7CH4Q45C_7CH4Q90C_E_0 DATE : 14/03/2014 REV. 0.

7CH4Q45C
and
7CH4Q90C
MICROPROCESSOR FOUR QUADRANT CONTROLLER FOR
PM DC MOTORS

- USER’S GUIDE -
 - CONTENTS -
ccaaaaaaa
INTRODUCTIONaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa ccaaaaPage 2

FEATURES Page 2

SAFETY Page 2

MECHANICAL DRAWING Page 3

INSTALLATION Page 4

WIRING DIAGRAM Page 5

I/O CONNECTOR

16 pins connector Page 6

4 pins connector Page 7

Power connections Page 7

CONTROLLER SETTINGS
7PROGLCD HANDHELD PROGRAMMER Page 8
SERIAL COMMUNICATION TESTER Page 10

PARAMETERS Page 15
RESET TO DEFAULTS Page 16
GENERAL SETTINGS Page 16
SPEED REFERENCE SETTINGS Page 17
REFERENCE’S DEADBAND Page 20
ELECTROBRAKE OUT PUT SETTING Page 20
MODE1 INPUT SETTING Page 21
BACKWARD SAFETY SETTINGS Page 21
LOW BATTERY LEVEL Page 21
RxI FUNCTION Page 22
RUN-AWAY FUNCTION Page 22
MOTOR CURRENT SETTING Page 22
OVERLOAD PROTECTION Page 23
BOOST CURRENT FUNCTION Page 25
DIGITAL INPUTS CONFIGURATION Page 25
SELF CUT-OFF Page 28
ALARMS ENABLE Page 28

ALARMS Page 29

SOFTWARE UPDATES Page 32

1
 - INTRODUCTION -
The controller 7CH4Q45C / 90C is a 4 quadrant chopper for PMDC motors powered by
battery 24/36V for traction applications.
The chopper is equipped with a powerful microprocessor for digital control of the speed,
current regulation and failures of the motor ; an efficient diagnostics of the failures and
wrong wiring connections, programmability of the main parameters .
The MOSFET power stage is an “H bridge” configuration operating with PWM.
The ripple of the current is very low so the efficiency of the system is very high .
The chopper is designed in accordance with the most important EC standards.

- FEATURES -
POWER SUPPLY BATTERY 24 – 36 V
RATED CURRENT 15A (7CH4Q45C) – 35A (7CH4Q90C)
MAX CURRENT ( Ta = 25°C) 45A (7CH4Q45C) – 90A (7CH4Q90C)
FREQUENCY 16 KHz
MAX HEATSINK TEMPERATURE 85 °C
OPERATING TEMPERATURE -10°C / 40°C
SPEED REFERENCE VOLTAGE (0-5Vdc)/POTENTIOMETER 1-10 KΩ
ON BOARD MAIN CONTACTOR 24V-40A CONTINUOS
REGENERATIVE BRAKING
PARAMETERS PROGRAMMABLE

SAFETY: • OUTPUT SHORT CIRCUIT PROTECTION

• MOSFET SHORT CIRCUIT PROTECTION
• THERMAL PROTECTION
• LOW VOLTAGE AND OVERVOLTAGE PROTECTION
• REVERSE BATTERY PROTECTION
• OVERCURRENT PROTECTION FUNCTION OF TEMPERATURE
• POTENTIOMETER AND WIRINGS FAULT

2
 - MECHANICAL DRAWING -

fig. 1

3
 - INSTALLATION -

fig.3a

Locate the chopper in a place protected against mechanical abuse, water and dirty.
Fix it with all the screws on a metal surface (aluminum if possible) to reduce the heath and
so for longer period of work.
If during the standard operations the thermal protection is activated very often an
additional heath-sink or fan is requested to assure longer periods of work.

4
- WIRING DIAGRAM -

fig.3

5
 - I/O CONNECTOR -
16v Molex connector (Molex p/n.39012160, contacts p/n.39000038)

fig.4

Pin 1: POSITIVE POTI INPUT

Positive Potentiometer Supply

Pin 2: REFERENCE INPUT

Central Potentiometer, or Voltage (0-5Vdc) Speed Reference Input
To change the input configuration see chapter “DIGITAL INPUTS CONFIGURATION”

Pin 3: NEGATIVE POTI INPUT

Negative Potentiometer Supply, or Gnd Voltage Speed Reference Input

Pin 4: V_MAX (OPTIONAL)

Max speed input potentiometer (>100 KΩ).

