Electric Drive Engineering EDE, Installation & Operating Manual

Page 1: ...Installation Operating Manual 48kW EDE Electric Drive Kit ...

Page 2: ...2 Technical Support and Warranty 3 Introduction 4 Packing List 5 System Overview 6 Components 7 Assembly 15 Operating Guide 17 Troubleshooting 18 Contact Information Electric Drive Engineering 10 52 Kent St Cannington Western Australia 6107 support electricdriveengineering com au www electricdriveengineering com au ...

Page 3: ...eeding User Responsibility We have endeavoured to make a safe and reliable product however since Electric Drive Engineering has no control over the integration of its products we can assume no responsibility for the safety or functionality of the completed vehicle machine It is up to the end user to determine the suitability of the products for the purpose employed and the end user assumes all ris...

Page 4: ...utting the harness Modification made to the DCF Excessive voltage or reversed polarity on input terminals Short circuits on output terminals Excessive voltages applied to control wiring Opening of housing and or modification of internals Severe impact damage Exposure to water We have taken great care to design a safe and reliable product but faults can happen If you believe this product has a faul...

Page 5: ... Kit Please notify us immediately if any damage has occurred during shipping About This Guide This installation guide provides instructions and guidelines for assembling mounting starting and operating your 48kW EDE Electric Drive Kit This guide is intended to be used in conjunction with the following Sevcon Gen4 Applications Reference Manual Sevcon Clearview Display Reference Manual ...

Page 6: ...c Mounting Bolts and washers 4 Secure motor Package 2 Weight 8kg Dimensions 390mm x 290mm x 120mm Item Description Quantity Purpose 2a Sevcon Gen4 Size 6 Controller 1 Inverter Controller 2b Multi leaf Connector 1 Connect B and Contactor 2c 500A Fuse attached to controller 1 Battery fuse 2d Gigavac GV200PA 1 Contactor to switch ON OFF battery power 2e Wire Harness 1 Control Aux Power CAN 2f Throttl...

Page 7: ...6 Installation Operating Manual System Overview ...

Page 8: ...a female connector for a 35 way AMPSeal plug which is a commercially available automotive plug developed by TE Connectivity This plug is used to attach input output I O communications and control power In the centre of the unit are three terminals labelled M1 M2 and M3 These terminals are for connecting each phase to the motor At the bottom of the unit are three terminals for connecting traction p...

Page 9: ...he surface mounted fuse Motenergy ME1616 The Motenergy ME1616 is a water cooled permanent magnet synchronous motor A diagram of the unit is shown in Figure 2 The ME1616 comes with the phase cables and 8 way plug already attached The 8 way plug passes rotor position and temperature data to the Sevcon controller Figure 2 Motenergy ME 1616 Features ...

Page 10: ...hen in a discharged state they temporarily behave as a short circuit drawing large inrush currents until fully charged These inrush current can be many times greater than the rated capacity of internal components and can cause serious damage Secondly when power is removed the capacitors maintain stored energy that takes time to discharge This leaves a short time window where the unit is OFF but st...

Page 11: ...rate from the phase and power cables as much as practical to minimise electromagnetic interference EMI Component Purpose A Auxiliary Power Supply Wires Provide auxiliary power supply for controller B Contactor Coil Wires Allows the controller to apply power to the relay coil to OPEN and CLOSE the battery positive cable C BMS Enable Wires Optional Allows connection to battery management system BMS ...

Page 12: ...on and temperature data to the controller G Programming Port Allows connection to PC IXXAT USB CAN interface Sevcon DVT software and licence required for use H 35 Way Connector Connects harness to Sevcon Gen 4 controller Figure 4 Harness components B Component Purpose I Ignition Turn system ON and OFF J Forward Neutral Reverse Switch Change direction of motor rotation K Brake Regen Adjust Control ...

Page 13: ...ic vehicle with regenerative braking the controller instead puts the electric motor in reverse and turns it into a generator which generates power The vehicle slows down gradually as the kinetic energy is turned back into electrical energy and then stored in the battery for later use The regen dial on the harness adjust the amount of regenerative braking It can be used as a dial or connected to a ...

Page 14: ...o the controller Water pump The Water Pump specifically designed for cooling EV motors and controllers The recommended cooling arrangement is shown in Figure 5 Do not run the water pump dry as this could lead to permanent damage Figure 5 Recommended liquid cooling setup The following are the recommended cooling system parameters Aluminium corrosion and freezing preventing coolant water glycol 50 5...

Page 15: ...ic Drive Engineering 14 Installation Operating Manual The chosen radiator needs to be dimensioned to dissipate the machine losses at the specified flow rate and fluid temperature generally a small radiator from motorcycle is sufficient ...

Page 16: ...lure to do so could result in damage to the motor windings Bolts should be tightened to 22Nm 3 Mount the controller Ensure the controller is securely mounted from a mechanical and thermal perspective See Sevcon Gen4 Applications Reference Manual for more details The provided bolts are suitable for a mounting plate thickness of 10mm minimum Please make alternative arrangements if mounting plate thi...

Page 17: ... the key switch is in the OFF position and the forward neutral reverse switch is in neutral 7 Connect the negative battery cable through an isolator not supplied to the B terminal of the controller as shown in Figure 6 At the same time connect the negative auxiliary wire from the harness to the same terminal 8 Connect the positive battery cable through an isolator not supplied to the contactor as ...

Page 18: ...e controller is securely mounted from a mechanical and thermal perspective Confirm motor coolant system is operational Confirm there is adequate and correctly ducted airflow for any fan cooling system Check the routing of cables is safe with no risk of short circuit overheating or cable insulation wear due to rubbing Check motor drive shaft is clear of obstructions Start up Procedure 1 Confirm the...

Page 19: ... au Avoiding Electromagnetic Interference Some precautions can reduce the level of electromagnetic emissions Keep signal wires particularly the motor encoder separate from power cables as much as practical Keep the controller and motor as close as practical to reduce power conductor length Keep all the motor phase cables as close together as practical in the routing from controller to motor Route ...