GOLD CONTROLLER USER MANUAL
Contents
1. 6 TRITIUM GOLD CONTROLLER USER MANUAL Revision 3 3 Date February 2003 Tritium Pty Ltd 2003 rew Terminal ignal Tritium Pty Ltd 2003 1 Connection and Operation A Tritium motor controller system is comprised of a number of components The description given in this section is for a typical arrangement of the motor drive system and associated peripherals Graphics shown are meant as an aid for system assembly and are only representative of components that could possibly be used I Gold Power Controller IV Gold Driver Controls Hall Effect Sensors V Gold Driver Display 3 Phase Motor VI Digital Encoder Figure 1 A typical arrangement for a motor controller system O Tritium Pty Ltd 2003 1 1 Gold Power Controller The Gold Power Controller is the hub of the drive system and the interface between the driver and the motor It has five high power connection points and a number of low power digital and analog I O ports that are accessed through various connector sockets 1 1 1 High Power Two of the high power connection points marked with labels are for the voltage bus The controller and all peripheral products are powered from this power source unless otherwise stated Breaking this power supply will disable all driving capabilities of the controller Residual charge in components will operate the controller for a very brief time aft2. TRITIUM O THROTTLE MULTIFUNCTION DISPLAY The motor controller uses PWM control when driving forward and current control in regen This control behaviour can be observed using the Throttle and Motor Current values If the OB 8 8 Luis user is driving forward the Throttle display Reese QO changes as the encoder is turned and Motor m EN MOTOR DRIVE STATUS DISPLAY Current displays a fixed value When changing into Regen the Throttle value becomes fixed Figure 10 The Multifunction LCD and the Motor Current reading will vary uad Ar LED Status Display The LED Driver Display is shown in Figure 10 bottom The two indicator lights left and right are green The remaining LEDs Forward Neutral and Reverse can be either red or green when turned on The following table shows how these three LEDSs will be arranged for different driving arrangements LEDs Forward Kill Switch is Off Off RED Off LH or RH Brake Switch is On braking RED GREEN RED Direction Switch 1s Off FWD Throttle zero controller in neutral GREEN GREEN Off Throttle gt 0 driving GREEN Off Off Throttle lt 0 regenerative braking Off Off RED Direction Switch is On REV Throttle zero controller in neutral Off GREEN GREEN Throttle gt 0 driving Off Off GREEN Throttle lt 0 regenerative braking RED Off Off Tritium Pty Ltd 2003 7
3. button instantly resets the slider back to the zero point on the bar The window to the top right of the bar shows the actual level that the controller is at There 15 a fourth slider figure 13 hat is used to control the current level for regenerative braking When driving the motor the button can be pressed at any time to begin braking regeneratively This also zeroes any of the drive signals Regen will only operate whilst the button is depressed Releasing the button will leave the motor free to coast Clicking on the Lock checkbox will put the controller into regen mode permanently until the box 1s unchecked Similar to the other sliders there is also a display window with up down buttons that change the set point in single step increments decrements 5 2 Configuration There are many parameters that can be modified TIT within the controller to configure its operation File Config Help for a specific motor or situation To download Edit Config the current configuration from the motor controller select Config Download Config Upload Config to MC Open Config from file from MC from the menu as shown in figure 15 Save Config to file To edit this configuration select Config Edit Config from the window menu and the Config Edit window will open as shown in Figure 16 Figure 15 The Config menu in the Once you have edited the configuration hit the program main window Rec
