RMS PM Hardware User Manual And RM User's (V3 0)
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7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com RMS PM/RM Hardware User Manual Revision 3.0 0A-0001-01 Everything you need to know to install, set up, and calibrate the PM family of AC drives on asynchronous and PM synchronous motors in your Electric or Hybrid vehicle 1/17/2018 RMS PM Hardware User Manual 1 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Table of Contents 1. 2. 3. SAFETY FIRST: ............................................................................................................ 3 FUNCTIONAL OVERVIEW: ......................................................................................... 4 INSTALLING THE PM DRIVE: ..................................................................................... 5 3.1 Liquid Cooling Connections: ...................................................................................................................7 3.2 PM100/PM150 External Signal Connectors: ........................................................................................ 10 3.2.1 J1 – 35p AMPSEAL Plug 776164-1 with crimp contact 770854-1 .................................................. 10 3.2.2 J2 – 23p AMPSEAL Plug 770680-1 with crimp contact 770854-1 .................................................. 12 3.3 PM250 External Connections: ............................................................................................................... 13 3.4 RM100 Signal Connections ................................................................................................................... 16 3.5 External Power Connections: ............................................................................................................... 19 3.5.1 DC+ / DC-: ....................................................................................................................................... 19 3.5.2 Phase A / Phase B / Phase C: ......................................................................................................... 21 3.5.3 Pre-Charge Circuit: .......................................................................................................................... 21 3.5.4 Main Contactor: ............................................................................................................................... 22 3.5.5 Main Fuse: ....................................................................................................................................... 23 3.5.6 Passive Discharge of the High Voltage DC Bus: ............................................................................. 23 3.5.7 12V Power: ...................................................................................................................................... 24 3.5.8 Grounding ........................................................................................................................................ 25 3.6 Typical Application Wiring Diagram: .................................................................................................... 26 3.6.1 Controller 12V Power Wiring ........................................................................................................... 27 3.6.2 Pre-charge Circuit ............................................................................................................................ 29 3.6.3 Analog/Digital Vehicle Control ......................................................................................................... 30 3.6.4 Motor Control (Typical Wiring) ......................................................................................................... 31 3.6.5 CAN Interface .................................................................................................................................. 32 3.6.6 RS-232 Interface .............................................................................................................................. 32 3.6.7 Encoder Interface (Not included on RM100): .............................................................................. 33 3.6.8 Resolver Interface: ........................................................................................................................... 34 4. VEHICLE INTERFACE SETUP .................................................................................. 35 4.1 Analog Inputs: ........................................................................................................................................ 35 4.2 Digital Inputs: .......................................................................................................................................... 37 4.3 Digital Outputs ........................................................................................................................................ 40 REVISION HISTORY ......................................................................................................... 42 1/17/2018 RMS PM Hardware User Manual 2 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 1. Safety First: When you see this sign, PAY ATTENTION! This indicates that something important is about to be said, that concerns your safety and the proper operation of the equipment. ATTENTION When you see this sign, you are being alerted to an IMMEDIATE DANGER that could cause severe injury or even death. You MUST review these sections carefully an do everything possible to comply with installation and operation requirements, or you risk injury or death to yourself or anyone else who uses the equipment or the vehicle. Failure to DANGER comply with safety requirements will void all warranties and could expose you as the installer to liability in the event of an injury. Use the equipment in the manner in which it was intended. When you see this sign, you are being advised that the issue under discussion has a serious safety or equipment reliability implication. Use caution and be conservative. Use equipment in the manner described in CAUTION this User’s Manual. Safety is entirely the responsibility of the installer of this equipment. RMS has done everything it can to ensure that the traction controller itself conforms to international standards for safety. This does NOT mean that your installation will be safe, or that it will not interfere with other systems on board your vehicle. It is your responsibility as the installer to review this entire User’s Manual, to understand the implications of each and every section, and to know what might be unique about your system application that presents a unique hazard or potential safety issue – and to solve it. RMS is committed to helping you solve these problems, but cannot take responsibility for the application of this traction controller. We can only promise to meet the specifications for this product and that it meets international safety standards when used in accordance with the instructions in this Manual. 