Italsea Manual 7BL00097
Italsea Manual 7BL00097
7BL00097
MICROPROCESSOR CONTROLLER
FOR BLDC MOTORS
English
7BL00097 | pagina 1
CONTENTS
1. SAFETY INSTRUCTIONS 3
2. INTRODUCTION 4
2a. Features 4
2b. Mechanical drawing 5
2c. Wiring diagram 6
3. I/O CONNECTOR 7
7. CONTROLLER SETTING 10
8. TESTER MODE 11
9. ALARMS 12
pagina 2 | 7BL00097
1. SAFETY INSTRUCTIONS
The controls described in this manual are to be considered and are sold as finished products to be installed only by
qualified personnel. Installation must be done in accordance with all safety regulations for the prevention of risks and
accidents applicable in the country of use.
Working on electric vehicles is potentially dangerous. Take all available precautions against burns, direct contact or
inhalation of acids, etc. (wear safety glasses, gloves, etc.).
Always follow the recommendations provided by the manufacturer of the batteries as they can deliver high currents in
the event of short circuits: completely disconnect the batteries before any intervention on the system (wiring operations,
checks on connections and various operations).
Controls for moving electric vehicles could cause you to lose control and create dangerous situations.
Disconnect the traction motor or lift the vehicle (also make other motors that could cause damage to persons or property
in appropriate safety) before starting any work on the circuits / connections.
The controls are protected against moisture by surface painting and direct circuit contacts with a partially open cover.
Place the controls in a dry, clean and ventilated position; avoid contact, in any form, with liquids such as water,
detergents, acids, oxides, etc.
The controls are high-powered devices and include various safety management of the electric vehicle.
The complete safety of the application cannot be left to control alone but must be integrated with the risk analysis of the
entire system by the manufacturer of the final machine.
Provide suitable fuses, battery disconnect switches (power switches, contactors, etc.), safety electro-brakes or
mechanical brakes and any other external component to safeguard the system and increase the safety level of the
electric vehicle.
In the event of a breakdown or serious alarm, assess in relation to the application whether the action of disconnecting
power from the motors is the best solution in terms of vehicle safety.
Avoid excessive length connections between controls, power source and motors.
The controls use the high-frequency PWM technology which may produce electromagnetic disturbances, partially already
filtered inside the circuits but which may not be sufficient in the final system due to the complexity or execution of the
system itself. It is advisable to build the system with cables of reduced length and to appropriately separate the power
cables from the signal ones. If necessary, use shielded cables or external filters to reduce electromagnetic disturbances.
7BL00097 | pagina 3
2. INTRODUCTION
The 7BL00097 is a controller designed for brushless PM motors powered by battery 24V - 36V.
The controller 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 chopper is designed in accordance with the EC standards related to the product.
2a. Features
pagina 4 | 7BL00097
2b. Mechanical drawing
Locate the inverter 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 heat 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.
7BL00097 | pagina 5
2c. Wiring diagram
pagina 6 | 7BL00097
3. I/O CONNECTOR
J1-16v Molex connector (Molex p/n.39012160, contacts p/n.39000038)
7BL00097 | pagina 7
4. MOTOR ENCODER/HALL SENSORS CONNECTOR
J2-8v Molex connector
pagina 8 | 7BL00097
6. WIRING DIAGRAM FIXED SPEED
7BL00097 | pagina 9
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” pages. 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”, and the first parameter will appear; 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 value with the button “MODE”. To return to the TESTER menu push together the buttons “MODE
“and “UP”, or wait few seconds.
IMPORTANT NOTE: the parameters modified with the handheld programmer are saved in Eeprom. The effective saving
happens when the user comes back to the tester mode (exits from parameters modification mode). It is important NOT TO
SWITCH OFF THE INVERTER WHEN IT IS STILL IN PROGRAMMING MODE.
pagina 10 | 7BL00097
8. TESTER MODE
The quantities visualized in the programmer are the following:
SOFTWARE RELEASE
Software version loaded in the board
7BL00097_3.1
SPEED REFERENCE
Speed reference (reference input voltage, rpm)
5,7V 1000rpm
CURRENT 23Arms
Actual current and speed
SPEED 1001rpm
BATTERY VOLTAGE
Actual battery voltage
25,3Volt
OVERLOAD LEVEL:
Actual overload level (at 100% there is alarm)
15% (at 23Arms)
HEATSINK TEMP
Actual heatsink temperature
29C° 84F°
J1:5,11
Ext. inputs state, encoder and hall sensors state
EN:a,B,U,v,W
HOURMETER
Working time
53hrs, 16min
7BL00097 | pagina 11
9. ALARMS
Handheld programmer can display the failures or alarms: in the following table there is the list, the meaning of this alarms,
and how to solve the problem.