Pin 5: BACKWARD SAFETY

Default N.C. input contact to +V_Batt for Backward safety. This input is active
when open.
To change the input configuration see chapter “DIGITAL INPUTS CONFIGURATION”

Pin 6: DISABLE
When the input is active the controller will decelerate (Neutral Ramp) , will check if
the motor voltage is near zero (motor stopped) and after the electro-brake delay
will inhibit the motor: appear the alarm A12 (to reset switch-off and on again the
key). If the contact will be open before the motor stop , the machine will restart at
the desired speed.
To change the input configuration see chapter “DIGITAL INPUTS CONFIGURATION”

Pin 7: ELECTROBRAKE COIL ( - )

Output active low 2 Amps max (short circuit protected) and internal diode.

Pin 8: ELECTROBRAKE / HORN COIL (+)

Common +V battery for electro-brake and horn coils.

Pin 9: HORN ( - )
Output active low ( close to –Battery) for the horn or light backward direction
(2 Amps max, short circuit protected, and internal diode).

6
Pin 10: ALARM
Connection for the diagnostic Blinking Led indicator (5Vdc-10mA) output : the
number of blinks means the alarm type (example 5 blinks means Alarm 5).

Pin 11: MODE1

Default N.O. input to +V battery; when active, this input changes set of maximum
speed and/or maximum motor current.
To change the input configuration see chapter “DIGITAL INPUTS CONFIGURATION”

Pin 12: FORWARD SWITCH

N.O. input to +V battery. Controller drives positive voltage on M1 output and
negative on M2 output.
To change the input configuration see chapter “DIGITAL INPUTS CONFIGURATION”

Pin 13: BACKWARD SWITCH

N.O. input to +V battery. Controller drives positive voltage on M2 output and
negative on M1 output
To change the input configuration see chapter “DIGITAL INPUTS CONFIGURATION”

Pin 14: COMMON HIGH

+V battery output for switches.

Pin 15: KEY IN

Logic stage positive supply input (+V battery).

Pin 16: HOURMETER

Hour-meter output ( +V battery when running, 100mA max).

4v Molex connector (Molex p/n.3901240, contacts p/n. 39000038)

Used for handheld programmer or communication to pc.

M5 power screws (M5)

fig.5
+ B: Positive DC power supply input,
- B: Negative DC power supply input,
M1: Positive Motor output ( in forward direction ),
M2: Negative Motor output ( in forward direction ),

7
 - CONTROLLER SETTING -
7PROGLCD HANDHELD PROGRAMMER

LCD 16X2:
Displays parameters, alarms and measures
(description and value).
UP Key:
Rolls up parameters and increases values.
MODE Key:
Confirms a selection and the change of value.
UP Key:
Rolls down parameters and decreases values.

At power-on, handheld programmer displays the “Tester Mode” page. In this pages , you’ll
find the motor current and voltage, speed reference input, internal aluminum heat-sink
temperature, battery voltage, hour-meter and software release.
To start the programming function push the button “MODE” .
Will appear the first parameter; pushing the “UP” button the number of the parameter will
be increased and with the “DOWN” button the number will be decreased. When a
parameter is selected , push the button “MODE” to enter in the change menu, change the
value with the buttons “UP” and “DOWN”, then confirm the parameter with the button
“MODE”. To return to the TESTER menu push together the buttons “MODE “and “UP”,
or wait few seconds.

fig.6

8
 SW RELEASE Software’s release number.
7CH4Q###_#

MOTOR CURRENT Motor current measure (measure unit=Amperes).

Imot= ## Amps

MOTOR VOLTAGE Motor voltage measure (measure unit=Volts).

Vmot = ##.# Volts

REF. VOLTAGE Speed reference voltage (measure unit=Volts);

potentiometer or voltage speed reference.
Vref = #.#Volts

HEATSINK TEMP. Internal heat-sink temperature

(measure unit C° and F° degrees)
T°= ##°C / ###°F

BATTERY VOLTAGE Battery supply voltage (measure unit=Volts)

Vbatt= ##.# Volts

Inputs monitor Connector’s J1 Inputs status (pin active when its

number is displayed)
J1:#,#,##,##,##

Overload level: Ammeter protection (overload) level; at 100% alarm

A10 is active.
##% (at ##Amps)

HOURMETER Measure of worked time (when motor is running).

#### hrs, ## min

9
SERIAL COMMUNICATION TESTER

Main Window
The Serial Communication Tester (SCT) is a Windows executable software utility that
connects the controller to a PC/Laptot using an USB port (Italsea’s 7RS2USB# cable is
required).
Once open the utility by double click on icon, will appear the main window.

fig.7

In the top side of the window is shown the toolbar; in toolbar are present the main
commands to operate with this application.
“Tester Pages” windows show in real time the controller’s measure as motor current and
voltage, heatsink temperature and so on.
“Parameters Pages” controls show and set the present and the new set value of internal
controller parameters; to set the parameter is necessary set before the correct password
value.
When the SCT software is just open, it doesn’t show the labels close the tester and
parameters windows; this labels will appear once connect the PC to controller.

