Sevcon MOS90 DC Traction and Pump Controller Datasheet1-1734225600
Sevcon MOS90 DC Traction and Pump Controller Datasheet1-1734225600
Sevcon MOS90 DC Traction and Pump Controller Datasheet1-1734225600
Tech/Ops BULLETIN
MOS90 RANGE
The new Sevcon MOS Range of D.C. Traction
and Pump Controllera combines the latest
state-of-the-art Mosfel and Microprocessor
technologies.
The result is a highly efficient and flexible
range of controUers for small to medium sized
electric vehicles such as pallet. warehouse.
reach and low capacity fork 11ft trucks plus
personnel carriers.
The powerful microprocessor used in the
MOSSO range offers advanced features
previously unavailable in such a compact
controller.
PRODUCT RANGE
VOLTAGE
MAXIMUM CURRENT
Quiet operallon
Increased battery shift life
Increased motor life
Increased conlaelor tip life
Simple Installation plus reduced set up time
Reduced maintenance troubleshooting time
Reduced peripheral hardware- costs
Waterproof
Suitable for cold storage applications
Designed to meet U,L. and E.E.C. Standards
Sevcontrol
Sev{'Qn
FEATURES:
Tripk faibafp
Contactor chopping across vo!tagp rangp
Built-in diagnostic L.E.!).
Environmental protection
Unckrvoltage protf'ctioll
Ramp start
OvertelllpcrattllT l'utba('k
COlllroHe[ input protedl(lll
Built -in contador ",uppressioll
Mllllipk
i\{'(Til'ratO[
inputs
24-4BV
1BO-600 AMPS
USER/MANUFACTURER BENEFITS:
I) Te-ch/Ops
Spc('d Clltback
OPTIONS:
Bypa,.,s
Field WeakeJlillg
Bdly switch control
Seat switch lilller
Hev{'rs{' battery protection
i'uw{'r s\{'er delay
Constant speed (paknt pending)
Pump controllers (up to ~l programmahlt' speeds)
11111111111. .
SpecificatiOilS ('ontitlued overleaf
r-l=~~~========================~~~~~~m
Sevcontrol . . . .lllnIDIlI
0
1I11111111111n IOJIUO:>A8S
O.27~
e
24/36v
24/-48V
5. 1"
I,oh
Inch
13J
1.40590 "6"
1010590 C
213 8.38
213 8..38
254 10.00
1.40S90 "6"
1.10590 C
MOS90 "D"
258 10.16
283 11.14
lJ6 13.23
17'
1A0590 A"
l40mm
mmM
_L_
mm
'"
174
5.24
5.24
6.BS
7.00
20J 8.00
256 10.07
OPTIONAL EgUIPMENT:
CaHbrator Unit:
MOS9OA
24-4SV
ISOA
7M
OperatlngAmblent
Storage
MOS90B
24-4SV
27M
12M
-30C+4QOC
-40"C + 9O"C
MOS9OC
24-4SV
400A
17M
MOS90D
24-4SV
600A
22M
Accelerator delay
Creep speed
Maximum & cutback speed
Bypass & field weakening levels
Power steer timer
Seat switch timer
Uft speeds (pump controllers)
Aleo act. . . Dilltal Volt Meter me_1II'InI:
Battery volts
Motor volts
Motor current
Heatslnk temperature
Vehicle diagnostics
AdjUllter Module:
Acceuorlea:
------- Note:
Tech/Ops
Sevcon Ltd
Gateshead
England NEll OQA
Tel: (0191) 487 8516
Telex: 53328
Fax: (0191) 4.824223
Sevcon SA
Paris
France 95100
Tol: (1) 3410 95 45
Telex: 698505
F",,: (1)_3410 6138
Sevcon Inc.
Burlington, Mass
U.SA 01803
Tel: (617) 272 3612
Fax: (617) 272 1953
SECTION 1
CONTENTS
SECTION
TECHNICAL SPECIFICATIONS
FEATURES
DIAGNOSTICS
PUMP CONTROLLER
10
APPENDIX I
APP.I
APPENDIX II
APP.II
APPENDIX III
APP.III
APPENDIX IV
APPLICATIONS GRAPHS
APP.IV
APPENDIX V
APP.V
APPENDIX VI
APP.VI
APPENDIX VII
APP. VII
APPENDIX VIII
APP. VIII
This manual covers all MOS90 units produced from serial no. 0591---- onwards.
units, please consult Sevcon.
Sec. 1-1
Rev5.1/92
1.1
Thank you for buying a controller from the SEVCON family of MOS90 pump and traction
controllers. These controllers are designed with you the user in mind. They provide easy
installation, many new features not available before on DC motor controllers, and diagnostics of
drive system faults. They are designed and manufactured to the highest quality standards for long
life and low failure rate. Both pump and traction controllers are available which use the most
modern and efficient semiconductors available (MOSFETS), coupled with a state of the art
microprocessor system that allows more features per controller than ever before.
