PRODUCT Tech/Ops BULLETIN MOS90 RANGE The microprocessor software facilities within the MOSOO The new Sevcon MOS Range of D.C. Traction range allow. significant number of features to be bullt and Pump Controllera combines the latest into the Controller ellminating additional hardware. state-of-the-art Mosfel and Microprocessor technologies. FEATURES: The result is a highly efficient and flexible Tripk faibafp range of controUers for small to medium sized Contactor chopping across vo!tagp rangp electric vehicles such as pallet. warehouse. Built-in diagnostic L.E.!). reach and low capacity fork 11ft trucks plus Environmental protection personnel carriers. Unckrvoltage protf'ctioll The powerful microprocessor used in the Ramp start OvertelllpcrattllT l'utba('k MOSSO range offers advanced features COlllroHe[ input protedl(lll previously unavailable in such a compact Built -in contador ",uppressioll controller. Mllllipk i\{'(Til'ratO[ inputs PRODUCT RANGE At'('t']('rat(H" billlre c\ejcctiOl] 24-4BV VOLTAGE Spc('d Clltback MAXIMUM CURRENT 1BO-600 AMPS OPTIONS: USER/MANUFACTURER BENEFITS: Bypa,.,s Quiet operallon Field WeakeJlillg Increased battery shift life Increased motor life Bdly switch control Increased conlaelor tip life Seat switch lilller Simple Installation plus reduced set up time Hev{'rs{' battery protection Reduced maintenance troubleshooting time i'uw{'r s\{'er delay Reduced peripheral hardware- costs Constant speed (paknt pending) Waterproof Pump controllers (up to ~l programmahlt' speeds) Suitable for cold storage applications Designed to meet U,L. and E.E.C. Standards •••••• 11111111111 .. Sevcontrol SpecificatiOilS ('ontitlued overleaf I) Te-ch/Ops Sev{'Qn r-l=~~~========================~~~~~~m O.27~ Sevcontrol .... lllnIDIlI 0 A8 1I11111111111 •• n •••• IOJIUO:> S l40mm _L_ M 5. 1" e mm Inch mm I,oh 1A0590 °A" 24/36v 213 8.38 13J 5.24 1.40590 "6" 213 8..38 5.24 '" 1010590 ·C· 254 10.00 174 6.BS 24/-48V 1.40S90 "6" 258 10.16 17' 7.00 1.10590 ·C· 283 11.14 20J 8.00 MOS90 "D" lJ6 13.23 256 10.07 Outline Specification: MOS90 RANGE MOS90D MOS9OA MOS90B MOS9OC 24-4SV 24-4SV 24-4SV Volu,e: 24-4SV 27M 400A 600A Current: ISOA 22M ContiD.uous Current: 7M 12M 17M OperatlngAmblent -30°C+4QOC Temperature: -40"C + 9O"C Storage Range: OPTIONAL EgUIPMENT: Provide. dJJltal adjutment of: CaHbrator Unit: Current limit Plugging level 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 Provides analog adjuatment of controller parameten AdjUllter Module: Full range of accelerators. contactors and contactor pane .. etc. Acceuorlea: ------- Note: Sevcon i. constantly atrivln& to improve ita This product bulletin is an outUne product. and reserves the rlfht to alter specification only. For specific appUcation speclflcation. without Dotice. data, tbe full enatneerlng specifications available from 8eVCOD should be ued. Sevcon Inc. Sevcon SA Sevcon Ltd Burlington, Mass Gateshead Paris U.SA 01803 England NEll OQA France 95100 Tol: (1) 3410 95 45 Tel: (617) 272 3612 Tel: (0191) 487 8516 Telex: 698505 Fax: (617) 272 1953 Telex: 53328 Tech/Ops F",,: (1)_3410 6138 Fax: (0191) 4.824223 Prmted In U. K. I P&S 12191 SECTION 1 CONTENTS SECTION INTRODUCTION & CONTENTS SAFETY 2 TECHNICAL SPECIFICATIONS 3 FEATURES 4 INSTALLATION & MECHANICAL DRAWING 5 POWER WIRING - TRACTION 6 CONTROL & ACCELERATOR WIRING - TRACTION 7 ADJUSTER & CALIBRATOR 8 DIAGNOSTICS 9 10 PUMP CONTROLLER APPENDIX I CALIBRATOR - MEASUREMENT & DIAGNOSTICS APP.I APPENDIX II FAULT FINDING FLOW CHARTS APP.II APPENDIX III SAFETY BUnON - METHOD OF OPERATION APP.III APPLICATIONS GRAPHS APP.IV APPENDIX IV CONTACTORS AND FUSES APP.V APPENDIX V APPENDIX VI SPARE PART NUMBERS APP.VI APPENDIX VII SAMPLE PUMP CONTROLLER WIRING APP. VII APPENDIX VIII SAMPLE TRACTION CONTROLLER WIRING APP. VIII This manual covers all MOS90 units produced from serial no. 0591---- onwards. For details of earlier units, please consult Sevcon. Sec. 1-1 Rev5.1/92 THE SEVCON MOS90 CONTROLLER 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 BATTERY MUST BE DISCONNECTED BEFORE REPLACING OR ATTEMPTING ANY REPAIRS OF THE CONTROLS. 