10
Toolbar
Toolbar is locate on tupper-left side in the main window.

fig.8

Exit:
Aborts program and return to other windows applications

Connect:
Connects the controller to PC.

Par. Read.:
Uploads/reads the parameters set inside the controller to SCT’s window.
NOTE: before Read parametrs:
1) connect the device to SCT utility,
2) wait until SCT utility reads the “Tester Pages”,
3) disconnect SCT utility,
4) Click on “Par.Read.” button.

Par. Set:
Writes/send the new parameters set on SCT’s utility inside the controller.

Config.:
Modifies the SCT’s default initializations. This utility is used mainly to change
the communications port setting; when clicked, will appear the following
window:

Communication Port,
Communication Speed (do not change),
Do not change,
Do not change,
Do not change,
Do not change,
Do not change,
Do not change,

fig.9
Exit and re-open the SCT utility is suggest after communication sets. The new
sets are stored in a “.ini” file in same SCT folder.

11
 Logger:
Displays the communications data (use by engineering tests).

Release:
Views the SCT’s release.

fig.10

Connect PC to Controller

To connect the SCT utility to controller, power-on the controller and than push “Connect”
on toolbar. At power-on, the controller checks for 10 seconds if PC is connected or not.
If the SCT utility is unread, after 10 seconds the controller enables only the communication
to 7PROGLCD.

Connection sequence:
1) Connect PC/Laptop to Controller using 7RS2USB# cable,
2) start-up SCT utility (double click on icon),
3) check serial port #ID (COM1, COM2…) by “Config.” on toolbar.
4) Power on the controller and than click on “Connect” on toolbar. If the SCT utility
doesn’t connect to controller, an error message will show. In this case, switch-off
the controller, close SCT utility, check connection and retry.
5) After few seconds, main window will refresh the labels close tester and parameters
pages.

12
Tester Pages

When the PC/SCT utility is connected, on toolbar are enabled only the “Connect” and the
“Exit” button.

fig.11
In “Tester Pages” are shown:
- Software Release: Controller’s firmware release.
- Motor Current: Actual Motor Current (1/10 Ampere) .
- Motor Voltage: Actual Motor Voltage (1/10 Volt).
- Speed Reference: Actual Speed Reference (1/10 Volt).
- Heatsink Temperature: Measure of heatsink aluminium plate (°C degrees).
- Supply Voltage: Battery voltage (/10 Volt).
- Overload Level: Percentage of current overload status (%).
- Alarm: Actual Alarm (if present).
- BW Safety Input Status: BackWard Safety Input status (1=active,0=not active).
- Disable Input Status: Disable Input status (1=active,0=not active).
- Mode1 Input Status: Mode1 Input status (1=active,0=not active).
- FW Switch Input Status: ForWard Input status (1=active,0=not active).
- BW Switch Input Status: BackWard Input status (h1=active,0=not active)
- Hourmeter (Hours): Count of worked time (hours count).
- Hourmeter (minutes): Count of worked time (minutes count).
- System ID: system management only.

13
Parameters Pages
NOTE: before Read parametrs:
1) connect the device to SCT utility,
2) wait until SCT utility reads the “Tester Pages”,
3) disconnect SCT utility,
4) Click on “Par.Read.” button

To modify values of internal parameters, set the value in password parameter before send
new sets to controller. User can modify only parameter form “Reset to default” parameter
to “Password” parameter; ask to Italsea for access to others parameter and for password
value.

fig.12

The setting range of every parameter is clamped by SCT software if set by control window
(increase/decrease by mouse); if the value is set by PC’s numeric keyboard, out of range
value is not accept by Controller and error message is shown.
Speed Reference parameter is not enabled in this connection mode.