1.2
This manual has been specially prepared to make installation of your MOS90 controller easy and
trouble-free. It outlines all the major facilities available with this outstanding new controller.
1.3
If you have any questions or suggestions about this manual please contact any of the subsidiaries
of Tech/Ops Sevcon where our engineering staff will be happy to provide you with all possible
assistance.
Sec.1-2
Rev4.11.91
SECTION 2
SAFETY
2.1
Electric vehicles can be dangerous. All testing, fault finding and adjustment should be carried out
by competent personnel. Where possible, the drive wheels should be off the floor and free to rotate
during the following procedures THE VEHICLE MANUFACTURERS MANUAL SHOULD BE
CONSULTED BEFORE ANY OPERATION IS ATTEMPTED.
2.2
The MOS90 controller contains a triple failsafe system to give the highest level of safety. If the
green diagnostic light emitting diode (LED) is not illuminated or flashes on and off, the safety circuit
has tripped and the truck may not drive.
2.3
To ensure continued safety of the MOS90 system, the failsafe circuit should be checked whenever
the truck is serviced. The maximum period between checks should not exceed 3 months.
2.4
2.5
2.6
Note for 24/48v units without a line contactor fitted, never connect a battery to the controller with its
vent caps removed, as an arc may occur due to the controller's internal capacitance when it is first
connected.
2.7
Before handling controller cables on 24-48v units, disconnect battery and connect B + and Bterminals via a t OR ohm 25 watt resistor to discharge the internal capacitor.
FAILSAFE
CHECK
2.8
Ensure drive wheels are clear of the floor and free to rotate.
2.9
Switch on, release brake and select drive, wheels should rotate and green LED on controller give a
steady illumination.
2.10
Switch off, disconnect battery and connect A and B- terminals with 10mm2 or greater, cable,
ensure no other fault that would allow drive.
2.11
Reconnect battery, switch on key with direction in neutral. The LED should flash 3 times. Select a
direction and check that direction contactors do not close and wheels do not rotate.
2.12
Switch off at key, remove A/B- connection switch on at key. Reselect power up sequence, LED
should now illuminate and truck wheels rotate.
IF THE TRUCK DRIVES IN 2.11, THE CONTROLLER IS FAULTY AND MUST BE REPLACED.
2.13
NOTES:
2.13.1
As blowout magnets are fitted to contactors, ensure that no magnetic particles can
accumulate in the contact gaps and cause malfunction. Ensure that contactors are wired
with the correct polarny to their power terminals (as indicated by the + sign on the top
moulding).
2.13.2
The MOS90 MUST NOT be used with permanently connected on-board chargers or
damage to the system may result.
Sec.2-1
Rev4.11/91
SECTION 3
TECHNICAL SPECIFICATIONS
3.1
The MOS90 series of controllers are available in 4 basic power frames of different current
capacity. These 4 basic power frames then have various levels of build to give differing features,
such as voltage, allocation of contactors, reverse battery protection etc. The product range sheet
which follows details these variants.
The complete power frame is then 'matched' with a logic to give the required level of options.
3.1.1
Voltage:
3.1.2
Frequency:
3.1.3
Motors:
Min. motor
24V-0.lmH
36V - 0.15mH
48V - 0.25mH.
3.1.4
3.1.5
Contactors:
QQiL
System
Voltage
24v
24v
24v
36V
48v
24v
36V
48v
36v
48v
Chopping
Y
Y
Y
N
N
Max.
Current
2.0A
2.0A
2.0A
1.5A
1.5A
Mosfet Devices:
3.1.7
Operating Ambient Temp: -30C to + 40C. As the controller will limit its maximum
current above 800C (see Section 4-2, paragraph 4.20) the
controller may be used in ambients above 40C. However,
if the controller is operated at higher ambient temperatures
and under heavy load conditions, it may be found that the
maximum current available is reduced below the Imax value
as the controller may have entered thermal cutback.
3.1.8
-40C to +90 oC
3.1.9
Humidity:
Controller Frame
Family(8) Size
Notes
(1 )
2 Min
(2)
1 Hr
(3)
Bypass
O/C
Power (6)
Conns.
(5)
H
Remarks
Basic
24v
MOS90A 180
MOS90B 270
MOS90C 400
75
125
175
4 (10mm2j
4 (10mm2j
4 (25mm2j
140
140
140
213
213
254
63
63
63
Direction contactor
drivers only.
Reverse battery
protection (7).
Options
24v
MOS90A 180
MOS90B 270
MOS90C 400
75
125
175
360
540
800
5 (10mm2j
5 (10mm2j
5 (25mm2j
140
140
140
213
213
254
63
63
63
Direction contactors
+ any 2 of Bypass
Field Weakening or
P. Steer. Reverse
battery protection (7)
Basic
24/48v
MOS90B 270
MOS90C 400
MOS90D 500
(600)'
125
175
225
140
140
140
258 63
283 63
336 63
Direction contactor
drivers only.