4. Controls on the controller front panel This plug connects to either the Driver Controls Section enable configuration changes to the controller see Section O Tritium Pty Ltd 2003 or to a PC to Figure 3 Pinout of the RS 485 communications socket 1 2 III 3 Phase Motor Apart from the three high power connections Plug Plug Pinout mentioned in Section Motor Temp Front View MotorTemp Front View there are four Pins additional signals between GND OO the motor and controller ase three hall effects and a Ping temperature sensor Side View These signals interface 7 with the controller using the plug uration sownin Figure 4 Motor signal plug pin diagram The mandatory pins to be connected are the 15V GND and Hall signals These provide power to the hall effects inside the motor and the outputs are sent via the Hall lines The MotorTemp pins are optional as they are intended to be used with a 10kQ thermistor with a negative temperature coefficient inside the motor 1 2 1 Inductors Depending on the type of motor being driven phase inductors may be reguired If this is Inductor the case then they are to be arranged as shown in Figure 5 Each phase lead will be connected to an inductor before the lead passes through a hall effect sensor see Section 3 br onto the power controller Figure 5 Motor wiring arrangement with inductors I
5. based program intended for bench testing the drive system and for changing Tritium MCI parameter settings of the controller To begin the program run the MCIprog exe file A window will appear asking you which comm port the computer is connected to the motor controller with Select the appropriate port and then click OK The program will only begin if the Gold Power Controller is turned on and the communications are operating correctly 5 1 System Control Menu Control Sliders MCI Progra n 1 04 2002 Tritium Pty Ltd File Config Help Parameter 27 11 02 12 01 04 AM Bad Packets PWM Set Point PWM Val ues 0 09 Bow Bus Voltage 0V R 2 PWM i Aer a Posl Controller Current 0A Heat Sink Temp 0 0C 100 0 0 100 0 Motor Temp 00 Controller Temp 00 Current Set Point Current SMPS Temp 0 0C 0 0A d Zero 0A 15V Rail Voltage 15V Adapter Frequency 0 0Hz 60 0A 0 6004 Adapter Channel 1 0 00V Adapter Channel 2 0 00V Velocity Set Point Velocity Adapter Channel 3 0 00V 0 0km h 4 T Velocity Control Mode Adapter Channel 4 0 00V General Status 000000000 183 6km h 0 183 6km h Hom B Hazards CR Regen Controls Set Point a 0 i SESA DISABLE CONTROLS 0 6004 Regen Lock Regen Slider Disable Figure 12 MCI Prog Main Window The program window in Figure 12 tan be used to control the motor and to view all available data Each paramet
6. 2 Hardware Block Diagram andino 9g AE 9 ASL ASL4 asuas onjeroduuo indui 20 A00Z OS jddns MOSL asuas oDe oA 35095 jus4n 134SOW J3AUG 5 1 5 ZHW OF 1055322014 PUBS jeybig 134SOW 13A V90PZ40ZESW L 5 3pls ubIH SJUSLUNASU SEX AS Addns samog Burwweiboig du umopinus BUTS JUAN AMO ASL J9MOd 10 U3 uonisag Jed uonoejoug pue jnduj 105095 uonisog IH SaUJ IMS pue 5331 571015 509 002511 JAN9ISUPI SgpsH Tritium Pty Ltd 2003 3 Software 3 1 Programming the Controller The controller uses a Texas Instruments TMSLF2407 DSP running at 4OMHz I Connect the RS 485 cable from the controller to a serial port on a PC you will require an RS 232 to RS 485 adapter board Tritium can supply these if reguired II Set the Program Run switch to the Program position III Reset the controller IV Download the compiled software using relevant tools Confirm that programming was successful V Return the Program Run switch to the position VI Reset the controller 3 2 Programming the Driver Controls The Driver Controls are operated by a Texas Instruments MSP430 controller I Connect a parallel port programmer Tritium can supply these if required to the PC II Using an 8 way IDC cable connect the programmer to the 8 pin IDC header on the Driver Controls III Reset the Driv
7. approaches this value SMPS Over Temp When the temperature of the internal switched mode power supply reaches this value or higher the controller O Tritium Pty Ltd 2003 14 will no longer drive the motor Users should experience a gradual performance drop as the temperature approaches this value Auxiliary Over Temp When the temperature of an auxiliary board within the controller reaches this value or higher the controller will no longer drive the motor Users should experience a gradual performance drop as the temperature approaches this value Table 2 Parameters of the Speed Control Loop dialog Speed Control Loop Constants Dependent Parameter Description Values P 1 The denominator of the proportional scaling term used in the speed control loop of the controller I 1 The denominator of the integral scaling term used in the speed control loop of the controller D 1 The denominator of the differential scaling term used in the speed control loop of the controller Table 3 Description of motor hall effect parameters Phasor Config Note The table in this dialog consists of three rows of data The top row is for the case that produced in phase path A B is positive The second row is for phase path B C and the bottom row is for phase path C A Parameter Description Dependent Values Hall Nr Hall numb