pagina 12 | 7BL00097
10. NORMAL PARAMETERS
7BL00097 | pagina 13
11. PARAMETERS UNDER PASSWORD
NUMBER NAME MINIMUM MAXIMUM DEFAULT DESCRIPTION
38 PAR_PWD 0 30000 0 password
39 PAR_KP_CUR 1 30000 180 current loop proportional gain
40 PAR_KI_CUR 1 30000 70 current loop integral gain
41 PAR_KP_VEL 1 30000 50 speed loop proportional gain
42 PAR_KI_VEL 1 30000 30 speed loop integral gain
43 PAR_KF_VEL 10 500 200 speed filter constant
44 PAR_KI_FW 0 30000 150 flux weakening integral gain
45 PAR_AWDIFF 80 100 95 small movements anti-windup
46 PAR_CPOLI 1 32 4 motor polar couples
47 PAR_R_STA 0 30000 14 stator resistance [Ohm/1000]
48 PAR_L_SQ 0 30000 8 synchronous q inductance
[Henry/100000]
49 PAR_PM_FLX 0 30000 166 permanent magnets linked flux
[Weber/10000]
50 PAR_HAL_ACT 0 1 0 hall active status (6)
51 PAR_ABI_ENC 0 2 0 encoder enable (7)
52 PAR_ENC_PUL 16 256 32 encoder pulses per revolution per
channel
53 PAR_SP_DB 10 1000 50 speed dead band [%]
54 PAR_54 0 30000 0
55 PAR_VBADJ 800 1200 1000 voltage measurement adjust
[thousandths]
56 PAR_IMADJ 800 1200 1000 current measurement adjust
[thousandths]
57 PAR_POT_DIR 0 1 0 reference direction (in wigwag)
58 PAR_POT_L 0 4095 0 backward potentiometer maximum
[bit]
59 PAR_POT_0 0 4095 320 stop potentiometer [bit]
60 PAR_POT_H 0 4095 3520 forward potentiometer maximum
[bit]
61 PAR_61 0 30000 0
62 PAR_62 0 30000 0
63 PAR_63 0 30000 0
pagina 14 | 7BL00097
12. PARAMETERS SAVED AT SWITCH-OFF
NUMBER NAME MINIMUM MAXIMUM DEFAULT DESCRIPTION
64 PAR_CNT_S 0 3599 0 hour meter seconds [s]
65 PAR_CNT_H 0 60000 0 hour meter hours [h]
66 PAR_NUM_WRI 0 60000 0 data-flash writing number
67 PAR_67 0 65535 0
68 PAR_68 0 65535 0
69 PAR_69 0 65535 0
70 PAR_70 0 65535 0
71 PAR_71 0 65535 0
Notes:
7BL00097 | pagina 15
13. RESET TO DEFAULT PARAMETER
DEFAULT: 0
RESET TO DEFAULT
MIN: no
######
MAX: 1
To reset all the parameters, set 1, save, exit from programming mode and power-off; at the next power-on, the controller
will update the defaults settings.
Brake ON
Motor ON
BRAKE DELAY
DEFAULT: 2.0
BRAKE DELAY
MIN: 0.0
#.# seconds
MAX: 30.0
pagina 16 | 7BL00097
15. SPEED REFERENCE SETTINGS
15a. Speed reference’s type
Speed reference’s type and range may be set by the sequences that follow:
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
7BL00097 | pagina 17
15b. Single ended calibration
Step 1:
Step 2:
Step 3:
Step 2:
Step 3:
pagina 18 | 7BL00097
15d. Wigwags calibration
Step 1:
Step 2:
Step 3:
Step 4:
NOTE:
The controller will drive motor at the speed percentages set in pages “FORWARD SPEED” and “BACKWARD SPEED”.
7BL00097 | pagina 19
16. REFERENCE’S DEADBAND
DEFAULT: 200 Use this parameter to increase, or
REF. DEADBAND
MIN: 50 decrease the speed reference stop
### mV
MAX: 500 position range.
DEFAULT: 50
MODE1 SPEED
MIN: 10
### % of MAX
MAX: 100
DEFAULT: 70
MODE1 CURR.
MIN: 20
## % of MAX
MAX: 100
DEFAULT: 0.0
BW SAFETY TIME
MIN: 0
#.# seconds
MAX: 5.0
DEFAULT: 30
BW SAFETY SPEED
MIN: 0
### % of MAX
MAX: 50
pagina 20 | 7BL00097
17. OVERLOAD PROTECTION
In the programming mode set the rated current and overload time for the motor:
DEFAULT: 30
RATED CURRENT
MIN: 10
## Arms
MAX: 30
DEFAULT: 10
OVERLOAD TIME
MIN: 10
### seconds
MAX: 120
The protection will be activated each time the current overcome the value In 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.
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).
5-J1 HW CONFIG.
N.O. switch
5-J1 HW CONFIG.
N.C. switch
6-J1 HW CONFIG.
N.O. switch
6-J1 HW CONFIG.
N.C. switch
7BL00097 | pagina 21
Pin 11 hardware configuration (Mode 1 input):
Stand-by input Active input
11-J1 HW CONFIG.
N.O. switch
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.
2-J1 P.up-down
pull-down active
2-J1 P.up-down
pull-up active
pagina 22 | 7BL00097
Pin 5 internal pull up/down selection (Backward safety input):
7BL00097 | pagina 23
Pin 13 internal pull up/down selection (Backward switch input):
DEFAULT: ENABLE
ENABLE ALARM A3
ENABLE alarm MIN: ENABLE
MAX: DISABLE
DEFAULT: ENABLE
ENABLE ALARM A4
ENABLE alarm MIN: ENABLE
MAX: DISABLE
DEFAULT: DISABLE
ENABLE ALARM A12
ENABLE alarm MIN: ENABLE
MAX: DISABLE
pagina 24 | 7BL00097
ITALSEA S.r.l.
Via Maestri del Lavoro 1/A | 36078 Valdagno | Vicenza | Italy
T +39 0445 431014 | F +39 0445 431048 | [email protected] | italseasrl.it amergroup.it
7BL00097 | pagina 25