4 (10mm2j
4 (25mm2j
4 (35mm2j
MOS90B 270
MOS90C 400
MOS90D 500
(600)'
125
175
225
540
800
1000
5 (10mm~
5 (25mm 2
5 (35mm2j
140
140
140
258
283
336
Direction contactors
+ any 2 of Bypass
Field Weakening or
Power Steer.
Options
24/48v
*
3.2
Mechanical
NOTES:
1 minute current
1im~
63
63
63
rating.
(1 )
Current limit ratings are with the controller at a max. of 60% ON.
(2)
1 hour ratings are at any %ON up to maximum and assume adequate contact
cooling of the controller.
(3)
This is the max. settable over current value, it is usually set at 1.5 times current
limtt - beware contactor and motor ratings'
(4)
(5)
(6)
5 power connections are required when bypass is fitted (options units only).
(7)
Reverse battery protected controllers only give this protection if used with the
correct contactors - See wiring drawings and contactor section (Section 6).
(8)
24 volt controllers may be used at 36 volts with a derating (refer to App. IV-2).
Sec.3-2
Rev4.11/91
SECTION 4
FEATURES
4.1 Encapsulated Enclosure:
An addttional contactor that operates wnh full throttle and, when the
delay has run out, to bypass the MOSFETS and allow absolute
maximum speed and efficiency. Bypass will also operate if the unn is
in current limtt for more than 1 second at full throttle.
4.6.2
4.6.3
4.6.4
4.6.5
4.11 Plugging:
The controller cuts out if'the battery dips below 13v, re-cycle through
neutral to restart.
Sec.4-1
Rev4.11/91
Built into logic unit for all contactors controlled by logic unit.
4.18 Anti-Rollback:
The unit must be in Neutral at Key ON, or drive will not be enabled.
When the heatsink exceeds 80 D C the current limit will linearly cut
back to zero at 90 DC.
SECTION 5
INSTALLATION
5.1
The controller should be bolted down to a flat (O.2mm max. deviation) paint free surface that has
been ligh~y coated with a thermal transfer compound, such as MS4 or Dow Corning #7, by the 4
bolt holes provided. Care should be taken not to trap any wires, etc., under the controller. The
mounting surface MUST be a substantial metal section of the truck for the full controller ratings to
be achieved.
5.2
Power connections should be made with flexible heat resisting cables of suitable cross-sectional
area for the current to be carried. These should be terminated in soldered or crimped lugs
attached to controller and the contactors. Note that nuts and washers are not supplied for the M8
connections on the controller. A battery disconnect switch should be used (EEe Directive).
5.3
Albright SW88 (MOS90 A), SW182 (MOS90 B & C) and SW202 (MOS90 D) are specified for use
with the controllers when 4 terminal motors are used. The equivalent single pole N.O. contactors
(SW80, 180, 200) are used for bypass and pump functions The field weakening contactor (if used)
may be of lower current rating than direction or bypass, viz:- it is possible to use an SW80 field
diversion contactor with SW182 direction contactor. When alternative manufacturers contactors are
used, coil currents pull in/drop out times should be investigated to ensure compatible operation.
5.4
Split field (3 terminal) motors can use single pole normally open type contactors for direction
function with controllers for 24v systems, BUT, controllers for 24/48v systems require changeover
contactors OR double pole normally open types (if armature field junction connection available) to
utilise the Reverse Battery Protection (RBP) feature.
5.5
The contactor mounting plane can affect performance; contactors should never be mounted with
their terminal studs vertically down. For further applications information on contactors, please
consult SEVCON
5.6
The controller may be supplied as a stand-alone unit, or pre-wired onto a baseplate with
contactors etc. If the controller is 'stand-alone', the control wiring should be terminated at the Molex
0.15" control socket If a 'panel' is supplied, the control wiring connector is usually an AMP 15 way
MATE-N-LOK type. The harness portion of the connector can be supplied with the controller as a
'loose equipment kit'.
5.7
Control wiring connections should be made using 1.00mm2 (AWG #) or equivalent stranded wire.
The correct pressure release crimping pliers MUST be used for long term connection reliability.
5.8
The main battery cable should be fused with a suitable air-break fuse. The keyswitch line must also
be fused at a level not exceeding 10 amps.
5.9
Hour meters MUST NOT have their negatives returned via the direction contactor drivers (Pins 1 &
10) as the controller will not function.
5.10
Pin 13 on control input must be connected to B-ve if not being used as speed control input.
Sec.5-1
Rev4.11/91
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SECTION 8
ADJUSTMENTS
8.1
The following procedure is relevant to both traction and pump controllers, except where otherwise
marked. The controller can be adjusted In several ways to its desired parameters:8.1.1
The unit is pre-set at Sevcon's factory, but may be re-adjusted later by one of the methods
below.