8. major unsigned 1 minor char 01 1 01 unsigned char file programmed Tong secs secs since 1970 Jan 1 Phasorsense config unsigned Vab Hall Nr char 0 or 1 Vab Hall Negate unsigned degrees Vab Hall Lead char char Phasorsense config unsigned Tritium Pty Ltd 2003 Hall Nr char 0 or 1 Vbc Hall Negate unsigned degrees Vbc Hall Lead char char Phasorsense config unsigned Vca Hall Nr char 0 or 1 Vca Hall Negate unsigned degrees Vca Hall Lead char char Hall Fwd Seq An array of the haTT 0x01 0x03 0x02 0x06 0x04 8 unsigned number 0x05 0x00 0x00 shorts FET current unsigned CCADCdi vvoTt OpAmpGain FETRe senseing scale short 5 10 17 FETRes 4mQ OpAmpGain 2 13V V ADCdivVolt 3223uV adcdiv Current Loop unsigned 0 025 65536 1638 Proportional short P term is 0 025 constant Current Loop unsigned 1 100A 200 Intergral term short minimum error before change Current Loop unsigned 1 100A 300 Intergral term short maximum didt I term is allowed to cause Speed Loop P unsigned 40 Constant short Speed Loop I unsigned 400 Constant short Speed Loop D unsigned 600 short over voltage Tong mv 180000 point empty voltage Tong mv 90000 point motor speed Tong uVs rad 360000 constant k motor A external Tong uH 200 inductance current Timit Tong mA 5000 poles of the Tong 40 motor wheeT diameter Tong mm
9. 500 PWM Freq Tong Hz 20000 Motor overtemp Tong mec 80 HeatSink overtemp Tong mec 100 Controller Tong mc 80 overtemp SMPS overtemp Tong mec 80 Auxiliary Tong mec 80 overtemp Bus Voltage Tong 313500 multiplier Bus Voltage Tong 1024 divisor Bus Voltage Tong 0 offset Bus Voltage unsigned 0 invert char Controller Tong 200000 current multiplier Controller Tong 1024 current divisor Controller Tong 101510 current offset Controller unsigned 0 current invert char Tritium Pty Ltd 2003 20 Motor current Tong 10 multiplier Motor current Tong 1 divisor Motor current Tong 0 offset Motor current unsigned 0 invert char Heat Sink Temp Tong 330000 multiplier Heat Sink Temp Tong 2048 divisor Heat Sink Temp Tong 0 offset Heat Sink Temp unsigned 0 invert char Motor Temp Tong 49029120 multiplier Motor Temp Tong 1 divisor Motor Temp offset Tong 165090 Motor Temp invert unsigned 1 char 15 multiplier Tong 23100 15 divisor Tong 1024 15 offset Tong 0 15 invert unsigned 0 char Can Address unsigned long Data Data type Unit step Comment TRITIUM char 7 Start of packet header Packet type char 8 set config info response Packet type ve char Packet Tength bytes Does not include the header short 16 bit check sum unsigned Does not include the header short 16 bit XOR unsigned Doe
10. inputs must be connected to work Each input pair also has a corresponding LED on the PCB This LED will turn on when the switch is in the on position Screw Switch Wire Terminal 7 p PE gt Tritium Pty Ltd 2003 The following labelled connections must should be connected before operation Label Reguired Function Description Enable Mandatory Switch When the kill switch is in the off position all motor driving functions are disabled regardless of user inputs When the kill switch is on then normal operation is resumed Spare Mandatory Fwd Rev The direction switch indicates the Switch direction forward or reverse in which to drive the motor LH amp RH Strongly Brakes Many applications using the Gold Brake Advised Controller will use a dual braking system for the motor regenerative braking and mechanical braking A switch that becomes closed when the mechanical braking is used should be connected to either or both if there is more than one mechanical system of these inputs It will zero the controls and place the motor controller into neutral This prevents the controller from driving the motor against the braking system 1 4 2 VI Encoder Board The digital encoder used to drive the controller is a combined rotary encoder and pushbutton It is connected to the Gold Driver Control via a 6 way locking connector cable To accelerate in the direction sele