14
PARAMETER DESCRIPTION DEFAULT
7CH4Q45C 7CH4Q90C
RESET TO DEFAULT Reset to default parameters DISABLE DISABLE
ACCELERATION RAMP Acceleration ramp 3.0 3.0
REVERSE RAMP Reverse deceleration ramp 0.5 0.5
NEUTRAL RAMP Neutral deceleration ramp 2.0 2.0
FORWARD SPEED Forward maximum speed 85 100
BACKWARD SPEED Backward maximum speed 100 100
MINIMUM SPEED Minimum speed 0 0
BATTERY VOLTAGE Battery Voltage 24 24
SPEED REFERENCE Speed Reference single-ended single-ended
REF. DEADBAND Reference Dead-band 0.100 0.100
BRAKE DELAY Brake delay 0.5 0.5
MULTIMODE SPEED Speed in Multimode 60 60
MULTIMODE CURRENT Current in Multimode 45 60
BW SAFETY TIME Backward safety time 2.0 2.0
BW SAFETY SPEED Backward safety speed 60 60
LOW BATTERY Low battery limit 23.0 23.0
RxI FUNCTION RxI function 50 50
RUN-AWAY Run-Away function no no
CURRENT LIMIT Controller’s current limit 45 70
RATED CURRENT Motor’s rated current 15 35
OVERLOAD TIME Motor’s overload time 60 60
BOOST CURRENT Motor’s boost current 45 70
5-J1 HW CONFIG Pin 5 – J1 hardware config. N.C. switch N.O. switch
6-J1 HW CONFIG Pin 6 – J1 hardware config. N.O. switch N.O. switch
11-J1 HW CONFIG Pin 11 – J1 hardware config. N.O. switch N.O. switch
2-J1 P.up-down Pin 5 – J1 hardware config. Pull down Pull down
5-J1 P.up-down Pin 6 – J1 hardware config. Pull down Pull down
6-J1 P.up-down Pin 11 – J1 hardware config. Pull up Pull up
11-J1 P.up-down Pin 5 – J1 hardware config. Pull down Pull down
12-J1 P.up-down Pin 6 – J1 hardware config. Pull down Pull down
13-J1 P.up-down Pin 11 – J1 hardware config. Pull down Pull down
SELF CUT-OFF System self cut-off 10 10
ENABLE ALARM 1 A1 alarm enabling. ENABLE ENABLE
ENABLE ALARM 2 A2 alarm enabling. ENABLE ENABLE
ENABLE ALARM 3 A3 alarm enabling. ENABLE ENABLE
ENABLE ALARM 4 A4 alarm enabling. ENABLE ENABLE
ENABLE ALARM 12 A12 alarm enabling. ENABLE ENABLE

15
NOTE: following pages show minimum, maximim and defaults values of the parameters: if
a parameter has different defaults (depending of controller’s P/N), it will be omitted.

RESET TO DEFAULT PARAMETER

DEFAULT: 0
RESET TO DEFAULT MIN: no
###### MAX: Default3

To reset all the parameters, set 2 and power-off ; at the next power-on, the controller will
update the defaults settings.

GENERAL SETTINGS
Acceleration ramp: time in
DEFAULT: 3.0
ACCELERATION RAMP MIN: 0.5 seconds from stop position to
#.# seconds MAX: 10.0 max settled speed.

Reverse direction deceleration

DEFAULT: 1.5
REVERSE RAMP MIN: 0.5 ramp: time in seconds from the
#.# seconds MAX: 10.0 current direction to reverse
direction.

Deceleration ramp: time in

DEFAULT: 1.0
NEUTRAL RAMP MIN: 0.5 seconds from max settled speed
#.# seconds MAX: 10.0 to stop position.

Forward direction maximum

DEFAULT: ---
FORWARD SPEED MIN: 20 speed: value in percent of battery
### % of Supply MAX: 100 voltage.

Backward direction maximum

DEFAULT: 100
BACKWARD SPEED MIN: 10 speed: value in percent of
### % of forward MAX: 100 forward direction max speed.

Minimum speed: value in percent

DEFAULT: 0
MINIMUM SPEED MIN: 0 of battery voltage.
## % of Supply MAX: 20

Battery supply voltage: set the

DEFAULT: 24
BATTERY VOLTAGE MIN: 24 value between options 24V or
Supply ## V MAX: 36 36V

16
 SPEED REFERENCE SETTINGS
SPEED REFERENCE’S TYPE:
Speed reference’s type and range may be set by the sequences that follow:
Choose “SPEED REFERENCE”
SPEED REFERENCE
########## + page, and confirm it by “MODE”
button

The controller can work mainly with 6 kinds of speed reference:

- Single-ended potentiometer:
potentiometer with two direction switches,

- Voltage 0-max:
analogue signal with direction switches,

- Wigwag1 potentiometer:
potentiometer with middle stop position and enable
switches,

- Wigwag2 potentiometer:
potentiometer with middle stop position without enable
switches,

- Fw/Bw switches:
internal speed reference (controller uses internal parameters
“forward speed” and “backward speed): only direction
switches are used

17
SINGLE ENDED CALIBRATION:
Step 1:
Choose “single-ended” option, and
SPEED REFERENCE
single-ended + confirm it by “MODE” button.

