177-52101 PowerpaK Series Traction Manual - En.es

TM
PAGS owerpa K
SEVCON
SERIE
Este manual del usuario detalla las características de los siguientes controladores y variantes de la serie PowerpaK.
1) Serie de tracción 24-48V, 300A, 450A, 650A Baja lógica de E / S
2) " 72-80V, 450A, 600A Baja lógica de E / S
3) " 24-48V, 300A, 450A, 650A Lógica de E / S media
4) " 72-80V, 450A, 600A Lógica de E / S media
5) " 24-48V, 300A, 450A, 650A Alta lógica de E / S
6) " 72-80V, 450A, 600A Alta lógica de E / S
7) Serie de bombas 24-48V, 300A, 450A, 650A Lógica de E / S de bomba
8) " 72-80V, 450A, 600A Lógica de E / S de bomba
Historial de modificaciones
Revisión Fecha de asunto Autor Cambios

Rev E 9 de abril de 1999 PRG Altos cambios de E / S / Nuevas variantes
Rev F 27 de octubre de 1999 AJK Cambios de características y adiciones
Rev G 14 de septiembre de 2001 PD Adiciones, RS232, Cableado, Detalles Mech
PS 14 de septiembre de 2001 Manual PowerpaK - Revisión G 1

CONTENIDO
HISTORIAL DE MODIFICACIÓN ................................................ .................................................. ........................................... 1
1 INTRODUCCIÓN ................................................. .................................................. .................................................. ..3
2 VARIANTES CONTROLADORES POWERPAK .............................................. .................................................. .............. 4
3 CARACTERÍSTICAS DEL CONTROLADOR CON LAS DIFERENTES VARIANTES DE LÓGICA .......................................... .......... 5
4 SEGURIDAD ................................................ .................................................. .................................................. .................... 6
5 ESPECIFICACIONES TÉCNICAS ............................................... .................................................. ............................ 6
6 CABLEADO DEL CONTROLADOR Y CONEXIONES ............................................. .................................................. .... 8
7 CALIBRADOR Y AJUSTES .............................................. .................................................. ................... 12
8 DIAGNÓSTICO ................................................ .................................................. .................................................. ...... 20
9 REGISTROS DE SERVICIO Y FALLAS (TODAS LAS LÓGICAS) ......................................... .................................................. ........ 21
10 OPERACIÓN DEL CONTROLADOR Y DESCRIPCIONES DE CARACTERÍSTICAS ............................................. ................... 22
11 PANTALLAS DEL TABLERO DE CONTROL - DESCRIPCIONES DE FUNCIONAMIENTO Y FUNCIONES ........................................... .31
12 DESCRIPCIONES DEL CIRCUITO DE POTENCIA ............................................... .................................................. ................. 39
13 INSTALACIÓN................................................. .................................................. ................................................. 40
14 DIRECTRICES DE EMC ................................................ .................................................. ............................................. 41
FIGURA 1 CABLEADO LIGERO - LÓGICA DE E / S BAJA. (FUNCIONES DE LA BOMBA EN SOPORTES.) ................................... 45
FIGURA 2 CABLEADO DE LUZ - LÓGICA DE E / S MEDIA ........................................ .................................................. ........ 46
FIGURA 3 CABLEADO LIGERO - LÓGICA DE E / S ALTA ........................................ .................................................. ............... 47
FIGURA 4 REGENERACIÓN DE TRACCIÓN EN SERIE ............................................. .................................................. ....................... 48
FIGURA 5 ENCHUFE DE TRACCIÓN DE LA SERIE ............................................. .................................................. ................ 49
FIGURA 6 BOMBA SERIE .............................................. .................................................. ................................................ 50
FIGURA 7 DETALLES MECÁNICOS .............................................. .................................................. ............................ 51
2 Manual PowerpaK - Revisión G PS 14 de septiembre de 2001

1 INTRODUCCIÓN
1.1 La gama de controladores PowerpaK utiliza un nuevo concepto en tecnología de conmutación de potencia para proporcionar una
gama completa de cuadros de potencia 24V-80V, 300A-650A en un paquete pequeño y altamente eficiente. Esto se logra
utilizando un nuevo esquema de conmutación de potencia y nuevas técnicas radicales de construcción, ambas objeto de
solicitudes de patentes, que permiten incorporar grandes potencias en paquetes muy pequeños.
La gama de controladores PowerpaK está disponible en formatos independientes de Tracción y Bomba, y la Tracción ofrece ya
sea Regen y frenos de enchufe o solo frenos de enchufe. Para mejorar la flexibilidad y la facilidad de servicio, la lógica se
conecta al cuadro de alimentación y se puede quitar fácilmente sin alterar las conexiones de alimentación ni tener que quitar la
cubierta del cuadro de alimentación.
Para aumentar aún más la flexibilidad y adaptar el controlador a aplicaciones específicas, existen 3 versiones principales de
lógica que varían en complejidad y la cantidad de E / S, funciones de entrada y salida, para ayudar a garantizar que se ofrezca el
paquete de controlador más rentable para un particular solicitud. La lógica de baja E / S es una lógica de característica mínima
dirigida a aplicaciones de carretillas elevadoras y carretillas elevadoras. La lógica media es más adecuada para vehículos más
sofisticados, incluidos los tipos de montacargas y carretillas retráctiles, mientras que la lógica de alta E / S está dirigida al
mercado de elevadores aéreos donde se requiere una mayor E / S. Todas las lógicas tienen comunicaciones CAN.
Todos los controladores PowerpaK están basados en microprocesador con software flexible y opciones de configuración, y utilizan
tecnología de conmutación de energía MOSFET de alta frecuencia. Los controladores han sido diseñados para satisfacer los
requisitos de las normas UL y EC relevantes. Los controladores PowerpaK se han optimizado para su uso con motores bobinados
de la serie DC. Hay una gama separada de controladores PowerpaK SEM.

2 VARIANTES DE CONTROLADOR PowerpaK
PP xxx Descripción del número de modelo
1er dígito Controlador 1 = ---------------

Tipo 2 = Tracción 3 = Bomba 4 =
--------------- 5 = --------------- 6 =
-------- ------- 7 = - Reservado -
(SEM)
2do digito voltaje 2 = --Reservado-- (24-36V)

Rango 4 = 24V - 48V 8 =
72V - 80V
3er dígito Actual 3 = 300A

Límite 4 = 450A 6 =
650A * (* Nota 600A a 80V)
Sufijo L = E / S baja, Tracción M = E / S

media, Tracción H = E / S alta,
Tracción P = E / S baja, Bomba
MODO PODER CONFIGURACIÓN LÓGICA NO. apagado TAMAÑO

L Poder DE LA UNIDAD
Terminales
PP243L 24-48V 300A Tracción Regen / Plug Baja E / S 66 142 x 142 x 140 mm
PP243M 24-48V 300A Tracción Regen / Plug Medicina. I / O 66 142 x 142 x 140 mm
PP343P 24-48V 300A Bomba Bomba de E / S 55 142 x 142 x 140 mm
PP243H 24-48V 300A Tracción Regen / Plug E / S alta 66 142 x 142 x 140 mm

3 CARACTERÍSTICAS DEL CONTROLADOR CON LAS DIFERENTES VARIANTES DE LÓGICA
Característica Lógica Bomba baja Lógica de baja Traction Med. Tracción alta.
lógica de E / E / S de Lógica de E / Lógica de E /
S tracción S S
Número de conectores 2 2 3 3
Número de entradas de interruptores digitales. 66 66 8 10
Cantidad de entradas analógicas 2 2 2 2
Número de salidas de accionamiento del contactor (2 amperios) 00 3 55 10
Operación 24V - 80V si si si si
Puede atender el rango de límite de corriente de 300A a 650A si si si si
Caja lógica incluida en IP65, caja de alimentación en IP55 si si si si
Control por microprocesador si si si si
Alta frecuencia (operación silenciosa) si si si si
Vigilancia interna que controla el funcionamiento del microprocesador si si si si
Contactor sin arco de conmutación y supresión de bobina incorporada n/A si si si
Uso de contactores de 24 V en todos los voltajes posibles n/A si si si
Baja impedancia, entradas bajas activas conmutadas a B-ve si si si si
Límite de corriente compensada térmicamente si si si si
Características seleccionables del acelerador si si si si
Velocidad de arrastre ajustable si si si si
Omitir con deserción actual + debilitamiento de campo n/A No si si
Temporizador de cambio de asiento si si si si
Operación de cambio de vientre n/A si No No
Contactor de dirección asistida controlador y temporizador n/A si si si
Freno regenerativo o de enchufe solamente n/A si si si
Frenado proporcional a la posición del acelerador n/A si si si
Frenado en neutral n/A si si si
Frenado con pedal de freno n/A si si si
Protección bajo y sobretensión si si si si
Detector de cable acelerador apagado n/A si si si
Instalaciones de avance lento y de avance lento n/A si si si
Entrada de bote económico n/A si si si
Detección de contactor de cortocircuito y circuito abierto n/A si si si
3 velocidades de reducción de tracción con retrasos de aceleración independientes n/A si si si
6 velocidades de bomba con aditivo, prioridad y compensación si n/A n/A n/A
Entrada para desactivar la operación de la bomba si n/A n/A n/A
Ajustes independientes de velocidad y compensación de la dirección asistida si n/A n/A n/A
Sistemas a prueba de fallas de hardware y software n/A si si si

+ Pin de salida de 12V si No si si
Diagnóstico con indicación LED si si si si
Ajustes realizados a través de un calibrador si si si si
Comunicaciones en serie (el módulo externo proporciona RS232) si si si si
Se puede configurar con una PC (a través del módulo externo anterior) si si si si
CAN comunicaciones en serie si si si si
Recuento de horas que muestra las horas de pulsación y tecla en el calibrador si si si si
BDI en calibrador si si si si
Variante de motor dual no proporcional con interruptores o potenciómetro n/A No No No
Los ángulos de dirección del motor dual se pueden ajustar n/A No No No
Motor dual independiente de subida / bajada de retardo ajustable n/A No No No
Facilidad de límite de velocidad disponible opcionalmente con sensor de velocidad n/A No si si
Servicio reiniciable y registros de fallas si si si si
Idiomas extranjeros seleccionables en el calibrador si si si si
Compatible con pantalla de panel estándar + funciones completas si si si si
Menú de configuración en el calibrador para habilitar varias opciones si si si si
Compatible con PC-PAK si si si si

44 LA SEGURIDAD
4.1 Los vehículos eléctricos pueden ser peligrosos. Todas las pruebas, detección de fallas y ajustes deben ser realizados por
personal competente. Las ruedas motrices deben estar fuera del piso y libres de girar durante los siguientes
procedimientos. EL MANUAL DEL FABRICANTE DEL VEHÍCULO DEBE SER CONSULTADO ANTES DE INTENTAR CUALQUIER
OPERACIÓN.
4.2 4.2 El controlador PowerpaK contiene un sistema triple a prueba de fallas para brindar un alto nivel de seguridad. Si el LED de diagnóstico
no está iluminado o parpadea, el circuito de seguridad puede haberse disparado y el camión puede no conducir.
4.3 4.3 Para garantizar la seguridad continua del sistema PowerpaK, se debe verificar el circuito a prueba de fallas cada vez que se
repara el camión. El período entre controles no debe exceder los 3 meses.
4.4 LA BATERÍA DEBE DESCONECTARSE ANTES DE REEMPLAZAR O INTENTAR CUALQUIER REPARACIÓN DE LOS
CONTROLES.
4.5 4.5 Antes de trabajar en los controles, desconecte la batería y conecte los terminales del controlador B + y B- a través de una
resistencia de 10 ohmios y 25 vatios para descargar los condensadores internos.
4.6 Nunca conecte el controlador a una batería con las tapas de ventilación retiradas, ya que puede producirse un arco debido a la capacidad
interna del controlador cuando se conecta por primera vez.
4.7 VERIFICACIÓN A PRUEBA DE FALLAS:
4.7.1 Asegúrese de que las ruedas motrices estén LIMPIO DEL SUELO Y LIBRE DE ROTAR.
4.7.2 Encienda, seleccione el interruptor del asiento, suelte el freno, seleccione la dirección y FS1, las ruedas deben girar y el LED de
diagnóstico debe proporcionar una iluminación constante.
4.7.3 Apague, desconecte la batería y conecte los terminales A y B junto con, al menos, 10 mm 2 cable. Asegúrese
de que no haya otra falla que permita la unidad.
4.7.4 Vuelva a conectar la batería, encienda la llave con la dirección en neutral. El LED debe permanecer apagado. Seleccione una
dirección y verifique que los contactores de dirección no se cierren y que las ruedas no giren.
4.7.5 Apague la tecla y retire la conexión A / B. Encienda la llave, vuelva a seleccionar la secuencia de encendido y verifique
que el LED se ilumine y que las ruedas del camión giren.
SI EL CAMIÓN SE CONDUCE EN 4.7.4 EL CONTROLADOR TIENE FALLA Y DEBE SER REEMPLAZADO.
4.8 Como los imanes de expulsión están instalados en contactores (excepto 24 V), asegúrese de que no se acumulen partículas magnéticas en
los espacios de contacto y causen un mal funcionamiento. Asegúrese de que los contactores estén cableados con la polaridad correcta a
sus terminales de alimentación como lo indica el signo + en la moldura superior.
4.8 El controlador PowerpaK NO se debe utilizar con cargadores integrados conectados permanentemente, ya que
podría dañar el sistema.
55 ESPECIFICACIONES TÉCNICAS
5.1 Eléctrico
5.1.1 Especificaciones de voltaje:
Modelo Batería Nominal de Voltaje Tensión de funcionamiento máxima absoluta
PP x4x 48V Unidades 24-48V 14.5 - 75V

PP x8x Unidades 80V 72-80V 43.0 - 97.5V
5.1.2 Especificaciones actuales:
Modelo Poder Límite actual (1 Operación segura

min) Área (SOA) Corriente continua
montado Clasificación
en una placa basede
de1aluminio
hora. de
780x380x10mm, a 20 ° C ambiente.
PP x43 48V 300A 300A 30 - 60% 90A
PP x44 48V 450A 450A 30 - 60% 135A
PP x46 48V 650A 650A 30 - 60% 200A
PP x84 80V 450A 450A 25 - 45% 125A

