An insulating sheet of 94V 0 G 10 fiberglass of 0 060 thickness is ideal for this purpose Battery connectors must be located where they will not come in contact with water or fine spray mists of road salt and where the connectors are free to drain and dry quickly if they do get wet Important Battery connectors must not sit on a horizontal surface where they could remain wet Battery cables must be of an appropriate voltage rating should not run near sharp edges and should be attached every 6 to 8 inches to an insulated surface Battery wires must be individually covered with protective wire loom and must remain separated from each other by 4 to 6 inches wherever possible to prevent conditions that might sustain an electric arc Arcs can be initiated by water and salt entering the battery plugs or by physical damage from a road accident Check voltmeter for proper range and lead connection before touching test probes to battery pack or connectors If the voltmeter is set to a current range or the test leads are plugged into the current inputs thi
85. ive if you have any questions regarding the features or assembly parts of your unit Figure 1 Components Block Diagram Computer for Fault Diagnosis Optional Speed Vehicle Controls f Universal Battery Motor A i charger attery 5 Controller Battery Pack UMOC Brake Light DC DC Converter Senso Power In Power Out 3 SOLECTRIA 3 SOLECTRIA How to Use This Manual SOLECTRIA How to Use This Manual The following section will aid you in your ability to quickly get the information that you need from this manual and help you perform tasks safely Short Cuts You do not need to hunt through the entire manual to locate the information you need to perform certain tasks The following steps describe what you can do in order to quickly find information that best fits your needs If all of the connections needed for installing your UMOC are already in place and you are only swapping your current UMOC with a replacement unit you can proceed to the Swapping Units section of the chapter titled Installation If your UMOC is already installed and you would simply like to run a systems check of your unit you can skip to the chapter titled Systems Check If you own a dual drive system and are working with mote than one UMOC at a time there are issues specific to installing your units To help you find information in text that relates to dual drive systems look for
86. l Unplug the motor and using an ohm meter check for any continuity between the motor case and any one of the three main motor wites There should be none Resistance readings should be infinite Identification of Thermal Damage Temperature sensors serve to limit motor temperature but should not be relied upon exclusively to protect the motor Even after a motor cooling system has failed it is still possible for a motor to operate at maximum temperature regardless of power level If this continues for several months the motor will slowly destroy itself Color Motors subject to extended periods of overheating will darken noticeably This is true of exterior as well as interior features The nameplate protective dip bearing grease sensor head winding varnish slot insulators and even metallic parts will assume a very dark color Smell All motors especially new ones produce a sweet smell when heated The smell can be quite strong This is not a sign of over temperature A motor that has overheated to the point of experiencing winding damage will have a burnt smell 103 Fault Diagnosis CAUTION motor shell and the motor wires when tested with an ohm meter discontinue using the motor The motor should be repaired before operating it any further In addition operation with a shorted motor may damage the grounding and filtering citcuits of the motor controller or vehicle and may cause internal fuse failure
87. l Solectria for details regarding the changing of your parameters in the user parameter screen and can be changed at any time see Appendix E Never attempt to change shaft direction by connecting motor wires phases in a different order The result will be no operation AA Direction Labels for Opposed Motor Dual Drives For opposed dual drive systems pairs of units are shipped from the factory configured as one clockwise and one counterclockwise Units are labeled accordingly with stickers The stickers are an aid to installation only In any case the stickers should be removed at the time of installation If the units have been exchanged by mistake they can be moved Encoder test When testing new installations if the motor does not spin or spins very slowly place the unit in neutral and turn off the switches on the test box if used Following safety precautions spin the motor shaft or drive wheel by hand If turning a drive wheel by hand make sure on one wheel turns block the other wheel if needed You should see the rpm reading change and be displayed on the user data screen left column If the rpm remains always at zero check the encoder connections Systems Check CAUTION Do not spin your motor mote than 2 000 RPM without the motor being under load Damage to the rotor may result CAUTION Loose hair or clothing can become entangled in rotating parts Also be sure to keep control cables away
88. lastic plug or remove the jackscrews from the plug if operating a computer from AC mains power Your UMOC s serial port is optically isolated from the unit Grounding the serial cable to the UMOC jackscrews will defeat this isolation Any fault current from a malfunctioning battery charger or other device flowing to the vehicle frame will then flow through the serial cable and through the computer to ground This may damage the computer s ground system SOLECTRIA Installation CAUTION Do not use any motor type which differs from the one listed on the nameplate unless you have received prior authorization from Solectria RS 232 Communications Interface RS 232 is a standard communication protocol and is compatible with a variety of computer based devices Only one computer can be connected to the RS 232 at a time AA For dual drive systems the same computer may communicate with both drives This requires two separate cables from the computer and two serial ports AA As an easier solution for connecting to dual drive systems is to swap the serial cable from one drive to another as needed Communications Software For Windows based computers the built in communications software HyperTerminal may be used For instructions on how to use HyperTerminal consult your Windows documentation or see Appendix E RS 485 Interface Connection The RS 485 interface is no longer supported due to very low custom