Step 2:
Set the potentiometer or throttle at
CALIBRATION
Stop pos = #.# V + STOP / NEUTRAL position, and
confirm it by “MODE” button.

Step 3:
Set the potentiometer or throttle at
CALIBRATION
Max pos = #.# V + MAX position, and confirm it by
“MODE” button.

The single-ended reference range is calibrated.

VOLTAGE 0-MAX CALIBRATION:

Step 1:
Choose “voltage 0-max” option, and
SPEED REFERENCE
voltage 0-max + confirm it by “MODE” button.

Step 2:
Set the voltage reference at STOP /
CALIBRATION
Stop pos = #.# V + NEUTRAL position, and confirm it
by “MODE” button.

Step 3:
Set the voltage reference at MAX
CALIBRATION
Max pos = #.# V + position, and confirm it by “MODE”
button.

The voltage 0-max reference range is calibrated.

18
WIGWAGS CALIBRATION:
Step 1:
Choose “wigwag 1” or “2” or “3”
SPEED REFERENCE
wigwag # + option, and confirm it by “MODE”
button.

Step 2:
Set the potentiometer or throttle at
CALIBRATION
Stop pos = #.# V + central STOP / NEUTRAL position,
and confirm it by “MODE” button.

Step 3:
Set the potentiometer or throttle at
CALIBRATION
Max BW pos = #.# V + MAX BACKWARD position, and
confirm it by “MODE” button.

Step 4:
Set the potentiometer or throttle at
CALIBRATION
Max FW pos = #.# V + MAX FORWARD position, and
confirm it by “MODE” button.

The wigwag reference range is calibrated.

FW/BW CALIBRATION:
Step 1:
Choose “FW/BW” option, and
SPEED REFERENCE
FW/BW + confirm it by “MODE” button.

NOTE:
The controller will drive motor at the speed percentages set in pages “FORWARD
SPEED” and “BACKWARD SPEED”.

19
 REFERENCE’S DEADBAND
Use this parameter to increase, or
DEFAULT: 100
REF. DEADBAND MIN: 50 decrease the speed reference
### mV MAX: 500 stop position range.

ELECTROBRAKE OUTPUT SETTING

Controller supplies the electro-brake coil when the motor is running: the coil is powered-off
with delay when the speed reference and direction switches are in stop position .

Brake ON

Brake OFF Time

Motor ON

Motor OFF Time

← BRAKE DELAY →
fig.13

DEFAULT: 0.5
BRAKE DELAY MIN: 0
#.# seconds MAX: 30.0

Note:
- If the value is set to 0, the controller drives both motor’s wires to minus battery.

20
 MODE1 INPUT SETTINGS
This input activates:
- maximum motor speed set at parameter “MODE1 SPEED”
- maximum motor current set at parameter “MODE1 CURRENT”.
The input is always active.

DEFAULT: 60
MODE1 SPEED MIN: 0
### % of Supply MAX: 100

DEFAULT: ---
MODE1 CURR. MIN: ---
## Amperes MAX: ---

BACKWARD SAFETY SETTINGS

The function operates in the backward direction as a safety function for the operator. It is
realized by mean of a contact that activates the function when switched: the machine will
decelerate, will reverse the direction at a programmed speed for the programmed time,
then will stop.
The normal operation will be obtained resetting the input, the direction switch if present
and speed reference. The function is inhibit with the safety speed equal 0.

DEFAULT: 2.0
BW SAFETY TIME MIN: 0.0
#.# seconds MAX: 9.9

DEFAULT: 60
BW SAFETY SPEED MIN: 0
### % of Supply MAX: 100

LOW BATTERY LEVEL

Low battery level: if battery
DEFAULT: 23.0
LOW BATTERY MIN: 19.0 voltage is lower than this value,
##.# Volts MAX: 28.0 after 5 seconds controller
reduces the motor maximum
speed and current as Mode1
function.
Note:
- once activated this protection, reset it only by switch-off sequence.

21
 RxI COMPENSATION:
Speed (voltage) compensation
DEFAULT: 50
RxI FUNCTION MIN: 0 by motor current: it is possible to
### mohm MAX: 500 increase motor voltage when
motor current increases.
Note:
- this is a “positive reaction”: check value starting from low sets. A wrong set value may
cause oscillations on voltage regulation.