PP x86 80V 600A 600A 25 - 45% 150A
5.1.3 Frecuencia de conmutación: Tracción de 16 KHz / Regeneración / Accionamiento de bomba y Frenado de enchufe de 6 KHz.
5.1.4 Aislamiento eléctrico: Recinto a cualquier parte viva = 1KV. Aislamiento interno del controlador
especificado a> 10M Ω @ 500V DC. Rigidez dieléctrica 1000V @ 50Hz por
1 minuto.
5.1.5 Polaridad de la batería: Un contactor de línea accionado por el interruptor de llave, con un diodo de 2A en serie
con la bobina, evitará el cierre del contactor de línea si las conexiones positivas y
negativas de la batería se invierten.
5.2 Ambiental
5.2.1.1 Protección - Lógica El gabinete está protegido a IP66. 1er dígito (6) = Protección contra la
entrada de polvo 2do dígito (6) = Protección contra chorros de alta presión
de
Riegue en cualquier dirección.
5.2.1.2 Protección - Marco de potencia El gabinete está protegido por IP55. 1er dígito (5) = Entrada de polvo
limitada permitida 2do dígito (5) = Protección contra chorros de baja
presión de
Riegue en cualquier dirección. Entrada limitada permitida.
5.2.2 Vibración: 6G, 40-200Hz durante 1 hora, en planos x, y y z.
5.2.3 Temperatura de funcionamiento: - 30oC a + 40oC ambiente alrededor del controlador.
5.2.4 Temperatura de almacenamiento: - 40oC a + 70oC.
5.2.5 Humedad: Máximo 95%, sin condensación.
5.2.6 Resistencia a la humedad: No hay defectos funcionales después de dejar el controlador a 60 ° C y 100% de humedad durante
una hora después del uso del congelador (-30 ° C mínimo).
5.2.7 HALT: PowerpaK ha sido sometido a pruebas de vida altamente acelerada.
5.3 Mecánico
5.3.1 Tamaño de la unidad (todas las unidades): Longitud 142 mm, ancho 142 mm, altura 140 mm con lógica instalada. (La altura es de 86
mm con lógica desconectada)
5.3.2 Recinto: Placa base de aluminio fundido a presión con marco de alimentación de plástico ABS
moldeado y cubiertas lógicas.
5.3.3 Conexiones de alimentación: Casquillos de potencia verticales de aluminio para conexión M8.
5.3.4 Fijaciones: 4 x agujeros de separación M6.
5.3.5 Peso: 1,8 kg
5.4 Especificaciones de E / S lógicas
5.4.1 Interruptor / entradas digitales:

Operación: Activa-baja (la entrada se activa cuando se conecta a la batería
negativa, de lo contrario inactiva).
Rango de voltaje: Bajo (cerrado) -1.0 a +1.8 V
Alto (abierto) + 4.5 a +150 V (o circuito abierto).
Impedancia de entrada: Max. resistencia al suelo para un 'bajo' = 500 Ω.
Min. resistencia al suelo para un 'alto' = 2.7 k Ω
Nota: los retornos negativos del interruptor deben estar conectados al terminal B del
controlador y no a la batería negativa.
5.4.2 Entradas analógicas: Entradas de 0-5V disponibles y entradas de potenciómetro 5K / 3V5-0V disponibles. I /
ps totalmente protegido y umbral configurable.
5.4.3 Suministro de salida: Una fuente de alimentación no regulada de + 12V, 5mA está disponible para suministrar
aceleradores, sensores de velocidad, etc.
5.4.4 Unidades de contactor: Corriente máxima: 2A.
Proteccion: Las unidades están protegidas contra la conexión directa a B + y B-.
Supresión: Supresión de la bobina incorporada.
+ suministro de cinco bobinas Depende de la variante lógica, vea los diagramas de cableado de las figuras 1-3

66 CABLEADO DEL CONTROLADOR Y CONEXIONES
6.1.1 Conexiones de poder
Vea los diagramas de cableado de alimentación para conexiones específicas.
6.1.2 Cableado de alimentación

Tamaños mínimos de cable: - Límites de corriente hasta 500 A 35 mm 2
650A 50mm 2
6.1.3 Clasificaciones de fusibles
Fusibles máximos: - Límites de corriente de hasta 300 A 325 A (corte de aire)

450A 500A (corte de aire) 650A
700A (corte de aire)
6.1.4 Tipos de contactores
Los contactores recomendados para controladores con límites de corriente de hasta 300A son: Línea
(Opcional) Albright SW80 Calificación continua

Dirección Albright DC88 Calificación intermitente
Regen (Opcional) Albright DC84 Calificación continua
Bypass de tracción (opcional) Albright SW80 Calificación intermitente
Debilitamiento de campo (opcional) Albright SW80 Calificación intermitente
Power Steer (Opcional) Albright SW80 Calificación continua
Los contactores recomendados para controladores con límites de corriente de hasta 450 A son: Línea
(Opcional) Albright SW180 Calificación continua

Dirección Albright DC182 Calificación intermitente
Regen (Opcional) Albright SW181 Calificación continua

Bypass de tracción (opcional) Albright SW180 Calificación intermitente
Debilitamiento de campo (opcional) Albright SW80 Calificación intermitente
Power Steer (Opcional) Albright SW80 Calificación continua
Los contactores recomendados para controladores con límites de corriente de hasta 650 A son: Línea
(Opcional) Albright SW200 Continuo Clasificación
Dirección Albright SW202 Intermitente Clasificación
Regen (Opcional) Albright SW201 Continuo Clasificación
Bypass de tracción (opcional) Albright SW200 Intermitente Clasificación
Debilitamiento de campo (opcional) Albright SW80 Intermitente Clasificación

Power Steer (Opcional) Albright SW80 Continuo Clasificación
Se recomienda utilizar contactores de 24 V junto con la función de corte.
6.1.5 Diodo Regen - disponible de SEVCON (840/44245) y conectado de la siguiente manera: Cátodo
Cable conectado a la terminal común del contactor Regen.
Ánodo Perno atornillado en el contactor Regen B-.
6.2 Conexiones de cableado de luz (Fig. 1)
La siguiente sección detalla los conectores en las lógicas Mínima, Media y Alta. La lógica mínima tiene 2 conectores, 1 para
las conexiones del vehículo / contactor y 1 para las comunicaciones en serie. La lógica de E / S media tiene 3 conectores, 1
para las conexiones del vehículo, 1 para las conexiones del contactor y 1 para las comunicaciones en serie. La lógica de
alta E / S también tiene 3

conectores en total, 1 para las conexiones del vehículo, 1 para las conexiones del contactor y 1 para las comunicaciones en serie.

CONECTOR DE CLIENTE Y CONTROLADOR INTERCONECTE PIN OUT'S
Pin Vehículo y panel Vehículo y panel Conector de Conector de

No. Conector Conector vehículo vehículo
Enchufe B Enchufe B Enchufe B Enchufe B
Bomba baja lógica Lógica de baja E / S Traction Med. Tracción alta
de E / S. Conector de tracción. Lógica de E / S. Lógica de E / S.
Molex de 12 vías. Conector Molex de Conector Molex de Conector Molex de
12 vías. 12 vías. 16 vías.
6 i / ps digital 2 i / 6 i / ps digital 2 i / ps 8 i / ps digital 2 i / ps 10 Digital i / ps 2
ps analógica analógico 3 Cont. analógico 1 + 12V o Analógico i / ps 1 +
Sin cont. Unidades Unidades /p 12V o / p
1) Llave sw Llave sw Llave sw Llave sw
2) Bomba sw 3 Fwd sw Fwd sw Fwd sw

3) Bomba sw 4 Rev sw Rev sw Rev sw
4) Bomba sw 5 FS1 / Sw barriga FS1 / Sw barriga FS1 sw
5) Ver nota 3 Asiento / timón sw Asiento / timón sw Asiento sw
6) Ver nota 3 Ver nota 1 Ver nota 1 Ver nota 1

7) Ver nota 3 Ver nota 1 Ver nota 1 Ver nota 1
8) - Fwd Cont Ver nota 1 Ver nota 1
9) - Rev Cont Ver nota 2 Ver nota 2
10) Accel 0V-5V Accel / F.Brake / Economy pot Accel / F.Brake / Economy pot Accel / F.Brake / Economy pot
(Bomba sw2 / Econ) / Sobre temperatura 0V-5V / Sobre temperatura 0V-5V / Sobre temperatura 0V-5V
11) Accel 3V5-0V F.Brake / Accel / Economy pot / Over Accel / F.Brake / Economy pot Accel / F.Brake / Economy pot
(Bomba sw1) Temp 3V5-0V / Over Temp 3V5-0V / Over Temp 3V5-0V
12) + 12V o / p Regen / Psteer Cont. + 12V o / p + 12V o / p
13) Ver nota 1

14) Ver nota 1
15. -
dieciséis. -
Nota 1. El usuario puede configurar estas entradas para que sean cualquiera de las siguientes: - Velocidad1, Velocidad2, Velocidad3, Pulgadas Fwd (Pines 6,8,13), Pulgadas Rev (Pines 7,14), Bomba, Disparador
de dirección asistida, Freno de mano , Freno de pie, carga lateral, cepillos desgastados.
Nota 2. El usuario puede configurar esta entrada para que sea cualquiera de los siguientes: - Speed1, Speed2, Speed3, Inch Rev, Pump, Power Steer Trigger, Handbrake, Footbrake,
Sideload, Brushes Worn, Speed Encoder.
Nota 3. El usuario puede configurar estas entradas para que sean cualquiera de las siguientes: - Interruptor de bomba 6, Interruptor de bomba 7, Disparador de la dirección asistida, Inhibición de la bomba,
Temperatura del motor, Cepillos de la bomba desgastados, Baja presión de aceite.
Pin Conector de Conector de Comunicaciones

No. panel Enchufe panel Enchufe Conector
C C Enchufe A
Traction Med. Tracción alta Todas las lógicas.
Lógica de E / S. Lógica de E / S.
Conector Molex de Conector Molex de Conector Molex

10 vías. 12 vías. de 6 vías
5 cont. Unidades 10 cont. Unidades RS232 y CAN
1) Cont. o / p Cont. o / p + 10V5
2) Fwd Cont Fwd Cont 0V
3) Rev Cont Rev Cont CAROLINA DEL NORTE
4) Regen / P.Steer Cont Regen + 10V5

5) Bypass / F.Contenido débil P.Steer PUEDE alto
6) P.Steer / F.Weak / Pump / Remote LED Derivación CAN baja
7) - F. Débil
8) - Pump Cont
9) - LED remoto
10) - Cualquiera de 2-9
11) Cualquiera de 2-9
12) -

6.2.3 Descripción general de CAN (red de área del controlador)
CAN es un acrónimo de Controller Area Network. Es un sistema de bus, lo que significa que es una colección
de "nodos" inteligentes que están conectados al mismo cable físico. Si un nodo transmite algo por el cable,
todos los nodos lo recibirán (incluido el que realiza la transmisión).
CANbus fue desarrollado (en 1984) por Bosch, el fabricante alemán de electrónica, para su uso en vehículos de carretera. El
objetivo de CANbus es reducir el cableado del vehículo, ya que todas las funciones eléctricas (como luces, ventanas eléctricas,
ignición) comparten el mismo cable físico. Su énfasis en la transmisión confiable de datos lo ha hecho popular entre los
fabricantes de equipos industriales y vehículos de manejo de materiales.
Las principales aplicaciones para las comunicaciones CAN son la electrónica industrial y automotriz donde se requieren
comunicaciones seriales de alta velocidad e inmunes al ruido para funcionar de manera confiable en entornos de alta vibración y
alta temperatura.
El sistema CAN de SEVCON se define como CAN 2.0A (CAN básico, error activo) y se implementa utilizando un
conjunto de chips Philips Semiconductor con un chip transceptor 80C250. El protocolo PowerpaK CAN establece la
velocidad en baudios en 100K bits por segundo. CAN es extremadamente flexible y versátil, lo que permite la
operación multimaestro en una red de comunicación en serie con un número casi ilimitado de nodos. Es posible
transmitir velocidades de datos de hasta 1 Mbit / s a distancias de hasta 40 metros, con una probabilidad muy baja
de errores no detectados. CAN es básicamente un sistema diferencial de par trenzado de 2 hilos con rieles de
suministro de 10V5 y 0v. Las conexiones se realizan a través de un conector Molex de 6 vías. Actualmente, el bus
CAN se utiliza para comunicarse con el calibrador. Se puede utilizar para comunicarse con una pantalla de tablero
y para el control remoto desde una PC host. A largo plazo,
Por ejemplo, cargadores de batería, controladores autónomos de dirección asistida, expansores de E / S del controlador ... etc.
Actualmente es posible conectar hasta 8 equipos en el bus CAN.

77 CALIBRADOR Y AJUSTES
Una unidad de ajuste manual sofisticada pero fácil de usar, llamada Calibrator, se utiliza para
realizar ajustes en el controlador y seleccionar configuraciones. El calibrador también se utiliza
como una herramienta de diagnóstico que muestra el estado de todos los voltajes, corrientes y
temperaturas dentro del controlador junto con la condición de todos los interruptores y entradas
analógicas del controlador.
El siguiente diagrama describe cómo se usa el calibrador. Las flechas izquierda y derecha se
mueven entre pantallas en el mismo nivel. Las flechas hacia arriba y hacia abajo se mueven
entre niveles y los botones + y - incrementan o disminuyen los parámetros en la cantidad
indicada en la columna PASO de las siguientes tablas.
Se puede especificar que el calibrador tenga varios niveles de acceso a ciertos

ajustes.
Encender
1 tracción OK 2 bomba
OK
1.1 Personalidades 1.2 Estado de 1.3 Prueba de 1.4 BDI de 1.5 Registro de fallas 1.6 Configuración de 1.7 Pantalla OK
de tracción tracción tracción tracción de tracción tracción
1.1.1 Trac Pers 1.1.2 Trac Pers
. Max 250 A Accel 0.5 s

7.1.1 Personalidades del controlador de tracción (ajustes del controlador)
California. Parámetro ajustado Lógica: Ajuste mínimo Max. Max. Max. Step Typical
Árbitro baja I / o (todas las unidades) ajustar la ajustar la ajustar size all Default
(* Nota: la corriente máxima de Med I / o unidad unidad 650A * units
80 V es 600 A) Hi i/o 300A 450A unidad
1.1.1 Current limit L,M,H 50 A 300 A 450 A 650 A 10 A 100% A