2.5 Pin 13 must be grounded if not being used as speed control input. 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 B­ terminals 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 2.10 Switch off, disconnect battery and connect A and B- terminals with 10mm 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: 24/36 and 24/48 volt units available. 3.1.2 Frequency: 200Hz nominal with variable mark/space ratio 3.1.3 Motors: Suitable for 3 (spm field) or 4 terminal motors. Min. motor inductances:- 24V-0.lmH 36V - 0.15mH 48V - 0.25mH. 3.1.4 Battery Lead Length: 24/48v units, 15m max. 24/38v units, see Rating Charts, Appendix IV-2 3.1.5 Contactors: Direction (2), forward/reverse, bypass and field weakening OR power steer, i.e. a maximum of 3 contactor functions may be mounted. Maximum coil current per input: Contactor System Max. Chopping QQiL Voltage Current 24v 24v Y 2.0A 24v 36V Y 2.0A 24v 48v Y 2.0A 36v N 1.5A 36V 48v 48v N 1.5A A chopping facility is available so that 24 volt contactors may be used on all system voltages. It is recommended that whenever 24 volt coils are used the chopping facility is used. An optional contactor/fuse mounting plate can be fitted onto the controller. 3.1.6 Mosfet Devices: Have a lower forward (conducting) loss and a much higher switching speed than SCR's or bipolar transistors. This improves controller efficiency and prolongs battery shift life. 3.1.7 Operating Ambient Temp: -30°C to + 40°C. 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 40°C. 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. o 3.1.8 Storage Ambient Temp: -40°C to +90 C 3.1.9 Humidity: 95% max. non-condensing Sec.3-1 Rev4.11.91 MOS90 CONTROLLERS - PRODUCT RANGE Current Rating (4) Mechanical Notes Frame (2) Controller (1 ) (3) Power (6) (5) Family(8) Size 2 Min 1 Hr Bypass Conns. W L H Remarks O/C 75 - 4 (10mm2j 140 213 Direction contactor Basic MOS90A 180 63 24v MOS90B 270 125 - 4 (10mm2j 140 213 63 drivers only. 400 175 4 (25mm2j 140 254 63 Reverse battery MOS90C - protection (7). 75 (10mm2j 213 Direction contactors Options MOS90A 180 360 5 140 63 24v MOS90B 270 125 540 5 (10mm2j 140 213 63 + any 2 of Bypass MOS90C 400 175 800 5 (25mm2j 140 254 63 Field Weakening or P. Steer. Reverse battery protection (7) - Basic MOS90B 270 125 4 (10mm2j 140 258 63 Direction contactor 400 175 4 (25mm2j 140 283 63 drivers only. 24/48v MOS90C - - MOS90D 500 225 4 (35mm2j 140 336 63 (600)' Direction contactors Options MOS90B 270 125 540 5 140 258 63 (10mm~ 2 400 175 (25mm 140 283 63 + any 2 of Bypass 24/48v MOS90C 800 5 MOS90D 500 225 1000 5 (35mm2j 140 336 63 Field Weakening or (600)' Power Steer. * 1 minute current 1im~ rating. 3.2 NOTES: (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) These figures assume an ambient of 25°C. (5) The optional contactor/fuse plate increases the overall height to 125mm. (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). 24 volt controllers may be used at 36 volts with a derating (refer to App. IV-2). (8) Sec.3-2 Rev4.11/91 SECTION 4 FEATURES For maximum environmental protection and tamper-proofing . 4.1 Encapsulated Enclosure: Using both hardware and software techniques to give rapid action 4.2 Triple Failsafe Mechanism: and cross checking at each power up. Prevents 'runaway' due to any accelerator lead becoming detached 4.3 Accelerator Failure Detect: or incorrectly connected. Only available when 5K variable resistor or accelerator type 656/12013 is used (input pin 14). 4.4 Bypass Option: 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. 4.5 Bypass Dropout: Releases the bypass contactor if the preset current is exceeded and retums to the pulsing mode of operation: recycle direction through neutral to re-engage bypass. 4.6 Speed Control Interfaces: Various speed control systems may be used, i.e.:- 4.6.1 Sevcon Linear Accelerator, type 656/12019 OV min. speed, 5V max speed. 4.6.2 Sevcon Linear Accelerator, type 656/12013 3.5V min. speed, OV max. speed. 4.6.3 Variable resistor 5K ohm min. speed, 0 ohm max. speed. 4.6.4 Centre tapped potentiometer (1 K + 1 K) or (10K + 10K) OV min. speed, 5V max. speed. 4.6.5 Hardellet type module (uses 10.5V feed from pin 3). 