1/17/2018 RMS PM Hardware User Manual 3 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 2. Functional Overview: The PM controller family is intended as a traction controller for EV and HEV drive systems, and includes both the motor control function and a rudimentary vehicle controller strategy in the same box. The motor control is a torque commanded, vector control technology has been used on AC Induction and PM Synchronous motors in many applications. The RM100 controller family is intended for the same type of EV/HEV applications however it has a much more limited set of inputs and outputs. The limited set of I/O prevents it from being properly used in the VSM mode where analog and digital inputs are used to control the operation of the inverter. The RM100 controller is intended for applications where CAN communications is used to control the controller. The motor control subsystem firmware is mated to a vehicle controller firmware implemented in the DSP controller. This vehicle controller subsystem handles the driver interface (accel and decel / brake pedal inputs, Fwd/Rev controls, etc) and the vehicle interface (power sequencing, built in test, fault handling and safety issues). It is essentially a state machine in front of the motor controller firmware with a defined interface between the two software processes. User Controls Vehicle Control Firmware Motor Control Firmware Motor By default, out of the box the parameters are set up in Torque Control Mode, with default motor parameters loaded. The parameters must be changed to match the load motor and operating characteristics before running for the first time. These parameters personalize the drive to the motor and the vehicle. 1/17/2018 RMS PM Hardware User Manual 4 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 3. Installing the PM Drive: The PM controller has 4 mounting locations, one at each corner. Mounting orientation is not critical. The controller should be mounted in a location that is not exposed to direct spray from water. Each mounting hole is sized to handle up to a M10 socket head cap screw. See PM250 Datasheet for more information on mounting the PM250. PM100 Dimensions – top and side views 1/17/2018 RMS PM Hardware User Manual 5 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com PM150 Dimensions – top and side views 1/17/2018 RMS PM Hardware User Manual 6 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 3.1 Liquid Cooling Connections: The controller must be cooled by passing liquid through it. The controller includes two ports to be used for liquid cooling. The fluid direction for the PM250 inverter is marked into the case of the inverter. The PM100 and PM150 has a more symmetrical design and is less sensitive to fluid direction. However, it is preferred that the rearmost plenum (the ports furthest from the 3 AC output terminals) be the fluid inlet, as this keeps the coolest fluid near the DC Link capacitor assembly. The PM250 has markings on the housing that indicate the required direction of the coolant through the inverter. See table below for coolant specifications: Coolant Type Coolant Temperature Coolant Flow Rate 50/50 mix ethylene glycol (antifreeze) / water or propylene glycol / water; with Aluminum corrosion inhibitor additive -30°C to +80°C full power Operation -40.. -30; +80.. +100°C with de-rated output 8 – 12 LPM (2 – 3 GPM), PM100/PM150/RM100 20 – 30 LPM (5 – 6 GPM), PM250 PM100, 0.3 bar (4.4 psi) @ 8 LPM @ 25°C Pressure Drop PM150, 0.4 bar (5.8 psi) @ 8 LPM @ 25°C PM250, 0.9 bar (13 psi) @ 20 LPM @ 25°C RM100, 0.06 bar (0.8 psi) @ 8 LPM @ 25°C PM100 and PM150, AN-6 PM250, SAE ORB -10 RM100, Custom O-ring port, the following options are provided to be installed in the unit, each kit includes materials Port Size 1/17/2018 for both ports. - ARaymond NT100 / 16mm Straight, RMS p/n G1-0023-01 - ARaymond NT100 / 16mm 45deg, RMS p/n G1-0024-01 - ARaymond NT100 / 16mm 90deg, RMS p/n G1-0025-01 - 16mm / 5/8” Hose Barb, RMS p/n G1-0026-01 RMS PM Hardware User Manual 7 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com ARaymond NT100 / J20 Straight, RMS Kit G1-0023-01 ARaymond NT100 / J29 90 degree, RMS kit G1-0025-01 ARaymond NT100 / J30 45 degree, RMS kit G1-0024-01 1/17/2018 RMS PM Hardware User Manual 8 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com For proper operation of the inverter the coolant must flow at a rate equal to or above the minimum specified flow rate at all times that the motor is enabled. The flow rate should not be reduced when the inverter is “not being run hard”. The design of the heat exchanger does not allow for reduced or no coolant flow. It is possible to adjust the fan speed on the coolant radiator as needed depending on the operating conditions of the inverter. Since the maximum coolant temperature is less than the boiling point of water the cooling system does not need to be operated under pressure. Other devices (e.g. motor, charger, DC/DC converter) that are added in series with the inverter increase the total pressure drop of the system. Even simple fittings and hose length will contribute to the total system pressure drop. The total system pressure may add up to a level that is beyond the capability of the chosen pump. The best practice is to measure the actual coolant flow after the system has been assembled. Certain pump types are not capable of driving any significant pressure. A pump may have a high flow rate, but it may not be able to drive any substantial pressure. The PM250 unit has an especially high pressure drop. An example pump suitable for the PM250 is the EMP WP 29. Pumps suitable for the PM100/PM150/RM100 are the Bosch 0 392 022 010 and the Pierburg CWA 50. As noted above proper coolant flow is essential to the operation of the inverter. If the flow rate is not sufficient the power module internal to the inverter can be damaged even though the indicated power module temperatures are below an over-temperature threshold. The power module temperature sensors are located in such a way that they are much closer to the temperature of the coolant than they are to the temperature of the transistors and diodes used inside the power module. Loss of coolant for even a few seconds can result in failure of the power module. RMS recommends that the user install a device to ensure that the coolant pump is operating properly at all times when the inverter is enabled. The inverter should be immediately stopped if the coolant is not flowing. There are many ways that coolant flow could be measured. A flow sensor could be added to the cooling loop. Often these types of sensors produce a pulse output. To read the pulse output would require the use of a device to interpret this signal (RMS does not supply this). 