8.1.2
The unit may be adjusted by means of an 'adjuster' which contains 7 potentiometers. These
are 'read' by the microprocessor and can be adjusted while the controller is in operation. The
settings are 'memorised' when the un~ is removed. External instrumentation (shunt, ammeter)
must be used with the adjuster. Only the first 7 parameters can be adjusted with the adjuster,
as illustrated below. In the case of the pump controllers, the potentiometers adjust speeds 1
to 7.
8.1.3
8.1.4
The adjuster as 8.1.2, once set, may be plugged into a series of controllers to set each in turn
to the same parameters. This is a useful feature as it allows rapid (1 second) configuration of
batches of controllers. Typically the adjuster unit(s) will have its potentiometers masked off
once set up.
8.1.5
A hand-held calibrator may be plugged into the adjustment socket and used to digitally increment/decrement the parameters. The present value of these parameters wiii be shown on an
LCD display. Additionally, the calibrator can perform certain measurements on the controller
(see diagnostics section). Removal of the calibrator again causes the controller to 'memorise'
the set figures. This system gives the greatest accuracy and repeatability.
The hand-held calibrator has a bar display, operated by the SELECT button, showing
parameter/measurement selected and an LCD display showing values that, provided they are
parameters, may be adjusted by the +/- buttons. This unit may also be used to perform certain tests on the wiring harness and accelerator.
Additional external instrumentation is not required when using the calibrator's measurement
feature.
IT.
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Sevcontrol
Rev4.11/91
Sec.8-1
ADJUSTER
8.2 Connect the adjuster to the controller as shown below:-
. DIAGNOSTIC LED
....
9 "V
L___________________ _________
The following applies to traction controllers only. For details of use with pump controllers, see Section 10-1, paragraph 10.3.
8.2.1
F~ ammeter to motor circu~, ensure that truck drive wheels are clear of floor and free to rotate. Insulate the bypass contactor tips (ij used). Switch on the controller and set the accelerator to maximum
wtth the brakes applied so that the wheels cannot rotate. Adjust IMax. to give the desired current
8.2.2
With the truck drive wheels still clear of the floor, remove bypass contact tip insulation. Switch on the
truck and allow to run up to full speed and the bypass contact or to close. Apply the brakes to load the
drive motor until the desired current is reached. Adjust the BYPASS pot counter-clockwise slowly until
the bypass contactor opens.
8.2.3
Remove ammeter and set truck on ground. Drive truck and adjust ACCEL to give acceptable 'feel'.
8.2.4
Drive truck with load and plug brake, adjust PLUG to set plugging level to suit application. Note that
plugging response can be affected by accelerator position on certain controller types, so that plugging must be set with the accelerator at maximum demand.
8.2.5
Creep Speed is set by adjusting CREEP so that with the drive selected, the truck is just about to move
at minimum accelerator position. This level may be set differently depending upon application.
8.2.6
Drive truck unloaded on a flat surface and measure speed. Adjust SPEED to limit speed to desired
level.
8.2.7
Repeat 6 above with speed limit 1 switch input at B- and adjust SPEED 1 for desired speed level.
8.2.8
Note: Only the first 7 settings can be adjusted using the adjuster. The full list of settings is described
on the next page.
Sec.8-2
Rev5.1/92
ADJUSTABLE
CUSTOMER
PARAMETERS
CALIBRATOR
TRACTION
Parameter
Min
Max
MOS90ATMoS90B
i MOS90C
50A
180A
270A
50A
180A
0.1
MOS90D
Units
+j
Step Size
--
Current Limit
(I MAX)
Plugging Current
(PLUG)
Accel. Delay
(ACCEL)
Creep Speed
(CREEP)
Bypass Dropout
(BYPASS)
Maximum Speed
(SPEED)
Cutback Speed 1
(SPEED 1)
Cutback Speed 2
(SPEED2)
Field Weakening
(F.wEAK)
P.Steer Delay
(TIMER)
Seat Swttch Delay
(SEAT)
400A
600A
: Amps
lOA
270A
400A
750A
Amps
10A
5 secs
5 secs
5 secs
5 secs
Secs
0.1S
0%
25%
25%
25%
25%
%VB
1%
50A
360A
540A
800A
1000A
Amps
10A
0%
100%
100%
100%
100%
% VB
1%
0%
100%
100%
100%
100%
%VB
1%
0%
100%
100%
100%
100%
%VB
1%
50A
180A
270A
400A
600A
Amps
10A
50 secs
50 secs
; 50 secs
50 secs
Secs
1sec
5 secs
5 secs
i 5 secs
5 secs
Secs
0.1sec
For details of use with pump controllers, see Section 10-1, paragraph 10.3.
1
I
.....,'
........"
"'"
.......
"'" ..
...
....
....
..
-...,-............, , ..,,"""" ......
....
......" g
....""