1.1.2 Acceleration delay L,M,H 0.1 S 5.0 S 5.0 S 5.0 S 0.1 S 1.5 S
1.1.2a Current Ramp delay L,M,H 0.0 S 2.5 S 2.5 S 2.5 S 0.1 S 0.0 S
1.1.3 Deceleration delay L,M,H 0.1 S 0.5 S 0.5 S 0.5 S 0.1 S 0.3 S
1.1.4 Creep speed L,M,H 0 % 25 % 25 % 25 % 1.0 % 5.0 %
1.1.5 Direction Plug Current L,M,H 50 A 370 A 560 A 810 A 10 A 75 % A
1.1.5a Plug Turn L,M,H 50 A 370 A 560 A 810 A 10 A 100 A
1.1.6 Neutral Plug Current L,M,H 10A (0 disables) 370 A 560 A 810 A 10 A 25 % A
1.1.6a Plugging Threshold L,M,H 50 255 255 255 1 153/180
1.1.6b Plug Drop L,M,H 50 A 370 A 560 A 810 A 10 A 100 A
1.1.7 Footbrake Plug Current L,M,H 10A (0 disables) 370 A 560 A 810 A 10 A 50 % A
1.1.8 Direction Regen Current L,M,H 50 A 300 A 450 A 650 A 10 A 200 A
1.1.8a Speed Limit Braking M,H 40 A/KPH 300 A 450 A 650 A 10 A 40 A/KPH
1.1.9 Neutral Regen Current L,M,H 10A (0 disables) 300 A 450 A 650 A 10 A 100 A
1.1.10 Footbrake Regen Current L,M,H 10A (0 disables) 300 A 450 A 650 A 10 A 150 A
1.1.11 Regen Delay L,M,H 0mS(0 plug only) 350 ms 350 ms 350 ms 10 ms 160 mS
1.1.12 Maximum speed L,M,H 0 % 100 % 100 % 100 % 1 % 100 %
1.1.13 Cutback speed 1 L,M,H 0 % 100 % 100 % 100 % 1 % 75 %
1.1.14 Acceleration delay 1 L,M,H 0.1 S 5.0 S 5.0 S 5.0 S 0.1S 1.5 S
1.1.16 Acceleration delay 2 L,M,H 0.1 S 5.0 S 5.0 S 5.0 S 0.1 S 2.0 S
1.1.18 Acceleration delay 3 L,M,H 0.1 S 5.0 S 5.0 S 5.0 S 0.1 S 2.5 S
1.1.19 Inch Speed L,M,H 0 % 25 % 25 % 25 % 1% 10 %
1.1.20 Burst Inch Delay L,M,H 0.1 S 5.0 S 5.0 S 5.0 S 0.1 S 2.0 S
1.1.21 Bypass Over Current M,H 10 A (0 disables) 450 A 680 A 970 A 10 A 100% A
1.1.22 Bypass Delay M,H 0.5 S 5.0 S 5.0 S 5.0 S 0.1 S 1.5 S
1.1.23 Field Weak Pull In M,H 0 A 300 A 450 A 650 A 10 A 100 A
1.1.24 Field Weak Drop Out M,H 0 A 300 A 450 A 650 A 10 A 200 A
1.1.25 Power Steer Delay L,M,H 0 S 60 S 60 S 60 S 1.0 S 5.0 S
1.1.26 Seat Switch Delay L,M,H 0 S 5.0 S 5.0 S 5.0 S 0.1 S 2.0 S
1.1.27 Electric Brake Delay L,M,H 0S 5.0 S 5.0 S 5.0 S 0.1 S 0 S
1.1.28 Accelerator Zero Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.29 Accelerator Full Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.30 Footbrake Pot ZeroLevel L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.31 Footbrake Pot Full Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.32 Economy Pot Zero Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.33 Economy Pot Full Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.34 O. Temp Pot Zero Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.35 O. Temp Pot Full Level L,M,H 0 V 5.0 V 5.0 V 5.0 V 0.02 V
1.1.36 Speed Limit M,H 0KPH(0 disables) 60KPH 60KPH 60KPH 1 KPH 0 KPH
1.1.37 Low Voltage Init L,M,H 14.5 V 48/80 V 48/80 V 48/80 V 0.5V 14.5/43V
1.1.38 Low Voltage Cutback L,M,H 14.5 V 48/80 V 48/80 V 48/80 V 0.5V 14.5/43V
1.1.39 High Voltage Init L,M,H 14.5 V 75/100 75/100 75/100 0.5V 70/95.0V
1.1.40 High Voltage Cutback L,M,H 14.5 V 75/100 75/100 75/100 0.5V 72.5/97.5
1.1.41 Protection Delay L,M,H 0.1 S 2.5 S 2.5 S 2.5 S 0.1 S 0.1 S
Note 1 : Depending on controller type and configuration some of the above may not be displayed. Note 2 : pressing the calibrator “down arrow” key
from 1.1.2 allows access to 1.1.2a, likewise for 1.1.5a, 1.1.6a and 6b. Note 3 : pressing the calibrator “down arrow” key from the potentiometer zero
and full personalities (1.1.28 to 1.1.35)
jumps directly to the associated voltage measurement in the test menu. Pressing this key from the test menu jumps back to the associated
zero level personality.

7.1.2 Traction Controller Status Information
Cal. Ref. Parameter Displayed Logic Type Min.Display Max.Display Step size Log Info.
1.2.1 Battery Voltage L,M,H 0V 127 V 0.1 V +
1.2.2 Traction Motor Voltage L,M,H 0V 127 V 0.5 V
1.2.3 Traction Motor Current L,M,H 0A 1200 A 6A +
1.2.4 Traction Controller Temp. L,M,H - 30 ° C + 225 ° C 1°C + -
1.2.5 Traction MOSFET Voltage L,M,H 0V 127 V 0.5 V
1.2.6 Capacitor Voltage L,M,H 0V 127 V 0.5 V
1.2.7 Speed Sensor Indication L,M,H 0 KPH 60 KPH 1.0 KPH
1.2.8 Key Switch Hours Count L,M,H 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.9 Traction Pulsing Hours Count L,M,H 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.10 Pump Pulsing Hours Count L,M,H 0 Hrs 65279.9 Hrs 0.1 Hrs
- Service Log Reset L,M,H press + followed by - to reset service log
Note1 : Log Info shows where the + and - keys can be used to access the service max and min data.
7.1.3 Traction Controller Test Information
Cal. Ref. Input Displayed Logic Type Min. Display Max.Display Step Size
1.3.1 Accelerator % Range L,M,H 0% 100 % 1%
1.3.2 Accelerator Voltage Range L,M,H 0.0 V 5.0 V 0.02 V
1.3.3 Footbrake Pot. % Range L,M,H 0% 100 % 1%
1.3.4 Footbrake Pot. Voltage Range L,M,H 0.0 V 5.0 V 0.02 V
1.3.5 Economy Pot. % Range L,M,H 0% 100 % 1%
1.3.6 Economy Pot. Voltage Range L,M,H 0.0 V 5.0 V 0.02 V
1.3.7 O. Temp Pot. % Range L,M,H 0% 100 % 1%
1.3.8 O. Temp Pot. Voltage Range L,M,H 0.0 V 5.0 V 0.02 V
1.3.9 Forward Switch L,M,H Open Closed -
1.3.10 Reverse Switch L,M,H Open Closed -
1.3.11 FS1 Switch L,M,H Open Closed -
1.3.12 Belly Switch L,M Open Closed -
1.3.13 Seat Switch L,M,H Open Closed -
1.3.14 Tiller Switch L,M Open Closed -
1.3.15 Speed Cutback 1 Switch L,M,H Open Closed -
1.3.18 Inch Forward Switch L,M,H Open Closed -
1.3.19 Inch Reverse Switch L,M,H Open Closed -
1.3.20 Handbrake Switch L,M,H Open Closed -
1.3.21 Footbrake Switch L,M,H Open Closed -
1.3.22 Power Steer Trigger Input Switch L,M,H Open Closed -
1.3.23 Pump Contactor Trigger Switch M,H Open Closed -
1.3.24 Speed Limit Switch L,M,H Open Closed -
1.3.25 Sideload Switch L,M,H Open Closed -
1.3.26 Speed Encoder Switch L,M,H Open Closed -
1.3.27 Brushes Worn Switch L,M,H Open Closed -
1.3.28 Software Version/Revision L,M,H 000.00 999.99 -
1.3.29 Controller Serial Number L,M,H 00000000 99999999 -
Note 1: As with the personalities, only relevant switch tests will be shown determined by configuration. Note 2: An asterisk will
appear on menu 1.3.2 when FS1 is closed.
7.1.4 BDI Adjustments (if enabled in setup menu)
Cal. Ref. Parameter Adjusted/Displayed Logic Type Min Setting Max. Setting Step Size. Default
1.4.1 Xxx % Charge remaining L,M,H,P display only
1.4.2 Battery Volt xx V L,M,H,P 24 V 96 V 2V Nominal V
1.4.3 Reset x.xx V/Cell L,M,H,P 2.00 V/Cell 2.50 V/Cell 0.01 V/Cell 2.09V
1.4.4 Empty x.xx V/Cell L,M,H,P 1.50 V/Cell 1.99 V/Cell 0.01 V/Cell 1.73V
1.4.5 Warning xx % L,M,H,P 0% 90% 1.0 % 30%
14 PowerpaK Manual - Revision G P.S. 14 September, 2001

1.4.6 Cutout xx % L,M,H,P 0% 90% 1.0 % 0%
- 7.1.5 Fault Log

Can be disabled via setup menu. See section 9 for more details.
7.1.6 Traction Controller Setup Menu (Enables/Disables features)
Cal.Ref Feature Logic Type Options

1.6.1 Contactor Chopping L,M,H 24 V / On / Off
1.6.2 Accelerator Type L,M,H Linear / Curved / 2* Slope/ Crawl
1.6.3 BDI L,M,H On / Off
1.6.4 Power Steer Trigger L,M,H None to FS1 +Dir+ Brake +Seat
1.6.5 Economy Cuts Traction Current L,M,H On / Off
1.6.6 Bypass in Current Limit M,H On / Off
1.6.7 SRO L,M,H On / Off
1.6.8 Braking L,M,H Proportional / Constant
1.6.9 Plugging Style L,M,H Constant Current / Fixed Percentage
1.6.10 Ride-on / Walkie truck L,M,H Ride-On / Walkie
1.6.11 Tiller switch L,M,H On / Off
1.6.12 Digital i/p 5 config (Skt B pin 6) L,M,H Inch Fwd (only Pins 6 & 8) / Inch Rev (only Pins 7 & 9) / Pump / Pst Trig /
1.6.13 Digital i/p 6 config (Skt B pin 7) L,M,H Handbrake / Footbrake / Speed cutback 1 / Speed cutback 2 / Speed
1.6.14 Digital i/p 7 config (Skt B pin 8) M,H cutback 3 / Speed Limit / Sideload / Brushes Worn / Speed Probe( only
1.6.15 Digital i/p 8 config (Skt B pin 9) M,H Pin 9)
1.6.16 Analog i/p 1 config (Skt B pin 10) L,M,H Accelerator / Footbrake / Economy / O. Temp
1.6.17 Analog i/p 2 config (Skt B pin 11) L,M,H Accelerator / Footbrake / Economy / O. Temp
1.6.18 Digital i/p 9 config (Skt B pin 13) H Inch Fwd (only Pin 13) / Inch Rev (only Pin 14) / Pump / Pst Trig /
1.6.19 Digital i/p 10 config (Skt B pin 14) H Handbrake / Speed cutbacks 1,2,3
1.6.20 Contactor 3 (Skt B pin 12 Low I/O) config . Low I/O Logic - P.Steer /Regen/Electric Brake Med I/O
(Skt C pin 4 Med/Hi I/O) L,M Logic - Regen /P.Steer High I/O Logic - Regen only
1.6.21 Contactor 4 config (Skt C pin 5) M Bypass / F.Weak

1.6.22 Contactor 5 config (Skt C pin 6) M F.Weak / P.Str / Pump / Remote LED / BDI Cut / E. Brake
1.6.23 Contactor 9 config (Skt C pin 10) H Forward / Reverse / Regen / P.Str / Bypass / F.Weak / Pump /
Remote LED / BDI Cut / E. Brake
1.6.24 Contactor 10 config (Skt C pin 11) H Forward / Reverse / Regen / P.Str / Bypass / F.Weak / Pump /
Remote LED / BDI Cut / E. Brake
1.6.25 Seat Switch Cuts Pump M,H On / Off
1.6.26 Fault Log L,M,H On / Off
1.6.27 Service Log L,M,H On / Off
1.6.28 Probe Speed M,H High / Low. Select High for Encoders which have a maximum frequency
of 100Hz to 2000Hz. Select Low for Encoders which have a maximum
frequency of 10Hz to 200Hz.
1.6.29 Full Speed M,H 5 to 60 KPH in 1 KPH steps default 20

1.6.30 Probe Frequency M,H If Probe Speed is set to High, then Probe Frequency has the range 100 to
2000Hz in 10 Hz steps (default 1000) , If Probe Speed is set to Low, then
Probe Frequency has the range 10 to 200Hz in 1 Hz steps (default 100) ,
1.6.32 Canbus Mode L,M,H Standalone / CAN Master

1.6.33 Switch Limits Speed L,M,H On/ Off
1.6.34 Inch E-Brakes L,M,H On/ Off
Note 1: Changes only take effect after a key-switch recycle
7.2.1 Pump Controller Personalities (Controller Adjustments)
Cal. Parameter Adjusted Logic Type Min adjust Max.adjust Max.adjust Step size Typical
Ref (all units) 450 A unit 650 A unit (all units) Default
2.1.1 Current Limit P 50 A 450 A 650 A 10 A 100% A
P.S. 14 September, 2001 PowerpaK Manual - Revision G 15

2.1.2 Ramp Up Delay P 0.1 S 5.0 S 5.0 S 0.1 S 0.5 S
2.1.3 Ramp Down Delay P 0.1 S 0.5 S 0.5 S 0.1 S 0.3 S
2.1.4 Creep Speed P 0% 25 % 25 % 1.0 % 5.0 %
2.1.5 Pump Speed 1 P 0 % (0=inhibit) 100 % 100 % 1.0 % 100 %
2.1.6 Pump Compensation 1 P 1 % (0 disables) 200 % 200 % 1.0 % 0%
2.1.7 Pump Speed 2 P 0 % (0=inhibit) 100 % 100 % 1.0 % 80 %
2.1.9 Pump Speed 3 P 0% 100 % 100 % 1.0 % 60 %
2.1.11 Pump Speed 4 P 0% 100 % 100 % 1.0 % 50 %
2.1.13 Pump Speed 5 P 0% 100 % 100 % 1.0 % 40 %
2.1.14 Speed 5 (Priority/Additive) P priority additive additive - priority
2.1.15 Pump Speed 6 P 0% 100 % 100 % 1.0 % 30 %
2.1.17 Pump Speed 7 P 0% 100 % 100 % 1.0 % 25 %
2.1.19 Power Steer Speed P 0% 100 % 100 % 1.0 % 15 %
2.1.20 Power Steer Compensation P 1 % (0 disables) 200 % 200 % 1.0 % 0%
2.1.21 Power Steer Ramp Up Delay P 0.1 S 5.0 S 5.0 S 0.1 S 0.3 S
2.1.22 Power Steer Ramp Down Delay P 0.1 S 0.5 S 0.5 S 0.1 S 0.3 S
2.1.23 Power Steer Delay P 0S 60 S 60 S 1S 2S
2.1.24 Seat Switch Delay P 0S 5S 5S 0.1 S 2 S
2.1.25 Accelerator Zero Level P 0.0 V 5.0 V 5.0 V 0.02 V
2.1.26 Accelerator Full Level P 0.0 V 5.0 V 5.0 V 0.02 V
2.1.27 Accelerator 2 Zero Level P 0.0 V 5.0 V 5.0 V 0.02 V
2.1.28 Accelerator 2 Full Level P 0.0 V 5.0 V 5.0 V 0.02 V
2.1.29 Low Voltage Init P 14.5 V 48V for 24-48Vunits, 80V for 72-80V 14.5/43V
2.1.30 Low Voltage Cutback P 14.5 V 48V for 24-48Vunits, 80V for 72-80V 14.5/43V
2.1.31 High Voltage Init P 14.5 V 75V for 24-48Vunits, 100V for 72-80V 70/97.5V
2.1.32 High Voltage Cutback P 14.5 V 75V for 24-4 8 Vunits, 100V for 72-80V 72.5/97.5
2.1.33 Protection Delay P 0.1 S 2.5 S 2.5 S 0.1 S 0.1 S
7.2.2 Pump Controller Status Information
Cal. Parameter Displayed Logic Max.Display (all Step size (all Log Info.
Ref Type Min.(all
Display
units) units) units)
2.2.1 Battery Voltage P 0V 127 V 0.5 V +
2.2.2 Pump Motor Voltage P 0V 127 V 1V
2.2.3 Pump Motor Current P 0A 1200 A 6A +
2.2.4 Pump MOSFET Voltage P 0V 127 V 0.5 V
2.2.5 Pump Controller Temp. P - 30 o C + 225 o C 1oC + -
2.2.6 Key Switch Hours Count P 0 Hrs 65279.9 Hrs 0.1 Hrs
2.2.7 Pump Pulsing Hours Count P 0 Hrs 65279.9 Hrs 0.1 Hrs
- Service Log Reset P press + followed by - to reset service log
Note : Log Info shows where the + and - keys can be used to access the service max and min data.
7.2.3 Pump Controller Test Information
Cal Input Displayed Logic Max.Display (all Step size (all