4.7 Accelerator Characteristics: Non linear relationship between accelerator position and motor voltage to give enhanced control in low speed travel (see App. IV-3). 4.8 Max. Speed: Limns the top speed of the vehicle. 2 speeds externally selectable and adjustable to required level. 4.9 Cutback Speeds: 4.10 Constant Speed Option: This is available as a Control software option. The motor speed is monnored by means of software and held constant at the accelerator (Patent pending) demand setting, independent of load. To use this option the motor characteristics are pre-set into the software. Constant current type, adjustable. Varied by footpedal or hand 4.11 Plugging: throttle posttion as standard. Software option - no variation wnh footpedal or hand throttle. 4.12 'Belly' Swttch option: Used to give operator protection on 'Walkies' in line wnh the EEC Directive (see Appendix III). The controller cuts out if'the battery dips below 13v, re-cycle through 4.13 Under-voltage Protection neutral to restart. Sec.4-1 Rev4.11/91 4.14 Reverse Battery Protection: Provided as standard on 24v systems, requires polarity sensitive line (RBP) contactor on 24vj48v systems. 4.15 Input Protection: All customer control wiring inputs are protected against connection to B + or B-. Calibrator adjuster socket is not protected. 4.16 Contactor Suppression: Built into logic unit for all contactors controlled by logic unit. 4.17 Contactor Drives: May operate at system voltage or via a chopping system which reduces the coil voltage for use with 24 volt contactors; stabilised against battery variations. Customer selectable. Chopping is recommended whenever 24 volt contact or coils are used. Chops at about 18 volts. Basic controllers have direction contactor drivers only. Options units have direction and 2 other contactor drivers. These drivers may be configured as any 2 of Bypass, Field Weakening, Power Steer, by software option. 4.18 Anti-Rollback: Allows full current when drive is reselected without a direction change, even if the vehicle is rolling backwards. 4.19 Start Sequence: The unit must be in Neutral at Key ON, or drive will not be enabled. D 4.20 Overtemperature Rollback: When the heatsink exceeds 80 C the current limit will linearly cut D back to zero at 90 C. 4.21 Field weakening option: An additional contactor that closes at full throttle to increase top speed by means of a resistor in parallel with the motor field, or a tap on the motor field. Contactor drops out when motor current exceeds preset level. 4.22 Static Return To OFF: Requires direction to be selected before FS1, or FS1 and direction, (SRO) within 2 seconds: The direction switch must be in the neutral position before the keyswitch is turned ON. 4.23 Power Steer option: Software selectable in place of field weakening or bypass. Delay adjustable between 0 and 50 seconds in 1-second increments. Delay triggered by releasing FS 1 . When FS 1 is not wired to the controller, the delay is triggered in neutral. 4.24 Seat Switch option: Software selectable in place of belly switch input. Delay adjustable between 0 and 5 secs in 0.1 sec increments. After opening seat switch, recycle direction, through neutral, or FS1 to restart. 4.25 Diagnostic LED: A single LED gives comprehensive diagnostic information. LED on equals controller healthy. LED off indicates a faulty controller. A flashing LED, 2-8 flashes, indicates a fault external to the controller. 4.26 Adjustor & Calibrator: Straightforward, hand-held calibrator unit for digital adjustments or traditional potentiometer adjuster unit. Calibrator also incorporates unique DVM feature and harness check facility. 4.27 Hours Counter: Hours counter records controller pulsing time up to 65,000 hours. 4.28 Service Log: Used in conjunction with calibrator unit, records maximum battery voltage and maximum and minimum temperatures controller has experienced. 