..... "",
..... .."" ,-.,,'
PUMP
lie
MNO
.....
.....
- ...,
v
v
.,
DIAGNOSTIC LED
,bJT
Cl.lBlU.f'OR
Sewcontrol
Rev4.11/91
8.3
No LED segment will be lit and the minutes/seconds count is displayed. The hours count is
displayed by pressing the' -' button and the 1,ODDs of hours count by pressing the' +' button
as described in Appendix 1-1. Pressing the select button reverts the calibrator to its normal
operation, i.e. the IMax segment will be IiI.
8.3.2
When the desired parameter has been selected, it may be increased or decreased by means
of the + and - buttons on the right of the calibrator. The range of adjustments are given on a
previous page.
8.3.3
Note that parameters 6, 7 and 8 (SPEED, SPEEDI and SPEED 2) may reduce current limit and
ramp climbing ability.
8.3.4
For details of the measurement and test functions, please refer to the DIAGNOSTICS section.
CD
CONNECT CALIBRATOR
r-
TO CONTROL LER~-
CD
POIJER UP
TRUCK
n~llIg
i
F.;~
i . ,......... ' .
.
1...
,b,I
""_Dlr!!l.J
LJ
USE OF CALIBRATOR
ADJUST
ro
-----=-
===~
NEI,I VALUE
'--J)
SELECT N[lJ
PARAMETER
Aev4.11/91
SECTION 9
DIAGNOSTICS
9.1
The controller is equipped with a diagnostic system using a green LED located on the connection plate
near the adjuster socket.
ADJ SKT
..... j ~ ............. ..
(t)O
~U!lfu----rrit-~3DIAGNOSTIC LED
9.2
9.3
The LED is extinguished H the controller is faulty, the fuses are blown, the failsafe is not operational,
the contactor driver protection has tripped, or the Mosfets fail to turn on during drive. If the contactor
driver transistors are short circuit, the contactors may close but the vehicle will not drive under single
fault cond~ions.
9.4
This applies only to traction controllers. See Section 10-1, paragraph 10.4 for pump controllers. The
LED will flash a number of times on power up, or during running, to indicate a fault external to the controller.
9.4.1
2 flashes
9.4.2
3 flashes
9.4.3
4 flashes
9.4.4
5 flashes
9.4.5
6 flashes.
9.4.6
7 flashes
9.4.7
8 flashes
Thermal cutback.
PUMP
CONTROLLER
SECTION 10
10.1
The MOS90 pump controller is a derivative of the range of traction controllers which has been optimised for the control of hydraulic pump motors in electric vehicles. The same powerful single chip
microprocessor, calibrator and diagnostic system are used.
10.2
Features
10.2.1
Three power frame sizes are available with current ratings of 275, 400 and 600A These units
are physically the same size as the MOS90B, C and 0 units, but with only 3 connection busbars.
10.2.2
10.2.5 SPEEDS t -7 are active high and these inputs must be connected to B + to enable the speeds.
SPEED 8 is active low to allow its use as a power steer speed. The input must be connected
to B + to disable this speed and either disconnected or connected to B- to enable it.
10.2.6
Lift speed (SPEED 1) may be infin~ely variable with the use of an external 5K variable reSistor,
or a 0-5v input from a linear accelerator unit.
Adjustment
The pump controller may be adjusted in exactly the same manner as the traction unit. Using the
calibrator, all 8 speeds, the ramp delay, creep, current limit and the 'extra' speed may be set and reset
with their values being displayed:10.3.1
10.3.2
Ramp up delay displayed as 0.10 to 1.00 representing seconds in increments of 20mS (0.02
secs).
10.3.3
10.3.4 Current limit adjustable between 50A and maximum controller rating.
10.3.5
10.4
Diagnostics
The diagnostic system is generally as described for the traction system. The number of flashes is defined
below:10.4.1 LED off
Mosfets did not turn on.
10.4.2 2 flashes
Pump inhibit input operating.
10.4.3 3 flashes
Short circuit across Mosfets, or motor open circuit.
10.4.4 7 flashes
Battery voltage less than 13v.
10.4.5 8 flashes
Thermal cutback operating.
The test sequencer function of the calibrator is generally as described for the traction controller in Appendix I, with the pump pot. (if fitted) being tested first, followed by switches 1-8, then the inhibit input.
Sec.l0-l
Rev4.11/91
...""
..,
06 SOH
l\a~/"2
H3~'mI.1HOJ
Sevcontrol
::::::![
'I
IIOlIUO:M.8S
I
~
T
Rev4.11/91
~o
I.e.
17
ICJRIIW..LY Cl.DSED
'.
'.
S\I8
sY4
IATTo<VlII KEY
sYI!
PUll'
CIIIT
IV)
t :;
am.
aT
SIr.!
!)
~
1M MX
a:tma:L
F'IISE
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5.~
7.!)
PUll' IIKIIT
a.4.