. Ref. Type Min.Display
(all units) units) units)
2.3.1 Accelerator 1 % Range P 0% 100 % 1%
2.3.2 Accelerator 1 Voltage Range P 0.0 V 5.0 V 0.1 V
2.3.3 Accelerator 2 % Range P 0% 100 % 1%
2.3.4 Accelerator 2 Voltage Range P 0.0 V 5.0 V 0.1 V
2.3.5 Pump Switch 3 P Open Closed -

2.3.10 Power Steer Trigger P Open Closed -
2.3.11 Inhibit P Open Closed -
2.3.12 Motor Temperature P Open Closed -
2.3.13 Brushes Worn P Open Closed -
2.3.14 Low Oil P Open Closed -
2.3.15 Software Version/Revision P 000.00 999.99 -
2.3.16 Controller Serial Number P 00000000 99999999 -
Note : pressing the calibrator “down arrow” key from 2.3.11 allows access to 2.3.11a.
7.2.4 Pump BDI (as Traction 7.1.4)
7.2.5 Pump Fault Log (as Traction 7.1.5)
7.2.6 Pump Setup Menu Enables/Disables features
Cal Feature Logic

Ref. Type Options
2.6.1 CANbus Mode P Standalone / CAN Slave
2.6.2 Accelerator Type P Linear / Curved / 2 *Slope / Crawl
2.6.3 Accelerator 2 P Lift / Economy / O. Temp
2.6.4 BDI P On / Off
2.6.5 Fault Log P On / Off
2.6.6 Service Log P On / Off
2.6.7 Seat and Pump P On / Off
2.6.8 Digital i/p 4 config (Skt B pin 5) P P.Switch 6 / P.Switch 7 / P. Steer / Inhibit /
2.6.9 Digital i/p 5 config (Skt B pin 6) Motor Temp / Brush Worn / Low Oil
2.6.10 Digital i/p 6 config (Skt B pin 7) P
2.6.11 Power Steer Active Sense P Open / Closed
Note: changes only take effect after a key-switch recycle.
7.3.1 Traction and Pump adjustment descriptions
Adjustment Logic type Description (T=Affects traction, P=Affects Pump)

Current Limit L,M,H,P Maximum allowable motor current.
Acceleration Delay L,M,H,P Time taken to ramp up from 0 to 100% on.
Current Ramp Delay L,M,H Time taken to ramp up current in plugging and drive.
Deceleration Delay L,M,H,P Time taken to ramp down from 100% to 0% on.
Creep Speed L,M,H,P Minimum applied % on when drive first selected. Only PS1 on pump
Dir.Brake Current (Plug) L,M,H Maximum Plug braking current during direction switch change.
Plug Turn Current (Plug) L,M,H Current at which braking ends and drive starts. (Fixed percentage only)
Neut.Brake Current (Plug) L,M,H Maximum Plug braking current in neutral.
Plugging Threshold (Plug) L,M,H Plug to Drive threshold. Higher numbers mean earlier plug exit
Plug Drop Current (Plug) L,M,H Current at which neutral braking ends. (Fixed percentage only)
Footbrake Current (Plug) L,M,H Maximum Plug braking current in neutral when F.brake switch active.
Dir.Brake Current (Reg) L,M,H Maximum Regen braking current during direction switch change.
Neut.Brake Current (Reg) L,M,H Maximum Regen braking current in neutral.
Footbrake Current (Reg) L,M,H Maximum Regen braking current in neutral when F.brake switch active.
Speed Brake Current M,H Maximum Braking current when speed limit braking.
Regen Delay (Reg) L,M,H Used to minimise delays for unsuccessful Regen attempts at low speeds. Higher numbers
give Regen at lower speeds. 0 forces plugging only.
Maximum Speed L,M,H Maximum allowable % on.
Cutback Speeds 1, 2 & 3 L,M,H Maximum allowable % on when cutback switches active.

Accel. Delay 1, 2 & 3 L,M,H Independently adjustable acceleration delays during speed cutbacks.
Inch Speed L,M,H Maximum allowable % on during inching operation.
Burst Inch Delay L,M,H Timer to allow inching for a set period only.
Bypass Over Current M,H Maximum allowable current in Bypass before contactor opens.
Bypass Delay M,H Time for Bypass contactor to close after 100% on reached
F.W. Pull In Current M,H F.Weak. contactor allowed to pull in at currents < pull in level.
F.W Drop out Current M,H F.Weak. contactor will drop out at currents > drop out level.
Power Steer Delay L,M,H Delay after power steer trigger removed until contactor opens.
Seat Switch Delay L,M,H,P Delay after seat switch opens until pulsing is inhibited.
Zero Levels L,M,H,P Used to select minimum voltage input level for function. E.g. an Accel Zero level=0.5V means
pulsing begins at 0.5V I/P
Full Levels L,M,H,P Used to select maximum voltage input level for function, E.g. an Accel Full Level of 4.0v
means 100% pulsing is reached at 4V I/P
Speed Limit M,H Used with external speed sensor to provide speed limit feature.
Low Voltage Init L,M,H,P Voltage at which controllers starts reducing the max available current limit to help reduce
voltage drops
Low Voltage Cutback L,M,H,P Voltage at which current limit is reduced to 0
High Voltage Init L,M,H,P Voltage at which controller changes from Regen braking to Plug braking to help prevent high
generated voltages damaging the battery or controller.
High Voltage Cutback L,M,H,P Voltage at which contactors will open, to prevent high voltage damage.
Battery Protection L,M,H,P Voltages below this level cause a battery low 7 flash fault
Protection Delay L,M,H,P Length of time the voltage can fall below the Battery Protection level for,
before a fault is indicated. This helps prevent spikes tripping a low batt fault
Pump Speeds 1-7 P Maximum allowable % on’s when respective switch active
Power Steer Speed P As above, but for Power Steer speed.
Pump Comp. 1-4 P Set-up compensation by adjusting the relevant pump speed to give the required minimum
no load speed, then set the associated compensation adjustment to give the same speed
under full load conditions
Power Steer Comp. P As above but for Power Steer speed compensation.
Power Steer Ramp up P Independent acceleration delay for power steer function.
P. Steer Ramp down P As above but deceleration delay.
Speed 5, 6 & 7 P Lower numbers have priority over higher numbers. Additive is where the speed 5, 6 or 7 is
Priority/Additive added to lower numbered switches.
Electric Brake Delay L,M,H Used to specify a variable time delay between the power steer trigger becoming inactive
and the electric brake contactor opening (brake on).
7.3.2 Setup Menu Descriptions
Setup menu Option Logic Description

Type
Contactor Chopping L,M,H 24V/On/Off - Set to 24V to obtain 24V across coils when a lamp is also being driven,
On when just contactor coils are being driven and Off when battery voltage contactor coils are used.
Accelerator type L,M,H, P Linear/Curved/2*slope/Crawl - Set to Linear for a straight line accelerator characteristic, Curved for more
low speed manoeuvrability, 2*Slope for a balance between Linear and Curved, and Crawl for a very shallow
low speed manoeuvrability curve. See graph 2 appendix.
BDI L,M,H, P On/Off - On enables the BDI (Battery Discharge Indicator) and any warning/cut-out settings, Off disables
the BDI feature and removes the BDI setup menu display.
Power Steer Trigger L,M,H None/FS1/Dir/F+D/Brake/F+B/D+B/F+D+B/Seat/F+S/D+S/F+D+S/B+S/F+B+S/D
+ B+S/F+D+B+S – These are the various triggers for power steer activation, FS1 or F
= FS1 switch, Dir or D = Direction switch, Brake or B = Foot brake and Seat or S =
Seat switch . e.g. setting to FS1 will trigger the power steer delay only when FS1 is close., whilst setting to
F+D+B will trigger the delay when either FS1 or Direction or the Brake switches are closed.
Economy cuts traction L,M,H On/Off - set to On for current limit to be reduced during economy or Off for just the
current standard acceleration delay increase.
Accelerator 2 Type P Lift is pump accel 2 or Economy for use as economy input (current limit reduced) or
O. Temp for use as overtemperature sensor input (current limit reduced)

Bypass in current limit M,H On/Off - On= Bypass at max %on and current limit, Off = just Bypass at max %on.
SRO L,M,H On/Off - On = SRO enabled, Off = SRO disabled
Braking L,M,H Prop/Const - Prop = Direction braking level is proportional to accelerator position,
Const = Direction braking is constant level.
Plugging Style L,M,H Constant Current = fixed current level plugging, Fixed Percentage plugging
Ride-on / Walkie truck L,M Ride-on / Walkie – Ride-on = Skt B pin 4 is FS1 input, pin 5 is Seat sw i/p
Walkie = Skt B pin 4 is Belly sw input, pin 5 is tiller sw i/pt
Tiller switch L,M On/Off - On= Tiller switch must be wired in, Off = leave Skt B pin 5 un connected
Digital Input L,M,H Inch Fwd/Inch Rev/Pump/Speed 1 cutback/Speed 2 cutback/Speed 3 cutback
Configuring /Handbrake/Footbrake/Pst. Trig/ Speed Limit/Sideload/Brushes Worn/ Speed Encoder
Digital Input P P.Switch 6 / P.Switch 7 / P. Steer / Inhibit / Motor Temp / Brush Worn / Low Oil
Configuring
Analog Input L,M,H None/Accel/Footbrake Pot/Economy pot/Over Temp pot Skt B pins 10 & 11
Configuring analog inputs can be configured to perform the above input functions.
Contactor Output 3-6 L,M,H Forward/Reverse/P.Steer/Regen/Bypass/F.Weak/Pump/Remote LED / BDI Cut /
configuring. E. Brake Skt B pin 12 (Low I/O logics only) and Skt C pins 4,5,6 (Med & High I/O Logics) and Skt C
pins 9 & 10 (High I/O logic only) can be configured to perform some of the above Contactor output
functions.
Seat switch cuts pump M,H On/Off - On = Seat switch cuts Traction and Pump, Off = just Trac.
Seat switch cuts pump P On/Off - On = Seat switch cuts just Pump, Off = disabled
Fault Log L,M,H, P On/Off - On = Fault Log enabled, Off = Disabled and no display.
Service Log L,M,H, P On/Off - On = Service Log enabled, Off = Disabled and no display.
Canbus Mode L,M,H, P Standalone – standalone operation, CAN Master – Canbus master for controlling display (L,M,H only),
CAN Slave – Canbus slave (P only)
Probe Speed, Full M,H These setup items are used to set up an encoder in the system. The Probe Speed item is used to select the
Speed and Probe frequency range of the encoder.. High Probe Speeds refer to Encoders in the range 100Hz to 2000Hz and
Frequency usually applies to encoders mounted on the Motor, Low Probe Speeds refer to Encoders in the range 10Hz to
200Hz and usually applies to encoders mounted on the Axle or Wheel. The Full Speed and Probe Frequency
items are used to calibrate the encoder. To set these up, find the output frequency of the Probe at the vehicles
top speed. For example, if a vehicle had an encoder mounted on the motor’s rotor and the encoder gave an
output frequency of 1500Hz at a top speed of 20KPH, then Probe Speed is set to High, Probe Frequency is set
to 1500Hz and Full Speed is set to 20KPH.
Switch Limits Speed L,M,H On/Off - On = speed limit applied if speed limit switch input is active, if speed limit
switch is inactive no speed limit is applied, Off = speed limit applied regardless of switch.
Power Steer Active P Open/Close - power steer is on when the digital input configured as P.Steer matches this setup state,
Sense otherwise the power steer is off (unless internally triggered)
7.3.3 BDI adjustment descriptions
BDI Adjustment Logic Description

Type
Charge remaining L,M,H Displays remaining battery charge. Display only, no adjustments can be made.
Battery Voltage L,M,H Adjustment used to enter the nominal battery voltage
Reset Volts/Cell L,M,H Sets the voltage at which the BDI resets to 100% at power up. E.g. the BDI will reset to 100% on a 48V
system, with the reset adjustment set to 2.20 Volts per cell, if the battery voltage is above 52.8V.
(48V/2)*2.20V
Empty Volts/Cell L,M,H Sets the voltage at which the BDI indicates the battery is fully discharged E.g. the BDI will eventually show 0%
on a 48V system, with the empty adjustment set to 1.60 Volts per cell, if the battery voltage is below
38.4V.(48V/2)*1.60V
Warning Level % L,M,H Sets the discharged level at which the warning threshold is reached, at which point the remaining lit segments
flash.
Cutout Level % L,M,H Sets the discharged level at which the cut-out threshold is reached, at which point all the segments flash together
and the cut-out action, Pump cut-out and Traction speed 2 limit initiated.