89. line labeled AD This represents the pedal voltage as seen by the microprocessor expressed in arbitrary units If the value is at five or below suspect a short circuit in the pedal connections or broken wire on pin 24 of the 25 pin connector circuit or a broken wire in the accelerator pedal cable connector SOLECTRIA Fault Diagnosis If the A D value is over 1000 suspect a broken wire on pin 13 of the 25 pin connector or a broken wire in the accelerator pedal cable or connector Please note that the safety interlock system will not allow operation to begin until the A D value falls to level below 100 Thus when turning on the system for the first time the pedal must first be released in order for the unit to function at all See below Mechanical The accelerator pedal linkage must be adjusted properly and the pedal potentiometer must be in good condition and working properly in order for the UMOC to start up and operate properly If the pedal linkage is adjusted such that the A D value never falls below 100 operation will be impossible Additionally pressing the accelerator pedal to the floor with the direction selector in off or neutral should increase the A D value seen on the user data screen to around 700 If not full power acceleration will not be achieved This example should serve as a good introduction to the importance of the user data screen for maintenance and troubleshooting of the drive syste
90. m As is becoming true for the entire automotive industry there are classes of problems that are impossible to solve unless the microprocessor system can be communicated with This is because the microprocessor is capable of talking about problems that may not be outwardly apparent SOLECTRIA Fault Diagnosis Relay Off It is also possible for a malfunction in the 25 pin cable or attached equipment to prevent closure of the main operating contractor relay inside the UMOC motor controller If the main contactor will not close no operation of the drive system is possible The main contactor closes with an audible clunk which is easily recognized by the experienced observer When using the test box the main contactor may be opened and closed with the on off switch if all other conditions are met This signal is on pin 14 of the 25 pin cable Please recall from the Operation section under closing the contactor that other factors may also prevent the relay from closing besides those related to the 25 pin cable noted here Direction Switch The ignition box or console contains interlock circuits that will also prevent the main contactor from closing When the ignition key is first turned on 12 Volts is applied to the UMOC 2 pin 12 Volt connector and to the ignition box 12 Volt input wire The signal to close the contactor will not be sent until the direction handle is moved to the neutral or off position
91. nal battery voltages from 144 to 250 are normally set to 15 volts battery limiting Limits to Torque and Battery Indicators In all cases of battery over voltage or under voltage the resulting action will be evident in the limits to torque column of the user data screen For your convenience it is not necessary to connect a computer to your unit to observe battery voltage limiting Instead a battery low limiting indicator may be connected to pin numbers 1 and 8 at the 25 pin connector of the ignition box SOLECTRIA Fault Diagnosis WARNING Do not operate or connect to a battety a unit that has been dropped been in a vehicle accident and or makes a noise of loose parts rattling or rolling around inside the case Use a standard LED lamp that can be driven by a current of 0 01 amperes A current limiting resistors is not necessary See Appendix C Many Solectria vehicles have low battery indicators installed as standard equipment Please contact Customer Service about warranty requirements before connecting any LED lamps to your ignition box or console Note Regarding Battery Indicators Some special purpose vehicles use the battery full LED indicator for another function Battery full indication is not available for customer use in this situation Relay Fault If the unit will not operate and relay fault is displayed in the status column of the user data screen return the unit for se
92. ng It is important for the motor speed sensor cable to have a good ground The metal connector shells become grounded to each other when the connectors are attached If the ground connection is lost due to breakage inside the cable motor operation will be erratic If the motor operates roughly or jerks at low rpm shut off the drive system and measure ground continuity of the cable It s also a good idea to ground the motor case to the vehicle 94 SOLECTRIA Fault Diagnosis frame if metallic or to the motor controller case if the frame is not metallic Special note Regarding Accessory and Motor Sensor Grounding Never ground any accessories to the motor or UMOC case Ground current flowing through the sensor cable will disrupt normal operation of the drive Improper grounding can also present a shock hazard Important After checking the ground circuit continuity insulate the nine pin connector shells with plastic automotive split wire loom so that the connector shells will not come in contact with any metal objects You can also tie the cable out of the way using cable ties Do not wrap the connector with tape This will trap moisture inside the connector if it becomes wet If the nine pin cable connector does intermittently touch against a metallic object while the vehicle is being driven a ground current will flow that will disrupt the normal operation of the drive This may cause the drive to shut down repeatedly Af