4.29 Electric Brake Option: Enabled after delay in neutral, and in conjunction with 'belly' switch. SecA-2 Rev4.11/91 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 substantial metal section of the truck for the full controller ratings to mounting surface MUST be a 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 controllers when 4 terminal motors are used. The equivalent single pole N.O. contactors with the (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'. 2 5.7 Control wiring connections should be made using 1.00mm (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 63 -------, I ,--r-' = ~ :;:: ::!t8r f " o 'V ~ en CD o r 1> -4 t:l Jl L Sevcont rol •••• IIIIIIIII~OS9q » C) >< '" ::j -< [$ , o I z ~6so"IIIIIIIIII... lOll UO:)A as C) .• 0 ~-, n o (J) o Z z 140 -4 -- -~L-; ~ -< $' 'W ;u Jl " CONTROLLER o , MM o '" INCH'S INCH'S MM r r f"'l ,F t:l ~ 24V ONLY MDS 90 'A' 213 8,38 173 6,81 , m '" Z I Jl -u MOS 90 'B' 213 8,38 173 6,81 c MOS 90 'C' ' 254 10,00 214 8.43 -< 1$ ; ; 24!48V MOS 90 'B' 258 10,16 218 8,58 I :;:: o '" 243 9,57 n MDS 90 'c' 283 I 11.l4 m >< C) f"'l MOS 90 'n' 3.36 I 13,23 29§. .11.65 _ L :I: ~G)tJ -< » z C) -.J » r- 7 C Jl ~" I .oj 'umoo ~'nMOC.,. 'W L"1 ! ~ 'Z " is' < .. ~ L J o> FIElD n VEAK -l 0 Z n 0 z 24V FAMILY CIlNTRDLLERS 24V FAHrLY CONTROLLERS -l JJ REVERSE BATTERY PROTECTED REVERSE BATTERY PRIlTECTED 0 PO'JER CONNECTIONS ;1 3: -1~~ J- B- ~ B- 13: 0 -l 0 JJ NOTES>- 1) CIlNTACTIlR PIJ'w'ER CIRCUIT CONNECTIDNS ARE POLARITY SENSmVE BECAUSE '0 (f) BLIJ'w' -DlJT MAGNETS ARE FITTED. NIlTE ' +' SIGN eN CDNT ACTOR MOULDINGS m () ii' ~ SEE CIlNTACTIlR SECTIlJ'j «(Ii>P.V> :::j < 0 "' Z r- , r­ n m '" ::tI '7' 24/48V FIoMJLY CONTRIlLLERS "'0 o NIl REVERSE BIo TTERY PROTECTION " ::E I«!TE ClIfiACTII! gH£CTl!)lS m ::tI SKIVING BYPASS .. FJELD M I 0- ___ , 'w'EAKENING CONNECTIONS :§ 0----, I ::tI I I Z I I G'> -j -j o :1 JYPASS :1 -= i> ... ... G'> ::tI » B- B- ;: .. -i iIIlTESo- 1> CONT 1oC~ P[)\{ER CIRCUIT CIHIECTIIJ'jS loRE PILIoRITY SENSITIVE BECAUSE BLD'w'-wr MAGNETS loRE FITTED. NIlTE '+' SIGN ON CDNTIoCTOR MDULDINGS ;: o .. SEE CONTIoCTOR SECTION (APP.V) d ::tI en 1!' < "'" "' 3: o r-------------~I~i~o><0__ B+ en I o> (") REV FWD REV FWD -i o Z (") o Z -i :0 24V fAMILY CDNTRILLERS o 24/48V fAMILY C!lNTRI'J i F'RS 24/48V fAMILY C!lNTm I F'RS 'r­ REVERSE BA~Y PRlJT£CTED r­ m NOT REVERSE BAnERY PROTECTED PD'WER 'WIRING 'JITH DPTIlJIS ,:0 PD'WER aH£CTIlIjS SKI'JJNG PIlYER CDNNECTlllNS 'JITH TD GIVE REVERSE BATTERY "0 BYPASS IF USED o BYPASS IF USED PROTECTION '.'HEN USED s ... s s ::E en m 'WITH D.P. NID CDNTACTOR NOTE CIlITACT!!R C!lt£CTJOO I :c ~ : ::E '" !~ '" Z G'l C I L-l I" I ~ I'! I i> " ---, ,G'l :0 I :I> I 3: -it} ;1 aYPASS ·1 aYPASS -1~ ~ -1~~ I- ~ i'.~ (jj B- I B- "0 r- :::j m " IIlTESt- 1> carr ACT!!R PIlYER CIRCUIT CDNNECTIIlNS ARE P!LARITY SENSmVE BECAUSE 5 BUl'w'-aJT MAGNETS ARE nnE». NOTE '+' SIGN ON carrACT!!R IOJLDINGS 1- .. SEE CDNT ACTOR SECTIIJoI P. 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'I' IIIU BE USED ::0 L.£AV£ LH::tH£CTED rI:R SPEED LIMITINi. l~!)--;,C-C-f1-ER-AT-OR-----~-ts-PE-ED--,1 S;ITCH IT'" ~ ~13 "'[' MAX PUSH :E (J> ~ ~. MAX SPEED 5. ~ nf'UT F"RCM DIREC'T'I[JoI S'w'ITD-L (1) ne M e. 16~ 5 :!! (") Z .... 17~ 6. JA TTERY + rEED F"R[Jt tcLYS'w'lTCH. 1G'l -+-----4---4Ie B- 7. SPEED LDttT 2 - aH£C1 TO 1+ n::R tIlRMAL IFERA TltK ; l> '" ! INEM fTTTTP[DA! 6»J1?Ot9 Z L.EAVE l.KDfr£CTElI ~ SPEED l.IMITlNG. C BASIC CONIRtl. \mUNG YUH SPEED LIHIT SUITABLE 8. FI:IN'ARD Df'UT rJt[Ji! DlR£CTl[IoI S'JITCH. FOR \r'ALKIE []R RIDE-DN TRUCKS. BYPASS L nELD n ,0 "'EAKENING ClF FITTI:D) ARE !NHlBITED "'HEN IN ,z 9. SlFPLY FlJif: CENTER-TN'PElI PDT ~ SJUJ. SlPPLY. z SPEED L!MJT. 90 RESISTANCE TRACK ~9® ,m SPEED ~ MIN lIJIEI::. THAT FSI OR SIMILAR S"'ITO£S MUST NCT 10. ~ARlI aJrffACTtJt am.. DRIVE. In , -! ,- e13 IDK MAX t BE USED 'WI£N A BELLY S'o'ITCH IS nTTED fl el3 1.L SPM[ DPUT . 10 .6 CONNECT PIN (2) m B+ FIR 3& AND 048 vm. T I ::0 '" CONTACTDR CDlLS, LEAVE UNCONNECTED FOR 24V COILS 1iW MAX SPEED e. t.2. F"Sl Df'UT ~ SJUl , "'[] MAX !lIP vm. TS B- (COIL CH!!PI'!NG) ; z 13. SEVa:Jt ACCfl FRATI:R DFUT aJV-sv twt: SPEElD, lK+1K CI PDr PQT$ 0Df'R TH.\H 5K caJrI£CT Tn I-VE JF trIJT USEID o Ie 0IF Tl£ SRI] FLN:TlI»I IS JIEIH(i USED I' -4 14. ~ PUT NTfl f'R4 TIll n-FUT C3.5V...qv MI\X. SPEElD I(J> TI£N PlN 9 IS I'IlT AVAllLAIlLE FIR USE AS AN ACCEl..ERA TtR stI'PI. Y. IN THIS 15. 