8 DIAGNOSTICS
Tr a ction and Pum p Fault M essages a n d L ED status/number of flashes

Calibrator Standard Display
Full Led Description and how to clear Check...
Message Feature
Display
0 OK on Traction operational and OK. No action required.
(lowest priority)
1 Testing... Run on Only displayed briefly at power up. No action required.
Tests
2 Trac Brush Trac TRAC Check brushes.
Brush BRUSHES on Traction brushes worn.
2 Pump Brush Pump PUMP Check brushes.
Brush BRUSHES on Pump brushes worn.
3 Pump Overtemp Pump PUMP on Pump over temperature. Allow controller to cool.
Hot HOT
4 Oil Fault Oil Fault OIL LOW on Oil pressure low. Check oil.
5 BDI Cutout BDI BDI Battery charged.
Cut CUT OUT 7F BDI enabled and cut-out action
initiated.
6 Thermal Cutback Over TRAC 8F Traction heatsink above 75 ° C. Allow Heatsinking, Mounting,
Temp. HOT controller to cool. Surfaces clean, fan req.
6 Thermal Cutback Over PUMP 8F Pump heatsink above 75 ° C. Allow Heatsinking, Mounting,
Temp. HOT controller to cool. Surfaces clean, fan req.
7 Speed Probe Speed SPEED 6F Speed limit feature enabled & wire Probe connections.
Probe PROBE off.
8 Accel. Fault Accel ACCEL 6F Accel. pedal pressed at power up, or
Fault FAULT wire off. Recycle FS1 and Direction. Accel wiring. Accel
& Full Zero
Personalities.
9 Contactor o/c Cont CONTACT 4F Contactor has bad contact or didn’t
o/c FAULT close, motor o/c. Recycle FS1 & Dir. Coil wiring,motor
powero/c.
wiring,
10 Contactor s/c Cont CONTACT 4F Contactor didn’t open or is welded. Welded tips, particles in tips,
s/c FAULT Recycle FS1 and Direction switch. wiring.
11 Sequence Fault Seq. SEQ 2F Direction or FS1 switch at power up. Dir and FS1 in neutral and
Fault FAULT Recycle Direction FS1 or both. Dir/FS1 wiring.
12 2 Dir. Fault 2 Dir 2 DIR 2F Two directions selected together. Direction switch wiring.
Fault FAULT Recycle both Directions and FS1.
13 SRO Fault SRO SRO 2F Dir. switch selected > 2 seconds after Dir first then FS1, FS1 and
Fault FAULT FS1. Recycle FS1 and Dir. Dir. switch wiring.
14 Seat Fault Seat SEAT 2F Drive selected and no seat sw. Seat switch, closed, seat
Fault FAULT Recycle Dir and FS1 switch wiring.
15 Inch Fault Inch INCH 2F Inch switch at power up , both inch Inch switch in neutral at power up
Fault FAULT switches selected or inching attempted with seat ,only 1 selected, Seat/Dir/FS1
switch or Dir/FS1 selected. Recycle inch switches open.
switches.
16 Battery High Bat. BATTERY 7F Battery > High battery personality. Correct battery voltage. Loose
High HIGH Recycle FS1 or Direction switch or missing B+ to controller.
17 Battery Low Bat. BATTERY 7F Battery < Low battery personality. Correct battery voltage,
Low LOW Recycle FS1 or Direction switch Discharged battery.
18 Pers Error Pers PERS 1F Personalities out of range at power Reset personalities out of range
Error ERROR up. (shown as ----.-).
19 CRC error CRC CRC 1F One or more personalities have been Check all personalities then
Error ERROR corrupted. recycle keyswitch.
20 Coil s/c Coil COIL 9F A contactor coil s/c or miswired. coil s/c, Drive connected
s/c FAIL Recycle Keyswitch directly to B+ve, wiring.
21 Mosfet s/c FET MOSFET 3F Bypass contactor s/c or MOSFET s/c A / P /B- power wiring,
s/c FAIL Recycle FS1 or Direction MOSFETs s/c.
22 Canbus Fault Canbus CAN 12 Can connection between
Fault FAULT FF Can connection
has between controllers
been disconnected controllers.

23 Various internal FAIL FAIL off If any of these message are displayed Contact Sevcon.
controller power up then the controller has failed one of its
messages internal power up checks.
(highest priority)
9 SERVICE AND FAULT LOGS (All Logics)
The Service and Fault Logs have been incorporated to allow end users and service personnel to inspect and note the
controller’s performance and fault history. Utilising the controller’s existing Status measurements and Diagnostics
capabilities, information (such as the maximum temperature the controller has operated at or the number and type of faults
that have been detected) can be stored in non-volatile memory and presented at a later date. Both the Service and Fault
logs can be selected/deselected via the setup menu on the calibrator, and when selected can be cleared at any time to start
recording new data.
9.1 Service Log
Service information is available in the Traction and Pump Status menus, where holding down the ‘+’ key shows
the maximum value of the current item, and holding down the ‘-’ key shows the minimum value. The following
items are logged:
- Maximum Battery Voltage

- Maximum Motor Current
- Maximum Controller Temperature and Minimum Controller Temperature. To clear the log, access the “Service
Log + to reset log” message at the end of the Status menu, and follow the prompts. The service log can be
enabled and disabled in the Setup menu.
9.2 Fault Log
The Fault log is available at location 1.5 on the calibrator. Faults are grouped together by “LED flash fault”; the
types of flash fault and whether each is logged is shown below. Generally faults that can occur during normal
operation e.g. a 2 flash driver procedure error or an 8 flash thermal cutback indication, are not logged.
- LED off faults Logged (Internal controller power up check faults)

- 1 flash faults Logged (Personality/CRC faults)
- 2 flash faults Not Logged (Driver procedure/sequence/wiring type faults)
- 3 flash faults Logged (MOSFET/Bypass wiring type faults)
- 4 flash faults Logged (Contactor o/c or s/c or wiring type faults)
- 5 flash faults Not Logged (Not used)
- 6 flash faults Not Logged (Potentiometer wire off type faults)
- 7 flash faults Logged (Battery low or high faults)
- 8 flash faults Not Logged (Thermal cutback faults)
- 9 flash faults Logged (Contactor coil s/c type faults)
Each of the above logged categories contains - The total number of faults of this type, the Key hours count of the most
recent fault and a text description of the fault. An example of how the Fault Log information is presented is shown below:
12*04F 12345.6hr Contactor This display shows that 12 4-Flash faults have occurred and been logged, the most recent at
o/c
12345.6 Key hours and it was a Contactor o/c fault. Once into the fault log menu, the left and
right arrows are used to view any
faults stored and at the end of the list a “Fault Log + to reset log” message is shown, where the Fault Log can be reset in a
similar way to the service log. The Fault Log can be enabled and disabled in the setup menu.

10 CONTROLLER OPERATION AND FEATURE DESCRIPTIONS
10.1 TRACTION OPERATION - Applicable to all Traction logics unless otherwise specified
10.1.1 Start Up Sequence - At keyswitch on, the Direction and FS1 switches must be in the neutral condition
simultaneously at least once before drive can be selected. This is a safety feature to help prevent unexpected
movement immediately after power up.
10.1.2 SRO (Static return to off)- This feature is optional in the setup menu and when specified, forces the following
sequences of switch inputs to be followed before drive is allowed: Keyswitch-Direction-FS1 or
Keyswitch-FS1-Direction (within 2 seconds of FS1) . Any other sequence will not allow drive. Drive will be
inhibited if FS1 is active for more than 2 seconds with no direction selected. In this case the FS1 will need to
be recycled.
10.1.3 Seat Switch - If the seat switch is opened and the seat switch timer has timed out during drive the controller will
stop pulsing and a seat fault will be indicated. Before drive can be restarted the seat switch must be closed, and
FS1 and the direction switch must be recycled through neutral. Note the start sequence for drive requires that the
seat switch is closed and both the direction and FS1 switches are in the neutral position simultaneously before
drive can be initiated. The time period is programmed by means of the Calibrator (Seat Switch Delay). As a setup
menu option the seat switch can also inhibit pump operation if required. There are also additional seat switch start
up sequences available as options, although the above described SEVCON standard is recommended.
10.1.4 Belly Switch - (Not available on High I/O logic) - A Belly Switch function is available when the controller is used on a
walkie type truck. The feature can be enabled in the setup menu. See this section and wiring diagrams for
additional information. Basic operation is as follows:-
Truck moving in Reverse and activating the Belly Switch, accelerator in reverse position:-
a) The contactors change direction to forward drive (this initiates plug braking). b)150% maximum plugging is
applied for a maximum of 1.5 seconds, when it will then revert to maximum plugging. c)The vehicle will
accelerate at full speed along the 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 the Belly switch is pressed again however, action as at c) above.
Accelerator in Neutral:- As above
Accelerator in Forward position :- Start at c) above
Truck moving in Forward and activating the Belly Switch, accelerator in forward position:Accelerator in Forward
position :- No effect
Accelerator in Reverse position :- Belly switch closed, truck drives as per start of c) above.
10.1.4 Handbrake Switch (Not available on Low I/O logic) - An input is provided for the
connection of a handbrake switch, which if operated will disable traction pulsing but leave the drive related
contactors in position to effect a minimum roll back hill start when drive is selected and the handbrake is
released.
10.1.6 Deceleration Delay - This is an adjustable delay to ramp down the pulsing from 100% on to 0% on, and can be used to
limit the inherent truck lurch when acceleration is interrupted. When neutral is selected, contactors are only opened
when the % on has ramped down to 0.
10.1.7 Creep - The Creep speed is adjustable and is used to select a minimum pulsing level as soon as drive is requested,
to minimise delays and dead-bands. The motor voltage is rapidly ramped to the creep level (equivalent to a
100mS acceleration delay).
10.1.8 Cutback speeds - Each one has an associated personality to adjust the maximum % on
when the switch is active. In addition each cutback has an independently adjustable acceleration delay
associated with it to further enhance low speed manoeuvrability. When both switches are active together, the
lower speed is selected together with the slowest acceleration delay. The cutback speed inputs are usually
normally closed so that a wire off type fault or bad connection initiates a lower speed.
If the speed limit feature is turned on when a cutback speed limit switch is closed, the cutback percentage will
be applied to the maximum speed setting.

When the BDI feature is enabled and the cut-out level is reached the speed 2 cutback is automatically initiated.
A maximum speed adjustment is also available to limit the maximum applied %on. (If the setting is less than 95%
then Bypass and Field Weakening are disabled).
10.1.9 Bypass - ( Not available on Low I/O logic) The Bypass contactor is used to short out the
main MOSFET switching device to increase speed and efficiency at high speeds and to allow higher motor
currents than the controller’s maximum current limit, to climb ramps laden or to escape from ruts or pot holes.
Bypass can be initiated in 2 ways:
Current-limit Bypass: the accelerator is fully depressed and the controller has been in current limit for longer
than 2 seconds. In order to prevent a sudden lurch of the truck the contactor will not be energised if the
motor voltage during current limit is less than 20% of battery voltage. This mode of operation can be disabled
via the setup menu.
High-speed Bypass: If the accelerator is fully depressed and the controller has been pulsing at maximum
% on for 1.5 seconds and the Bypass Delay personality has timed out. The Bypass delay timer is a feature
that can be used to allow the truck to obtain full speed, before contactor closure.
The bypass contactor will be de-energised if the accelerator demand is reduced below 86%, or if the motor
current exceeds the Bypass over-current dropout level, adjustable by the calibrator. To allow for initial
overshoots the over-current test is disabled for the first 2 seconds of Bypass. Although the software attempts to
minimise arcing when the contactor opens, some arcing is inevitable under certain load conditions. After an
over-current drop out, the Bypass function will be inhibited until neutral is recycled to prevent repeated opening
and closing of the tips under heavy current conditions.
Bypass can be disabled by setting the over-current drop out to 0 A. Also Bypass will be disabled if either of the 2
speed cutback switches are enabled and the settings are adjusted below 95% or the maximum speed setting is
less than 95%. Applying the footbrake switch or economy > 0% will also prevent Bypass closure.
10.1.10 Field Weakening - (Not available on Low I/O logic) This is carried out by connecting a low value/high wattage
resistor connected in series with a contactor across the traction motor field to weaken the field and hence
increase speed whilst reducing torque. As a guide line the value of the resistor should be the same as the
motor field resistance and it should be rated to carry field current.
At full accelerator depression and maximum %on, and after bypass contactor closure (if fitted) the field
weakening contactor is energised providing the current is below the Pull-In level. If the motor current increases
above the Drop-out level or the accelerator demand is less than 86% or the bypass contactor is de-energised,
the Field Weakening contactor will be opened. Both the Field Weakening Drop-Out and Pull-In current levels are
adjusted with the calibrator.
10.1.11 Power Steer, Traction Controller - A contactor drive is available to control a separate Power Steer motor. An
adjustable delay allows the motor to operate for a set time, after the power steer trigger or power steer demand
has been removed. SEVCON’s standard trigger,
i.e. when the contactor is closed, is when either FS1 or the Footbrake switch is closed, or the Traction unit is
pulsing. It is an either-or situation , so any one of these 3 inputs is sufficient to trigger the Power Steer.
This standard trigger is designed to give power steer when ever the truck is moving, but not to have a situation
where the Power steer could be on continuously, i.e. on a direction switch where the truck could be left with a
direction selected and the Keyswitch left on. If FS1 or the Footbrake is applied then the vehicle is either about to
move or is moving, and the Traction pulsing is used if the truck was neutral braking (pulsing) down a long ramp,
when it is conceivable that neither of the 2 switches would be closed. On a tow-tractor, power steer is disabled
during inching.
An independent input pin (see figures 2 & 3) also exists to trigger Power Steer operation. This is normally used
in conjunction with a steer on demand system where an output is

generated when the steering wheel is turned. This gives Power steer on demand and is more efficient since
typically no steering delay, or only a short delay is needed. The independent trigger only, or other trigger
combinations can be configured if necessary in the setup menu.
Some vehicles derive the power steering assistance from the main Pump Hydraulic motor, instead of having a
separate Steer motor. In this situation the trigger is fed to the Pump controller and runs the pump at the speed
set by the P. S. Speed personality. Independent ramp up and ramp down delays are provided when Power steer
assistance is derived from the main Pump controller, to help tune steering responsiveness without affecting the
main pump operation.
10.1.12 Regen Braking -Regen provides vehicle braking by controlling the motor as a generator and returning the generated
energy back to the battery. Regen braking reduces motor heat dissipation compared with plug braking.
Regenerative braking can be initiated in 3 ways, each with an independently adjustable braking level, as follows:
i) A direction switch change will initiate Regen braking at a level set by the Direction Brake Current level.
Braking effort is proportional to the accelerator position, with a minimum accelerator pedal position giving
50% of the set brake level increasing to 100% for a fully depressed pedal. The proportionality range allows
the driver to modify the braking effort without allowing freewheeling. The proportionality feature is optional
and can be configured in the setup menu to give fixed braking at the set personality level.
ii) Closure of the foot-brake switch in neutral, will initiate Regen braking at the Footbrake personality level. An
input is provided to allow braking effort to be proportional to the Footbrake position if a potentiometer is fitted.
Setting a 0 into the personality disables braking on the Footbrake switch.
iii) When neutral is selected, Regen is initiated at the Neutral Brake Current level. Setting a 0 into the
personality disables neutral braking and allows freewheeling. Neutral braking will only be attempted if the % on
in the previous direction exceeded 20% above the set creep level. This helps minimise unnecessary delays and
contactor operations. Regen braking is not possible at low speeds depending on the motor characteristics. To
help minimise delays attempting to Regen, a Regen Time adjustment is offered which can be set so that Regen
is only attempted for a short period of time, which is sufficient to initiate Regen at medium to high speeds but
not to cause unnecessarily long delays at very slow speeds where Regen is not possible. If the Regen Time
setting is increased then Regen can be initiated at lower speeds. Setting the Regen Time to 0 disables Regen
and forces plug braking only.
If Regen is not possible due to low vehicle speed, the following action will be taken:
1) For direction braking, plugging will be used to slow, then reverse the vehicle.
2) For neutral or footbrake braking, the vehicle will freewheel. The switching
frequency in Regen is high frequency and silent.
10.1.13 Plug Braking - Plug braking is achieved by controlling the rotating motor armature as a generator and dissipating
most of the energy in the motor and the plug diode. For plugging-only controllers, the conditions for initiating
braking are identical to those for Regen controllers: on a direction change, footbrake switch and in neutral.
Plugging also operates on Regen controllers if the truck has been travelling to slowly to initiate Regen direction
braking.
The switching frequency in the Plug braking mode is 6KHz.
10.1.14 Inching - This facility is normally used on Tow Tractors to manoeuvre the Tractor towards the load from the rear of the
vehicle, using 2 inching buttons, one for forward and one for reverse. The inch speed is adjustable via the
calibrator.
Inching will only operate if the main direction control and FS1 switches are in the neutral position and the seat
switch is open, and handbrake off. These safety interlocks prevent anyone from sitting in the driver’s cab whilst
an operator is using the inching switches at the rear.