93. ng a self cleaning action To ensure the continued benefit of this feature clean the contact Surfaces and lubricate the connector Use a white lithium grease which may be obtained from hardware stores and automotive parts suppliers 2 Melting Connectors Connector housings overheat and melt for many reasons To prevent this A Examine the crimp between cable and contact Improper crimping corrosion and broken wires result in unnecessary resistance causing the contact to heat up like a toaster B Check contact crown surfaces for signs of pitting caused by dirt or disengaging connectors under load One badly pitted contact particularly in a connector attached to a battery charger can lead to pitting on crown surfaces of other contacts If not corrected this can result in an epidemic of bad connectors throughout a fleet of electric vehicles and in chargers and batteries C Check to see if batteries are being disconnected while the charger is still on This causes the contacts to arc at the tips with progressive pitting and silver removal from tip to crown If this practice is occurring discontinue it now to avoid major repairs in the future 3 Other Conditions If any of the following conditions exist the connector housing contact and or cable should be replaced immediately A Housing Cracks missing pieces evidence of excessive heat discoloration B Contacts Pitting burns corrosion excessive wear cracked crimp barrel
94. not exceed 100 ohms 20 c Resistance change must be smooth with steady increase decrease Note The potentiometer used is of special manufacture If the potentiometer is replaced with a stock item of the same resistance and form factor it will not be possible to obtain the above readings Please contact Solectria if test results are outside of these specs 137 SOLECTRIA Appendices Appendix G Pedal Potensiometer Settings Pedal Potentiometer Accel Regen Zones NS EN Regen Zone Coost Zone Motoring Zone Potentioneter Relative Position d 0 3 1 0 Resistance Lower Leg to Viper 0 0K 15K 2 0K 5 0K Resistance Upper Leg to Wiper 5 0K 3 5K 3 0K 0 0K 138 Appendices 36 SOLECTRIA In Coming Fresh Air Duct For Fresh Air Flange for Connecting Duct to Fan Fan Body SS a mmm a Fas an Heat Sink Shroud UMOC Main Body Appendix H Example for Cooling Fan Appendix H Example Ductwork Duct W ork 139 SOLECTRIA Appendices Appendix Mounting Location for Flange Grounding Location for Grounding Wire Mounting Rubber Surface Metas oun 140 SOLECTRIA Appendices Appendix J UMoC Driver Signals 25 pin Connector Digital GND Main ignition witch to digital digital Forward and Reverse Regenerative Braking Xdigital switch to GND for regen off Power Saver variable resistance 0K to 5K 0K to analog GND
95. ns regarding the placement of your UMOC if your unit is being installed into a Hybrid Electric vehicle platform Your unit must be located away from sources of intense heat such as combustion engines or exhaust manifolds Besides reducing power output high temperatures will shorten the overall life of the unit Do not to locate your UMOC in an engine compartment The unit can become covered with an oily film from small oil leaks or crankcase vapors This will complicate matters if the unit is returned for repairs or upgrades Vibration Mounts All electronic systems must be isolated from vehicle vibration This is done through the use of vibration mounts Figure 2 UMOC Vibration Mounts SOLECTRIA Installation All UMOCs are shipped from the factory with vibration mounts in the accessory kit If the UMOC is bolted directly to the vehicle frame without the vibration mounts in place it will be difficult to obtain a unit lifetime of greater than two yeats The factory supplied vibration mounts must be operated in compression with the weight of the UMOC on them For improved vibration protection or when the UMOC is not mounted face up heavy duty Barry mounts must be used Barry mounts are available through Solectria or from Barry Controls Cooling Air Requirements Ample quantities of outside air must be available to cool your unit Your UMOC is air cooled because this gives greater overall electrical efficiency along wi
96. oving your UMOC never lift the unit by the wires See the Maintenance section regarding waterproofing UMOC connectors Mounting Your UMOC Once you have decided on the best location for your UMOC based on specifications you can now mount it into position Environmental Considerations Choosing a good location will result in improved performance and longevity of the unit Your UMOC should be mounted face up and located in a position that provides easy access for servicing and replacement Your UMOC should be kept dry at all times It is understood however some water splash to the underside of your vehicle is unavoidable Your UMOC is factory sealed to withstand small amounts of moisture We ask that you use the following guidelines regarding placement of your UMOC Avoid locations were your unit will be routinely exposed to water Do not wash your unit with a pressure sprayer Large amounts of water will cause a malfunction If you have reason to believe water has entered the unit do not open the case Disconnect your unit and return it for service as soon as possible Keep the protective plastic cap over the unit s serial data port when not in use Units with extensive water damage may not be repairable Customer units returned to Solectria with the factory seal broken will be ineligible for warranty service SOLECTRIA Installation e Special Notes Re Hybrid Vehicle Owners There are certain consideratio
97. pen if Caps Lock is on and P is pressed to bring up the parameter screen then is pressed a any time subsequently until the unit is shut off or B is pressed Customer units with user data screen function shipped after June 30 1998 are not subject to this restriction Viewing the User Data Screen Use the following procedures to view the user data screen on your computer 1 Prepare the laptop with the communication software 2 Connect the serial cable to the serial data port on the side of the UMOC The UMOC must be connected to battery voltage using the large battery connector on the side of the UMOC 3 Bring up the communication software on the computer 4 Turn on the ignition key of the vehicle or supply 12 volts to the 2 pin 12 volt connector of your UMOC 3 SOLECTRIA Test Drive 5 When you see the banner line press the enter key once or twice to clear the password buffer see note directly below 6 Enter the password The user data screen will appear If it doesn t check your communication settings The password may have been changed by another user If the password is lost or forgotten it can be re programmed by returning the unit for service or contacting Customer Service for password changing software More recent units only require pressing the Enter key on the computer to display the user data screen and do not require a passwotd Special Note Regarding Pa