1/17/2018 RMS PM Hardware User Manual 9 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Another option is to monitor the pressure in the cooling system. Typically the inverter would be placed near the end of the cooling loop, just before the radiator. So a typical cooling loop might look like pump outlet, inverter, radiator/reservoir, pump inlet. Typically the reservoir is at ambient error pressure. So the inverter should be at a pressure that is higher than ambient. If a pressure switch is placed at the input coolant port of the inverter it should be able to detect that coolant is flowing. Various types of coolant pressure switches exist. If a type is used that closes the switch when the pressure is above a certain level is used then this could be inserted in series with the ground connection of the forward/reverse switches (for VSM mode applications) or just connected directly to one of the inputs for monitoring via CAN. A pressure switch that closes when the pressure is above about 6 psi (~0.4 bar) should be suitable for the PM100 and PM150. For the PM250 the required pressure is higher and should be about 10 psi (~ 0.7 bar). 3.2 PM100/PM150 External Signal Connectors: Two sealed automotive connectors are provided to connect to the internal I/O resources. J1 and J2 are standard AMPSEAL connectors by AMP/Tyco: 3.2.1 J1 – 35p AMPSEAL Plug 776164-1 with crimp contact 770854-1 GEN2 refers to PM100 Units w/ serial number less than 344 GEN3 refers to PM100 Units w/ serial number of 344 or greater and all PM150 units Pin # Pin Name Description Notes 1 XDCR_PWR +5V @ 80mA max Accel Pedal Power 13 AIN1 Analog Input 1 0-5VFS Accel Pedal wiper 24 AIN2 Analog Input 2 0-5VFS Motor Temperature Sensor 2 AGND Analog Ground Accel Pedal GND 14 XDCR_PWR +5V @ 80mA max Spare 5V transducer power 25 AIN3 Analog Input 3 0-5VFS Brake Pedal 3 AIN4 Analog Input 4 0-5VFS 15 AGND Analog Ground 26 XDCR_PWR +5V @ 80mA max 4 RTD1 1000 Ohm RTD Input 1/17/2018 RMS PM Hardware User Manual Spare 5V transducer power 10 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com GEN2 4 GEN3 16 GEN2 16 GEN3 27 GEN2 27 GEN3 5 GEN2 5 GEN3 AOUT Analog Output 0 – 5V RTD2 1000 Ohm RTD Input AIN6 Analog Input 6 0-5VFS RTD3 1000 Ohm RTD Input RLY6 Hi-Side Relay Driver RTD4 100 Ohm RTD Input RTD1 RTD Input (PT100 or PT1000) 17 AGND Analog Ground 28 XDCR_PWR +5V @ 80mA max RTD5 100 Ohm RTD Input 6 GEN2 6 GEN3 18 RTD2 RTD Input (PT100 or PT1000) Available for user-defined functionality Available for user-defined functionality, CAN control. Software selectable input type. Spare 5V transducer power Software selectable input type.DO NOT CONNECT AIN5 Analog Input 5 0-5VFS DO NOT CONNECT RLY5 Hi-Side Relay Driver 7 /PROG_ENA Serial Boot Loader enable 19 AGND Analog Ground 30 DIN1 Digital Input 1 – STG(1) Forward Enable Switch 8 DIN2 Digital Input 2 - STG Reverse Enable Switch GEN2 18 GEN3 29 GEN2 29 GEN3 1/17/2018 RMS PM Hardware User Manual Available for user-defined functionality Available for user-defined functionality, CAN control. 11 of 43 7929 SW Burns Way Suite F Wilsonville, OR 20 DIN3 Digital Input 3 - STG Brake Switch 31 DIN4 Digital Input 4 - STG REGEN Disable Input (if used) 9 DIN5 Digital Input 5 – STB(2) Ignition Input (if used) 21 DIN6 Digital Input 6 - STB Start Input (if used) DO NOT CONNECT DIN7 Digital Input 7 - STB DO NOT CONNECT DIN8 Digital Input 8 - STB 22 GND Ground 33 CANA_H CAN Channel A Hi 11 CANA_L CAN Channel A Low 23 CANB_H CAN Channel B Hi 34 CANB_L CAN Channel B Low 12 TXD RS-232 Transmit 35 RXD RS-232 Receive 32 GEN2 32 GEN3 10 GEN2 10 GEN3 (1)– 3.2.2 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Available for user-defined function. Available for user-defined function. Switch to GND; (2) – Switch to Battery J2 – 23p AMPSEAL Plug 770680-1 with crimp contact 770854-1 Pin# Pin Name Description Notes 1 XDCR_PWR +5V @ 80mA max Encoder Power 9 ENCA Encoder Channel A input Used with Induction Motors 16 ENCB Encoder Channel B input 2 ENCZ Encoder Channel Z input (Index) 10 GND GND Encoder GND 17 EXC Resolver excitation output Used with PM Motors 3 GND Resolver excitation return 1/17/2018 RMS PM Hardware User Manual 12 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 11 SIN Resolver Sine winding + 18 /SIN Resolver Sine winding - 4 COS Resolver Cosine winding + 12 /COS Resolver Cosine winding - 19 GND 5 DO NOT CONNECT 13 DO NOT CONNECT 20 DO NOT CONNECT 6 GND Main 12V return Chassis GND 14 GND Main 12V return Chassis GND 21 RLY1 Hi-Side Relay Driver Pre-Charge Contactor Drive 7 RLY2 Hi-Side Relay Driver Main Relay Drive 15 RLY3 Lo-Side Relay Driver OK Indicator Drive / 12V Power Resolver Shield GND Relay Drive 22 RLY4 Lo-Side Relay Driver Fault Indicator Drive 8 BATT+ Main 12V power source 12V Ignition Power Input 23 BATT+ Main 12V power source 12V Ignition Power Input 3.3 PM250 External Connections: The PM250 has two external connectors. J2 is a 41 pin circular connector, J1 is a 26 pin circular connector. J2 contains mostly signals that would go to the vehicle harness. J1 contains mostly signals that would go to the motor. A connector kit that contains both J1 and J2 can be purchased from RMS as G1-0016-01. J1 Connections Pin# Pin Name Description A EXC Resolver excitation output B GND Resolver excitation return C SIN Resolver Sine winding + D /SIN Resolver Sine winding - E COS Resolver Cosine winding + F /COS Resolver Cosine winding - G RTD1P RTD1 Positive 1/17/2018 RMS PM Hardware User Manual Notes Used with PM Motors Can be either PT100 or PT1000 13 of 43 7929 SW Burns Way Suite F Wilsonville, OR H RTD1N RTD1 Negative J GND GND K HALL C Hall Input C L HALL A Hall Input A Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Encoder GND For use with certain motors that support Hall encoders. M ENCZ Encoder Channel Z input (Index) N ENC A Encoder Channel A input Quadrature encoder used with Induction Motors P XDCR_PWR +5V @ 80mA max Encoder Power R RTD2P RTD2 Positive Can be either PT100 or