0 00 0000000 OOOc;::;;J
~~
SVI
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Je.~
13.
sY7
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NTIl .....TIlIt
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,.
-(:
IA
Filii
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aT
16.
sY'
~IE
!II(
sY1)
..
Rev4.11191
Sec. 10-3
APPENDIX
CALIBRATOR
1.1
MEASUREMENT
DISPLAY
Selection of the last five segments on the display gives the following results:
1.1.1
BAn
1.1.2
MOTOR V.
This displays motor voltage and can be used to set speed limit.
1.1.3
MOTOR AMP. This displays motor current as the truck is being driven.
1.1.4
TEMP
1.1.5
TEST
This invokes the diagnostic test routines to check truck switches, accelerator,
harnesses etc.
c.
1.2
The BAnERY VOLTAGE test ..lIows the state of battery voltage to be continuously monitored during
drive. This test assists In the diagnosis of battery faults. Max voltage is recorded t>y service log.
1.3
If MOTOR VOLTAGE is monitored during driving at a Particl)lar speed and loading, it can be related
to a percentage of battery voltage and uSed to set speed cutback.
1.4
Use of the MOTOR AMP test will reveal if the motor is running at max. current up gradients etc. This
test will aid setting current limit to optimise battery life.
1.5
The TEMP test can be used durina prolonged running. of the tr\lck to check that no high temperature
conditions exist, due to poor neatsinkrng or unTIerspeciflcation.
Min/max temperatUres are
recorded by the service log.
1.6
2.
3.
This data is displayed by selecting the measurement section on the calibrator (either BAn or TEMP) and
then using the' +' and '.' buttons to display the maximum and minimum excursions.
E.g., select battery voltage on the calibrator and press the' +' button to display the maximum battery voltage
the controller has ever measured.
HOURS COUNTER
The counter records pulsing hours, and displays the count when the calibrator is first plugged in (with no
LED segment lit). Once the select button is pressed, the calibrator reverts to its normal operation, i.e.
stepping on to displaying the present current limit setting.
Initially a minute/second count is displayed. By pressing the'' button, hours are displayed and by pressing
the' +' button 1,O~~s of hours are displayed.
E.g., a count of 11,436 hours 27 minutes and 20 seconds would be:
1.
2.
3.
Releasing the buttons reverts back to the minute and 10's of second display. The decimal point 'blinks' every
second during drive. The counter will record up to 65,500 hours before rolling over to o.
App.ll
Rev4.11/91
CALIBRATOR
DIAGNOSTICS
~-~--~~~~~~~~~~
1.7
With the calibrator connected to the controller and the truck powered up, use the SELECT button to
select the TEST LED. If the SELECT button is pressed at any time during the tests, they will be
terminated and the minutes/seconds count will be displayed.
The first test selected is the accelerator test. This displays acceleration output as 0-100% as the
accelerator is moved from min. to max~
1.9
The
1.10
After test 10, the sequence will loop back to the accelerator test, then test 1.
+ and - buttons step through the tests as shown on the following page.
-
~-
Sequence No
---
-------
-~------
Test
Traction
Accelerator
1
2
3
4
Fwd. Switch
Rev. Switch
FSI Switch
Speed 1 Switch
Speed 2 Switch
Belly/Seat Switch
Spare I/P, pin 11
5
6
7
8
9
10
I
I
Chop. Select
I
!
----
----~-
Pump
Display
Speed Pot.
SWI
SW2
SW3
SW4
0-100%
SW5
SW6
SW7
SW8
Inhibit
..
C ustomeL.
Con nector Pin
1
CUOP
CUOP
CUOP
CUOP
CUOP
CUOP
CUOP
CUOP
CUOP
CUOP
CL = Switch input at B + ve
OP = Switch input at B-ve or disconnected
ACCELERATOR TEST
AT 851. PUSH
()) - CLOSED
FOOTS'WITCH I
(3)
OPEN
Rev4.11/91
App.l-2
APPENDIX
II
At battery connection, the LED should not illuminate. At key ON, the LED should illuminate steadily. If
the LED illuminates and remains steady, but no drive can be selected, the calibrator can be used to
test the wiring harness.
11.2
2 FLASHES
(TRACTION
ONLY)
Procedure Fault
Illegal start up sequence, 2 directions selected, no seat switch closed,
static return to off, (SRO) in operation.
Drive inhibited.
Flashes until fault is cleared
- - - ----- .. -I
Retry
I
_J
1------ .-,,--~---. i
Check for S.R.O. operation_
~-~--
Il
---- -,-------
J
---
dir~cti.~n b~~re-
fselect
FSI-.-j
, OR direction or FS I before
___ ----'<Elysw~ch
l ____
~---
-- "-
II--~f:ature
speci~c~:~_r
switch is not permanently KcI~;~J
,-------1_ ._ ___
- - - .... -
-~
2 FLASHES - Check pump inhibit input (Pin 1) for high input (BDI, etc)
(PUMP ONLY)
App.II-1
Rev4.11/91
11.3
3 FLASHES
(TRACTION
& PUMP)
-.--------- ....------:-1
Check bypass contactor (traction OnIY)J---
...