98. r The LED Power error indicates a problem in the power supply section of the motor controller It is a serious error but depending on model LED power error when not combined with other errors can be considered normal This is because some UMOC models such as the 440 switch off certain power supplies while performing the self test This causes the error to appear see next paragraph Do not return a unit for service if the only error indicated is LED Power error If you cannot find any other indications of a problem to aid in troubleshooting contact the Solectria Customer Service Department for assistance Power On Self Test CAUTION Every time the keyed 12 volts signal is applied to the motor controller the processor begins a series of routine diagnostic tests If all tests proceed normally and no problems are found operation may begin One of the tests measures critical power supplies to determine if output voltages are correct As mentioned above a power supply named LED powert is shut off during the diagnostic test sequence on some models During power on testing the processor may elect to perform re calibrations This may add slightly to start up time In general testing will not last for more than five seconds Start up usually takes about one second Note Units built before January 1 1999 do not self calibrate Do not intentionally connect a replacement UMOC to a motor that is known to have a short citcuit
99. r pins and cable shells Waterproof connectors include Deutsch Packard Non Waterproof Connectors include 9 amp 25 pin D Sub Anderson Molex and Amp White Plastic 125 3 SOLECTRIA 126 SOLECTRIA Appendices Appendices 127 SOLECTRIA Appendices Appendix A UMOC Interface Packages of Dual amp Single Drive Systems Single Drive Systems Item Quantity ABC 1 REV 2 1 F R Switch Assembly Power Saver Pot Regen disable Switch Mini IB95 97 25pin Cable Assembly 200A 500v Semi Ampl1F Plug Molex 4M Plug Molex 2F Mini Plug Packard Seal 18 22awg Packard 2F Tower Packard 4F Tower SB175 Grey SB175 PP180 2awg pin Slide Term Insul F 22 18 Amp F Pin Molex M Pin Molex Mini F Pin Packard F Pin 1 Rubber Isolator EMI Sock eB A A m Ne m RP A mh Ln 128 SOLECTRIA Appendices Zip tie Large Black 4 V gr8 SAE w 14 20 Nyloc Nut 8 Dual Drive Interface Item Quantity Regen Brake Harness 1 UMOC 12V Power Supply 2 25 Pin Extension Cord 2 Charger Drive Disable Cable 1 Ignition Connector 1 Throttle Extension Cord 1 SB175 Grey 2 SB175 PP180 2awg Pin 4 DeutschF 18contact 2 DT06 2S 1 W2S 1 1 Rubber Isolator 8 EMI Sock 2 Zip tie Med Black 8 SS L w 16 14 20 SS Hex Nut 16 129 SOLECTRIA Appendices MAX TORQUE 9 4 MAX TORQUE Appendix B Torque Decrease VS Heatsink Temp For UMOC440 100
100. rameters The Solectria Customer Service Department is willing to provide assistance with setting drive parameters to their proper values Additionally all drive systems are configured and tested at the factory It is not necessary to change any parameter settings in order to bring up a new installation All Solectria complete drive systems are delivered for plug and play operation Test Drive CAUTION If command processing proceeds in a way other than expected and the caps lock indicator is illuminated switch off or reboot the UMOC at once Do not write the long term memory Doing so may reconfigure the unit Switch off the power for 30 seconds then power up the unit and check the configuration and settings before driving the vehicle Be sure caps lock is not activated on the computer 3 SOLECTRIA Test Drive Passwords Units that were shipped from the factory with a password use the following password std UMoC You must enter the capitalization correctly and CAPS LOCK must be off Note it is very important never to use the caps lock feature when communicating with a UMOC motor controller Units shipped with version 1 6 software and later do not require a password however the user may add a custom password if desired Special Note Regarding Caps Lock Correct operation will no longer be possible if the default parameters have accidentally been written to long term memory This will hap
101. ria provides you with an excellent customer service support staff and a comprehensive component warranty 3 SOLECTRIA vi 3 SOLECTRIA Table of Contents ORWARD III CAUTION TO REPORT ERRORS IN THE MANUAL INTRODUCTION SPECIFICATIONS 1 aming Convention for the Solectria Universal Motor Controller 4 FEATURES 6 HOW USE THIS MANUAL 9 hort Cuts 10 afety 11 INSTALLATION 13 9 PIN ENCODER SPEED SENSOR CONNECTION 29 SYSTEMS CHECK 59 EST DRIVE 71 FAULT DIAGNOSIS 81 CONCLUSION 117 WARRANTY 119 MAINTENANCE 123 APPENDICES 127 MOC INTERFACE PACKAGES OF DUAL amp SINGLE DRIVE SYSTEMS 128 3 SOLECTRIA INDEX INDEX 149 150 3 SOLECTRIA 3 SOLECTRIA Specifications 3 SOLECTRIA Specifications Naming Convention for the Solectria Universal Motor Controller The following defines the alphanumeric nomenclature that appears in the model title of your UMOC UMOC440 T F A or S x 10 Max Battery Voltage x 100 Peak Motor Current T High Efficiency F Heavy Duty Cooling Standard s Sensotless UMOC A Auxiliary For Example A UMOC640 has a 600A peak motor current and a 400V peak battery voltage 3 SOLECTRIA Specifications Table 1 9 5 5 ls En BS 2
102. rvice For safety reasons the contactor relay system is supervised by the microprocessor and includes a fail safe function If the relay fails to close the microprocessor will wait for 10 seconds and then try closing the relay again If the relay fails to open the microprocessor will remove power from the motor as a safety precaution Relay fault will be displayed and the yellow status light will be illuminated when equipped Damage Relay faults although rare are normally caused by damage to the contactor relay The damage is typically mechanical not electrical Moisture If poor installation results in moisture entering the unit the relay contacts may become oxidized This will result in poor electrical connection The microprocessor will detect this and generate a relay fault It will be necessary for the relay to be repaired or replaced Relays are not field serviceable 100 SOLECTRIA Fault Diagnosis G Force Limit The relay is designed with breakaway plastic clips that will fail if the relay experiences shock in excess of 200 G s If the entire unit is accidentally dropped it s a good idea to return it for service Relay fault will be indicated on the user data screen if the relay has become damaged Excessive Cycling of Relay In cases of battery charger malfunction or other circumstances which can cause the relay to cycle on and off rapidly the relay system will shut down and a relay fault w
