Sevcon MillipaK Manuale utente
Document History
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MillipaK PUMP Controller Manual Page 2 07/11/05
Document History
Author Reviewer
Initials Date Initials Date Version Reason for Modification
PB 10/08/01 00.01 Original.
PR 16/11/01 0.50.00(A) Updated the Fault list, calibrator map and
added personalities.
DC 23/04/04 0.50.00 (B) Added omitted Flash Faults and seat
functionality description.
DC 07/11/05 0.50.00(C) Clarified Digital I/O configuration table
Contents
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MillipaK PUMP Controller Manual Page 3 07/11/05
CONTENTS
INTRODUCTION .........................................................................................................................................................5
SAFETY .........................................................................................................................................................................6
INSTALLATION...........................................................................................................................................................7
MOUNTING ...................................................................................................................................................................7
MILLIPAKPUMP POWER WIRING .................................................................................................................................8
MILLIPAKPUMP LIGHT WIRING...................................................................................................................................9
CALIBRATOR ............................................................................................................................................................10
CALIBRATOR SECURITY LEVELS ................................................................................................................................11
NAVIGATION ..............................................................................................................................................................12
ADJUSTMENTS ............................................................................................................................................................13
STATUS AND TEST INFORMATION...............................................................................................................................14
CONFIGURATION ....................................................................................................................................................15
SYSTEM CONFIGURATION...........................................................................................................................................15
System Voltage.......................................................................................................................................................16
System I/O Configuration ......................................................................................................................................17
Analogue Functions...............................................................................................................................................18
Accelerator Full /Zero Setting ...............................................................................................................................20
PERFORMANCE ...........................................................................................................................................................21
Lift and Power Steer Ramps ..................................................................................................................................21
Creep Speed...........................................................................................................................................................22
Maximum Speed.....................................................................................................................................................23
FEATURES..................................................................................................................................................................24
STANDARD CONTROLLER FEATURES..........................................................................................................................24
Lift Switch Inputs - Priority ...................................................................................................................................25
Lift Switch Inputs - Additive ..................................................................................................................................26
Compensation ........................................................................................................................................................27
Seat Switch.............................................................................................................................................................28
Power Steer Input ..................................................................................................................................................29
Lift Inhibit Input.....................................................................................................................................................30
Cooling Fan...........................................................................................................................................................31
Pump Hours Meter ................................................................................................................................................32
Personality Checksum ...........................................................................................................................................33
System State ...........................................................................................................................................................33
SAFETY FEATURES .....................................................................................................................................................34
Fail-safe.................................................................................................................................................................34
CONTROLLER PROTECTION FEATURES .......................................................................................................................35
Temperature Monitoring .......................................................................................................................................35
Maximum Temperature Logging ...........................................................................................................................35
Timed Current Cutback .........................................................................................................................................36
Safe Operating Area (SOA) ...................................................................................................................................37
Under-voltage protection.......................................................................................................................................38
COMMISSIONING CHECKLIST ............................................................................................................................40
PERSONALITY RECORD...............................................................................................................................................41
FAULT FINDING .......................................................................................................................................................42
FAULT CLEARANCE ....................................................................................................................................................43
USING STATUS AND TEST MENUS ..............................................................................................................................43
FAULT REPORTING FORM ...........................................................................................................................................45
Contents
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MillipaK PUMP Controller Manual Page 4 07/11/05
SOFTWARE VERSION AND SERIAL NUMBER INDICATION ............................................................................................46
SPECIFICATIONS .....................................................................................................................................................47
POWER CONFIGURATIONS ..........................................................................................................................................47
EMC STANDARDS.......................................................................................................................................................47
SOCKET BPROTECTION ..............................................................................................................................................47
CONTACTOR DRIVE RATINGS ......................................................................................................................................47
ANALOGUE INPUT IMPEDANCE...................................................................................................................................47
DIGITAL INPUT IMPEDANCE........................................................................................................................................47
EMC GUIDELINES....................................................................................................................................................48
ORDERING INFORMATION...................................................................................................................................49
Introduction
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MillipaK PUMP Controller Manual Page 5 07/11/05
Introduction
The MillipaK PUMP (series motor) range of controllers provides a new range of power frames for
24V-48V, 180A - 600A in one of two small, highly efficient packages. This is achieved using a
Sevcon patented power switching scheme and radical new construction techniques, which enable
large powers to be incorporated into very small packages.
The MillipaK provides a completely sealed (IP66) unit containing both power and logic circuitry,
as well as all suppression components.
MillipaK supports Sevcon’s existing MOS90 calibrator for adjustment of pump characteristics.
Controllers are FLASH microprocessor based enabling field re-programming for new features and
have numerous user set-up options. The MillipaK uses high frequency (silent) MOSFET power
switching technology, to control a Series power frame comprising Armature circuit only.
Armature currents are monitored. Controllers have been designed to satisfy the requirements of
the relevant UL and EC standards.
Safety
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MillipaK PUMP Controller Manual Page 6 07/11/05
Safety
The MillipaK 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.
The MillipaK controller may be used with suitable onboard chargers, as supplied by Sevcon.
Installation Mounting
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MillipaK PUMP Controller Manual Page 7 07/11/05
Installation
The small footprint of the MillipaK controller gives maximum flexibility to the user for mounting
options. The following section gives details of certain criteria that should be considered when
situating the controller on a vehicle.
Mounting
The MillipaK and MillipaK HP units provide 4 x M6 clearance holes for mounting. The
controllers should be mounted onto a metal base plate, as large as possible to provide heat-
sinking. The surface finish should be flat, clean and burr free and thermal compound should be
applied to the controller base before fitting.
MillipaK HP Controller Dimensions
Maximum terminal torque: M8 terminals – 10NM
M6 terminals – 7NM
Installation Wiring/Power
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MillipaK PUMP Controller Manual Page 8 07/11/05
MillipaK Pump Power Wiring
NOTE: The Pump battery positive power terminal may be wired directly to the battery positive
(via a suitable fuse) or via a line contactor if used in a Traction / Pump system.
It should be considered whether or not pump operation is required if a traction fault causes the
line contactor to drop out.
Installation Wiring/Light
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MillipaK PUMP Controller Manual Page 9 07/11/05
MillipaK Pump Light Wiring
NOTES:
The line and auxiliary contactors coils are wired to B+, on the switched side of the key-switch.
The second analogue input on pin 11 is also available for use as a digital input. See system
configuration section for how to configure the second analogue input as a digital switch input.
Pin 12 on the Core and Standard HP variants is available for 100mA supply, typically used for
(but not limited to) accelerator modules.
Pins 13,14 & 15 are general-purpose suppression connections and may be used to suppress spikes
generated by contactors opening / closing. The internal configuration is shown below:
Pin 16 on the Core and Standard HP variants is used to select FLASH memory program update
mode and should normally be left unconnected.
Calibrator Calibrator/General
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MillipaK PUMP Controller Manual Page 10 07/11/05
Calibrator
The Calibrator is a hand-held adjustment unit which can be used to configure and test the system.
The MillipaK is designed to work with the Calibrator currently in use with SEVCON's MOS90
system. See diagram below. The menu structure is shown in the Calibrator Map located near the
end of this manual.
C AL IB R A TOR
Sevcontrol
+
-
SELECT
1.8.8.8
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