11. check sum unsigned Does not include the header short 16 bit unsigned Does not include the header short Set Point PWM Tong 0 1 speed 0 if sending Set Point motor Tong mA Always send current current Set Point Tong mm sec Send 0 if sending speed velocity Auxillary Command unsigned Tong Code commands to do simple tasks 0x00000001 Horn 0x00000002 Brake 0x00000004 Right Indicator 0x00000008 Left Indicator 0x00000010 Stop Mode Data Data pe TRITIUM char 7 Start of packet header Packet type char 2 motor controller info Packet type ve char Packet Tength um bytes Does not include the header short 16 bit check sum DATE Does not include the header short 16 bit XOR unsigned Does not include the header short Adj Set Point Tong 0 1 PWM Adj Set Point Tong mA motor current Adj Set Point Tong mm sec Velocity Adj Auxillary unsigned Tong Code commands to do simpTe tasks Command 0x00000001 Horn 0x00000002 Brake 0x00000004 Right Indicator 0x00000008 Left Indicator 0x00000010 Stop Mode Actual PWM Tong 0 1 Actual motor Tong mA current Actual Velocity Tong mm sec Bus Voltage Tong mv Controller Tong mA current Tritium Pty Ltd 2003 18 Heat Sink Temp Tong moc Motor Temp Tong moc Controller Temp Tong moc SMPS Temp Tong moc 15V Tong mv Adapter PCB Freg Tong Hz Adapter PCB Tong mv Analog Chann
12. cted by the Direction switch described in Section the encoder is turned in the clockwise direction This increases the encoder value To reduce the acceleration at any time the encoder can be turned in the anticlockwise direction Pressing down on the encoder shaft will push the button which zeroes the encoder and hence the throttle value Once the encoder value has reached zero by either turning the encoder anticlockwise or pressing the pushbutton continuing to turn the encoder anticlockwise will activate the regenerative braking system Similarly to acceleration turning the encoder anticlockwise from zero will indicate the level of braking desired The encoder value will be negative during regenerative braking Turning the encoder clockwise will then reduce become more positive the level of braking until the encoder value reaches zero Again pressing on the pushbutton will reset the controls to zero and braking will cease There is also a red LED on the encoder PCB The intensity of this LED increases as the magnitude of the encoder value increases Tritium Pty Ltd 2003 6 1 5 V Multifunction LCD Driver Display The Multifunction Driver Display Higure 10 top uses a single pushbutton labelled Select to cycle through four predetermined telemetry values delivered from the Gold Driver Control The displays are 8 segment numeric and show up to four digits They are connected and powered by an IDC ribbon cable
13. el 1 Adapter PCB Tong mv Analog Channel 2 Adapter PCB Tong mv Analog Channel 3 A apter PCB Tong mv Analog Channel 4 General Status unsigned Tong Coded reason for ignoring a driver control command 0x00000001 Invalid Quadrant requested 0x00000002 Overvoltage 0x00000004 Heat Sink over temp 0x00000008 Motor over temp 0x00000010 15v rail down 0x00000020 SMPS over temp 0x00000040 Controller over temp Configuration Mode In configuration mode there are two types of packets there are as follows Data Data type Unit step Comment TRITIUM char 7 Start of packet header Packet type char 5 reguest current config info Packet type ve char 5 Packet Tength ee bytes Does not include the header short 16 bit check sum Does not include the header short 16 bit XOR unsigned Does not include the header short Data Data type Unit step Comment TRITIUM char 7 Start of packet header Packet type char if sent from controller in response to packet type 5 6 current config info if sent to controller 7 set config info to Packet type ve char 6 7 Packet Tength ane toned bytes Does not include the header short 16 bit check sum unsigned Does not include the header short 16 bit XOR une igned Does not include the header short Controller text char 32 Eg GOLD CONTROLLER TRI07V4 ID Controller serial unsigned 000031 number long code build number
14. el 2 Adapter Not Used Channel 3 Adapter Not Used Channel 4 General The general status bits from the communications packet Status displayed as a hexadecimal number For descriptions of what each bit represents refer to the communications specification in Section 6 Tritium Pty Ltd 2003 17 6 Controller Communications Protocol Comms specs for TRI07v4 TRI22v1 TRI23v1 as of 3 3 2003 David Finn James Kennedy All packets are to be sent most significant byte first MSB first Operation mode In operation mode there are 4 types of packets they are as follows The driver controls are the master for the network At a frequency of between 4 and 10 Hz the driver controls must issue a driver controls info packet Faster then 10Hz can casue the controller to become over run and not all the packets will be received this does not worry the controller but will become confusing to the driver controls as it will not always get a response to every packet it sends Slower then 4Hz will casue the controller to time out when this happens the controller zeros the power to the motor until it gets the next good packet Data Data pe ep O TRITIUM char 7 Start of packet header Packet type char 1 driver controTs set points Packet type ve char 1 Packet Tength bytes Does not include the header short 16 bit