1YPASS/P!I'o'ER STEIlt 13fT ACTtR am.. CASE C!HIECT Tl£ POSItIVE END I:F Tl£ 16. Ell.Y/S£AT S'w1iQf DrfI'UT. .ccELEAATDR PI!T m PIH 3 VIA A 470 _ 1/2 "'An RESlSIIR. 17. nn..DIDIVERSJIIt.IPD'WDt STEER aM'N:11It COIL ~ < '" ~ 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 The adjuster as 8.1.2 may be permanently connected to the controller. 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 incre­ ment/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 cer­ tain tests on the wiring harness and accelerator. Additional external instrumentation is not required when using the calibrator's measurement feature. I J \ \ I T. nON P"" ... ..... .. .... ... ....... """ .... .. ax "'"'- ....... .... ..... I ..... .. ...... ... ..... .. ..... . - ...... • ..... " ..... .. ..... ,.",.,. • ... COUP .... g ax KAT -- • - ...... ... "'" - .-- M .' " . .. .. n v D .",. v SEL£CT ... .... ,... CALIBRATOR //// "' "'" Sevcontrol Rev4.11/91 SEYCON MOS90 POTENTIOMETER MODULE (ADJUSTkR) AND CAl,..lIlRAT[]R 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 Sec­ tion 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. Insu­ late 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 plug­ ging 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 Step Size i Units -- - +- MOS90ATMoS90B i MOS90C MOS90D j I Current Limit 50A 180A 270A i 400A 600A : Amps lOA (I MAX) Plugging Current 180A 270A 400A 750A Amps 10A 50A (PLUG) Accel. Delay 0.1 5 secs 5 secs 5 secs 0.1S 5 secs Secs (ACCEL) Creep Speed 25% 25% 25% %VB 1% 0% 25% (CREEP) Bypass Dropout 50A 360A 540A 800A 1000A Amps 10A (BYPASS) 100% 100% 1% Maximum Speed 0% 100% 100% % VB (SPEED) Cutback Speed 1 100% 100% 100% %VB 1% 0% 100% (SPEED 1) 100% 1% Cutback Speed 2 0% 100% 100% 100% %VB (SPEED2) 400A 600A Field Weakening 50A 180A 270A Amps 10A (F.wEAK) P.Steer Delay 50 secs 50 secs Secs 1sec 0 50 secs ; 50 secs (TIMER) i 5 secs 5 secs 0.1sec Seat Swttch Delay 0 5 secs 5 secs Secs (SEAT) For details of use with pump controllers, see Section 10-1, paragraph 10.3. CONNECT CALIBRATOR TO CONTROLLER] I \ 1 I PUMP •• .....,' ...... "'" - ....... lie "'" - ... .... " .... .... .. .. .... .. ...... .... , "" , .... , - , .... " DIAGNOSTIC LED ...... ...... .. ,- g ... ...."" .. , ..... , "" .. -"" MNO ,-- "" .. .. .. v .,,' v ..... ,bJT ..... ., C£l.l BlU.f'OR ..., - - Sewcontrol Rev4.11/91 CONNECTION OF CALIBRATOR TO CONTROLLER Sec.6-3 8.3 Connect the calibrator as shown below and power up the vehicle. 8.3.1. 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 J CONNECT CALIBRATOR LER~- r- TO CONTROL CD POIJER UP TRUCK ~ n~llIg i F.;~ . ,b,I i .. , ......... ' .. 1... ""_Dlr!!l.J LJ USE OF CALIBRATOR -----=-===~ ADJUST ro NEI,I VALUE '--J) SELECT N[lJ PARAMETER Aev4.11/91 SETIING PARAMETERS WITH CALIBRATOR Sec.B-4 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 CONTROL VIRING SKT ~ ..... j ~ ............. .. (t)O ® ~U!lfu----rrit-~3- DIAGNOSTIC LED 9.2 On power up the LED will be illuminated if the system is functioning correctly. 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 con­ troller. 9.4.1 2 flashes Incorrect start procedure fault. Both forward and reverse selected. 9.4.2 3 flashes Bypass contactor welded - recycle through neutral to clear. Contactor coil short circuit - recycle the keyswitch to clear. 9.4.3 4 flashes Direction contactor welded. 9.4.4 5 flashes Direction contactor did not close, or open-circuit motor. 9.4.5 6 flashes. Faulty accelerator input. 9.4.6 7 flashes Low battery voltage. 9.4.7 8 flashes Thermal cutback. See Appendix II for detailed fault-finding flowcharts. Sec.9-1 Rev4.11/91 SECTION 10 PUMP CONTROLLER 10.1 The MOS90 pump controller is a derivative of the range of traction controllers which has been op­ timised 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 bus­ bars. 10.2.2 Voltage range 24-48v. 10.2.3 Reverse battery protected w~h polar~y sens~ive line contactor; capable of operation without a line contactor. 10.2.4 Up to 8 programmable speeds, with the priority of SPEED 1 highest, SPEED 8 lowest. 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. 