RUN-AWAY FUNCTION
Machine’s free-run protection: if
DEFAULT: no
RUN-AWAY MIN: 10 the machine moves itself, when it
## Volts MAX: 15 runs at set speed (voltage) the
controller stops the machine.
Note:
- the protection/function is active only if battery are connected,
- if the machine is off, the controller switches on, it brakes the motor, after 20 seconds it
switches off.
- If the machine is on, it brakes to stop motor; after stop sequence if the machine moves
again, the controller brakes again.

MOTOR CURRENT SETTING

DEFAULT: ---
CURRENT LIMIT MIN: ---
### Amperes MAX: ---

Maximum output motor’s current: this value is used also to calculate the ammeter/overload
protection.

22
 OVERLOAD PROTECTION
In the programming mode set the rated current and overload time for the motor:

DEFAULT: 35
RATED CURRENT MIN: 5
## Amperes MAX: 35

DEFAULT: 60
OVERLOAD TIME MIN: 1
### seconds MAX: 60

The protection will be activated each time the current overcome the value In +10% and the
overload time is as shorter as higher is the overload according to the function. After the
integration time the controller will stop the machine and an alarm (A11) will be activated.

First of all, the ammeter constant ( K ) has to be calculated using the heat-sink
temperature, the maximum current and the rated current as follow:
In = rated motor current,
2 2 Imax = max motor current,
K= ( Imax - In )*t t = overload time at the max current,

Once calculated the “K”, is possible to calculate the ammeter time protection at your
working current:
In = rated motor current,
K
t= Iwrk = working motor current,
( Iwrk2 - In2 ) K = ammeter constant,

NOTE: ammeter time depends on heatsink temperature too; if the temperature is

higher than 50°C the protection time is reduced (at 80°C is about 1/4 of calculated
time).

Example:
• Current limit = Imax = 45 Amps, • Working current = Iwrk = 25 Amps,
• Rated current = 15 Amps, • Heatsink temperature = T°diss = 50°C
• Overload time = t = 10 seconds,

Step1: K calculation:
K = ( Imax2 - In2 )*t = (452-152)*10 = 18000
Step2: protection (ammeter) time:
K 18000
t= = = 45 seconds
( Iwrk2 - In2 ) ( 252 - 152 )

The application can work at 25 Amps ( heatsink temperature lower than 50°C) for 63
seconds before the Alarm 11 is activated.

23
Ammeter protection diagram (@ Imax=45A, In=15A, Tn=10s, T°=50°, 65° and 80°C)

AMMETER PROTECTION
300
(Imax=45A, In=15A, Tn=10s)

240

AMMETER TIME (s)

180

120

60
fig.14
Chart shows ammeter 0
response at 3 different 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45
MOTOR CURRENT (Amps)
heatsink temperature
(50°C,65°C and 80°C). T°=50 T°=65 T°=80

AMMETER PROTECTION (17-25Amps zoom)

120
110
100
AMMETER TIME (s)

90
80
70
60
50
40
30
20
10
0
fig.14.a 17 18 19 20 21 22 23 24 25
MOTOR CURRENT (Amps)
Zoom of the lower motor
current range. T°=50 T°=65 T°=80

AMMETER PROTECTION (25-45Amps zoom)

50
45
40
AMMETER TIME (s)

35
30
25
20
15
10
5
0
fig.11.b 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
MOTOR CURRENT (Amps)
Zoom of the higher motor
current range. T°=50 T°=65 T°=80

24
 BOOST CURRENT FUNCTION

DEFAULT: ---
BOOST CURRENT MIN: ---
### Amperes MAX: ---

A boost current function is available on controller: the parameter sets the level of this
temporary higher current limit.
If the parameter is set equal or less the current limit parameter the function is not active.
To enable the boost, set the boost value (for example 110Amps).
If the motor requires more than 90Amps (for instance to start uphill), the controller changes
its current limit to boost current value for maximum 10 seconds.
Once used all the boost time (10 seconds), this time is “refill” of 1 second each 10 seconds
at motor current lower than current limit. This means that the boost is used for 5 seconds,
the controller can supply other 5 seconds in boost condition or if not necessary, wait other
50 seconds to have all the 10 seconds.
Boost current is available only if heat sink temperature is lower than 60°C.

DIGITAL INPUTS CONFIGURATION

Each pin 5, 6 and 11 hardware configuration (pin normally closed or open) can be set by
user as need by further parameters.
Once changed, power off to enable the changes.