15. er Control board by cycling the power IV Download the compiled software using relevant tools Confirm that programming was successful V Disconnect the IDC connector from the board VI Reset the Driver Control by cycling the power 4 Operation Procedures 4 1 Connection and Testing It is important to verify that the required components of the drive system are all functioning correctly before operating outside of controlled conditions Our recommended testing procedure is as follows 1 Connect the Gold Power Controller Driver Controls encoder board and Driver Display as outlined in Section 1 2 Connect the power source to the controller and turn on the system You should verify that all products have turned on and that the displays appear to be showing the correct values 3 Turn off the power and connect the motor 4 Turnon the power and again verify that all units are powered and the displays are operating correctly Configure the motor using PhasorSense as outlined in Section 3 5 Using the digital encoder carefully increase the power to the motor until it is spinning at a reasonable speed approx 100rpm Operate the motor for a brief period verifying that the driver displays are operating correctly It will be O Tritium Pty Ltd 2003 immediately obvious if there is a connection problem with the motor Turn the digital encoder back to a zeroed position and allow the motor to coast to a halt 6 Repeat this test for
16. er Temp 000 mC Motor Temp 49099120 eso Controller Over Temp ew mc 15 Volt Rail 7 r SMPS Over Temp 00008 mc Auxiliary Over Temp mC Figure 16 The Config Edit window allows users to modify parameters within the controller Table 1 Parameters of the Config Edit win dow Config Edit Parameters Parameter Description Values Dependent Last Programmed Date and the controller was programmed time stamp of the last time MC Serial Number Unique serial number identifying the motor controller Code Build program Version and Revision of the software MC CAN Address Can be set to the desired CAN address to identify the controller on a CAN Bus network Over Voltage Cutout functions set above When the input voltage is at this value or higher all controller system reset is required to continue operation This SHOULD NOT be stated in Section 1 will be disabled and a the a NH bus voltage Under Voltage Cutout functions When the input voltage is at this value or lower all controller system reset is reguired to continue operation This SHOULD NOT be will be disabled and a Tritium Pty Ltd 2003 13 set below the minimum bus voltage given in Section Motor Speed Const k The speed constant of the motor being driven by the controller Motor Inductance The induc
17. er value is displayed down the right hand side of the window and is updated automatically Further explanations of these parameters are given in Section There is a large button labelled DISABLE CONTROLS that turns the on screen controls on and off to prevent accidental driving of the motor There are three control sliders that can be used to set the PWM current or velocity to drive the motor at One of these sliders is shown in F The program uses either a PWM control method or a velocity control method which is selected by checking the box above the appropriate slider When in either of these modes the Tritium Pty Ltd 2003 11 controller will attempt to reach the desired PWM or velocity level whilst keeping within the limits set by the Current Set Point slider PWM Set Point Each control slider operates diea ime PWM Mode in the same manner The slider is initially at the zero point on the bar If it is moved to the right then the set point is changed in the forward direction whilst Figure 14 PWM Control Slider a moving it to the left changes IPA r sata Ragen Lock the set point in the reverse direction The level set by Figure 13 Regen control slider the slider is reflected in the window on the top left of the slider For finer control over the set point value buttons that increment or decrement the value in single steps are placed to the right of the set point window Pressing the Zero