103. s discoloration C Cable Exposed copper near housing cracked cable peeling or frayed insulation D Handles Loose attachment and such signs of damage as missing or loose hardware and cracked or broken plastic Handles should be used for connectors that are hard to reach or move E Cable Clamps Loose attachments signs of abraded cable jacket missing or loose hardware Cable clamps should be used to relieve strain on unmounted cable NOTE See the enclosed connector maintenance checklist Make copies to have a supply whenever maintenance procedures are conducted 144 SOLECTRIA Appendices Connector Crimping amp Soldering 3 Crimping The best preparation will be defeated if inadequate tools or im proper crimping procedures are employed Never use a hammer and chisel or the squeeze in a vise method They won t do the job and will lead directly to substantial reduction in connector life Use a crimping tool It effectively compresses the contact barrel tightly around the cable strands so that all of them are pressed tightly against each other and the inside wall of the contact barrel Doing this requires that the stripped cable be inserted all the way into the barrel of the contact and that the contact point is centered in the crimping tool When the crimp has been completed check the appearance of the contact A properly crimped contact barrel is compacted tightly with the outer strands The outer stran
104. s best not to change parameters unless the correct parameters are known beyond a doubt Motor Operates but then Shuts Down The most common cause of this problem would be a power stage fault Connect a laptop and monitor the user data screen during the shutdown The status column is a good place to look By carefully examining the screen it is usually possible to determine the cause of the shutdown 108 SOLECTRIA Fault Diagnosis Miscellaneous Problems Brake lights stay on all the time new installations 4 Pin Packard Disconnect the four pin connector containing the brake light Connector for circuit at the motor controller If the brake lights remain on Regen Brake the problem is in the brake light relay circuit or vehicle Lights witing If the brake lights go out disassemble the four pin connector on the vehicle side of the wiring harness not the motor controller side and reverse pins C and D Then reconnect the four pin connector If the brake lights do not come on operate the vehicle to verify correct function of the regen brake lights If function 1s not correct or if the brake lights remain on all the time put back the wires in positions C and D to their original locations and return the motor controller for service AA For dual drive systems if the regen brake lights do not operate unplug the 4 pin connector from the brake light relay to the UMOC and instead plug the connector from the relay into the
105. s for Dual Drive Systems Pedal settings of motor controllers used on dual drive systems must be identical The units will not torque share properly if the pedal settings differ The resulting torque imbalance may damage drive system hubs or components This concludes the text describing the function installation and fault diagnosis of your Solectria Universal Motor Controller UMOC 116 3 SOLECTRIA Conclusion Your UMOC was constructed with the highest standards for quality and design possible We hope that this service manual will enable you to more fully understand the workings of your unit and to use it safely If you have had any questions regarding the contents of this manual ot would like to know more about the features of your UMOC please feel free to contact the Solectria Customer Service Department at the phone numbers provided in your warranty 117 3 SOLECTRIA 118 3 SOLECTRIA Warranty 119 SOLECTRIA Warranty Solectria Components Warranty Policy In an effort to keep our customers completely satisfied with the quality and performance of items purchased from Solectria the following warranty policy applies Solectria Corporation shall pay for the repair or replacement at our option of any component found to be defective due to flaws in materials and or workmanship within the first 12 months following the date of sale with no US 0 00 deductible with the exceptions noted below
106. s provided in your warranty before proceeding SOLECTRIA Installation Installation 3 SOLECTRIA Installation System Requirements You must have the following three items in order to ensure that your UMOC will operate properly with the drive system that you have developed a battery pack of sufficient voltage and capacity an accessory kit with interface box and accelerator pedal unit connections a motor with an incremental rotary encoder that has been configured to match the programming of the UMOC Note Motors that use a sensorless UMOC with no sensor do not require a shaft encoder Use table 1 in section 1 to help determine that the UMOC you have purchased is compatible with your motor and drive system SOLECTRIA Installation Interface Kit Your UMOC comes with a kit that contains parts for connecting the unit to your drive system These include an interface box forward reverse switch assembly accelerator pedal box cable and connector kit Some configurations include a driver console in place of or in addition to the interface box It is important to remember that there are two distinct types of interface kits one is for single motor systems and the other is for dual motor systems Check the items listed in mo A Interface Kit Contents to make sure that you equipment directly to ave the appropriate kit for your UMOC the UMOC without Note Any damage resulting from bypassing