10.2.7 Creep speed adjustable (but overridden by lower selected speed). 10.2.8 Soft start (ramp-up) delay is adjustable. 10.2.9 Current limit adjustable. 10.2.10 Additive speed feature increases % ON when speed switch 8 (normally power steer) is selected together with any other pump function. The speed increase depends upon the 'EXTRA' speed setting and gives a measure of speed compensation. 10.2.11 An inhibit input is provided which can be used in conjunction with a B.D.I. low battery signal to prevent SPEEDS 1-7 operating. SPEED 8 is still allowed to operate. 10.3 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 values being displayed:- with their 10.3.1 Speeds displayed as 0-100% representing 0-100% of battery voltage. 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 Creep adjustable between 0 and 25% of battery voltage. 10.3.4 Current limit adjustable between 50A and maximum controller rating. 10.3.5 Using the adjuster, the first 7 speeds may be set. 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 Ap­ pendix 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 MOS90 PUMP CONTROLLER MECHANICAL AND POWER CONNECTIONS L ... "" 06 SOH l\a~/"2 H3~'mI.1HOJ .. , Sevcontrol ::::::![ I 'I , IIOlIUO:M.8S + ~ I ~ T Rev4.11/91 MOS90 PUMP CONTROLLER - CONTROL WIRING SOCKET HOUSING (VIEVED FROM HARNESS SIDD ~o 0 00 0000000 OOOc;::;;J 1 17 PUll' IIKIIT I. ~ • ~ • 1M MX a:tma:L ICJRIIW..L Y Cl.DSED S\I8 e. F'IISE a. ~ IGV SQ'PLY sY4 4. • ~ sYI! 5. PUll' 0 • ~ CIIIT IATToy 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 unTIer·speciflcation. Min/max temperatUres are recorded by the service log. 1.6 TEST displays are explained on page 1·2. HOURS COUNT AND SERVICE LOG PARAMETER LOGGING The following data will be logged:· 1. Max battery voltage. 2. Max heatsink temperature. 3. Min heatsink temperature. 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. Initial display would be 27.2 indicating 27 mins, 20 secs. 2. Hold down '.' button to display hours, i.e. 436. 3. Hold down' +' button to display 1,000 hours, i.e. 11. 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.l·l 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. *** SAFETY! *** WHEN TEST IS SELECTED, THE TRUCK CAN STILL OPERATE! 1.8 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 + and - buttons step through the tests as shown on the following page. 1.10 After test 10, the sequence will loop back to the accelerator test, then test 1. ~- - --- -~------ ------- .. - ----~- ---- Test C ustomeL. Pump Display Con nector Pin Sequence No Traction - Accelerator Speed Pot. 0-100% 1 SWI 1 Fwd. Switch CUOP ! 2 Rev. Switch SW2 CUOP FSI Switch SW3 CUOP 3 i SW4 4 Speed 1 Switch CUOP I 5 Speed 2 Switch SW5 CUOP , I Belly/Seat Switch SW6 CUOP 6 I 7 Spare I/P, pin 11 SW7 CUOP 8 Chop. Select SW8 CUOP - CUOP 9 - I ! Inhibit CUOP 10 - CL = Switch input at B + ve OP = Switch input at B-ve or disconnected FOOTS'WITCH I FOR 'WARD S'WITCH ACCELERATOR TEST (3) - OPEN ()) - CLOSED AT 851. PUSH Rev4.11/91 App.l-2 APPENDIX II FAULT FINDING FLOW CHARTS ILl 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 Procedure Fault Illegal start up sequence, 2 directions selected, no seat switch closed, (TRACTION ONLY) static return to off, (SRO) in operation. Drive inhibited. Flashes until fault is cleared --- ----- .. -I Retry I _J 1------ .-,,--~---. - J fselect dir~cti.~n b~~re-FSI-.-j i Check for S.R.O. operation_ --- , OR direction or FS I before ___ ----' 4V5 in drive 0-5V input:- Voltage> 1V on power up Controller pulses at creep setting. Flashes until fault cleared. I Check opef:~fs~~ua;rf~!e;at-~;-:~~l--f __ -_-R-:cti;y/r_epla::-_-__ J , - __ ~=~-T= n heCk pot operation with voltmeter 1_ ~ Adjust as necessary or replace I for voltage at minimum setting '---_____ _ ___ __ __ __ _______ J ~ , , " .. -.