A burst inching feature is also available which uses inching in conjunction with an adjustable timer to
provide inching for a limited period. This is typically used in conjunction with an electromechanical brake to
provide inching on gradients and to help prevent against unlimited travel if an inching button became
jammed in the closed position or failed short circuit.
The controller can be configured to release the electrobrakes when inching occurs, by setting menu 1.6.33,
Inch E-Brake, to on. If this is set-up item is set to off, the electrobrakes will not be released during inching.
10.1.15 Anti-Rollback - This is a standard SEVCON feature and is used to help prevent roll back conditions on ramps. If the
driver reselects the previous direction after a neutral condition, braking is not attempted, and full drive power is
available to restart on a hill.
10.1.16 Analogue Inputs - The accelerator/analogue inputs are flexible in the range of signal sources they can
accommodate and can be adjusted to minimise dead-bands and mechanical tolerances. Each analogue
inputs has 2 adjustments associated with it, that allow the input voltage range to be determined.
For the Traction Accelerator, for example, the 2 adjustments are called the “Accelerator Zero Level” and the
“Accelerator Full Level”. If these were set to 0.20V and 4.80V then 0% pulsing would start at 0.20V at the input,
increasing to 100% pulsing at 4.80V. For accelerators with decreasing voltage outputs, the Zero adjustment
might be set to 3.5V and the Full adjustment to 0.0V. The Calibrator test menu shows the instantaneous voltage
reading, and the equivalent % “push” for each input, and to allow easy set-up, pressing the “down” key on the
calibrator from either of these test displays, allows a direct jump to the Zero voltage and Full voltage personality
settings. Note that a 6 flash fault will occur if the full and zero levels are set within 0.50V of each other. For
wiring details see Figures 1 to 3.
10.1.17 Traction Accelerator - When Drive is selected and the accelerator is first pressed, pulsing will commence at the
Creep Speed setting increasing towards the maximum %on. If the accelerator is depressed at power up, pulsing
will be inhibited and a 6 flash fault will be indicated, until the pedal is released. In case of a wire off type fault,
pulsing will be limited to the creep setting and a 6 flash fault will also be given.
Various accelerator characteristics i.e. relationship between accelerator push and the applied motor voltage,
can be selected via the setup menu. There are 4 options: Linear, Curved, 2*slope and Crawl. Set to Linear for
a straight line accelerator characteristic, Curved for more low speed manoeuvrability, 2*Slope for a balance
between Linear and Curved, and Crawl for a very shallow low speed manoeuvrability curve. See graph 2 for
actual characteristics.
10.1.18 Footbrake Potentiometer - This input is available to allow a potentiometer to be fitted to the Footbrake pedal for
proportional braking. It can be connected and set-up as per the accelerator input. Note that footbrake
operation drops out both Bypass and Field weakening.
10.1.19 Footbrake Switch - This input is available to allow a switch to be fitted to the Footbrake pedal for constant braking.
Note that footbrake operation drops out both Bypass and Field weakening.
10.1.20 Economy Potentiometer - This potentiometer, normally available to the driver of the truck, varies the acceleration
ramp delay from its set value to its maximum value. It can be adjusted as per the accelerator input. As a setup
menu option the economy function can reduce the traction current limit, instead of increasing the acceleration
delay. Note that the economy function drops out both Bypass and Field Weakening.
10.1.21 Over-Temperature Sensor - This input is available for overtemperature sensors which are attached to the traction
or pump motors. The input will reduce the traction or pump current limit from maximum to 1/3 current limit,
similar to the economy cuts current limit function. If a Full Feature Display is fitted, the over temperature
symbol (thermometer) and the traction or pump identifier will be displayed.
10.1.22 Digital Switch Inputs - The digital inputs on the controller can be configured as Active Low inputs, where the
switches are wired to B-ve. Active High inputs, connecting to B+ve,

are not available. The SEVCON standard is Active Low, and is recommended for its low impedance input stage
and immunity to moisture related problems.
A further configuration allows each input to be specified as normally open or normally closed. Most switches are
normally open, with the exception of the 3 speed cutback switch inputs which are normally closed, so that a wire
off type fault, or bad connection initiates the cutback speed, rather than a higher speed. On compensated Pump
systems the Power Steer input can be conveniently configured as normally closed.
10.1.23 Contactors - The Pump logic has no contactor drives. The Low I/O logic has 3 outputs for driving contactors, the
medium I/O has 5 outputs and the High I/O has 10. On Medium and High I/O logics it is also possible to
reconfigure an output, as an external LED or Lamp driver to allow dashboard indication of the controller’s integral
LED. The controller can diagnose open circuit (o/c) and short circuit (s/c) problems with certain contactors, as
described in the diagnostic section. Generally, following a request to open a contactor, the controller will report a
4 flash fault and a calibrator message if a successful operation was not detected after approximately 500ms. To
help prevent against minor tip contaminants causing spurious diagnostic trips when closing a contactor, if a
closure is not detected after 500ms, pulsing up to a maximum of 25% is allowed. This is designed to pass a
controlled amount of current to try and break through any contaminant present to allow uninterrupted drive. If a
closure isn’t detected on reaching 25%, then the contactor drive is removed and a 4 flash fault is indicated.
An optional Line Contactor, not controlled from the controller, can be connected between the B+ terminal of the
controller and battery positive. A diode should be fitted in series with the line contactor coil to prevent large
currents flowing through the battery connectors and into the internal capacitors when the controller is first
connected to the battery. After the keyswitch has been switched, and once the capacitors have charged up (via
internal resistance) the line contactor will be energised. An internal diode fitted in the keyswitch line will prevent
any contactor energising if the polarity of the battery voltage is reversed. On Pump controllers the Line
Contactor also gives a mechanical break. Under normal operating conditions contactors will operate without
arcing. However, under certain fault conditions, contactors may arc when opening. The Bypass contactor may
also arc during Bypass over-current drop out conditions.
10.1.24 Contactor chopping - This feature allows 24 V contactors to be used at all battery voltages 24V - 80V, by
continuously monitoring the battery voltage and chopping the contactor output pins accordingly, to present an
average voltage suitable for 24V coils. Chopping is selectable by the calibrator. All the contactor drives will be
either chopped or not chopped. It is not possible to select individual drives to chop. Care must be taken to
ensure that chopping is always selected if 24V contactors are being used on battery voltages higher than
24V. In applications > 24 volts contactors must be fitted with blow out magnets.
Chopping can reduce the overall dissipation in the coils and allows only one set of contactors to be stocked
for all battery voltages.
Chopping Frequency approx. = 650Hz (Slightly audible at higher battery voltages) Typical contactor
coil voltage during chopping = 16 volts.
Typical contactor coil voltage during energisation = 24 volts for 1 second. There are 3 contactor chopping
options available via the setup menu: Off, On and 24V. The off setting is used for nominal battery voltage coils,
and the On setting is for 24V coils on higher voltage vehicles. Setting to 24V provides chopping for 24V coils and
lamps without the drop to 16V after 1s.
10.1.25 Fail-safe - The controller’s safety system includes a microprocessor watchdog which can detect software failure,
and a hardware fail-safe system which can prevent dangerous runaway conditions in the event of certain
hardware failures.
Every time the controller is powered-up, the software checks that the fail-safe circuit is able to switch off the
MOSFETs and open the contactors.

10.1.26 Speed Limit - (Not available on Low I/O logic) A traction speed limit in KPH can be set via personality 1.1.36 (0
KPH disables the feature). As the speed of the vehicle approaches the limit, the maximum motor voltage is
reduced. If the speed limit is exceeded by more than 2 KPH (when the vehicle is travelling down-hill for
example) electrical braking will be used until the speed of the vehicle falls to below the limit. Speed limit
braking may operate in normal drive (as described above), to increase existing braking torque if the vehicle
over-speeds, or if the vehicle is rolling in neutral. The actual limit speed of the vehicle is typically ± 2 KPH of
the personality setting, depending on motor loading. When the feature is enabled, a probe “wire-off” feature
will limit the motor voltage if the probe is disconnected.
Calibration of the feature is made via the set menu items “Full Speed” (1.6.29) and “Probe Frequency” (1.6.30).
Full Speed should be set to the maximum speed of the vehicle, unloaded on level ground. The Probe Frequency
setting should be the output frequency of the sensor at that speed.
The recommended sensor is an active low (i.e. NPN) inductive proximity switch. The output is connected to
the customer connector, pin 9. A +12V supply on the customer connector pin 12 can be used for most types
of sensor. The negative supply of the sensor should be connected to the controller’s B- terminal. Contact
SEVCON for further recommendations if required.
If the speed limit feature is turned on when a cutback speed limit switch is closed, the cutback percentage will
be applied to the maximum speed setting.
10.1.27 Sideloader - (Only available on High I/O logic when contactors 9 & 10 are configured to Forward and Reverse).
If the sideloader switch is active, this will reverse contactors 9 & 10 when compared to contactors 1 & 2 e.g.
if the forward direction is selected and the sideloader switch is active, contactor 1 (FORWARD) = CLOSED,
2(REVERSE) = OPEN, 9(FORWARD) = OPEN and 10(REVERSE) = CLOSED. The sideloader switch is
only acted upon when the controller is in a neutral state (no driving or braking). The application must ensure
that the vehicle is at a standstill before the switch input is changed.
10.2 PUMP OPERATION
10.2.1 Pump Operation - There is no start-up sequence, so pulsing will be initiated after a small delay at power-up if one or
more of the pump switches is selected. There are adjustable ramp up and ramp down delays. A Pump contactor
can be specified as an option. There are facilities for prioritising pump speeds, for having different pump speeds
added together and for having speed compensation for different load conditions.
10.2.2 Pump Speeds and Priorities - Each of the 5 pump switch inputs has its own speed setting. The pump speeds are
prioritised in numerical order so that Speed 1 has priority over all other speeds and Speed 2 has priority over
Speeds 3 to 5, etc. Example:- If Speed 1 is set to 10%, Speed 2 to 20% and Speed 3 to 30% then selecting
Speeds 1 and 3 will give 10% and selecting Speeds 2 and 3 will give 20%.
10.2.3 Additive speeds - Pump switches 5 and 6 can be adjusted to have an “Additive” speed. In this mode, the switch is
excluded from the priority system described in 10.2.2; instead its speed is added to the prioritised pump speed to
the give increased power required to handle simultaneous pump operations.
Example:- If speed 2 is set to 40%, speed 5 is set to 25% and speed 6 is set to 10%, then selecting all three
switches will give a demand of 75%, and selection 2 and 6 alone will give a demand of 50%.
10.2.4 Pump accelerator inputs - The pump accelerator demands are associated with Speeds 1 &
2. The pump will operate at the Creep Speed setting when the accelerator is at minimum demand and change
linearly to Speed 1 or 2 as the accelerator is increased to the maximum demand. The pump pot accelerator
input can be connected and adjusted as per the previously described traction accelerator input.

10.2.5 Economy Potentiometer - This potentiometer if configured varies the pump current limit. 0% economy gives maximum
current and 100% economy gives 1/3 of maximum current.
10.2.6 Power Steer speed - On compensated pump systems this setting can be used to control the power steer speed from
the main pump motor. This speed is selected from the power steer trigger input as previously described and can
be compensated for as described in the section below. The power steer also has independent ramp up and ramp
down delays. See the section 10.1.11 on Power Steer for more information.
10.2.7 Pump Speed Compensation - Some trucks utilise the main hydraulic pump motor to provide power steering
assistance, instead of a separate power steer motor. This feature provides speed compensation so that the
pump motor always provides steering assistance, whilst allowing the motor to slow down when assistance isn’t
required to minimise noise and improve efficiency. Pump speeds 1 - 4 and the Power Steer speed can be
compensated if required.
The compensation is a straight line characteristic set up using 2 personalities. The set up procedure may
require some repetition to give optimum performance of low load (low noise) and full compensated load. The
low load speed is normally set up to run the pump motor at its lowest permissible lubrication speed to keep
audible noise to an absolute minimum.
The calibrator’s base speed sets up the low load speed and the compensation factor sets the amount of boost
when the controller detects a current increase due to the pump motor load increasing. The controller monitors the
motor current and changes the motor voltage to ensure that the motor remains on this compensated speed line.
Set up Procedure - Set both the base speed and the compensation factor to 0. Activate the pump switch
associated with the speed to be compensated. Ensure that the motor has its minimum load. Increase the Base
speed until the correct operating speed at minimum load is achieved. Increase the load associated with this pump
speed to its maximum. Increase the compensated speed until varying the load has little or no effect on the speed.
Example - Power steer compensation where the main pump motor provides the hydraulic steering assistance. Set
the Power Steer personality base speed and compensation factor to
0. Activate the Power Steer Trigger input and increase the Power Steer base speed until the pump motor is
running at its desired low speed. Operate the steering. Very little assistance will be given if the pump is going slow.
Increase the Power Steer compensation setting until the required amount of assistance is given when the steering
is operated. The set-up is an iterative process so it may be necessary to change the base speed again and repeat
the procedure to obtain optimum results.