1-----
1-'-----'--Replace controller
L._
11.4
4 FLASHES
(TRACTION
ONLY)
1--"
[-C-h-eC-k-P-o-w-er
~ring
for shorts -
---)/..--
' - - - - - - "j . - - - - - - -
Rectify
--------------
---.
Rectify
--
CheC;fi.t~~~t~~~a~~me-~:~-l
Replace controller
1_ _ _ __
-----_._-,
_----.J
--~----
[~
r--__ _ ~ectify
---I
!
-~
App.II-2
Re\l4.11/91
11.5
5 FLASHES
(TRACTION
& PUMP)
:--
' - - - 1 -.---.-----I
I,
--'y"------~. .
1_
J.
power & control
..
- - - . - - -.
Repair/replace
-c J
~-
..
_,-----
-----~~-
Rectify
---~-
. - - - - - - - - -- -
1
Replace controller
App.II-3
Rev4.11/91
11.6
Accelerator faults.
3V5-OV input:- Voltage < 2V5 on power up
Voltage > 4V5 in drive
0-5V input:Voltage> 1V on power up
Controller pulses at creep setting.
Flashes until fault cleared.
6 FLASHES
(TRACTION
ONLY)
opef:~fs~~ua;rf~!e;at-~;-:~~l--f
,-_~=~-T=
Check
1_
minimum
setting
___ for voltage at
__ __
__ _______
J
,,
__
-_-R-:cti;y/r_epla::-_-__
~ Adjust as necessary or
replace
'---_____ _
Replace contron=--_ _ _
11.7
7 FLASHES
(PUMP &
TRACTION)
Change/charge battery
__
Repair/replace
L__ _
_"_--~--~~ectifY
App.II-4
Rev4.11191
II.B
B FLASHES
Thermal cutback
Heatsink temperature> BOoC (Current limit will be zero at 90C)
Allow unit to cool down, to clear flashing
(TRACTION
& PUMP)
----------
---
.1"-i
------
Re-set
_._1
--------
Reclify
--
-->l
-~epair--::ndlor
L__
'-------
bYPass~
Ii-t
fault
occurs
frequently
~J
_______
____
______
~
---I
1____ _
-------""
Replace controller
. ___
LED off
11.9
----
~n~-l
I
i~t::----l _ _.____.__
T-
,---------,
-"'--
_ _I
i
i
j " - -----
W.i~ng,-~.~es
Check supply
calibrator I
unit stili function?
-
Reclify
I
!
Reclify
--
~.
---~--- ...J
---.------- - - - _ .
ontroller is faulty:
) Autofailsafe check failed. LED turns
off when a direction is first selected
after power up. Recycle keyswitch.
Contactor drive SIC. LED resets if
short circuit clears.
Mosfets did not turn on, recycle
direction to neutral to clear fault
indication.
Replace controller
-~
App.II-5
Rev4.11/91
APPENDIX
III
III. 1 Condition
Result
pos~ion
a)
b)
c)
d)
e)
111.1.2 In neutral
Same as above.
111.2 Condition
Result
No effect.
App.III-1
Rev4.11/91
---~==~
APPENDIX
MOS90
RANGE
IV
APPLICATIONS
10-
7-
:::.::
01:
.~
0
0..
5-
01:
I-
@lIE
3 -
@A
0
12
24
36
BATTERY VOLTAGE
48
c:
App.IV-l
Rev411/91
s::
o
en
500
CD
:D
450
l>
"0
1:'
<:
.z,
400
,....
v.I
a..
24 VDLT BATTERY
----------- 36 VOLT BATTERY
C>
. MOS 90C
en
...........................................
350
<{
OJ
........................
"V"
~
w
/1\ 300 -i
<{
200
...............................
MOS 90B
'-
0:::
~ 1250
u
MOS 90A
.... ........
------
:D
-<
.........
"'--.....
~
............
..... ....
-....-----
------
:D
~
<
A
"
-~
C>
:::t
-I
........
en
,m
.........
.... ~
150
. -I
4
567
METRES <TOT AU
'"""--
10
MOS90
ACCELERATOR
------------~---------
RESPONSE
----- ---
ex>
:r:
(I)
:J
Q..
..0
(\J
o
o.-4
(]'I
ex>
If')
SllO/\
~OIOW
("')
(\J
o
......
App.IV-3
Rev4.11/91
0::
D
I-
4:
0::
W
--1
W
U
U
4:
~
APPENDIX V
CONTACTORS
AND
FUSES
V.l
The MOS 90 series of controllers are designed to cover virtually the full spectrum of electric
vehicles. The contactors used with these controllers can have various different ratings. Sevcon
recommend and fit Albright contactors, the optional fuse/contactor plate available with the MOS 90
being drilled to accept Albright contactor fixing centers.
V.2
The table on the following page details the recommended types of contactor that are used on the
MOS units, depending upon amperage and type of motor.
V.3
Exploded views of contactors are given on the following page to aid repair. Note that contacts are
normally only available in sets and MUST NEVER be filed.
V.4
V.6
Contactors whose coils are driven from the controller, should not be fitted with suppression diodes.
All other contactors and electromagnetic devices must be suppressed.
V.7
Three basic types of contactor are used with the MOS 90 system.
V.7.1
V.7.2
V.7.3
V.8
Coil Voltage
With the MOS 90 system, 24 volt contactor coils may be used irrespective of the system voltage,
provided contactor coil chopping is used.
V.9
Polarity
All contactors are fitted with blow-out magnets, so the' + ' terminal must be connected to the most
positive voltage. This ensures that, under a fault condition, any arc produced during contact or
opening is blown away from the contact or ..
AppV-l
Rev4.11/91
V.l0
Coil Ratings
Various different types of contactor coil are available to match different contact or duty cycles. It is
important that the correct replacement types are used. If in doubt - consult SEVCON.
Controller
COntactors
MOS90A
SWOO/88
150
Recommended type
MOS90B
SWOO/88
SW100/182
150
275
Recommended type.
May be used ~ the panel
is being used at its full
rating to give longer life.
MOS90C
SW100/182
325
Recommended type
MOS90D
SWI82/180'
425
SW200/202
425
Recommended type
An increase in contactor tip life can be obtained by using L (large) area contactor tips in these
SW180/182 applications. Especially for pump use.
The above are recommended air-break fuse sizes that are mounted on panels supplied by SEVCON.
Similar sizes are normally mounted for pump and traction applications. Control fuse rating should
not exceed 10 amps.
App.V-2
Rev4.11/91
APPENDIX VI
SPARE PART NUMBERS
VI. 1
All genuine SEVCON spare parts have an 8 digit part number and a serial number incorporating a
date code, viz: 0590xxxx, May 1990 manufacture. ALWAYS use the correct spare parts and refer to
Sevcon in cases of doubt.
Part no.
Description
631/40001-10
631/40011-20
631/40021-30
631/40031-40
631/40041-50
631/40051-60
631/40061-70
631/40071-80
631/40081-90
631/40091-100
631/40101-10
631/43001-15
631/43016-30
631/43031-45
631/44001-15
631/44016-30
631/44031-45
631/44046-60
631/44061-75
130/15114
130/15115
130/15116
858/27001
858/81991
858/82331
858/81990
858/80038
681/11011
151/82954
In-line fuse-holder
Fuse mounting blocks without hardware
661/27059
967/28023
662/14001
662/13091
656/12013
656/12019
932/92007
927/11042
927/11043
661/27035
661/27060
~-----1
il
'-------
-----
. J1::I:\
l~""
'-./1
Rev4.11/91
-4J--Ej-
~DRNG.NO.
~ 182/18289
..l
II
l~
I ~I
~
In
DO NOT SCALE
1
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"'1
}+
;
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a>fTACTIII
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"'" '"
~
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CD" IIIlJP
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III'
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FF
........ r
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I i iI
I:
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Ii
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I",
:;.
SPlI NJTOI 2
'II
ClJST1)4[R
cmrr.
00' m..CT
<S[
IlTE IJ
SPAItE
1l1TPU'T PLUG
'
'
I Ii!
I I
1- I
rt-.~'-+
I u"'-'" """-
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or ....,
! I
,,
_ t!!
-rbl
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MII'CTlOII S\I.
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SI-IlYM tB298
rr-
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I ~och/Op1
--,
p
TECH/DPS LIMITED
CR{F1LHED
S[V~
1+ , S VRE S1 " $2
run.
~ CHANGED
11
PS . .
IMS.
ITL[
TtLERANttS
rr..m
-~t~~~~~-~-=-------f;:r.;j~r:1f"""~::,::::,,::,c-=-<==~;;;;;;;------1:-:t;r.~=-e.
: ......,.
REVISION
F
B
C
D
E
A
1
I
I
nllGTC 4'!!I o\D1IED
I-I_
-t
:IJ
>
AlUJSTER/CAllBRA mR
(M)
(B-)
TOTY -
ISSUE
R[VlSlDN
DCCII'T .....
PS . .
aI ...
:IJ
(')
Z
~~
~ ~ ~
(Al~1
I(:tl 1&
m
-t
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SUoT/r.i DELAY!
IIlru -
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r-
-t
::
18~18289
....
REV.
:IJ
Z
C)
...:....
IIIU _ . .
:IJ
1!W 1
CONTACTOR
EXPLODED
VIEWS
:~,
SW80
SW180
SW200
SW202
App.V-3
Rev4.11/91