Pin 5 hardware configuration ( Backward safety input ):

Stand-by input Active input
5-J1 HW CONFIG.
N.O. switch

Stand-by input Active input

5-J1 HW CONFIG.
N.C. switch

Pin 6 hardware configuration ( Disable input ):

Stand-by input Active input
6-J1 HW CONFIG.
N.O. switch

25
 Stand-by input Active input
6-J1 HW CONFIG.
N.C. switch

Pin 11 hardware configuration ( Mode 1 input ):

Stand-by input Active input
11-J1 HW CONFIG.
N.O. switch

Stand-by input Active input

11-J1 HW CONFIG.
N.C. switch

Pin’s 2, 5, 6, 11, 12 and 13 internal pull-up or pull-down may be activate by next

parameters.
Once changed, power off to enable the changes.

Pin 2 internal pull up/down selection ( speed reference input ):

2-J1 P.up-down 2-J1 P.up-down

pull-down active pull-up active

Pin 5 internal pull up/down selection ( Backward safety input ):

5-J1 P.up-down 5-J1 P.up-down

pull-down active pull-up active

26
Pin 6 internal pull up/down selection (Disable input ):

6-J1 P.up-down 6-J1 P.up-down

pull-down active pull-up active

Pin 11 internal pull up/down selection (Mode1 input ):

11-J1 P.up-down 11-J1 P.up-down

pull-down active pull-up active

Pin 12 internal pull up/down selection (Forward switch input ):

12-J1 P.up-down 12-J1 P.up-down

pull-down active pull-up active

Pin 13 internal pull up/down selection (Backward switch input ):

13-J1 P.up-down 13-J1 P.up-down

pull-down active pull-up active

27
 SELF CUT-OFF TIME

DEFAULT: 10
SELF CUT-OFF MIN: 0
### minutes MAX: 60

If the system is on and not used for the Self Cut-Off time ( minutes ), the controller
switches-off itself.
To reset, switch-off the key switch, wait few seconds and switch-on again.
To disable the function, set “self cut-off” time to 0.

ALARMS ENABLE

DEFAULT: ENABLE
ENABLE ALARM A1 MIN: ENABLE
ENABLE alarm MAX: DISABLE

DEFAULT: ENABLE
ENABLE ALARM A2 MIN: ENABLE
ENABLE alarm MAX: DISABLE

DEFAULT: ENABLE
ENABLE ALARM A3 MIN: ENABLE
ENABLE alarm MAX: DISABLE

DEFAULT: ENABLE
ENABLE ALARM A4 MIN: ENABLE
ENABLE alarm MAX: DISABLE

DEFAULT: DISABLE
ENABLE ALARM A12 MIN: ENABLE
ENABLE alarm MAX: DISABLE

28
 - ALARMS -
Handheld programmer, SCT utility (“Alarm” on Tester Pages) and Alarm led (onboard
and/or external by counting flashes) display the failures or alarms: in the following table
there is the list, the meaning of this alarms, and how to solve the problem.

ALARM 1: Forward switch closed at power-on.

ALARM A1 Led alarm status = 1 blinks.

FW Switch ON

Controller has detected the Forward switch on at the power on; to reset the alarm, put
speed reference to zero position and open the FW switch. If the application needs the
switch on at power-on, it is possible to disable the alarm by setting parameter “ENABLE
ALARM 1 ”.

ALARM 2: Backward switch closed at power-on.

ALARM A2 Led alarm status = 2 blinks.

BW Switch ON

Controller has detected the Backward switch on at the power on; to reset the alarm, put
speed reference to zero position and open the BW switch. If the application needs the
switch on at power-on, it is possible to disable the alarm by setting parameter “ENABLE
ALARM 2”.

ALARM 3: Potentiometer fault..

ALARM A3 Led alarm status = 3 blinks.

Pot. FAULT

Controller has detected the Speed Reference voltage out of maximum range. Check
Speed Reference/potentiometer wires. If the application opens one or more
potentiometer wires (for instance at the zero position ), it is possible to disable the alarm
by setting parameter “ENABLE ALARM 3”.

ALARM 4: Potentiometer out of neutral position at power-on.

ALARM A4 Led alarm status = 4 blinks.

Ref OUT Neutral

Controller has detected the Speed Reference voltage out of stop position at power-on.
Move the potentiometer to neutral position or if it is in neutral position yet, calibrate the
speed reference; it is possible to disable the alarm by setting parameter “ENABLE
ALARM 4”.
29
ALARM 5: Thermal protection.

ALARM A5 Led alarm status = 5 blinks.

Overtemperature

Heatsink temperature is higher than 85°C. Power-off, wait few minutes and check motor
consumption.

ALARM 6 / ALARM 6b: Controller’s power stage damaged

ALARM A6 Led alarm status = 6 blinks.

POWER STAGE

Controller’s self-check has detected a failure on internal power-stage. Change the

controller.

ALARM 7: Overcurrent (short circuit)

ALARM A7 Led alarm status = 7 blinks.