10.3 GENERAL OPERATION
10.3.1 Operating Frequency - The drive frequency of both the Traction and Pump power frames is 16KHz, for silent
operation. For Traction Regen-braking the frequency is also 16KHz, whilst Plug braking is 6KHz.
10.3.2 Temperature Monitoring - If the temperature of either power frame exceeds 75oC its maximum available current
will be reduced. Note, however, that if the set current limit is less than the maximum available current limit
actual cutback will occur at progressively higher temperatures than 75oC. The thermal cutback ensures that
the maximum heatsink temperature is limited to 95oC (See Graph 1). When cutback occurs the diagnostic
LED will flash 8 times.
10.3.3 Safe Operating Area (SOA) - The controller’s current may be limited at high and/or low duty cycles depending
on its current and voltage specification. This is to reduce the thermal stress on the power components in order to
increase long term reliability. See Graph 2. The “Safe Operating Area” is a characteristic of the MOSFETs and
Freewheel Diodes which make up the power-frame. The MOSFET SOA restricts current at high duty cycles on
all configurations, and the Diode SOA tends to restrict the current at lower duty cycles on lower voltage
applications.
For most applications SOA will have little or no effect on the operation of the controller. Its effect is more
significant in protecting the controller against adverse loads such as damaged motors and static test rigs.
10.3.4 Under-voltage and over-voltage protection - In order to prevent a sudden loss in power, the controller will begin to
linearly ramp down the current limit, once the average battery voltage falls below a pre-set under-voltage start
level. The current will be ramped down to 0 and a 7 flash fault indicated if the averaged battery voltage falls
below the under-voltage cutout level.
To protect the controller from over-voltage caused by prolonged regen braking, regen braking will be
terminated and plug braking initiated when the average battery voltage reaches the over-voltage start level. If
the voltage exceeds the over-voltage cutout level in braking then all contactors will open and freewheeling will
occur, requiring the vehicle’s mechanical brakes to be used.
Under any other circumstances if the battery voltage exceeds the over-voltage cutout level, all pulsing is stopped
and a 7-flash fault is indicated. This protects against incorrect battery connection.
Nominal Under-voltage Under-Voltage Over-voltage Over-voltage

Battery Cutout Start Start Cutout
Voltage
24 V 14.5 V 18.0 V 40.0 V 45.0 V
48 V 29 V 36.0 V 65.0 V 70.0 V
80 V 43.0 V 60.0 V 95.0 V 97.5 V

10.3.5 Diagnostic LED - This is mounted between the connectors on the front of the controller. It serves as a simple diagnostic
tool as explained below:
Constant illumination - No fault, normal condition LED

extinguished - Internal controller fault
1 flash - Personality out of range
2 flashes - Illegal start condition
3 flashes - MOSFET Short Circuit
4 flashes - Contactor fault or Motor Open-Circuit
5 flashes - Not used
6 flashes - Accelerator or Speed Probe wire off fault
7 flashes - Low or High battery voltage or BDI cut-out operating
8 flashes - Over temperature
9 flashes - Contactor coil s/c
12 flashes - CANbus fault
Further explanation of the LED flashes are displayed on the calibrator fault message section.
10.3.6 Fault Clearance - Any fault indication will be cleared by re-initiating the start sequence after the cause of the fault has
been removed.
10.3.7 Software Version and Revision indication - For identification purposes and to assist in queries, the Software
version and revision, and the controller serial number are indicated in the calibrator Test Menu.
10.3.8 Dashboard Displays - SEVCON’s existing CAN based standard and full feature displays are compatible with
PowerpaK controllers.
10.3.9 Setup Menu - A setup menu has been added to the Calibrator that allows various features to be enabled and
disabled. See section 7 for more information.
Note. Once a change has been made to the setup menu, the Key switch must be recycled for the change to be
operational.
10.3.12 Multi Languages - Non-English languages can be specified for displaying on the Calibrator. Languages can be
presently specified as either English, German, Spanish, Italian or French. NOT AVAILABLE AT PRESENT.

11 DASHBOARD DISPLAYS - OPERATION AND FEATURE DESCRIPTIONS
SEVCON offers 2 dashboard mounted CAN (Controller Area Network) Displays for any SEVCON controller equipped with
serial CAN communications, including the PowerpaK range. A standard display offers a compact design compatible with 2”
dashboard hole mounting, and a full-feature display offers a higher specification LCD. Both are back-lit for use in low
ambient light conditions. Both displays have BDI Indication. and 4 hours-counters. The hours counters are retained in the
display in the event of the controller or the controller’s logic being replaced in the field.
11.1 STANDARD DISPLAY

The unit consists of a 2x16 alphanumeric LCD display housed in a standard 50mm circular plastic case, with a
rectangular front facia. The display incorporates a 10 segment BDI (Battery Discharge Indicator), a 6 digit hours
counter and a 10 character area for diagnostic and status messages. When there are no diagnostic messages
the area can be used to indicate a variety of system status readings.
11.1.1 STANDARD DISPLAY FEATURES.

* One unit for 24V-96V.
* Standard 50mm circular case with rectangular front facia, enclosed to IP65
* Alphanumeric display 2x16 characters.
* Readily understandable display format consisting of numbers, text and segments.
* 10 segment BDI indication, with low charge warning and cut-out warnings.
* 10 character text based diagnostic/status display.
* 6 digit hours counter with 0.1 hour indication, and flashing “egg timer” counting symbol.
* Capable of counting up to 99999.9 hours. Equates to 34 years @ 8 hour shift per day
* Keyswitch, Traction and Pump hours count can be shown, identified as K, T, P.
* Hours count retained in display in the event of a controller or logic replacement.
* Display connected via single cable, no external power connections necessary. Display example
showing diagnostic message

11.1.2 STANDARD DISPLAY TECHNICAL SPECIFICATIONS
11.1.2.1 Environmental
Protection (front face): IP65
Protection (rear): IP34
Vibration: 6G, 0-150Hz for 1 hour
Operating Temperature: - 5oC to +50oC
Storage Temperature: - 40oC to +85oC
Humidity: 95% maximum, non-condensing
Humidity Resistance: No functional defects after display is left at 60oC and 100%
humidity for one hour after freezer use (-30oC minimum).
11.1.2.2 Mechanical
Mounting Hole: 2” Nominal. (See mechanical drawing)
Unit weight: 0.12 Kg (including mounting bracket)
Enclosure: Injection moulded plastic case, with transparent front facia.
Connections: One 6 way AT socket.
Fixings method: Mounting bracket supplied
11.1.3 Electrical
Power Supply: Derived from CANbus
Supply Current 60mA (typical)

11.2 FULL-FEATURE DISPLAY
The unit consists of a custom graphic LCD display housed in a SEVCON designed rectangular plastic case.
The display incorporates a 10 segment BDI (Battery Discharge Indicator), a 6 digit hours counter and a 14
character area for diagnostic and status messages. The display has 11 warning symbols which can be lit by
the controller (via the CANbus) or by 8 active low switch inputs. When there are no diagnostic messages the
top line of the message area can be used to indicate one of a number of status readings (see “display related
adjustments” below). In addition there are two multipurpose indicators, that can be reprogrammed using the
calibrator to show one of a selection of system status readings.
11.2.1 FULL-FEATURE DISPLAY FEATURES

* One unit for 24V-96V.
* SEVCON-designed full-custom LCD with LED backlight.
* Readily understandable display format consisting of numbers, text and segments.
* 10 segment BDI indication, with low charge warning and cut-out warnings.
* 14 character text based diagnostic/status display.
* 6 digit hours counter with 0.1 hour indication, and flashing “egg timer” counting symbol.
* Capable of counting upto 99999.9 hours. Equates to 34 years @ 8 hour shift per day
* Keyswitch, Traction and Pump hours count can be shown, identified as K, T, P.
* Hours count retained in display in the event of a controller or logic replacement.
* Speed indication (indicator #2), can be reprogrammed via calibrator.
* Text status area can show one of a selection of system status readings.
Full Feature Display with all

segments lit.

11.2.2 FULL-FEATURE DISPLAY TECHNICAL SPECIFICATIONS
11.2.2.1 Environmental
Protection: The enclosure is protected to IP65
Vibration: 6G, 40-200Hz for 1 hour
Operating Temperature: - 20 ° C to +70 ° C
Storage Temperature: - 40 ° C to +85 ° C
Humidity: 100% maximum, with condensing
11.2.2.2 Mechanical
Mouting hole: 128mm x 87mm (see mechanical drawing)
Unit weight: 0.35 Kg.
Enclosure: Injection moulded plastic case, with transparent front facia.
Connections: One 6 way AT socket, One 12-way.
Fixings method: Mounting bracket supplied
11.2.2.3 Electrical
Power supply: Derived from CANbus
Supply current: 60mA (typical)
Backlight supply 14.5V to 150.0V
Backlight supply current 50mA (typical)
11.2.2.4 12-Way Connections
Pin Type Description

1 Digital i/p Traction Motor Temperature Warning
2 Digital i/p Pump Motor Temperature Warning
3 Digital i/p Power Steer Motor Temperature Warning
4 Digital i/p Traction Motor Brush Wear
5 Digital i/p Pump Motor Brush Wear
6 Digital i/p Power Steer Motor Brush Wear
7 Digital i/p Oil Warning
8 Digital i/p Diagnostic/Service Warning
9 0V Return for swtich inputs, pins 1-8
10 PSU i/p Battery negative (backlight supply)
11 spare 12
PSU i/p Battery positive (backlight supply)

11.3 DISPLAY RELATED ADJUSTMENTS
11.3.1 Hours counter, Display status and Contrast adjustments (On pump only systems located in Pump sub menu 2.8 )
Cal. Minimum or default Maximum or other Step size.

Ref. DISPLAY
Parameter Adjusted setting. settings.
1.8.1 Main Hours Trac Pump, Key, Work n/a
1.8.2 Status Off Ver # n/a
1.8.3 Contrast (standard only) 0 127 1
1.8.4 Indicator 1 (FFD Only) Off Ver # n/a
1.8.5 Indicator 2 (FFD Only) Off Ver # n/a
1.8.6 Fault Messages On Off n/a
1.8.1 The main hours adjustment is used to select which of the hours counters: Keyswitch (“K”), Traction (“T”)
or Pump (“P”) hours, remains on the display after power-up sequencing, Normally this is Key (“K”).
1.8.2,4,5 Selects a system status reading for display (or indication on the full-feature display) from: Off, Traction
motor current, Traction motor voltage, Pump motor current, Pump motor voltage, vehicle speed in KPH,
vehicle speed in MPH, Accelerator pushes and display software version number (not available on indicator
1 or 2).
1.8.3 Sets the contrast of the standard display.
11.3.2 BDI adjustments (Located at the end of the first Traction sub menu 1.4, or in Pump sub menu
2.4 ) Cal.
Ref. BDI Parameter Adjusted or Minimum setting or Maximum or Step size
displayed displayed value other settings
1.4.1 xxx % Charge remaining n/a n/a n/a

1.4.2 Battery Volt xx V 24V 96V 2V
1.4.3 Reset x.xx V/Cell 2.00 2.50 V/Cell
1.4.4 Empty x.xx V/Cell 1.50 1.99 V/Cell
1.4.5 Warning xx % 0% 90% 1.0 %
1.4.6 Cutout xx % 0% 90% 1.0 %
WARNING: The BDI Empty level must be set in accordance with the specification of the battery
fitted to the vehicle. Setting the Empty level lower than the battery manufacture’s specified discharged
level can result in permanent damage to the battery.
1.4.1 Displays the remaining battery charge. No adjustments can be made.
1.4.2 Adjustment used to enter the nominal battery voltage.
1.4.3 Sets the voltage at which the BDI resets to 100% at power up. E.g. the BDI will reset to 100% on a 48V
system, with the reset adjustment set to 2.20 Volts per cell, if the battery voltage is above 52.8V =
(48V/2)*2.20V.
1.4.4 Sets the voltage at which the BDI indicates the battery is fully discharged E.g. the BDI will eventually show 0%
on a 48V system, with the empty adjustment set to 1.60 Volts per cell, if the battery voltage is below 38.4V
= (48V/2)*1.60V.
1.4.5 Sets the discharged level at which the warning threshold is reached, and the unlit segments flash.
1.4.6 - Sets the discharged level at which the cut-out threshold is reached. All BDI segments flash, pump operation is
cut, and cutback 2 is applied to traction.

11.4 BDI OPERATION
The state of battery charge is indicated by 10 segments on the display. When the battery is deemed fully
charged, all 10 segments will be lit. When the battery is deemed fully discharged all segments will be
extinguished, with each 10% drop in capacity extinguishing 1 segment. There are 5 adjustments associated
with the BDI as described on the previous page, adjustable by the hand held calibrator.
When the battery charge drops below an adjustable warning level, typically set to 30%, the remaining lit
segments will flash to warn the driver of this. When the charge drops further to below an adjustable cut-out level,
typically 20%, all 10 segments will flash. At the cut- out level, Pump operation will be inhibited at the end of its
present operating cycle, and cutback 2 personalities will be applied to the Traction.
The state of battery charge is retained even when power is removed, and is stored in the controller’s non-volatile
EEPROM memory. At power up the display will always indicate the previous state of charge for approximately 1
second, whereupon it will either continue to display this, or revert to a fully charged indication if the battery is
deemed to have been charged in the meantime. The BDI system uses an averaged, accurate battery voltage to
deduce the state of charge. Pin 10 on connector 2 is the Battery voltage measurement input for the BDI and to
maintain accuracy should be connected as close as possible to the actual battery terminals, without overriding
safety disconnects.
11.5 HOURS COUNTER (INDEPENDENT FROM CONTROLLER HOURS COUNT)

A 6 digit hours counter is provided to indicate Traction pulsing, Pump pulsing and Key switch hours. The last
digit displays tenth’s of hours, i.e 6 minute intervals, with the counter capable of displaying up to 99999.9 hours
in total. As a guideline, this is equivalent to approximately 34 years operation if the truck was used for an 8 hour
shift every day. At power up the hours count display initially indicates Key switch hours for approximately 3
seconds, followed by Pump pulsing hours for 3 seconds( if applicable), followed by Traction pulsing hours
which remains permanently displayed. This order can be changed using the calibrator as described on the
previous page. When the hours are being counted, a flashing egg timer symbol is displayed to indicate this.
Hours counting accuracy is approx.
+ /- 2%. The display has its own integral non-volatile memory to retain all the hours counts in the event of the
controller or controller logic being replaced.
11.6 DIAGNOSTIC/STATUS TEXT MESSAGES

The controller can transmit text messages for diagnostic and status indication. On the standard display these
appear over the status area, and on the full-feature display, they also overwrite the hours counter until the fault
condition has cleared. This feature can be disabled via personality 1.8.6 as described on the previous page.
Some messages may be displayed with one or more symbols. The following table shows the fault message
and symbols displayed for each fault condition.

Message Symbols Displayed Fault Description
TRAC
1 Traction brushes worn.
BRUSHES
PUMP
2 Pump brushes worn.
BRUSHES
PUMP
3 Pump over temperature.
HOT
OIL
4 Oil pressure low.
FAULT
PUMP
6 Pump motor too hot.
HOT
BDI CUT
7 BDI enabled and cut-out action initiated.
OUT
TRAC
8 Traction heatsink above 75°C. Allow controller to cool
HOT
PUMP
9 .Pump heatsink above 75°C. Allow controller to cool.
HOT
SPEED
10 Speed limit feature enabled & wire off.
PROBE
ACCEL
11 Accelerator wire off. Recycle FS1 and Direction.
FAULT
ACCEL Accelerator pedal pressed at power up, or wire off.