PT1000 S RTD2N RTD2 Negative T GND U AIN2 Resolver Shield GND Analog Input 2 Used with certain motors for temperature sensing. V AIN4 Analog Input 4 Used with certain motors for temperature sensing. W AGND Analog Ground Ground reference for use with AIN2 and AIN4 X XDCR_PWR +5V @ 80mA max Y HALL B Z GND AA or a ENCB Encoder Channel B input AB or b AIN2PU Pull-up resistor on AIN2 For use with pull-up resistor. Hall Input B If connected to XDCR_PWR will enable a 1K ohm pull-up resistor to be connected to AIN2. AC or c AIN4PU Pull-up resistor on AIN4 If connected to XDCR_PWR will enable a 1K ohm pull-up resistor to be connected to AIN4. J2 Connections Pin # A 1/17/2018 Pin Name CANB_H Description Notes CAN Channel B Hi RMS PM Hardware User Manual 14 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com B CANB_L CAN Channel B Low C RLY2 Hi-Side Relay Driver Main Relay Drive RLY3 Lo-Side Relay Driver OK Indicator Drive / 12V Power D Relay Drive Available for user-defined E RLY5 Hi-Side Relay Driver F DIN1 Digital Input 1 – STG(1) Forward Enable Switch G DIN2 Digital Input 2 - STG Reverse Enable Switch H DIN5 Digital Input 5 – STB(2) Ignition Input (if used) J DIN7 Digital Input 7 - STB K GND Main 12V return L GND Main 12V return M BATT+ Main 12V power source 12V Ignition Power Input N BATT+ Main 12V power source 12V Ignition Power Input P AIN1 Analog Input 1 0-5VFS Accel Pedal wiper R AGND Analog Ground Accel Pedal GND S AIN3 Analog Input 3 0-5VFS Brake Pedal T AIN5 Analog Input 5 0-5VFS U AIN6 Analog Input 6 0-5VFS V AGND Analog Ground W CANA_H CAN Channel A Hi X GND Ground CAN B Shield Y RLY1 Hi-Side Relay Driver Pre-Charge Contactor Drive Z RLY4 Lo-Side Relay Driver Fault Indicator Drive AA or a RLY6 Hi-Side Relay Driver AB or b DIN3 Digital Input 3 - STG Brake Switch AC or c DIN6 Digital Input 6 - STB Start Input (if used) AD or d GND Main 12V return AE or e BATT+ Main 12V power source 1/17/2018 RMS PM Hardware User Manual functionality, CAN control. Available for user-defined function. Available for user-defined functionality Available for user-defined functionality Available for user-defined functionality, CAN control. 12V Ignition Power Input 15 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com AF or f XDCR_PWR +5V @ 80mA max Accel Pedal Power AG or g AGND Analog Ground AH or h XDCR_PWR +5V @ 80mA max Spare 5V transducer power AI or i XDCR_PWR +5V @ 80mA max Spare 5V transducer power AJ or j CANA_L CAN Channel A Low AK or k GND Ground AM or m RXD RS-232 Receive AN or n DIN4 Digital Input 4 - STG AP or p DIN8 Digital Input 8 - STB AQ or q /PROG_ENA Serial Boot Loader enable AR or r TXD RS-232 Transmit AS or s AOUT Analog Output 0 – 5V AT or t GND Ground CAN A Shield REGEN Disable Input (if used) Available for user-defined function. Serial I/O GND 3.4 RM100 Signal Connections The RM100 uses a single 35 pin Ampseal connector for the I/O Signals. Mating connector is Tyco part number 776164-1, mating contact is 770854-3 for 16-20 AWG wire. Must use Tyco crimper 58529-1 (AMP Pro-Crimper II). A kit of the connector and contacts is available from RMS as part number G1-0021-01. Pin # Pin Name RLY1 (Pre- 1 Description High Side Driver charge) Notes If pre-charge function is used this output serves as the pre-charge contactor output. 2 AIN1 Analog Input 1 0-5VFS Accel Pedal wiper 3 AIN2 Analog Input 2 0-5VFS Motor Temperature Sensor /PROG_ENA Serial Boot Loader enable This pin is grounded when power 4 is applied to enable reprogramming of the firmware. 5 CANA_H CAN Channel A Hi 6 CANA_L CAN Channel A Low 1/17/2018 RMS PM Hardware User Manual CAN Communications channel 16 of 43 7929 SW Burns Way Suite F Wilsonville, OR 7 CANB_H CAN Channel B Hi Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Secondary CAN Communications channel, currently not used. 8 CANB_L CAN Channel B Low 9 CAN Shield 10 TXD RS-232 Transmit Used for RMS GUI and C2prog 11 RXD RS-232 Receive Used for RMS GUI and C2prog 12 GND RS-232 Ground RLY2 (Main) High Side Driver Connection of CAN cable shield. 13 If the pre-charge function is used this output serves as the main contactor output. 14 AIN3 Analog Input 3 0-5VFS Brake Pedal 15 DIN1 Digital Input 1 – STG Forward Enable Switch 16 DIN2 Digital Input 2 - STG Reverse Enable Switch 17 /EXC Resolver excitation return 18 COS Resolver COS winding 19 SIN Resolver SIN winding 20 RTD1- Return side of RTD1 RTD2+ Positive side of RTD2 21 Temperature Sensor software configurable for PT100 or PT1000. 22 RTD2- Return side of RTD2 23 XDCR_PWR +5V @ Transducer power output BATT+ 12V/24V Input Input power for inverter. Must be on a switched connection as 24 this input will always draw current. BATT+ 12V/24V Input 25 Redundant connection can be used if desired of needed for additional current capability. 26 1/17/2018 BATT_RTN 12/24V Return Normally tied to vehicle power system chassis. RMS PM Hardware User Manual 17 of 43 7929 SW Burns Way Suite F Wilsonville, OR BATT_RTN 12/24V Return 27 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Redundant connection can be used if desired of needed for additional current capability. 28 EXC Resolver excitation SHIELD Resolver Cable Shield Resolver cable shield should connection connected to this pin. Do not 29 connect the shield to the case of the motor. 30 31 /COS Resolver COS winding return /SIN Resolver SIN winding return RTD1+ Positive side of RTD1 32 Temperature Sensor software configurable for PT100 or PT1000. HVIL IN High Voltage Interlock Input 33 HVIL IN to HVIL OOUT is a circuit loop that will read shorted when all HV connectors are plugged in. 34 35 1/17/2018 HVIL OUT High Voltage Interlock Output AGND Analog Ground Ground reference from analog inputs. RMS PM Hardware User Manual 18 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 3.5 External Power Connections: 3.5.1 DC+ / DC-: DC/Battery power is provided to the controller via two wire ports located at the rear of the controller (PM100 and PM150 shown). The DC power ports are marked clearly DC+ DCon the front face of the PM250 J1 & J2 controller. The DC power must be run through an external pre-charge circuit to safely charge the capacitors inside the controller before the main contactor engages (refer to application schematic). The main contactor provides a safety disconnect of the DC power in case of a fault condition. Make sure that the wire to the drive is sized properly to handle the current. DANGER: Before changing the wiring make sure that the internal DC bus capacitors are discharged. The voltage should be measured at the terminals before disconnecting. If there is any doubt about the safety wait at least 1 hour after power has been removed before touching the terminals. ATTENTION Refer to the PM100 HV Connection Manual for more information on how to install the wires into the inverter. On the PM250 unit the DC connections are marked “+” for the DC+ and “-“ for the DC-. 