107. s will blow a fuse or damage the voltmeter This may cause personal injury 45 SOLECTRIA Installation Wotk with one hand behind the back when making connections This greatly reduces the chance of heart failure caused by an electric current flowing through the chest area Workers should be trained in CPR and correct response procedures regarding electrical shock Never open your UMOC Residual stored energy may exist for several hours after disconnection from the battery Note New product warranty coverage does not apply to units that have been opened Do not touch the metal terminals of the UMOC battery plug Do not allow children to handle the DC battery connector plugs of electric vehicles As long as battery plugs remain connected there is little or no danger Unplugging the connectors exposes the holes containing the live contacts down inside the plugs Keep fingers away from internal contacts when working on battery plugs When working on high voltage systems never work alone 3 SOLECTRIA Battery Capacity For good system performance battery capacity must be at least one fourth the maximum battery current This is a good rule of thumb and is derived from limits to battery voltage swing due to discharge and regeneration current demands from the drive system Information is based on commonly available sealed lead acid battery types For example using the information in table 1 a UMOC 840 req
108. sswords If the user password is changed for any reason and is then lost or forgotten it may be necessary to return the unit to Solectria for reprogramming Contact the Customer Service Department for details Diagnosing Faults by Looking at the User Data Screen As mentioned the user data screen provides a wealth of information for troubleshooting purposes If a drive system malfunctions a laptop should be connected and the user data screen consulted to find the source of the malfunction Because a computer screen is only capable of displaying 80 columns by 25 rows of text the information has been abbreviated Please refer to the user data screen examples in Appendix E for explanation of all abbreviations The first step to fault diagnosis is to connect the computer and begin communicating with the unit See the section titled Connecting Your Computer to Your UMOC Power Acceleration should be brisk for a properly sized system Try the different settings of the Tri Power Selector if equipped 3 SOLECTRIA Test Drive WARNING Regen braking like regular braking can cause wheels to skid if applied too strongly This can lead to loss of vehicle control Smoothness Vehicle operation should be free of shuddering bucking and other instabilities Instabilities can result from a number of problems including incorrect parameter settings See the section entitled miscellaneous problems under Fault d
109. t rating for the internal DC DC converter 15 28A at 12V or 14 at 24V Internal DC DC converters cannot be paralleled with external converters Note When using a UMOC with internal DC DC converter there is a small standby battery current drain The drain of a standard UMOC consists only of leakage currents that are essentially zero SOLECTRIA Installation Connecting Regen Brake Lights Itis very important the vehicle brake lights come on whenever the UMOC enters regenerative braking mode The stop lamp signal is supplied via the UMOC s 12 volt auxiliary connector Regenerative or regen braking is capable of slowing the vehicle rapidly while returning energy to the battery Unwanted kinetic energy is converted to electrical energy Regen Brake Light Connection If desired the UMOC features an additional 12 volt output circuit that may be programmed by special request UMOC 12 volt auxiliary outputs are isolated dry contact type solid state relays with a 4 amp continuous rating Outputs are reverse polarity protected If connected in reverse outputs remain on continuously as a diagnostic Outputs must be fused with external 4 amp fuses Your UMOC accessory kit contains a forward reverse selector switch that also features a dry contact output to supply power to the vehicle reverse lights Current capacity is higher than the UMOC s programmable light output The forward reverse selector switch contac
110. ter performing any service work on the vehicle always check the nine pin connector shells to be sure they are insulated from touching nearby metal objects This will enable smooth operation Faults Related to Temperature Controller If the microprocessor has determined an over temperature condition exists power will be reduced proportionally to the severity of over temperature On the user data screen heat sink temperature is indicated This is a very accurate measurement SOLECTRIA Fault Diagnosis When unit temperatures reach over 50 Centigrade the motor controller will begin to limit power in order to forestall further overheating The temp indicator light when equipped will be illuminated Motor In the Limits to Torque column of the user data screen see Note Re limits to torque just below motor temperature values are used as a guideline to protect the motor Temperature sensors are embedded in the actual copper windings inside the motor stator At very high temperatures the copper wire insulation will begin to break down The temperature sensors prevent this by supplying data to the microprocessor Motor torque is reduced see below and the temp indicator is illuminated when equipped At all motor temperatures below the limit full motor power is available For this reason is important to cool the motor properly Otherwise torque may suddenly be lost and vehicle performance will suff
111. th reduced system cost Your UMOC cooling system is maintenance free However performance and lifetime will both be reduced if cooling air 1s not available Consider this when choosing a location for the unit Some points to keep in mind Cooling fans are not designed to draw air through ductwork more than two feet long with bends or of a smaller cross section than the fan air intake opening If ductwork is required additional blowers must be added to restore the airflow rate to the same level as a unit operating in free air See appendix H To check for proper airflow operate the unit under the most demanding conditions for example at high ambient temperatures or hill climbing for 15 minutes Exhaust air temperature measured at the cooling fins should not exceed 50 degrees Centigrade during this period The unit should not be routinely exposed to ambient temperatures above 50 degrees C unless equipped with high power cooling fans designed for warmer climates See the chart in appendix B for temperature de rating curves SOLECTRIA Installation Regarding the use of Ductwork The use of ductwork is not recommended At the same time heated exhaust air exiting the unit must not be allowed to reenter the air intake grilles If this happens temperatures will quickly rise Power will be automatically reduced to prevent further heating This constitutes misuse and if returned for service discoloration of internal plastic parts
