tech/Ops SEVCON SC2000 Series Manual de usuario
22nd October 2004 SC2000 Manual – 177/52301 Rev G Page 1
SEVCON
SC2000 MANUAL
This manual details the features of the following SC2000 core controllers and variants.
1. SC21xx Integrated Traction + Pump Controller.
2. SC22xx Standalone Traction Controller.
3. SC23xx Standalone Pump Controller.
4. SC24xx Integrated Traction Dual Motor Non Proportional Controller + Pump.
5. SC25xx Integrated Traction + Traction Dual Motor Proportional Controller.
Revision History
Revision Comments
F DT Complete rewrite to reflect the new features introduced by version 6.XX software
G JP Add wiring diagrams. Change Index. Add Personalities 1.6.16 Fixed Plugging,
Work Hours Count 2.2.9 and Seat 2.3.11. Remove SC26XX variant and drawings
D.Thomson. 12th December 1997 Issue F. (SC2MAN_F.doc)
J. Punton. 22nd October 2004 Issue G. (SC2MAN_G.doc)
Page 2 SC2000 Manual – 177/52301 Rev G 22nd October 2004
CONTENTS
1. INTRODUCTION .................................................................................................................3
2. SC2000 CONTROLLER VARIANTS ................................................................................... 4
3. CONTROLLER FEATURES ................................................................................................ 5
4. SAFETY............................................................................................................................... 6
5. TECHNICAL SPECIFICATIONS ......................................................................................... 7
6. CONTROLLER CONNECTIONS....................................................................................... 10
7. CALIBRATOR AND ADJUSTMENTS................................................................................ 14
8. DIAGNOSTICS ................................................................................................................. 21
9. SERVICE AND FAULT LOGS ........................................................................................... 22
10. CONTROLLER OPERATION AND FEATURE DESCRIPTIONS...................................... 23
10.1 TRACTION OPERATION ...................................................................................... 23
10.2 PUMP OPERATION .............................................................................................. 29
10.3 GENERAL OPERATION........................................................................................ 31
11 DASHBOARD DISPLAYS - OPERATION AND FEATURE DESCRIPTIONS.......................... 33
12 POWER CIRCUIT DESCRIPTIONS ........................................................................................ 39
13 INSTALLATION........................................................................................................................ 40
14 EMC GUIDELINES................................................................................................................... 41
OPERATING SEQUENCE DESCRIPTIONS ................................................................................ 42
ACCELERATOR CHARACTERISTICS......................................................................................... 43
THERMAL CUTBACK CHARACTERISTICS ................................................................................ 43
SAFE OPERATING AREA GRAPHS ............................................................................................ 44
FIG 1 CONTROL WIRING DIAGRAM........................................................................................... 45
FIG 2 SC21XX POWER CIRCUIT................................................................................................. 46
FIG 3 SC22XX POWER CIRCUIT................................................................................................. 47
FIG 4 SC23XX POWER CIRCUIT................................................................................................. 48
FIG 5 SC24XX POWER CIRCUIT................................................................................................. 49
FIG 6 SC25XX POWER CIRCUIT................................................................................................. 50
FIG 7 SAMPLE POWER WIRING DIAGRAM ............................................................................... 51
MECHANICAL DIMENSIONS ....................................................................................................... 53
22nd October 2004 SC2000 Manual – 177/52301 Rev G Page 3
1 INTRODUCTION
1.1 The SC2000 range of Controllers use a powerful microprocessor to control two power frames
- Traction (with regen or plug braking) and Pump. Both power frames are integrated within
one compact enclosure and use state-of-the-art mosfet technology.
The SC2000 is available in a wide range of voltage/current variants and power-frame
configurations. As well as the Traction + Pump controllers, the two power-frames within the
unit can also be configured as a Traction Dual Motor non - proportional + Pump controller or
as a Traction + Traction proportional unit. In addition standalone Traction or standalone
Pump units can be offered.
1.2 The controllers have been designed to satisfy the requirements of the relevant UL and EC
standards.
1.3 The controllers have been optimised for use with D.C. series wound motors. For other motor
types contact SEVCON.
Page 4 SC2000 Manual – 177/52301 Rev G 22nd October 2004
2 SC2000 CONTROLLER VARIENTS
SCxxxx Model number description
1st digit Controller range identification (always 2)
2nd digit Controller 1 = Traction+Pump
Type 2 = Traction
3 = Pump
4 = Traction+Pump Dual Motor Non Proportional
5 = Traction+Traction Dual Motor Proportional
6 = Traction Dual Motor Non Proportional
3rd digit Voltage 2 = 24V - 36V
Range 4 = 24V - 48V
8 = 72V - 80V
9 = 72V - 96V
4th digit Current 2 = 250A Width = 230mm
Limit 5 = 500A Height = 113mm
6 = 650A
1 = 1000A
MODEL POWER CONFIGURATION # Power
Terminals
UNIT
Length
SC2126 24-36V 2x650A Traction + Pump 7 424mm (D)
SC2145 24-48V 2x500A Traction + Pump 7 360mm (C)
SC2445 “ Traction Dual Motor Non Proportional + Pump 9 424mm (D)
SC2545 “ Traction + Traction Dual Motor Proportional 8 360mm (C)
SC2542 24-48V 2x250A Traction + Traction Dual Motor Proportional 8 360mm (C)
SC2146 24-48V 2x650A Traction + Pump 7 424mm (D)
SC2446 “ Traction Dual Motor Non Proportional + Pump 9 488mm (E)
SC2185 72-80V 2x500A Traction + Pump 7 488mm (E)
SC2485 “ Traction Dual Motor Non Proportional + Pump 9 552mm (F)
SC2585 “ Traction + Traction Dual Motor Proportional 8 488mm (E)
SC2186 72-80V 2x650A Traction + Pump 7 552mm (F)
SC2586 “ Traction + Traction Dual Motor Proportional 8 552mm (F)
SC2286 72-80V 1x650A Traction 5 360mm (C)
SC2386 “ Pump 4 360mm (C)
SC2296 72-96V 1x650A Traction 5 360mm (C)
SC2396 “ Pump 4 360mm (C)
SC2291 72-96V1x1000A Traction 5 488mm (E)
22nd October 2004 SC2000 Manual – 177/52301 Rev G Page 5
3 CONTROLLER FEATURES
3.1 The SC2000 range of controllers offer the following features:
* 24-48V, 72-80V and 72-96V operation. Current limits of 500, 650A and 1000A.
* Enclosed unit to IP34 with Field-replaceable logic.
* Traction + Pump motor controllers in one enclosure.
* Also standalone Traction and standalone Pump controllers available.
* Microprocessor control.
* High frequency (silent operation).
* Start-up safety sequence and Static return to Off (SRO).
* Internal watchdog monitoring microprocessor operation.
* Arcless contactor switching and built-in contactor coil suppression.
* Use of 24V contactors at all voltages possible.
* Switch inputs configurable to be normally open or normally closed.
* Active low inputs switched to B-, or active high inputs switched to B+ (Factory option).
* Low input impedance for protection against water (active low inputs).
* Thermally compensated current limit.
* Selectable accelerator characteristics.
* Adjustable creep speed.
* Bypass with over current drop out.
* Field weakening.
* Seat switch timer.
* Power steer contactor and timer.
* Regenerative or Plug braking only, both high frequency and silent.
* Braking proportional to accelerator or optionally non proportional.
* Electric braking in neutral.
* Electric braking with brake pedal. (Switch or Potentiometer required)
* Under-voltage and over-voltage protection.
* Accelerator wire-off detect.
* Flexible accelerator interface with minimum/maximum voltages programmable.
* Inching and timed burst-inching facilities.
* Economy pot input initiating either increased acceleration delays or reduced current limit.
* Short-circuit and open-circuit contactor detect.
* 2 Traction cut-back speeds with independent acceleration delays.
* 7 pump speeds with Priority, Additive and Compensation features available.
* Inhibit input to disable pump operation, from external source such as BDI.
* Independent Power Steer speed and compensation settings, with ramp up/down delays.
* Hardware and Software fail-safe protection + autofailsafe check every power-up.
* Contactor drive short circuit detection.
* Fault detection with LED display.
* Serial communications bus (CANbus).
* Adjustments made using plug-in calibrator with optional levels of access.
* Diagnostics & Service information with calibrator.
* Hours Counter displaying Key Switch, Pump and Traction pulsing hours on calibrator.
* BDI. Battery discharge indicator with adjustable warning and cut out levels.
* Dual motor non proportional and proportional variants with steer switch or steer pot inputs.
* Dual Motor steer angles can be adjusted to match truck geometry when using a steer pot.
* Dual Motor independently adjustable ramp-up / ramp-down settings for smooth cornering.
* Controller extrusion has ‘T’ slots for direct mounting of Albright contactors.
* Speed limit facility optionally available with speed sensor.
* Resettable Service and Fault logs.
* Non-English Languages selectable on calibrator.
* Standard Dashboard Display available displaying BDI, Hours, Steer angle and diagnostics.
* Full Feature Dashboard Display also available. As above but custom LCD with graphics.
* Setup menu on calibrator to enable and disable common options.
Page 6 SC2000 Manual – 177/52301 Rev G 22nd October 2004
4 SAFETY
4.1 Electric vehicles can be dangerous. All testing, fault-finding and adjustment should be carried
out by competent personnel. The drive wheels should be off the floor and free to rotate during
the following procedures. THE VEHICLE MANUFACTURER'S MANUAL SHOULD BE
CONSULTED BEFORE ANY OPERATION IS ATTEMPTED.
4.2 The SC2000 controller contains a triple fail-safe system to give a high level of safety. If the
diagnostic LED is not illuminated or flashes, the safety circuit may have tripped and the truck
may not drive.
4.3 To ensure continued safety of the SC2000 system, the fail-safe circuit should be checked
whenever the truck is serviced (See 4.7). The period between checks should not exceed 3
months.
4.4 THE BATTERY MUST BE DISCONNECTED BEFORE REPLACING OR ATTEMPTING ANY
REPAIRS OF THE CONTROLS.
4.5 Before working on the controls disconnect the battery and connect the B+ and B- controller
terminals via a 10 ohm 25 watt resistor to discharge the internal capacitors.
4.6 Never connect the controller to a battery with it's vent caps removed as an arc may occur due
to the controller's internal capacitance when it is first connected.
4.7 FAIL-SAFE CHECK:
4.7.1 Ensure the drive wheels are CLEAR OF THE FLOOR AND FREE TO ROTATE.
4.7.2 Switch on, select seat switch, release brake, select direction and FS1, the wheels
should rotate and the diagnostic LED should give a steady illumination.
4.7.3 Switch off, disconnect battery and connect the F1 and B- terminals together with, at
least, 10mm2 cable. Ensure that no other fault that would allow drive is present.
4.7.4 Reconnect battery, switch on key with direction in neutral. The LED should stay off.
Select a direction and check that the direction contactors do not close and the wheels
do not rotate.
4.7.5 Switch off at key and remove the F1/B- connection. Switch on at key, reselect the
power-up sequence and check that the LED illuminates and the truck wheels rotate.
IF THE TRUCK DRIVES IN 4.7.4 THE CONTROLLER IS FAULTY AND MUST BE
REPLACED.
4.8 NOTES:
4.8.1 As blow-out magnets are fitted to contactors (except 24V) ensure that no magnetic
particles can accumulate in the contact gaps and cause malfunction. Ensure that
contactors are wired with the correct polarity to their power terminals as indicated by
the + sign on the top moulding.
4.8.2 The SC2000 controller must NOT be used with permanently-connected on-board
chargers or damage to the system may result.
22nd October 2004 SC2000 Manual – 177/52301 Rev G Page 7
5 TECHNICAL SPECIFICATIONS
5.1 Environmental
5.1.1 Protection: The enclosure is protected to IP34.
1st digit (3) = Protection against objects > 2.5mm
entering controller enclosure. 2nd digit (4) = Protection
against low pressure jets of water in any direction.
Limited ingress permitted.
5.1.2 Vibration: 6G, 40-200Hz for 1 hour, in x,y and z planes.
5.1.3 Operating Temperature: -30oC to +40oC ambient around controller.
5.1.4 Storage Temperature: -40oC to +70oC.
5.1.5 Humidity: 95% maximum, non-condensing.
5.1.6 Humidity Resistance: No functional defects after controller is left at 60oC and
100% humidity for one hour after freezer use (-30oC
minimum).
5.2 Mechanical
5.2.1 Unit length/weight A unit n/a n/a
B unit n/a n/a
C unit 360 mm 7.50 kg
D unit 424 mm 9.25 kg
E unit 488 mm 11.00 kg1.
F unit 552 mm 12.75 kg
5.2.2 Unit width: All units 230mm
5.2.3 Unit height: All units 93 mm (excluding power terminals).
113 mm (including power terminals).
5.2.4 Enclosure: Aluminium ‘U’ extrusion forming base and walls with
plastic extruded top cover.
5.2.5 Contactor mounting: Extrusion has 2 M6 ‘T’ slots running down the length of
the controller for the direct mounting of Albright
contactors.
5.2.6 Fuse mounting: Using suitable brackets fuses can also be fitted to the
‘T’slot.
5.2.7 Power connections: Aluminium vertical power bushes for M8 connection.
5.2.8 Fixings: 6 x M6 clearance slots.
5.3 Electrical
5.3.1 Voltage specifications:
Model Voltage Nominal
battery
voltage
Operating
voltage
30 sec.
voltage
surge
SC2x2x 24V Units 24-36V 14.5-45V 50V
SC2x4x 48V Units 24-48V 14.5-70V 80V
SC2x8x 80V Units 72-80V 43.0-100V 115V
SC2x9x 96V Units 72-96V 43.0-130V 150V
Page 8 SC2000 Manual – 177/52301 Rev G 22nd October 2004
5.3.2 Current specifications:
Model Power Current
limit
(1 min)
Trac.+
Pump
Safe
operating
Area (SOA)
Continuous Current 1
Hour rating, with unit
mounted on an
aluminium baseplate
780x380x10mm, at
20°C ambient.
SC2x26 24V 2x650A 650A 30 - 60% 225A (1 side only)
SC2x45 48V 2x500A 500A 30 - 60% 170A (1 side only)
SC2x46 48V 2x650A 650A 30 - 60% 225A (1 side only)
SC2x85 80V 2x500A 500A 0 - 50% 170A (1 side only)
SC2x86 80V 1x650A 650A 0 - 45% 225A (1 side only)
SC2x96 96V 1x650A 650A 0 - 45% 225A (1 side only)
5.3.3 Switching Frequency: 15.7 kHz (Traction Drive and Braking and Pump).
5.3.4 Electrical Isolation: Enclosure to any live part = 1kV. Controller internal
insulation specified at > 10MΩ @500V DC. Dielectric
strength 1000V @ 50Hz for 1 Minute
5.3.5 Battery Polarity: An internal diode fitted in the keyswitch line will prevent
line contactor closure if the battery positive and negative
connections are reversed. When a line contactor is
used no damage to the controller will result.
5.3.6 Switch/Digital Inputs: Connector 1 (24 way) Pins:-
1, 2, 3, 4, 5, 6, 7, 8, 13, 14, 15, 16, 17, 18, 19 & 20
Operation: Active-low (The input becomes active when connected
to battery negative, otherwise inactive).
Voltage Range: Low (Closed) -1.0 to +1.8 V
High (Open) +4.5 to +150 V
(or open-circuit).
Input Impedance: Max. resistance to ground for a 'low' = 500 Ω.
Min. resistance to ground for a ‘high’ = 2.7 kΩ
Note : negative switch returns must be connected to controller B- terminal and not at
battery negative.
5.3.7 Active-high Inputs: The switch/digital inputs are available as a factory set,
hardware active-high option. Active-high inputs are
higher impedance and are more susceptible to moisture
problems.
Active-low inputs are recommended.
Operation: Active-high (The input becomes active when connected
to battery positive, otherwise inactive).
Voltage Range: Low (Open) -1.0 to 4.0 V
(or open circuit)
High (Closed) +8.75 to 150 V
Input Impedance: Max input impedance = 35 kΩ
5.3.8 Analogue Inputs: Connector A (24 way) pins:- 9, 10, 21 & 22
22nd October 2004 SC2000 Manual – 177/52301 Rev G Page 9
Three of the above inputs, pins 9, 10 & 21 have supply
outputs associated with them, pins 11, 12 & 23
respectively. Various connection options are available.
Voltage Range: 0V - 5.0V
Using the calibrator, the minimum and maximum
levels can be defined to equal any two voltages in the
above range.
Option 1: Potentiometers wired as ‘2 wire’ systems between the
input pins and B-ve. The wiper will be connected to
either the input or B-ve. Leave the associated supply pin
unconnected. This option available on all 4 analogue
inputs.
Nominal potentiometer resistance range: 1k to 10k.
Option 2: Potentiometers wired as ‘3 wire’ systems will be
connected between B-ve and the associated supply pin,
with the wiper connecting to the input pin.
This option only available on input pins 9, 10 & 21.
Nominal potentiometer resistance range: 2K to 20K.
Option 3: Voltage source type inputs, such as solid state
accelerator units that derive there own supply, should
feed directly into the analogue input pin. Connecting the
associated supply pin to B-ve disables an internal pull
up resistor and presents the analogue pin as a high
impedance input.
This option only available on input pins 9, 10 & 21
Nominal voltage input range: 0 to 5.0V
Absolute Max. Voltages: -1 V to +150 V.
An example of each connection option is shown in the light wiring diagram (figure 1)
5.3.9 Supply output: Connector A (24 way) pin 24
An unregulated +12V power supply is available for
supplying speed sensors etc. Contact SEVCON for
details before using this pin.
5.3.10 Contactor Drives: Connector B (12 way) pins:- 1, 2, 3, 4, 5, 6, 7 & 8
Maximum Current: 2A.
Protection: Drives are protected against direct connection to
B+ and B-.
Suppression: Coil suppression built-in.
+ve coil supply: Connector B (12 way) pin 11
All the contactor coils must be supplied from this pin
and NOT from the keyswitch or B+ directly.
There are a maximum of 8 contactor drives available.
Page 10 SC2000 Manual – 177/52301 Rev G 22nd October
2004
6 CONTROLLER CONNECTIONS
6.1 Power Connections (Figs. 2 to 7)
Power wiring must be made with 35mm2 cable (minimum).
6.1.1 Controller Connections - These are made via M8 terminals depending on unit
configuration, as follows:
All Controllers:
B+ Connected to Battery positive via the fuse and line contactor (if fitted).
B- Connected to Battery negative.
Traction Controllers, not Dual Motor:
A1 Connected to the normally closed contacts of the direction contactors
F1 Connected to the negative end of the Traction motor field.
S1 Connected to the positive end of the Traction motor field.
Pump Controllers:
F2 Connected to the negative side of the Pump motor.
S2 Connected to the positive side of the Pump motor.
Traction Controllers, Dual Motor Non-Proportional:
D1 Connected to the positive end of the Right Traction Motor Field.
D2 Connected to the positive end of the Left Traction Motor Field.
Traction Controllers, Dual Motor Proportional:
A2 As per A1 for second Traction Motor.
F2 As per F1 for second Traction Motor.
S2 As per S1 for second Traction Motor.
6.1.2 Contactor Connections
Line (Optional) + terminal to Fuse, other terminal to the B+ terminal of
the controller and the regen contactor if fitted.
Direction See power wiring diagrams (figs 2,3,5,6,7)
Regen (Optional) Common to Direction contactor, normally open contact
to controller B+ terminal, normally closed contact to
controller B- terminal.
Power Steer (Optional) + terminal to battery positive via fuse, other terminal to
the power steer motor.
Bypass (Optional) + terminal to F1 terminal of controller, other terminal to
Battery Negative.
Field Weakening (Optional) + terminal via resistor to S1 terminal of controller, other
terminal to F1 terminal of controller.
Pump Bypass (Optional) + terminal to F2 terminal of controller, other terminal to
B-ve.
Pump F.Weakening + terminal to top of Field and other terminal to F2.
Este manual sirve para los siguientes modelos
16
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