1/17/2018 RMS PM Hardware User Manual 19 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com The RM100 Unit uses the Amphenol PowerLok™ 300 for the high voltage connections. These connectors utilize the Amphenol RADSOK™ technology. Each connection is a specific color and keying so that the cables cannot be interchanged. PowerLok™ Color PowerLok™ Key DC+ Red W DC- Black Y Phase U Green V Phase V Orange X Phase W Yellow U Inverter Connection The housing of the RM100 is marked with the HV Connection designations. The PM Family of inverters uses the Phase A, B, C designation instead of the RM Family U, V, W. References in documentation to Phase A refer to Phase U, Phase B to Phase V, and Phase C to Phase W. The PowerLok™ 300 is available for many different sizes of wires. information about ordering connectors/cables. 1/17/2018 RMS PM Hardware User Manual Contact RMS for more 20 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.5.2 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Phase A / Phase B / Phase C: Phase A, Phase B, and Phase C are wired to the motor. It is important the 3 wires be wired to the motor such that they give the proper direction of rotation. The motor wires are the most likely to generate EMI and they also carry a higher average current than the DC power wires. When installed in the vehicle these wires should be kept B A as short as possible. It is also C recommended that shielded wire be used for the motor wires. This can be done by adding a copper braid over the wires, or using wire that includes a shield. All of the PM100/150/250 family units are shipped with cable glands that are metallic and designed to accommodate shielded wire. The PM250 AC motor connections are marked on the unit with the letters “A”, “B”, and “C”. On the RM100 the phases are marked with “U”, “V”, and “W”. 3.5.3 Pre-Charge Circuit: An external pre-charge circuit must be used with the controller. The circuit limits peak inrush current into the controller when the main contactor is engaged. The pre-charge circuit adds a resistor, relay, and fuse in parallel with the main contactor. When the controller is powered on the controller will first engage the pre-charge relay to charge the capacitors internal to the controller. If the capacitors charge properly then the main contactor will engage. The pre-charge resistor should be sized to rapidly charge the capacitor, but not dissipate too much power in a fault condition. The pre-charge resistor should be sized so that if the controller had a short on its input the pre-charge resistor would not fail. The pre-charge relay will only remain closed for about 3 seconds. The pre-charge sequence must complete before this time or the inverter will declare a fault condition and open the pre-charge relay. The pre-charge circuit should be fused with a small fuse appropriate to the wire used. Since the pre-charge current is generally very low, approximately 0.5 amps in the example below, 1/17/2018 RMS PM Hardware User Manual 21 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com small wire can be used (recommend 18 AWG). A 5 amp fuse would be appropriate for this wire. Sizing Example: A typical application could have a maximum DC bus voltage of 320 volts. If a 600 ohm resistor were chosen this would result in a power dissipation of 171 watts. This is within the short term rating of a 50 watt wire-wound resistor. The internal capacitance of the controller is approximately 500uF. It takes approximately 3 time constants before the controller will close the main contactor, thus in this example it will take 0.9 seconds for the pre-charge to complete. RMS can provide the following parts if needed. Reference the following: Pre-charge Relay (30A, 12V COIL): RMS p/n 77-0026 for DX inverters Pre-charge Relay (50A/1000V, 12V COIL): RMS p/n 77-0034 for DZ inverters Pre-charge Resistor (600 ohm 50W): RMS p/n 53-0006 for DX inverters Pre-charge Resistor (1K ohm 100W): RMS p/n 53-0008 for DZ inverters Pre-charge Fuse (5A 500V): RMS p/n G1-0013-01 for DX inverters Pre-charge Fuse (5A 1000V): RMS p/n G1-0015-01 for DZ inverters 3.5.4 Model Internal Capacitance Maximum Precharge Resistor RMS Part PM100DX/PM100DXR 440uF 1200 ohms 53-0006 PM100DZ/PM100DZR 280uF 2000 ohms 53-0008 PM150DX/PM150DX 880uF 600 ohms 53-0006 PM150DZ/PM150DZR 560uF 1000 ohms 53-0008 PM250DZ 645uF 1000 ohms 53-0008 PM250DX 1500uF 400 ohms n/a RM100DX 570uF 1000 ohms 53-0006 RM100DZ 250uF 2000 ohms 53-0008 Main Contactor: The main contactor is the switching element between the DC high-voltage power source (typically a battery) and the controller. The main contactor must be sized to handle the operating currents of the controller. In addition the main contactor must be able to open under a fault condition. Generally only one contactor is needed, the application schematic 1/17/2018 RMS PM Hardware User Manual 22 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com shows the main contactor in series with the positive path from the battery to the controller. RMS has successfully used the following: Tyco/Kilovac p/n EV200AAANA. This contactor is available from RMS, contact us for more information (RMS p/n 77-0025). The contactor must be rated to handle DC voltage, AC only rated contactors and relays must not be used. DC rated contactors are usually polarity sensitive. That is the normal operating current should flow in a particular direction. Refer to the contactor data sheet for more information. 3.5.5 Main Fuse: The DC Power input to the controller must be fused. The fuse must be rated for the voltage of the battery as well as rated to open under the short circuit current that the battery can produce. Generally, this fuse (or equivalent fusible link) may be a part of the battery pack, but if the pack protection is not present or adequate, this fuse is required to prevent a potential battery pack fire. The fuse should be rated to handle the maximum DC input current of the controller. A semiconductor type fuse is recommended. Bussmann type FWP-400A is a suitable choice in many applications. 