112. the metal case and cable connectors of your unit If the carton is lost Solectria will supply a replacement carton for a fee If the unit must be shipped immediately you must triple wrap it with large cell bubble pack and place it securely in a double walled corrugated carton for shipment back to Solectria Any repair costs for the unit that are associated with case damage due to improper shipment will be borne by the carrier or the customer and will affect your warranty Returned items should be sent to Solectria Corporation Component Repair Department 33 Industrial Way Wilmington MA 01887 USA All items returned for repair must include a letter indicating return address and contact model number serial number date of purchase or receipt of purchase and reason for return If this information is not provided the repair will be delayed Customer will be charged an evaluation fee for Non Warranty items returned to Solectria Warranty items returned to Solectria that are found operable will also incur an evaluation fee Call Solectria s Customer Service Department for details 121 SOLECTRIA Warranty 122 SOLECTRIA Maintenance Maintenance 123 3 SOLECTRIA CAUTION Do not use a pressure sprayer to clean drive system components including the UMOC Spray will be forced inside the UMOC case encoder housing and connectors This will cause a malfunction and may result in a shock hazard
113. then shuts down 108 Motor Over Heating 78 Motor Power Wires 24 motor shaft 67 93 Motor short circuited 102 Motor Spin Test 67 Motor temperature sensor 94 Motor turns very slowly 107 mounting 17 26 34 40 Mounting 18 nameplate 51 55 103 106 neutral interlock 66 No communications 85 No Communications 79 No rpm indication 108 null modem 53 60 73 Observing Your Vehicles Diagnostics 62 On charge voltage 60 operation 6 17 24 27 34 35 37 42 55 57 60 62 64 66 67 68 69 75 76 78 80 85 86 87 88 89 90 91 92 94 95 98 99 101 102 105 Operation is not smooth 109 Other causes 112 Overcooling 23 Over current error 106 Over voltage 97 107 Parameter Screen 73 Parameters 74 75 99 Passwords 76 77 Pedal and linkage design 114 pedal error 88 Index Pedal error 87 Pedal settings 75 116 pedal settings for dual drive systems 116 Phasing 24 25 68 Plugs exchanged 85 polarity 39 44 48 Polarity 48 potentiometer 89 110 111 114 Power 21 24 35 37 48 65 77 87 99 101 102 105 Power on self test 65 Power stage fault 101 power switch 66 Power on self test 105 pre charge delay 64 65 Processor fault 85 Protector Cap 52 reduced power 23 regen brake lights 109 Regeneration at low rpm 113 Regeneration Disable 78 Relay Connection 40 Relay fault 100 101 Relay off 90 replacement unit
114. ting the 25 pin cables incorrectly can result in a Pedal Error message appearing on your computer screen Vehicle operation can become unpredictable or stop altogether AARe 12 Volt Power for Console Dual drive systems will not function if 12 Volt power to the console is lost If both drive systems operate with a test box but neither drive operates with the console check the 12 volt power input to the console and also the inline fuse s SOLECTRIA Installation Systems without proper UMOC or motor grounding will blow the fuse in the console in the following manner If a 12 volt accessory is grounded to either the motor shell or UMOC case and either the motor or the UMOC is not grounded to the vehicle frame the only ground path for the 12 volt accessory will be through the ground of the 25 pin cable To return to vehicle grounding the ground current then flows through the console s 12 volt return inline fuse This fuse is not sized to carry large currents The condition described above is known as a ground loop Ground loops must be avoided for reliable vehicle operation The console circuit board will be damaged if the inline fuse is removed or replaced with a larger fuse Instead it is best to ground the drive system properly to prevent short circuits or poorly grounded accessories Once you have made all of the connections necessary for operating your ignition box or driver console you can now connect your system
115. ts are rated at 10 amps To make contact between the 4 pin Packard connector from your dash and the other from your UMOC simply push the two sides of the connector together until you hear the click of the two halves locking into place SOLECTRIA Installation Brake Light Direct Connection For small lightweight vehicles using LED brake lights without large ballast resistors ot vehicles with small incandescent lamps the brake light circuit may be connected directly to the brake light output of your UMOC An external four amp fuse must be included in the circuit A smaller size fuse may be used Do not use a fuse size larger than 4 amp or connect loads larger than 4 amp Brake Light Relay Connection For larger vehicles using several incandescent brake lights with a total current drain exceeding four amps the brake lights are connected to external brake light relay supplied by Solectria The brake light relay then connects to the regen brake output of your UMOC In all cases the brake lights are connected such that the pressing the brake pedal activates the brake lights as well See Appendix D for the relay connection diagram Brake Light Fuses Auxiliary circuit fuses are not located within the sealed UMOC case This makes fuse replacement easier External easily accessible fuses may be installed in a convenient location by the customer To prevent damage to internal solid state relays in the event of a short circuit