18. er which the controller will become inert disabling any functionality of the electronics WARNING The main supply to the controller should never be turned off whilst the controller is still under load ie driving the motor The remaining 3 high power connection terminals labelled A B C in are the three phase connections from the motor Note Cable lugs should be firmly attached by nuts in the screw terminals Users should avoid excessive tightening of these terminals as they can cause physical stresses on internal circuitry that can lead to a reduced product life cables and connectors should be rated appropriately and are chosen at the discretion of the user 1 1 1 1 Protection Tritium recommends that users should always fuse the connection between the high power source and the motor controller The fuse should be placed inline and be preferably a DC fuse of the fast blow variety Doing so will minimise damage to the controller caused by an external high power fault 1 1 2 Controller Front Panel G TRITIUM Program Run Current A Status Reset Controls Figure 2 The front panel of the motor controller Tritium Pty Ltd 2003 2 Label Function Motor The connection socket for the motor signal cable described in Section Controls The connection socket for the RS 485 communications This cable can come frara the Driver Control Board or a PC Further details are in Section 1 4 Program Ru
19. ers 0 1 2 correspond to Hall pins 1 3 on the motor connection outlined in Section Their row position in the table corresponds to which of the hall effect lines from the motor is active when phase A B B C and C A are active For example if the number 2 was in the top row then Hall Effect 2 from the motor will be active when the EMF of phase path A B is positive Hall Lead The number of electrical degrees that a hall effect signal will lead or lag if negative the phase voltages Hall Negate If a hall effect sensor is placed too far out of alignment with a phase winding in the motor then the hall effect value may need to be negated to obtain the best performance O Tritium Pty Ltd 2003 15 Table 4 Scaling parameters Scaling Config Dependent Parameter Description Values Multiplier The number that the corresponding parameter is multiplied by when scaled Divisor The number that the corresponding parameter is divided by when scaled Offset The number that is added after the parameter has been scaled using the multiplier and divisor Invert If checked then the parameter value will be inverted before it is scaled by the multiplier divisor or offset Formula parameter x multiplier divisor loffser Bus Voltage The voltage at the input terminals to the controller MC Current The current supplied from the power s
20. n This is a two position switch used when reprogramming the controller DSP During normal operation it should be set to the position It should only be set to Program when programming the controller as outlined in Section 3 Current This is the 4 way connection socket for the hard current hall effect sensors Section General Pushbutton A General Pushbutton B Status The three status LEDs indicate the following GREEN This will be on when there is power to the electronics in the controller YELLOW This LED will flash on and off when the controller is receiving valid communications packets RED This is a fault indicator and if activated the controller will not respond to any driving input signals The controller will only resume normal operation if the Reset button is pressed or the power is cycled The LED is off during normal operation Constant flashing indicates a hard current limit shutdown A repeated pattern of two flashes followed by a pause indicates that the controller has shut down due to a bad hall effect signal from the motor A repeated pattern of three flashes followed by a pause indicates the controller has shut down due to an overvoltage Reset Pressing this button resets the software in the controller 1 1 2 1 RS 485 Communications The connector pinout for the RS 485 Front View communications are shown in Figure 3 This plug is labelled