3.5.6 Passive Discharge of the High Voltage DC Bus: As noted above the inverter contains a large amount of DC bus capacitance. This capacitance will store energy long after the high voltage has been removed from the unit. If other provisions have not been made for discharging these capacitors then the unit wiring should not be touched for at least 5 minutes after the high voltage has been removed from it. The voltage will slowly decay due to internal resistors inside the unit. The resistor values are shown in the table below: Model Resistance Value Capacitance 3 Time Constants PM100DX/PM100DXR 120K ohms 440uF 158 s PM100DZ/PM100DZR 120K ohms 280uF 101 s PM150DX/PM150DX 120K ohms 880uF 317 s PM150DZ/PM150DZR 120K ohms 560uF 202 s PM250DZ 188K ohms 645uF 364 s PM250DX 188K ohms 1500uF 846 s RM100DX 40K ohms 570uF 68 s 1/17/2018 RMS PM Hardware User Manual 23 of 43 7929 SW Burns Way Suite F Wilsonville, OR RM100DZ 40K ohms Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 250uF 30 s For reference the value of 3 time constants is shown. This time would dissipate the voltage to less than 5% of the original value. Three time constants would allow the voltage to decay to a value that is normally safe to touch. However, the capacitors will still have some energy stored in them. The passive resistance value shown in the table in connected to the high voltage DC bus at all times. The inverter will draw a corresponding amount of current from the high voltage at all times. For example if a PM100DX is being used at 320V it would draw 320/120K = 2.7mA even when the inverter is disabled. If it is desired to have the DC bus voltage discharge faster the user must either provide an external method of discharge or consider the use of the Active Discharge feature of the inverter. 3.5.7 Consultant the manual RMS Inverter Discharge Process. 12V Power: The inverter requires a source of 12V power to operate. Normally, this power will be on a switched circuit. The inverter will turn on and communicate without high voltage present. This allows setup of parameters without high voltage. When the vehicle is turned OFF - the 12V power is removed from the controller by a switch. This switched 12V power is connected to the BATT+ terminals (refer to pin list for pin designation). The ground return for 12V power is connected to the GND terminals (refer to pin list for pin designation). For normal applications only one pin is necessary. If necessary more than one pin can be used for applications that push higher 12V or GND currents through the controller. Input currents: 12V Operating Power Input Range Input Current 12V Input Current @ 9V, operating 2.1A_typ PM100 2.5 A_typ PM150 2.1 A_typ PM250DZ 1/17/2018 RMS PM Hardware User Manual 24 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 12V Input Current @ 14V, operating 1.5A_typ PM100 1.8 A_typ PM150 1.6 A_typ PM250DZ 12V Input Current @ 14V, non-operating (PWM off) 0.5 A_typ PM100 0.6 A_typ PM150 0.8 A_typ PM250DZ The RM100 allows for operation from both 12V and 24V systems (the PM family does not have this capability). Valid range of operation for the RM100 is 9 to 32V. operating currents are shown below. RM100DX @ 12V, non-operating 0.9 A RM100DX @ 12V, operating 1.7A RM100DX @ 24V, non-operating 0.44A RM100DX @ 24V, operating 0.80A RM100DZ @ 12V, non-operating 0.9A RM100DZ @ 12V, operating 1.3A RM100DZ @ 24V, non-operating 0.5A RM100DZ @ 24V, operating 0.6A RM100 typical These currents do not include any high-side or low-side drivers: Any hi-side driver output currents, including the main and pre-charge contactor relay drive currents, will come through the BATT+ pins and will add to the above currents. Any low-side driver output currents, including indicator lamp current, will come through the GND pins, and should be considered in sizing this connection. 3.5.8 Grounding The inverter housing has a location for connecting the case to ground. The inverter housing must be connected to the motor case. It must also be connected to the vehicle chassis and this assumes that the vehicle chassis is at the same potential as the 12V GND. The inverter housing should not be allowed to be more than a few volts above the 12V GND. If the inverter housing was disconnected hazardous voltages could develop on the housing. 1/17/2018 RMS PM Hardware User Manual 25 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 3.6 Typical Application Wiring Diagram: The wiring diagrams covers following areas: Starter & Power Generation Precharge Circuit Motor & Encoder Transmission Control RS232 Programming CAN Interface Motor Temperature Sensor PM Controller Starter & Power Generation Pre-charge Circuit Vehicle Control Motor Control 1/17/2018 RS232 Programming RMS PM Hardware User Manual CAN Interface 26 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.6.1 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Controller 12V Power Wiring This circuit can be configured in two different ways: NOTE: RM100 can only use the Simple ON/OFF Configuration. (a) Simple ON/OFF Configuration In this configuration an external switch or controller is responsible for control of the 12V power. Thus the inverter will have a less controlled shutdown process as power could be removed while it is actively controlling the motor. When using this configuration set the EEPROM parameter Key_Switch_Mode_EEPROM to 0. Controller 12V Power Wiring - Configuration 0 +12 V Power BATT+ Switched ON when Inverter ON 12 V Return / Vehicle Chassis GND 1/17/2018 RMS PM Hardware User Manual 27 of 43 7929 SW Burns Way Suite F Wilsonville, OR (b) Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Typical Ignition Configuration (PM Products Only) In this configuration an external, user supplied relay, diode, and switch are used to control power. When the Ignition Switch is put into the IGN position power is supplied through the diode. Once the controller completes an initial power up sequence it then turns on the RLY3 output to turn on the external 12V relay. The controller monitors DIN5 to control the relay. When it is detected that Ignition has been removed (via DIN5) an orderly shutdown process is initiated. When the process is completed the RLY3 output is turned off and power is removed from the controller. In this mode the START position of the switch is used to actively turn on PWM to the motor (VSM mode). The diode should have a current rating of at least 3 amps. Starter & Power Generation - Configuration 1 Note: Only PM100/PM150 Connections shown, refer to PM250 connector for equivalent pins. 1/17/2018 RMS PM Hardware User Manual 28 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.6.2 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Pre-charge Circuit Note: Only PM100/PM150 Connections shown, refer to PM250/RM100 connector for equivalent pins. 1/17/2018 RMS PM Hardware User Manual 29 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.6.3 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Analog/Digital Vehicle Control If using VSM Mode then analog / digital signals can be used to control the operation of the inverter. The limited I/O of the RM100 prevents this functionality. XDCR_PWR Accel AIN1 AGND XDCR_PWR Brake AIN3 AGND DIN3 Brake DIN1 Forward DIN2 Reverse DIN4 Regen Disable GND 1/17/2018 RMS PM Hardware User Manual 30 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.6.4 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Motor Control (Typical Wiring) Only PM100/PM150 Pins are shown. 