116. uiring a maximum of 500 Amps battery current should be used with a battery rated for no less than 125 Ampere hours For hybrid vehicles using both a battery and another source of power subtract the continuous current rating of the other device Again using table 1 if the other source can supply 100 Amps continuous this reduces the maximum battery current needed to 400 Amps Only a 100 Ampere hour battery is then required Battery Voltages The maximum battery voltage parameter sets the level to which battery voltage will rise during regeneration The minimum battery voltage parameter sets the level to which a battery may become depleted during operation until operation is not possible The trade off is range and battery life If the settings are too close together vehicle range is reduced and battery life is extended This refers to battery life measured in months years or hundreds of cycles If the settings are too far apart range will be good but the batteries may be destroyed in a short time Battery voltage parameters must be set to conform with battery manufacturer requirements Types of Batteries Battery voltage settings differ depending on how many cells are in the battery and which type of battery chemistry is Installation CAUTION For belt drive systems motor current is limited to prevent damage to belts Exceeding the recommended maximum motor current will result in rapid belt wear or failure
117. unded stator 103 grounding 22 26 35 36 95 Grounding 25 26 53 94 heat sink temperature 80 82 95 Hybrid Vehicle Owners 19 HyperTerminal 16 25 54 Identification of thermal damage 103 ignition box 28 31 32 35 66 82 84 86 90 92 99 100 110 111 incandescent lamps 40 I ndex 150 Induction motor 115 Initial driving 97 installation 17 23 24 27 31 34 41 50 55 67 75 80 100 124 Installation 10 13 54 Interconnects 49 interface box 14 15 Interface Kit 15 Internal damage 102 Index Internal DC DC Converter 38 IPM fault 102 junction box 102 103 Keyed 61 keyed 12 volts 37 61 62 leakage current 82 LED 40 62 100 105 Limits to torque 99 108 Limits to Torque 78 87 94 96 Limits to torque and battery indicators 99 long term memory 56 57 74 75 76 Low battery indication 98 Maintenance 123 Mechanical 89 Miscellaneous problems 109 model number 55 65 79 85 Moisture 100 Monitoring the User Data Screen 68 motor v 14 15 22 23 24 25 26 27 28 29 31 34 35 36 37 42 48 49 51 55 60 62 64 67 68 76 78 82 85 86 87 90 92 93 94 95 96 98 100 102 103 104 105 106 107 108 109 112 114 115 116 124 Motor v 22 23 24 25 48 60 67 78 93 94 96 102 103 Motor Cooling Requirements 22 Motor currents 48 motor heating 48 152 3 SOLECTRIA Motor operates but
118. unit and check the configuration and settings before driving the vehicle Be sure caps lock is not activated on the computet DANGER It is dangerous to operate a vehicle with a problem in the pedal circuit Vehicle acceleration could become unpredictable No matter how many safety systems are implemented there will always be s ght chance of unintended acceleration This is true for any drive by wire vehicle No level of complexity can eliminate this possibility completely In the UMOC a four level safety system has been implemented to make this occurrence as remote as practically possible Fault Diagnosis If you do not see the banner when switching on the unit either the unit is not communicating or there s a problem with your communications software serial data port or cable See appendix E Banner is Garbled If you turn on the power and see a line of unreadable characters on the screen you probably need to adjust your communication settings Follow the above procedure and when finished turn the power to the UMOC off and then back on again If you now see the banner line clearly you are ready to communicate with the unit Unit Communicates but no Motor Operation Once communication is established it will now be possible to see inside the unit for very easy fault diagnosis Clues to the causes of most faults will appear somewhere in the various columns of the user data screen Many units requ
119. w safety procedures and reserve one interconnect until after all wiring is completed and all polarities are checked e When wiring new or replacement battery packs from individual modules omit one interconnect from the centermost battery in the string This way the maximum available voltage present during any assembly accidents will be halved 50 SOLECTRIA Installation Placement of Current Shunts If you are using a current shunt place it in the negative battery connection This assures correct function of Solectria plug and play accessories Solectria components such as amp hour counters can be damaged if you install the current shunt in the battery positive connection Handling Battery Connector Tips The battery and motor connectors are silver plated for excellent conductivity long life and to reduce the effects of oxidation Never file or wire brush the connector tips This will remove the silver plating and give an inferior connection prone to oxidation and heating Soldering Battery Connections If battery connections cannot be crimped properly then they should be soldered Avoid getting any flux or solder on the pin mating surface or the reverse side of the pin tip where it locks into the housing If this should happen heat the pin until the solder melts then wipe it clean with a wet sponge Do not allow solder residues of any kind to remain on the mating surfaces Note Re Battery Voltages and Plugs
120. without the proper tools or knowledge required for the work can result personal injury and product damage To Report Errors in the Manual If while reading through this manual you discover an error in the technical information provided Solectria asks that you notify its Customer Service Department at the phone number provided in your warranty Please be prepared to provide the following information e Your name e Name and edition of your manual e Page number s where the error s appear Serial number of your unit iii 3 SOLECTRIA Forward Please feel free to call with any suggestions that you may have regarding the content of your manual O 1999 Solectria Corporation 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 Solectria Corporation This applies to all text illustrations tables and charts iv 3 SOLECTRIA Introduction Cossiga on your purchase of a Solectria Universal Motor Controller UMOC By choosing the Solectria UMOC you join others that have made a commitment to the high efficiency and exceptional design that has set the standard in the electric vehicle industry A UMOC is a self contained microprocessor controlled three phase AC vector control power converter for AC induction or

UMOC Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents