NetGain Motors HyPer 9HV IS Manuale utente

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 1 of 28

User Manual

HyPer 9HV IS™

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 2 of 28

Table of Contents

Warning and Caution ..............................................................................................................................................................4

Safety Information .............................................................................................................................................................. 4

DISCLAIMER: .......................................................................................................................................................................5

X144 Main Wiring Diagram.....................................................................................................................................................6

X144 K1 Wire Harness Pinout ................................................................................................................................................. 7

HyPer 9HV Motor Plug Wiring Instructions ............................................................................................................................8

HyPer 9HV Motor Plug Pinout.................................................................................................................................................9

Motor Encoder Pin Positions .............................................................................................................................................. 9

Motor Thermistor Pin Positions..........................................................................................................................................9

X144 Main Contactor Wiring.................................................................................................................................................10

12/24V Coil Driver, High Voltage Contacts, and Key Switch In.........................................................................................10

Compact Display Pinout........................................................................................................................................................11

Compact Display Mating Female Plug...............................................................................................................................11

Controller Specifications.......................................................................................................................................................12

Controller Communication ...............................................................................................................................................12

Controller EMC..................................................................................................................................................................12

Controller Safety Certification ..........................................................................................................................................12

Controller Operating Environment Specifications............................................................................................................12

Pre-startup Steps ..................................................................................................................................................................13

Download SME Smarview Sys Program: ...........................................................................................................................13

Download* the Latest Controller Firmware: ....................................................................................................................13

Download* Your HyPer 9HV Clone File:............................................................................................................................13

Quickstart Guide ...............................................................................................................................................................13

Post-startup Steps.................................................................................................................................................................17

Throttle Mapping..............................................................................................................................................................17

Brake Regen Mapping.......................................................................................................................................................17

Regen on Neutral Operating Profiles................................................................................................................................17

Neutral Torque Mapping ..................................................................................................................................................18

Battery Mapping ...............................................................................................................................................................18

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 3 of 28

HyPer 9HV Motor Temperature Derating.........................................................................................................................18

X144 controller Temperature Derating.............................................................................................................................19

Signal: Inputs and Outputs................................................................................................................................................20

Controller I/O Table ..........................................................................................................................................................20

Diagnostic Code Guide..........................................................................................................................................................23

Additional Support............................................................................................................................................................28

Figure 1 - Standard X144 Wiring Diagram.............................................................................................................................. 6

Figure 2 - Standard X144 Pin Order Assignment..................................................................................................................... 7

Figure 3 - Motor Plug Wiring Photo ........................................................................................................................................ 8

Figure 4 Compact Display Male Connector........................................................................................................................... 11

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 4 of 28

Warning and Caution

Safety Information

This is not an all-inclusive list. Use common sense and act responsibly, electric motor controllers and

motors are extremely powerful and could cause death, dismemberment or other serious injury if misused

or not safely handled!

Wear protective or safety equipment such as safety shoes, safety glasses and gloves when working with

motors and controllers.

Remove all metal jewelry and metal objects from hands, wrist, fingers, etc. before working on any

electric motor or controller.

Insulate any tools that are used in proximity to connection points that have any voltage potential to

prevent shorts if the tool is accidentally dropped onto the terminals/connections.

Use caution when operating any controller or motor. If you're not sure what you're doing, or do not feel

comfortable with the situation, find a knowledgeable person to advise you.

Make certain the motor and controller are disconnected from any power source before servicing. If any

doubt exists of the voltage that might exist, measure with proper metering devices that are in good

functional condition, and rated for the voltages that could exist.

Verify and re-verify proper wiring connections.

Take extreme caution around series-connected batteries to avoid placing hands across live connections. It

is generally good practice to avoid the use of both hands when working around high voltage circuits. This

reduces the risk of an accidental short across the chest cavity.

If working on an electric vehicle, make certain the vehicle is positioned securely with the drive wheels

safely clear of the floor and blocked up so that the drive wheels cannot make contact with the floor under

any circumstances. Block the non-drive wheels if they remain in contact with the floor so that the vehicle

cannot roll in either direction.

Motors and controllers must only be connected to a power source by knowledgeable and experienced

personnel.

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 5 of 28

Motors should NEVER be run without a load. Running a motor without a load could result in harm to

people or the motor. Absence of a load is considered misuse and could prove dangerous to anyone in the

vicinity and void the motor warranty.

Portions of the motor or controller may become hot and proper precautions must be taken.

Motors and controllers should never be operated beyond the limits established by the manufacturer.

Motors and controllers must not be modified in any manner; doing so will void warranty and could prove

extremely dangerous.

Motors are heavy and are likely to become damaged if dropped, or cause damage to anything they fall

upon (including people and body parts). Use extreme caution when working with motors!

Motors contain moving parts that could cause severe injury if the proper precautions are not taken.

Never touch an operating motor.