21. nductor Inductor 1 3 IL Hall Effect Sensors The Gold Power Controller uses a dual system for regulating current flowing through the controller to either the motor or power source The first system controls the current in response to driver reguests and adheres to set parameters This is performed by the onboard hardware The second system is a failsafe that protects the controller by shutting down the hardware in the Controller event of an exceptional current surge outside of the set limits This hard current system requires that two high current hall effect sensors each be placed around a phase lead from the controller to the motor It does not matter which phase leads are used A B or C or what orientation the sensors are arranged in The hall effect sensors are connected to the controller by Figure 7 Pinout for means of 4 way micro fit cables They are daisy chained the Hall Effect socket in any order and then connected to the socket on the controller front panel shown in Section 1 1 2 Figure 6 Blue lines indicate direction of phase leads through sensor windows Front View 15V 15V B A Tritium Pty Ltd 2003 4 1 4 IV Gold Driver Control The Gold Driver Control acts as a junction box for driver interfaces telemetry and controller commands The Gold Power Controller 7 communicates with the Driver Control via a custom RS 485 serial cable shown in Figure 9 The driver co
22. ntrol sends the requested driving conditions to the controller which in turn sends all telemetry information back to the driver controls For more information regarding the communications protocol between the driver controls and the motor controller refer to Section Figure 8 Connector functions of the Gold Driver Display The standard DB 9 serial connector is an RS 232 output port designed to convey telemetry data to a Wireless modem or computer for performance analysis The baud rate for this port is fixed at 115200bps Figure 9 RS 485 Cable plugs and socket There is also a 6 way locking connector that goes to the Digital Encoder refer to and two IDC output ports that send selected telemetry data to the Gold Driver Displays V Up to six Driver Displays can be daisy chained on each IDC ribbon cable 1 4 1 Screw Terminals Signals The 16 green screw terminals require some of the input switches to be attached before operation of the motor controller of these switches should be normally open two position The current and voltage levels used by the control board are small and will not supersede the power ratings of the chosen switches and do not pose an electrical shock hazard to the user The terminals are arranged in connection pairs for each function The inputs are adjacent to each other and will be labelled with the function name on one terminal input and GND on the other Both of these
23. ord and Close button to close the Config Edit window and return to the main program window In the Config menu select Upload Config to MC Once this has completed successfully your changes will have been permanently recorded in the controller The Open Config from file and Save Config to file options allow you to save and load custom configurations without having to retype parameter values every time the controller configuration is changed WARNING Changing settings incorrectly may damage the power controller and associated parts Tritium Pty Ltd 2003 12 MCIProg Config Edit Last Programmed 27 11 02 05 05 25 PM Current Control Loop Constants r Speed Control Loop Constants In xl Motor Controller ID Black ContollerTRIO V3 5 0 03333 1638 MC Serial Number 1 B 163 i 033333 Code Build 1 i D 0 33333 D1 655 Address C320A Over Voltage Cutout 180000 m Phasor Config Under Voltage Cutout 30000 my A ca cea mel Negat Motor Speed Const k 360000 uVs rad 1 E 0 Motor Inductance 0020 Current Limit 0000 mA Scaling Config FET Current Scale Factor EE 1 mA adcdiv Multiplier Divisor Offset Invert Nr of Poles in motor poles Bus Voltage n 3500 1 024 Do Wheel Diameter 500 mm MC Current oon o4 PWM Frequency 20000 Hz Motor Current fo is Do Motor Over Temp mC Heatsink Temp 330000 Heatsink Ov
24. ource to the controller negative if in ie current flows from the controller back into the power source Motor The current that the controller is supplying to the Current motor This is negative if the motor is in Heatsink The temperature of the heatsink casing of the Temp controller Motor The internal temperature of the motor Temp 15 Volt Rail The voltage level of the controller s internal 15V supply rail 5 3 Parameter Values Parameter Description Formula Bad Packets This is a red progress bar that will increase each time a communications packet was not transmitted or received correctly between the PC and the controller It will decrease with each correctly transmitted packet Bus Voltage The voltage at the power input terminals to the controller Controller The current supplied by the power source to the controller Current Heatsink The temperature of the heatsink casing of the controller O Tritium Pty Ltd 2003 16 Motor The internal temperature of the motor Temp Controller The internal ambient temperature of the controller case Temp SMPS Temp The temperature if the internal switched mode power supply of the controller 15V Rail The voltage level of the controller s internal 15V supply rail Voltage Adapter Not Used Freguency Adapter Not Used Channel 1 Adapter Not Used Chann