1/17/2018 Refer to motor specific manuals for details. RMS PM Hardware User Manual 31 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.6.5 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com CAN Interface The PM controller has one active CAN interface CAN A. The controller contains hardware to support a second CAN interface (CAN B), but currently only CAN A is active. CAN B is reserved for future use. Refer to the RMS CAN Protocol document for the various ways that the CAN bus can be configured. The CAN interface has multiple purposes: Provides direct control of the motor Provides diagnostic and monitoring capabilities Provides user-adjustable configuration The user can change the following hardware related configuration parameters: Inverter Command Mode: Setting this parameter to 1 allows the CAN mode to become active. CAN Bus Speed: Allowed speeds are 125 Kbps, 250 Kbps, 500 Kbps, or 1 Mbps. Enter 125, 250, 500, or 1000 to program the configuration parameter. CAN Terminator Resistor: The resistor can be applied or opened (PM Family only). For more information on CAN interface and messages, please refer to the “RMS CAN Protocol” document. 3.6.6 RS-232 Interface There is one RS-232 serial interface. This port can be used to set up and tune the controller, and to download controller software updates from a PC. RMS provides a simple Windows PC based software package for monitoring and changing parameters (RMS GUI). The drive can also be placed in a data-logging mode, and used with a PC or other serial device the unit broadcasts datasets at 3Hz of a number of parameters that allow performance and energy consumption data to be gathered in real time. For more information on RS232 data logging refer to the “RMS SCI Data Acquisition” document. 1/17/2018 RMS PM Hardware User Manual 32 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Note: Only PM100/PM150 Connections shown, refer to PM250/RM100 connector for equivalent pins. 3.6.7 Encoder Interface (Not included on RM100): The induction motor control software currently mandates the use of a position encoder on the motor. The encoder provides information about motor speed that is used by the induction motor control software. The controller provides a 5V interface to power the external encoder and to receive, level translate, and filter the signals from A, B and INDEX channels. For induction motor applications the INDEX channel is not used, but it may be wired. The encoder is connected internally to the TI DSP QEP Module (Quadrature Encoder Peripheral), which has special hardware for wide dynamic range speed and angle calculation from the encoder data. The drive has internal pull-up resistors on these inputs, and works with encoders that have either bi-polar or open-collector outputs. +5V 1.0K TO DSP ENC_x 100R 1000pF 1500pF Schematic of Encoder Inputs 1/17/2018 RMS PM Hardware User Manual 33 of 43 7929 SW Burns Way Suite F Wilsonville, OR 3.6.8 Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Resolver Interface: A resolver is a position sensor that is often used with Permanent Magnet type motors. There are various types of resolvers. The resolver requires an excitation voltage and provides a SIN and COS feedback. Currently all PM type motors used with the RMS controller require a resolver for position feedback. The PM Controllers have a resolver excitation frequency that matches the PWM frequency (12kHz). The excitation voltage from the PM controller can be adjusted as needed. The RM Controllers have an excitation frequency of 10kHz that is not synchronized with the PWM frequency. The RM controllers use a dedicated Resolver to Digital Converter. 1/17/2018 RMS PM Hardware User Manual 34 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 4. Vehicle Interface Setup 4.1 Analog Inputs: There are 4 analog inputs on GEN 2 units (AIN1-4), 6 analog inputs on GEN 3 units (PM100/PM150/PM250) as AIN1-6, and 3 analog inputs on the RM100 (AIN1-3). The inputs are intended for general analog signal sensing (0 – 5V). There are 5 dedicated RTD sensor inputs (three 1,000 Ohm and two 100 Ohm calibrated RTD channels) on GEN 2 units. There are 2 RTD inputs on GEN 3 units and RM100, selectable as PT 100 or PT1000 by software. Schematic of Analog Inputs The vehicle control system assigns the analog inputs as follows: Input Name Function ACCEL AIN1 The input should be tied to the vehicle accelerator. The input can be used with either a 0-5V signal or a potentiometer. Motor thermistor AIN2 The motor thermistor can be connected between this input and analog ground. An external pull-up resistor will be required. BRAKE AIN3 The input should be tied to the brake pedal. The input can be used with either a 0-5V signal or a potentiometer. AIN4 1/17/2018 Not assigned. For some motor types may be assigned to a secondary motor temperature. RMS PM Hardware User Manual 35 of 43 7929 SW Burns Way Suite F Wilsonville, OR AIN5 Not assigned. AIN6 Not assigned. Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com A 5V power supply (XDCR_PWR) is provided for powering sensors or potentiometers. This supply is available on several pins of J1 and J2 to ease connection. However, the total supply current available from this supply is limited to 80mA. The analog signals should be referenced to one of the analog ground (AGND) pins available on J1. This will reduce noise. Analog ground should NOT be connected to GND or the vehicle chassis. Description Parameter Value Vrange 0 - 5.00V Offset Voltage Vofs +50mV Gain Accuracy G +5% Analog Inputs Input Range ADC Resolution 12b Pull-up Resistance RTD Inputs – PT 1000 type Offset – 25ºC ambient Temperature error – additional error over temperature RTD Inputs – PT 100 type Rpu 300 k Ω 1000 Ω / 0ºC ±3ºC ±3ºC 100 Ω / 0ºC Offset – 25ºC ambient Temperature error – additional error over temperature ±3ºC ±3°C The controller uses two-wire type RTDs. One side of the RTD should be connected to the RTD input. The other side should be connected to Analog Ground or the dedicated RTD ground pin (RTDxN). 