Do not defeat any safety circuits or safety devices.

Under no circumstances should you push in any contactor of an electric vehicle while the drive wheels are

in contact with the floor. Pushing in a contactor when the drive wheels are in contact with the floor can

cause serious property damage, personal injury or death.

DISCLAIMER:

NetGain Motors, Inc. has no control of third party installation procedure or the use of this motor and control

system. Accordingly NetGain Motors, Inc. assumes no liability for vehicle functionality or safety durring or after

third party installation of the motor and controller. It is the responsibility of the vehicle designer and component

installer to test and qualify their application and ensure proper safety and functionality. NetGain Motors, Inc

assumes no responsibility for this product in any use.

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 6 of 28

X144 Main Wiring Diagram

X144 ONLY!

12V-24V

Key Switch

For X1 wkring see:

HyPer 9 IS User

Manual

Figure 1 - Standard X144 Wiring Diagram

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 7 of 28

X144 K1 Wire Harness Pinout

Figure 2 - Standard X144 Pin Order Assignment

Must Be

Assigned

See Motor Plug

Wiring

Instructions for

Termination Steps

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 8 of 28

HyPer 9HV Motor Plug Wiring Instructions

1. Choose a location to fasten the Male 4P and 2P Receptacles from your HyPer Motor.

2. Route multipair cable atleast 6 inches from the motor case. Fasten this cable securely so it is restrained

from movement. Line cable up with motor’s Male Receptacles.

3. Using Cable Cutters - trim excess length from mulitipair cable, leave 4-6” extra to ensure cable will

reach motor Receptacles.

4. Using a co-ax stripper or scissors –carefully strip multipair black jacket atleast 4.5” from cable end.

This length should allow 4P and 2P wires to reach their respective Receptacle. Be careful not to cut into

the foil shilding or wire insulation underneath the jacket. A razor blade or X-acto knife can be used to

carefully slice a releif strip down the stripped jacket length, so it can be easily removed.

5. Slide ½” diameter heatshrink over multipair cable. Slide heatshrink past the newly exposed foil, and

rest heatshrink on remaining jacket material for future adhesion.

6. Slide ¼” diameter heatshrink over each of the 3 shileded twisted pairs. Rest heatshrink near jacket for

future adhesion.

7. Peal back 1.5” of foil shield and plastic wrap.

8. Slide yellow Plug Seals onto each wire with the smaller diameter end of each Seal facing the wire end.

9. Strip ¼” of insulation from the end of each 20awg wire.

10. Using an Open Barrell Crimper for “Amp” brand Pins –Crimp the provided “Strip Pins” onto the

copper of each wire.

11. Place pins in their proper position according to Motor Plug Pinout on the next page.

12. Fasten the red locking plate on the front of each plug. Verify all six pins are fully inserted.

13. Slide yellow Plug Seals into wire cavites.

14. Plug the newly assembled Plugs into the matching Male Plugs on your HyPer motor.

15. After the pre-start up steps are complete, and correct system operation is verified, apply heat to

heatshrink using a heat gun. Adhere the heatshrink as close to the plug as possible without putting strain

on the inserted wires.

Figure 3 - Motor Plug Wiring Photo

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 9 of 28

HyPer 9HV Motor Plug Pinout

Important: The Motor Encoder must be mounted securely and restrained from movement. Keep Encoder wires

as far as possible from High Voltage cables and the motor’s field.

Motor Encoder Pin Positions

Motor Encoder - 4 Position Connector

Name

Position

Encoder I/O Ground

K1-9

Encoder Cos 1

K1-33

Encoder Sin 1

K1-21

+5V Out

K1-35

Motor Thermistor Pin Positions

Motor Thermistor - 2 Position Connector

Name

Position

Motor Thermistor

K1-32

Analog Ground

K1-12

K1-9 K1-33 K1-21 K1-35

Included in HyPer 9HV IS:

Amp Superseal 4 POS

Plug Part# 282088-1

Pin Part# 282110-1

Seal Part# 281934-2

Included in HyPer 9HV IS:

Amp Superseal 2 POS

Plug Part# 282080-1

Pin Part# 282110-1

Seal Part# 281934-2

K1-12 K1-32

HyPer 9HV IS User Manual Version 06

NetGain Motors, Inc.

Page 10 of 28

X144 Main Contactor Wiring

12/24V Coil Driver, High Voltage Contacts, and Key Switch In

X144 Main Contactor –External PWM

Terminal

Name

X144 Position

Driver Output 1

K1-26

Coil Return

K1-25

A2-

Controller HV+

B+ Terminal*

A1+

Precharge

B+ Precharge**

* This HV circuit should include proper fuses and disconnect switches.

Included in HyPer 9HV IS:

Gigavac 500+ Amp, 12-800Vdc

- 12/24V External PWM Coil

Part# GV200PA-1

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