12
FAULT Recycle FS1 and Direction.
CONTACT Contactor has bad contact or didn't close, motor o/c.

13
FAULT Recycle FS1 & Dir.
CONTACT Contactor didn't open or is welded. Recycle FS1 and

14
FAULT Direction switch.
SEQ Direction or FS1 switch at power up. Recycle Direction

15
FAULT FS1 or both.

2 DIR Two directions selected together. Recycle both
16
FAULT Directions and FS1.
SRO Dir. switch selected > 2 seconds after FS1. Recycle FS1
17
FAULT and Dir.
SEAT Drive selected and no seat sw. Recycle Dir and FS1
18
FAULT switch
BELLY
19 Belly switch has pressed
FAULT
Inch switch at power up , both inch switches selected or inching attempted

INCH
20 with seat switch or Dir/FS1 selected.
FAULT
Recycle inch switches.
BATTERY Battery < Low battery personality. Recycle FS1 or

21
LOW Direction switch
BATTERY Battery > High battery personality. Recycle FS1 or

22
HIGH Direction switch
PERS
23 Personalities out of range at power up.
ERROR
CRC
24 One or more personalities have been corrupted.
ERROR
COIL
25 A contactor coil s/c or miswired. Recycle Keyswitch
FAIL
MOSFET Bypass contactor s/c or MOSFET s/c Recycle FS1 or

26
FAIL Direction
If any of these message are displayed then the controller

27 FAIL
has failed one of its internal power up checks.

12 POWER CIRCUIT DESCRIPTIONS
The main switching element of the PowerpaK consists of a bank of power MOSFET transistors connected in
parallel. These are switched at high frequency (16KHz) to give silent operation. Switching speeds have been
optimised to minimise switching losses. Fast-recovery Freewheel diodes, also connected in parallel but
arranged to share current, are used to maintain circulating current around the motor when the main MOSFETs
are turned off.
Both the MOSFETs and Freewheel diodes have their temperatures monitored. The software will cutback
motor current to prevent either thermal stress, or operation outside their safe operating areas.
Electrolytic capacitors are fitted internally between B+ve and B-ve to maintain constant current in the battery
leads and to keep a constant battery voltage across the controller. In traction power frames a Plug Diode is
internally connected across the motor armature to limit the generated voltage during plugging so that controlled
braking can be achieved. This diode is not necessary for Pump motor controllers.
On traction controllers, Regen is achieved by adding an extra single pole change over contactor and an
optional regen diode which connects the top of the motor armature to B- ve during braking, to allow circulating
generated current to flow round the motor loop after the direction contactors have been reversed and the motor
excited. The generated armature voltage charges the motor field with current when the MOSFETs are on.
When they are off, this current flows through the freewheel diodes back into the battery. This has the effect of
returning a small amount of energy back to the battery and minimising heat dissipation in the motor during
braking.
A current shunt is connected in series with the motor armature to monitor motor currents, during all operations
including drive, regen and plug braking modes. On traction controllers the direction contactors should be used
to switch the armature. A line contactor can be used to offer reverse battery connection protection, minimise
any battery connector arcing when powering up, and to give a mechanical break in pump controller systems.
The line contactor is optional, and is not operated by the Controller. Bypass operation is possible on traction
systems to short out the main MOSFET devices for maximum efficiency and high speed or high current
operation. Field Weakening operation is also possible on traction controllers by controlling a contactor to switch
in resistor in parallel with the motor field. An output for controlling a power steer contactor is also provided.

13 INSTALLATION
13.1 The controller should be bolted down to a flat (0.2mm max. deviation) paint free surface that has been lightly
coated with a thermal transfer compound, such as GE G641 or Dow Corning heatsink compound, by the 6
fixing 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.
13.2 Power connections should be made with flexible heat resisting cables of suitable cross- sectional area for the
current to be carried (See section 6.1.2). These should be terminated in soldered or crimped lugs attached to
controller and the contactors. Note that nuts and washers are supplied for the M8 connections on the controller.
A battery-disconnect switch should be used (EC Directive).
13.3 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.
13.4 The controller may be supplied as a stand-alone unit or pre-wired onto a base-plate with contactors etc. If the
controller is 'stand-alone', both Connectors 1 and 2 will be used. If a 'panel' is supplied, only Connector 1 will be
used as Connector 2 will contain the contactor wiring. The mating halves of the connectors can be supplied with
the controller as a 'loose equipment kit'.
13.5 Control wiring connections should be made using 1.00mm2 (AWG#18) or equivalent stranded wire. The
correct pressure release crimping tools MUST be used for long term connection reliability.
13.6 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 A when using the specified Albright contactors.
13.7 The return wiring for the accelerators should be connected to the B- terminal on the controller to prevent large
currents altering accelerator signals.
13.8 Fixing torque for power connectors M8
terminals 11NM

14 EMC GUIDELINES
The following guidelines are intended to help vehicle manufacturers to meet the requirements of the EC
directive 89/336/EEC for Electromagnetic Compatibility. Any high speed switch is capable of generating
harmonics at frequencies that are many multiples of its basic operating frequency. It is the objective of a
good installation to contain or absorb the resultant emissions.
All wiring is capable of acting as a receiving or transmitting antenna. Wiring should be arranged to take
maximum advantage of the structural metal work inherent in most vehicles. Vehicle metalwork should be
electrically linked with conductive braids.
14.1 Power Cables
All cables should be routed within the vehicle framework and kept as low in the structure as is practical - a cable
run within a main chassis member is better screened from the environment than one routed through or adjacent
to an overhead guard. Power cables should be kept short to minimise emitting and receiving surfaces Shielding
by the structure may not always be sufficient - cables run through metal shrouds may be required to contain
emissions.
Parallel runs of cables in common circuits can serve to cancel emissions - the battery positive and negative
cables following similar paths is an example.
Tie all cables into a fixed layout and do not deviate from the approved layout in production vehicles. A re-routed
battery cable could negate any approvals obtained.
14.2 Signal Cables
All wiring harnesses should be kept short. Wiring should be
routed close to vehicle metalwork.
All signal wires should be kept clear of power cables or made from screened cable Control wiring should be kept
clear of power cables when it carries analogue information - for example, accelerator wiring.
Tie all wiring securely and ensure wiring always follows the same layout.
14.3 Controller
Thermal and EMC (emissive) requirements tend to be in opposition. Additional insulation between the controller
assembly and the vehicle frame work reduce capacitive coupling and hence emissions but tend to reduce
thermal ratings. A working balance needs to be established by experiment.
The complete installation should be documented, in detail, and faithfully reproduced on all production vehicles.
When making changes, consider their effect on compliance ahead of any consideration of cost reduction or other
“improvement”.

STANDARD SEVCON POWER UP, SEAT SWITCH AND SRO SEQUENCING DESCRIPTION KEY SWITCH POWER UP
TRUTH TABLE (NO SRO ENABLED)
Key Sw. Seat Sw. Direction Sw. FS1 Sw. Drive Fault Indicated
1-8 0 x x x No None
9 1 0 0 0 No None
10 1 0 0 1 No None
11 1 0 1 0 No None
12 1 0 1 1 No Seat Fault
13 1 1 0 0 No None
14 1 1 0 1 No None
15 1 1 1 0 No None
16 1 1 1 1 Yes None
KEY SWITCH POWER UP SEQUENCE TABLE (NO SRO ENABLED)
1 Key Seat Direction FS1 Yes None
2 Key Seat FS1 Direction Yes None
3 Key Direction Seat FS1 No Seat Fault
4 Key Direction FS1 Seat No Seat Fault
5 Key FS1 Seat Direction No Seat Fault
6 Key FS1 Direction Seat No Seat Fault
7 Seat Key Direction FS1 Yes None
8 Seat Key FS1 Direction Yes None
9 Seat Direction Key FS1 No Power Up Fault
10 Seat Direction FS1 Key No Power Up Fault
11 Seat FS1 Key Direction No Power Up Fault
12 Seat FS1 Direction Key No Power Up Fault
13 Direction Key Seat FS1 No Power Up Fault
14 Direction Key FS1 Seat No Power Up Fault
15 Direction Seat Key FS1 No Power Up Fault
16 Direction Seat FS1 Key No Power Up Fault
17 Direction FS1 Key Seat No Power Up Fault
18 Direction FS1 Seat Key No Power Up Fault
19 FS1 Key Seat Direction No Power Up Fault
20 FS1 Key Direction Seat No Power Up Fault
21 FS1 Seat Key Direction No Power Up Fault
22 FS1 Seat Direction Key No Power Up Fault
23 FS1 Direction Key Seat No Power Up Fault
24 FS1 Direction Seat Key No Power Up Fault
SEAT SWITCH TRUTH TABLE (NO SRO ENABLED)

Seat Sw. Seat Timer Direction Sw. FS1 Sw. Drive Fault Indicated
1 0 0 0 0 No No
2 0 0 0 1 No No
5 0 1 0 0 No No
6 0 1 0 1 No No
7 0 1 1 0 No No
8 0 1 1 1 Yes No
9 1 x 0 0 No No
10 1 x 0 1 No No
11 1 x 1 0 No No
12 1 x 1 1 Yes No
13 1 x 0 0 No No
14 1 x 0 1 No No
15 1 x 1 0 No No
16 1 x 1 1 Yes No
SEAT SWITCH SEQUENCE TABLE (NO SRO ENABLED)
1 Seat Direction FS1 Yes No
2 Seat FS1 Direction Yes No
3 Direction Seat FS1 No Seat Fault
4 Direction FS1 Seat No Seat Fault
5 FS1 Seat Direction No Seat Fault
6 FS1 Direction Seat No Seat Fault
SRO (Static Return to Off) TRUTH TABLE

Direction Sw. FS1 Sw. Drive Fault Indicated
1 0 0 No None
2 0 1 No None
3 1 0 No None
4 1 1 Yes None
SRO (Static Return to Off) SEQUENCE TABLE
1 Direction FS1 Yes None
2 FS1 Direction within 2 Yes None
seconds
3 FS1 Direction after 2 No SRO FAULT
seconds

Accelerator Characteristics
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100
Linear Curved 2 Slope Crawl
Thermal Cutback Characteristic

Safe Operating Area Graphs
24-48V Controllers
100
90
80
70
60
% of Max Current
50
40
30
20
10
0 10 20 30 40 50 60 70 80 90 100
% On
72-80V Controllers
100
90
80
70
60
% of Max Current
50
40
30
20
10
0 10 20 30 40 50 60 70 80 90 100
% On

Figure 1 Light Wiring - Low I/O Logic. (Pump Functions in brackets.)

Figure 2 Light Wiring - Medium I/O Logic

Figure 3 Light Wiring - High I/O Logic

Figure 4 Series Traction Regen

Figure 5 Series Traction Plugging

Figure 6 Series Pump

Figure 7 Mechanical Details
NB: Diagram shows controller with Medium I/O Logic fitted

Mounting holes are for M6 bolts.

177-52101 PowerpaK Series Traction Manual - En.es

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TM

1) Serie de tracción 24-48V, 300A, 450A, 650A Baja lógica de E / S

2) " 72-80V, 450A, 600A Baja lógica de E / S

3) " 24-48V, 300A, 450A, 650A Lógica de E / S media

4) " 72-80V, 450A, 600A Lógica de E / S media

5) " 24-48V, 300A, 450A, 650A Alta lógica de E / S

6) " 72-80V, 450A, 600A Alta lógica de E / S

7) Serie de bombas 24-48V, 300A, 450A, 650A Lógica de E / S de bomba

8) " 72-80V, 450A, 600A Lógica de E / S de bomba

Revisión Fecha de asunto Autor Cambios

PS 14 de septiembre de 2001 Manual PowerpaK - Revisión G 1

HISTORIAL DE MODIFICACIÓN ................................................ .................................................. ........................................... 1

1 INTRODUCCIÓN ................................................. .................................................. .................................................. ..3

2 VARIANTES CONTROLADORES POWERPAK .............................................. .................................................. .............. 4

4 SEGURIDAD ................................................ .................................................. .................................................. .................... 6

5 ESPECIFICACIONES TÉCNICAS ............................................... .................................................. ............................ 6

6 CABLEADO DEL CONTROLADOR Y CONEXIONES ............................................. .................................................. .... 8

7 CALIBRADOR Y AJUSTES .............................................. .................................................. ................... 12

8 DIAGNÓSTICO ................................................ .................................................. .................................................. ...... 20

9 REGISTROS DE SERVICIO Y FALLAS (TODAS LAS LÓGICAS) ......................................... .................................................. ........ 21

10 OPERACIÓN DEL CONTROLADOR Y DESCRIPCIONES DE CARACTERÍSTICAS ............................................. ................... 22

11 PANTALLAS DEL TABLERO DE CONTROL - DESCRIPCIONES DE FUNCIONAMIENTO Y FUNCIONES ........................................... .31

12 DESCRIPCIONES DEL CIRCUITO DE POTENCIA ............................................... .................................................. ................. 39

13 INSTALACIÓN................................................. .................................................. ................................................. 40

14 DIRECTRICES DE EMC ................................................ .................................................. ............................................. 41

FIGURA 1 CABLEADO LIGERO - LÓGICA DE E / S BAJA. (FUNCIONES DE LA BOMBA EN SOPORTES.) ................................... 45

FIGURA 2 CABLEADO DE LUZ - LÓGICA DE E / S MEDIA ........................................ .................................................. ........ 46

FIGURA 3 CABLEADO LIGERO - LÓGICA DE E / S ALTA ........................................ .................................................. ............... 47

FIGURA 4 REGENERACIÓN DE TRACCIÓN EN SERIE ............................................. .................................................. ....................... 48

FIGURA 5 ENCHUFE DE TRACCIÓN DE LA SERIE ............................................. .................................................. ................ 49

FIGURA 6 BOMBA SERIE .............................................. .................................................. ................................................ 50

FIGURA 7 DETALLES MECÁNICOS .............................................. .................................................. ............................ 51

2 Manual PowerpaK - Revisión G PS 14 de septiembre de 2001

de la serie DC. Hay una gama separada de controladores PowerpaK SEM.

PS 14 de septiembre de 2001 Manual PowerpaK - Revisión G 3

PP xxx Descripción del número de modelo

1er dígito Controlador 1 = ---------------

2do digito voltaje 2 = --Reservado-- (24-36V)

3er dígito Actual 3 = 300A

Sufijo L = E / S baja, Tracción M = E / S

MODO PODER CONFIGURACIÓN LÓGICA NO. apagado TAMAÑO

PP343P 24-48V 300A Bomba Bomba de E / S 55 142 x 142 x 140 mm

PP344P 24-48V 450A Bomba Bomba de E / S 55 142 x 142 x 140 mm

PP346P 24-48V 650A Bomba Bomba de E / S 55 142 x 142 x 140 mm

PP384P 72-80V 450A Bomba Bomba de E / S 55 142 x 142 x 140 mm

PP386P 72-80V 600A Bomba Bomba de E / S 55 142 x 142 x 140 mm

44 Manual PowerpaK - Revisión G PS 14 de septiembre de 2001

Entrada para desactivar la operación de la bomba si n/A n/A n/A

Ajustes independientes de velocidad y compensación de la dirección asistida si n/A n/A n/A

Sistemas a prueba de fallas de hardware y software n/A si si si

PS 14 de septiembre de 2001 Manual PowerpaK - Revisión G 55

4.7 VERIFICACIÓN A PRUEBA DE FALLAS:

5.1.1 Especificaciones de voltaje:

Modelo Batería Nominal de Voltaje Tensión de funcionamiento máxima absoluta

PP x4x 48V Unidades 24-48V 14.5 - 75V

5.1.2 Especificaciones actuales:

Modelo Poder Límite actual (1 Operación segura

66 Manual PowerpaK - Revisión G PS 14 de septiembre de 2001