25. s not include the header short Tritium Pty Ltd 2003 21 NOTICE Tritium Pty Ltd Tritium reserves the right to make changes to their products or to discontinue any product or service without notice We would also advise customers to ensure that all relevant information they obtain is current and complete products are sold subject to the terms and conditions of sale supplied at the time of order acknowledgement Tritium warrants performance of its products to the specifications given at the time of sale in accordance with the standard warranty Products are tested to a suitable level to support these specifications although not all parameters will be tested for each individual product Customers are expected to take necessary precautions to minimise operational hazards involving the use of a Tritium product Tritium accepts no responsibility for resulting damage or loss to or by a product when operated outside the specified limits All intellectual property pertaining to products remains the sole property of Tritium Information published regarding third party products or services is not an indication of Tritium s endorsement or recommendation of these products in any way Copyright O 2002 Tritium Pty Ltd Tritium Pty Ltd 2003 22
26. tance of the motor as seen by the controller This value should include any external inductors connected to the motor Current Limit The maximum current supplied by the controller to the motor This is not the same as the current supplied to the controller by the power source FET Current Scale NOT ADJUSTABLE Factor Constant set by MOSFET hardware Nr of Poles in motor characteristics The number of magnetic poles in the motor Wheel Diameter Effective diameter of the wheel including the tyre for a wheel motor This value should be scaled according to any gearing systems used if the motor is not a wheel motor PWM Freguency NOT ADJUSTABLE The frequency that the MOSFETs are switched at in the controller Motor Over Temp When the motor temperature reaches this value or higher the controller will no longer drive the motor Users should experience a gradual performance drop as the temperature approaches this value Heatsink Over Temp When the heatsink temperature measured by the controller reaches this value or higher the controller will no longer drive the motor Users should experience a gradual performance drop as the temperature approaches this value Controller Over Temp When the ambient temperature within the controller casing reaches this value or higher the controller will no longer drive the motor Users should experience a gradual performance drop as the temperature
27. the motor in reverse 7 Again test the motor and peripherals in both directions but this time use the regenerative braking to halt the motor 8 Once these systems are operating correctly connect any further peripherals desired and test them 9 Test the motor driving and regenerative braking for higher speeds and powers 4 2 PhasorSense The PhasorSense feature of the Gold Power Controller is custom software that will detect the phase hall effect configuration of the motor After a motor has been connected to the controller the PhasorSense routine needs to be run only once The detected configuration is recorded by the motor controller Turning the power off and on will not erase the configuration The PhasorSense routine must be operated each time a new motor is connected or the existing motor is reconnected 1 Hold down the B button shown in 2 While still pressing the B button press and release the Reset button Release the B button 3 Make note of the configuration of the LEDs on the controller 4 Manually spin the motor to a reasonable speed and wait for the LED pattern to change 5 Your phase configuration has now been recorded you may operate the controller as normal Hall 1 Figure 11 Hall effect output and phase back EMF relationship Tritium Pty Ltd 2003 10 5 Motor Controller Interface Program The Motor Controller Interface MCI program is a Windows
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