1/17/2018 RMS PM Hardware User Manual 36 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 4.2 Digital Inputs: There are up to 8 digital inputs for general interface to the vehicle and for feedback from external contactors and switchgear as required in the application. Some inputs are “Switch To Battery” (STB) inputs. These inputs are designed to be used in an application that switches the input to a positive battery potential. Some of the inputs are “Switch To Ground” (STG) inputs. These STG inputs are designed to be used in an application that switches the input to ground. Switch to Battery (STB) Input Schematic Switch To Ground (STG) Input Schematic 1/17/2018 RMS PM Hardware User Manual 37 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com The vehicle control system software currently assigns these inputs as follows: Input Type Signal Name Function This input should be connected to a switch DIN1 STG FWD_ENA that grounds this input when the user is commanding forward direction. DIN2 STG REV_ENA This input should be connected to a switch that grounds this input when the user is commanding reverse direction. This input should be connected to a switch DIN3 STG BRAKE that grounds the input when the brake is pressed. This input should be connected to a switch DIN4 STG REGEN Disable that grounds the input to enable this feature (that is, disable REGEN). If used, this input is assigned to the IGNITION DIN5 STB IGNITION DIN6 STB START DIN7 STB Not assigned Input available for user. DIN8 STB Not assigned Input available for user. feature. If used, this input is assigned to the START feature. Not all inputs are available on each unit. Below is a table showing which inputs are available (n/a indicates not available). PM100 (Gen2) PM100 (Gen3) PM150 PM250 RM100 Input Type DIN1 STG Yes Yes Yes DIN2 STG Yes Yes Yes DIN3 STG Yes Yes n/a DIN4 STG Yes Yes n/a DIN5 STB Yes Yes n/a DIN6 STB Yes Yes n/a 1/17/2018 RMS PM Hardware User Manual 38 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com DIN7 STB n/a Yes n/a DIN8 STB n/a Yes n/a The electrical parameters of the digital inputs are shown in the table below. Description Parameter Value Voltage level for “ON” VSTG-ON <0.9 V Voltage level for “OFF” VSTG-OFF >4.2 V Pull-up resistor to 5V VSTG-PU 2.4 kΩ Maximum Voltage on Input VSTG-MAX 18 V Voltage level for “ON” VSTB-ON >2.5 V Voltage level for “OFF” VSTB-OFF <1.3 V Pull-down resistor RSTB-PD 10 kΩ Maximum Voltage on Input VSTB-MAX 18 V Switch to Ground Inputs ( DIN1-4 ) Switch to Battery Inputs ( DIN5-8 ) 1/17/2018 RMS PM Hardware User Manual 39 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com 4.3 Digital Outputs There are up to 6 digital outputs available. See the table below for more specifics on availability across each model. There are two types of outputs available depending on the particular model. Schematic of High-Side Driver Schematic of Low-Side Driver The vehicle control system assigns the outputs as follows: Output Name Type RLY1 HSD RLY2 HSD Function Name PRECHARGE DRIVE MAIN DRIVE Function This output provides power to the pre-charge relay. This output provides power to the main contactor. This output provides a grounded signal to the OK RLY3 LSD OK INDICATOR indicator. The indicator turns on when power is applied to the drive and the drive has completed the pre-charge sequence. If used, this output is also used to power the external 12V power relay. RLY4 LSD FAULT INDICATOR This output provides a grounded signal to a fault indicator. The indicator will blink a fault code if the drive has detected a fault. RLY5 HSD n/a Not assigned. Available for use through CAN. RLY6 HSD n/a Not assigned. Available for use through CAN. 1/17/2018 RMS PM Hardware User Manual 40 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com The table below documents the availability of each output type across the different inverter models. PM100 (Gen2) PM100 (Gen3) PM150 PM250 RM100 Input Type RLY1 HSD Yes Yes Yes RLY2 HSD Yes Yes Yes RLY3 LSD Yes Yes n/a RLY4 LSD Yes Yes n/a RLY5 HSD n/a Yes n/a RLY6 HSD n/a Yes n/a Description Parameter Value Io_cont 1.5A Io_pk 7A Io_cont 1.5A Io_pk 3A Hi-Side Drivers (RLY1-2 and RLY 5-6) Output Current - Continuous Output Current – Surge Low-Side Drivers (RLY3-4) Output Current - Continuous Output Current - Surge 1/17/2018 RMS PM Hardware User Manual 41 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Revision History Version 1.8 Description of Versions/ Changes Added that RTDs should be connected to analog ground. Updated by Date Azam Khan 9/18/12 Azam Khan 1/15/14 Chris Brune 2/20/14 Chris Brune 3/24/15 Chris Brune 5/11/16 Chris Brune 11/29/2016 Chris Brune 12/6/2016 Chris Brune 12/19/2016 Chris Brune 4/5/2017 Updated diagrams that show the dimensions of 1.9 PM100 and PM150 drives. Rearranged subsections in section 3.4, PM Motor Controller 2.0 Distinguished Gen2 connections on J1 – 35p AmpSeal connector from that of Gen 3. Added connector information for the PM250. 2.1 Updated signal information to reflect the Gen 3 control board used in the PM100, PM150, and PM250. Added additional comments about the cooling system 2.2 and pressure switches. Added notes about the passive resistor on the DC bus. Added lower case pin designations to the PM250 2.3 connectors. Clarified the schematic images only show the PM100/150 pinouts. Added note about housing grounding. Removed 2.4 references that are PM100 specific. Improved clarity across different PM Family members. 2.5 2.6 Corrected wording about pressure switch. Removed reference to 3/8” NPT. Clarified information about cooling. 2.7 Added information about RM100 Chris Brune 6/8/2017 2.8 Corrected the color/key information about the RM100. Chris Brune 8/29/2017 Chris Brune 9/13/2017 Added information about RM100 cooling. 2.9 Clarified that VSM mode is not available for RM100. Additional clarifications of I/O capability of RM100. 1/17/2018 RMS PM Hardware User Manual 42 of 43 7929 SW Burns Way Suite F Wilsonville, OR Phone: 503 344-5085 Fax: 503 855-4540 sales@rinehartmotion.com Formatting on RM100 coolant ports. Added RM100 input current info. 3.0 Updated the Digital Input section to clearly show which inputs are available. Updated Chris Brune 1/17/2018 Digital outputs section to show which are available. Clarified analog inputs availability. 1/17/2018 RMS PM Hardware User Manual 43 of 43
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