-- ----------..' Replace contron=--___ I L 11.7 7 FLASHES Battery voltage < 13V (PUMP & Drive inhibited TRACTION) Recycle to neutral to clear flash Change/charge battery Check battery voltage with voltmeter ______ _ 1. __ ~ Repair/replace L __ _ r _"_--~--~~ectifY App.II-4 Rev4.11191 Thermal cutback II.B B FLASHES (TRACTION Heatsink temperature> BOoC (Current limit will be zero at 90°C) Allow unit to cool down, to clear flashing & PUMP) ~ ---------- - --- i Re-set ~heck c~rre~ limit selling .1"- [ _._1 ------ -~-- -------- Reclify Check mounting and. heatsinking Of]. __________ _ controller -- -->l ·-~epair--::ndlor Ii-t bYPass~ Check if bypass is operating (if mounted) r fault occurs frequently ~J L__ _______ ____ _ _____ ~ '------- ---I i r Use larger controller i 1 ____ _ -------"" ---- C Replace controller . ___ J Unit not powered up or controller faulty, or LED faulty. 11.9 LED off battery is connected ~n~·-l·­ Check keyswitch is on I ,---------- -"'-- j"- ----- , i~t::----l ___ . ____ . __ Check all fuses are I 1 Reclify __ I ! ·T-· I Check supply W.i~ng,-~.~es calibrator I Reclify unit stili function? - I -- i - ---~--- ...J ~. ---.------- ---_. ontroller is faulty: Replace controller ) Autofailsafe check failed. LED turns ~ off when a direction is first selected I 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. -~ App.II-5 Rev4.11/91 APPENDIX III SAFETY BUTTON (BELLY SWITCH) - METHOD OF OPERATION TRUCK MOVING IN REVERSE AND ACTIVATING THE BELLY SWITCH III. 1 Condition Result 111.1.1 The accelerator in reverse pos~ion a) The contactors change direction to forward drive (this initiates plug braking). b) 150% maximum plugging is applied maximum of 1.5 seconds; it will then revert back to maximum plugging. c) The vehicle will accelerate at full speed along the standard accelerator curve. d) All drive will cease 1.5 seconds from the start of (c) above. e) The controller will wait for neutral to be selected before drive will operate. If belly switch pressed again however, action as at (c)above. 111.1.2 In neutral Same as above. 111.1.3 Accelerator in forward position Already in plugging cycle. Action as at start of (c) above. TRUCK MOVING FORWARD AND ACTIVATING THE BELLY SWITCH 111.2 Condition Result 111.2.1 Accelerator in forward position No effect. 111.2.2 Accelerator in reverse position When belly switch closed, truck drives forward as at start of (c) above. App.III-1 Rev4.11/91 ---~==~ APPENDIX IV MOS90 RANGE APPLICATIONS HOY TO CHOOSE THE CORRECT CONTROLLER fOR YOUR APPLICATION THIS GRAPH ASSUMES - 10 MOTOR EFFICIENCY OF 851. AND ADEQUATE COOLING TO VECHICLE CHASSIS, 9 - ONLY AVAILABLE IN 24/48V VERSIONS - lIE 8 ® ONLY AVAILABLE IN 24/36V VERSIONS A - 7 ~ :::.:: ® © - 6 01: w .~ 0 - 5 0.. © 01: 0 4 - @lIE I- 0 ~ - 3 © ® ® - 2 ® @A - 1 @ 0 12 24 36 48 BATTERY VOLTAGE c: App.IV-l Rev411/91 s:: o THIS IS APPLICABLE FDR 2~/36V CONTROLLERS en CD NO DERATING IS NECESSARY f"DR 2~/48V CONTROLLERS. o 500 • :D I » 24 VDLT BATTERY . -I 450 ----------- 36 VOLT BATTERY Z I C> . MOS 90C en 400 ,.... l> v.I ........................................... "0 OJ 1:' a.. <: ~ 350 .z, <{ ........................ ~ "V" m ............................... :D ~ /1\ 300 -i MOS 90B -< '- ......... w , 0::: m ---- ......... ~ .... .... -- .... "'--..... ..... .... » ~ 1250 - .... c u -- --- I -- " x ---- m 200 ~ MOS 90A -~ <{ z .... ........ ~ C> ........ -I .... ~ :::t 150 , en 0 1 2 3 4 567 8 9 10 METRES :r: (I) :J Q.. 0:: 0 D ..0 I- 4: 0:: W --1 W U U 4: 0 ~ ~ o (\J o o 0 o o o o o If') ("') (\J (]'I ex> .-4 ...... SllO/\ ~OIOW % App.IV-3 Rev4.11/91 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 The contact stud securing nuts must not be overtightened. 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 Single Pole Normally Open contactors. These contactors are normally used for Bypass, Field Weakening, Pump or Power Steer functions. They are also used in pairs for direction contactors on 3 terminal motor applications. (SW80, 180 and 200 types). V.7.2 Double Pole Normally Open contactors. These contactors are only used for direction function on split field motors where the armature/field function Is available as a power terminal and where reverse battery protection is required on 24/48v family controllers. (SW822, 192 types). V.7.3 Double Pole Changeover Pair contactors. These contactors are available as reversing pairs and are used for direction functions with 4 terminal motors as well as 24/48v family controllers with split field motors where reverse battery protection is not required. Note that these contactors may be wired either normally open to battery positive or normally closed to battery positive depending upon the motor type (SW88, 182,202 types). 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 150 Recommended type. SWOO/88 SW100/182 275 May be used ~ the panel is being used at its full rating to give longer life. Recommended type MOS90C SW100/182 325 MOS90D 425 Can be used at lower SWI82/180' currents but life will be shortened. 425 Recommended type SW200/202 • 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 MOS90C controller (options) 24/36v system 631/40011-20 MOS90B controller (options) 24/36v system 631/40021-30 MOS90A controller (options) 24/36v system 631/40031-40 MOS90D controller (options) 24/36v system 631/40041-50 MOS90C controller (pump) 24/48v system 631/40051-60 MOS90B controller (pump) 24/48v system 631/40061-70 MOS90B controller (options) 24/48v system 631/40071-80 MOS90D controller (options) 24/48v system 631/40081-90 MOS90A controlier (basic) 24v system 631/40091-100 MOS90B controlier (basic) 24/48v system 631/40101-10 MOS90C controller (basic) 24/48v system 631/43001-15 MOS90A & B panels 3T motors 24/36v 631/43016-30 MOS90A & B panels 3T motors 24/48v 631/43031-45 MOS90C panels 3T motors 24/48v 631/44001-15 MOS90C panels 4T motors 24v 631/44016-30 MOS90A & B panels 4T motors 24/36v 631/44031-45 MOS90A & B panels 4T motors 24/48v 631/44046-60 MOS90C panels 4T motors 24/48v 631/44061-75 MOS90D panels 4T motors 24/48v 130/15114 MOS90A & B contactor plate 130/15115 MOS90C contactor plate 130/15116 MOS90D contactor plate 858/27001 Air brake fuse 150A 858/81991 Air brake fuse 275A 858/82331 Air brake fuse 325A 858/81990 Air brake fuse 425A 1.25 x 0.25 control fuse 7A 858/80038 In-line fuse-holder 681/11011 151/82954 Fuse mounting blocks without hardware 661/27059 Loose equipment kit Crimping pliers for loose equipment kit 967/28023 662/14001 Calibrator 662/13091 Adjuster 656/12013 Linear foot pedal unit (3.5v to Ov) 656/12019 Linear foot pedal unit (Ov to 5v) 0 932/92007 5K ohm 30 potentiometer 0 927/11042 10K ohm 330 centre tapped pot 0 927/11043 10K ohm 330 standard pot 661/27035 Plug kit linear accelerator (019) Plug kit linear accelerator (013) 661/27060 App.VI-1 Rev4.11/91 APPENDIX VII - SAMPLE PUMP CONTROLLER WIRING ~-----1 il • '------- ----- - .• J1::I:\ 1 l~"" - '-./1 Rev4.11/91 B A I C E F G H D ~DRNG.NO. ctPYRJGHT TEovtPS, UMITElI 1989 THIS DRAIJING IS CDNF"IllEHTlAL DO NOT SCALE ~ 182/18289 AND tlJST JCJT IE IIU'RDlU::ElJ IN PMT [II: VKlLE V}'ntJUT T)£ -4J--Ej- 'w'R'ITTEN PlRHlS$lLi4 ~ TLCHItF'S LIMITED ~ - ~ 1 ..l II I ' ! ,<.---- ...... "'1 » I I "'TTOY "U , ' "U ....l- - l~ TIt#oCTJtJI '"'" m :T Z Mnurr LX + I ~I /UIO< ..... FU .. C ........ '" "'" '" X }+ , ; a>fTACTIII ~ ~.a:n.. I J I CD" II£IlJP ~ ctJITIIL - . ....., I JEllY S'W. ~ """ < In + ~ ~rrttA - ~ Iii I r; t ... ~:" ---0 rvJ MII£'CTlOII S\I. ~ -, I ., I" II£V , , " , , II CTR TN' P'DT. • aT ...., "-----c> ~ 2 · ~. L. -rbl I'\JP t'o/. :: I I , I I , :;. """ SVITO< 1 "U I I I I SP££lI NJTOI 2 :;. r­ , 1- I I Fill'! III' ; ,I ,j~~} • tDV o\CCD... SLP9'l T aT 1tEGD.J m FF _ t!! cmrr. 00' m..£CT aJlTN:TtaS. -t ~ WID IJIDIi mTPI VII. T AGES I:r :. .. 4IV 00 NOT lIE( [)CPII'1JG (Mo, aN«.C:T I"DI 2 - 1+' :IJ - o AlUJSTER/CAllBRA mR ~~ ~ ~ ~ r­ (Al~1 I(:tl 1&£ (B-) > (M) r­ m [ Cll11tHI :IJ -<... :0 C 1~~T~~V~~~El .. 2 NlJ\( SI-IlYM tB298 "l~ ~ I ~och/Op·1 TECH/DPS LIMITED --, ~ DmIIiII VEIII ..,.... lEA! N IIlAT COKCTDII .... 18163 CR{F1LHED S[VCDN DIY. UJ(, 4 ~ S[V~ DIY. USA :IJ p ~ 1+ , S V£RE S1 " $2 S[VCON DIV< FRANCE 11 IMS. ITL[ Z ~ 2 run. PLLIi [lJTPI.lT PIN ~ CHANGED PS .. TtLERANttS IJIRING DIA. 24V 3 TERM. C) DCCII'T ..... rr .. m nllGTC 4'!!I o\D1IED TOTY - ISSUE PS .. - ...:.... .... / REV. I -~t~~~~~-~-=-------f;:r.;j~r:1f"""~::,::::,,::,c-=-<==~;;;;;;;------1:-:t;r.~=-e. : .... ..,. 18~18289 D 1!W 1 _ REVISION I- R[VlSlDN aI ... _ IIIU _.. _ B C D E F G H A 1 I I CONTACTOR EXPLODED VIEWS :~ , SW80 SW180 SW200 B SW202 App.V-3 Rev4.11/91