OVERCURRENT

Controller has protected itself by an external short circuit; check the motor’s wires and if
ok and the controller repeats this alarm, change it.

ALARM 8: Power fuse or on-board contactor damaged.

ALARM A8 Led alarm status = 8 blinks.

POWER FUSE/RELAY

Controller detects a failure on the external power fuse or power connections. If the
controller repeats this alarm and the power connections are ok, change it.

ALARM 9: Undervoltage.

ALARM A9 Led alarm status = 9 blinks.

UNDERVOLTAGE

Battery voltage lower than value 18,0V; check battery’s charge.

30
ALARM 10: Overvoltage.

ALARM A10 Led alarm status = 10 blinks.

OVERVOLTAGE

Battery voltage upper than 45V: check the battery status.

ALARM 11: Overload protection.

ALARM A11 Led alarm status = 11 blinks.

Overload Current

Check the motor working current, parameters “rated current” and “overload time”.

ALARM 12: Disable switch on.

ALARM A12 Led alarm status = 12 blinks.

DISABLE ON

Disable input switch is active: this alarm will reset by power-off. It is possible to disable
this alarm by setting parameter “ENABLE ALARM 12”.

ALARM 13: Key-off sequence detected.

ALARM A13 Led alarm status = 13 blinks.

KEY-OFF

Key switch was opened: check the key switch connections.

ALARM 14: internal memory fail..

ALARM A14 Led alarm status = 14blinks.

EEPROM FAIL

Check your parameter settings: if the controller repeats this alarm, change it.

31
 - SOFTWARE UPDATES -
To upgrade the controller’s management firmware (7ch4q###.mot), FDT#.#.exe
application with 7RS2USB# cable must to be used.
To install cable’s drivers and FDT#.#.exe application, read 7RS2USB#’s user guide.
In this chapter is explained how to set FDT application for this controller.

UPDATE SEQUEQUENCE

Step 1: execute FDT#.#.exe

Double click on FDT’s icon; will appear main window or simple interface. If main window is
shown, choose on menu “Tools” the option “Simple Interface..” as shown.

fig.12.a: FDT#.#’s Simple Interface fig.12.b: FDT#.#’s Main window

Step 2: Check Settings

On FDT’s Simple Interface check the communication and new firmware settings as shown
in fig.13. To change settings refer to chapter “PORT AND DEVICE SETTINGS”
Active Device: R5F21356A.

Active Port: COM#.

(check on Windows System
Management where the USB
cable is connected).

Firmware to download..:
Check “Download File” and
browse to select the new
“.mot” file.

fig.13: settings
32
Step 3: Download Firmware

1) if controller is off, connect the program cable to PC/Laptop, to Controller and then
switch-on the Controller.
2) Click “Program Flash” on FDT’s Simple Interface,
3) When will appear the window “Block Erase Check”, check default settings (fig.14)
and click on “OK” button.
4) Wait the complete writing of memory (fig.15) and click on “Disconnect”
button(fig.16).
5) Power-off the controller and then disconnect cable from it.
6) To update another controller, repeat sequence.

fig.14: Block Erase Check

fig.15: Download in progress….

fig.16: Download complete,

disconnect button active.

33
PORT AND DEVICE SETTINGS

To change Port or Device settings, click on “Back to Project”, when main window appears
choose on menu “Configure Flash Project” (fig.17).

Notes:
- New sets are immediately available,
- When you close FDT utility from Main window, next time FDT will be execute, main
window will appear,
- Check port id each time you use FDT; in fact the connected port id changes if you
change plugged USB port.

fig.17:
Access to Port and Device settings

fig.18: “Communication” and “Device” options location.

- Option “Communication” is used to change Port settings,

- Option “Device” is used to change Device setting.

34
PORT SETTINGS

1) Double click on COM# label (COM4 in example on fig.19.a)

fig.19.a
2) On window “Communication Port” select where USB cable is plugged (fig.19.b), then
click on “Next” button,
3) On window “Connection Type” set all items as shown in fig.19.c, then click on “Next”
button,

fig.19.b fig.19.c
4) Verify new sets on “Communications” (fig.19.d)

fig.19.d

35
DEVICE SETTINGS

1) Double click on Device’s value (R5F21256 in example on fig.20.a)

2) On window “Choose Device And Kernel” select R5F21356A (fig.20.b); use the filter
window to point immediately the right device name

fig.20.a fig.20.b
3) Click on “Next” Button to confirm the Port Settings or modify them as explained in
chapter “PORT SETTINGS”
4) Verify new sets on “Device” (fig.20.c)

fig.20.c

36