RMS PM100 Software User Manual (V3 3)
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7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com RMS PM Software User Manual Revision 3.3 1/5/2016 RMS PM100 Software User Manual 1 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Document Organization This document has been organized such that a new user can follow sections in this document in a step-by-step manner after receiving the inverter. Firmware Step 1 Firmware Download & store the software release package (SWRP) Step 2 Re-flashing the inverter RS232 Data Acquisition Data Formats Step 3 (GUI + this document) RMS GUI Step 4 Programming & saving EEPROM parameters EEPROM Parameter Configuration Monitoring Parameters Calibration Processes Step 5 1/5/2016 Resolver Current Offsets VDC RTD SIN/COS Encoder Calibration Hall Sensor Encoder Calibration Vehicle State Machine RMS PM100 Software User Manual 2 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Table of Contents TABLE OF CONTENTS ..................................................................................... 3 1. FIRMWARE ...................................................................................... 6 1.1 Firmware Release Package ............................................................................ 7 1.1.1 1.1.2 1.1.3 Firmware .................................................................................................................................... 7 Tools .......................................................................................................................................... 7 Documentation .......................................................................................................................... 9 1.2 Saving Firmware Release Package .............................................................. 10 2. C2PROG – FIRMWARE PROGRAMMING GUIDE .................................. 12 2.1 2.2 2.3 Required Hardware ....................................................................................... 12 Required Software ........................................................................................ 12 Programming Steps ...................................................................................... 12 3. RMS DATA ACQUISITION GUIDE...................................................... 16 3.1 3.2 Required Hardware ....................................................................................... 16 Required Software ........................................................................................ 16 3.2.1 3.2.2 Data Records ........................................................................................................................... 16 Update Rate............................................................................................................................. 16 3.3 Data Acquisition Parameters ......................................................................... 17 3.3.1 3.3.2 Data Capture Tools ................................................................................................................. 17 Utilizing the Captured Data: ..................................................................................................... 17 4. 5. DATA FORMATS ............................................................................. 18 RMS GUI – EEPROM PARAMETERS GUIDE ................................... 20 5.1 5.2 5.3 5.4 5.5 5.6 Required Hardware ....................................................................................... 20 Required Software ........................................................................................ 20 Programming Steps ...................................................................................... 20 Saving EEPROM values ............................................................................... 21 Uploading EEPROM values .......................................................................... 21 Switching back to SCI mode ......................................................................... 22 6. 7. 8. 9. EEPROM PARAMETER SETUP (VIA GUI EEPROM VIEW) ................ 23 MONITORED PARAMETERS VIEW (VIA GUI MEMORY VIEW) ................ 24 CALIBRATION PROCESSES .............................................................. 26 VEHICLE STATE MACHINE ............................................................... 28 9.1 Start State (VSM_state = 0): ......................................................................... 28 9.1.1 9.1.2 9.1.3 12V Power-up: ......................................................................................................................... 28 Load from EEPROM: ............................................................................................................... 28 Power on Self-Test (POST): .................................................................................................... 28 9.2 Pre-charge Sequence: .................................................................................. 31 1/5/2016 RMS PM100 Software User Manual 3 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 9.2.1 9.2.2 9.2.3 Pre-charge Initialization (VSM_State = 1) ............................................................................... 31 Pre-charge Active (VSM_State = 2) ........................................................................................ 31 Pre-charge Complete (VSM_State = 3)................................................................................... 31 9.3 Wait State (VSM_state = 4): .......................................................................... 32 9.3.1 9.3.2 Key Switch Mode 0 .................................................................................................................. 32 Key Switch Mode 1 .................................................................................................................. 32 9.4 9.5 9.6 Ready State (VSM_State = 5): ...................................................................... 33 Motor Running State (VSM_State = 6): ......................................................... 33 Fault State (VSM_State = 7): ........................................................................ 33 9.6.1 9.6.2 Fault Priority:............................................................................................................................ 35 Clear Faults Command: ........................................................................................................... 35 9.7 9.8 Shutdown in Process State (VSM_State = 14): ............................................. 35 Recycle Power State (VSM_State = 15): ...................................................... 35 APPENDIX A MOTOR CONFIGURATION PARAMETERS .................................. 36 APPENDIX B SYSTEM CONFIGURATION PARAMETERS ................................. 37 APPENDIX C CAN CONFIGURATION PARAMETERS ..................................... 43 APPENDIX D CURRENT PARAMETERS ........................................................ 44 APPENDIX E VOLTAGE & FLUX PARAMETERS ............................................ 45 APPENDIX F TEMPERATURE PARAMETERS ................................................ 46 APPENDIX G ACCELERATOR & TORQUE PARAMETERS................................ 48 APPENDIX H SPEED PARAMETERS ............................................................ 54 APPENDIX I PID REGULATOR PARAMETERS ............................................. 57 APPENDIX J SHUDDER COMPENSATION PARAMETERS ................................ 59 APPENDIX K BRAKE PARAMETERS ........................................................... 62 APPENDIX L GUI DISPLAY PARAMETERS .................................................. 66 APPENDIX M POST FAULTS ..................................................................... 69 APPENDIX N RUN FAULTS ........................................................................ 71 REVISION HISTORY ...................................................................................... 74 1/5/2016 RMS PM100 Software User Manual 4 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This page is intentionally left blank 1/5/2016 RMS PM100 Software User Manual 5 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 1. Firmware RMS firmware is a single file in hexadecimal format that can be downloaded and programmed into the RMS controller over the serial port. The title of the firmware file follows the date versioning scheme. This scheme uses the year followed by the month and then date. The format is ‘RMS_yyyymmdd_nnnn_option.hex’. In addition to the date code, the RMS firmware version number also contains a software release number (nnnn). The “option” refers to specific features. As noted below the main firmware is labelled as Group_1 or Group_2. An example of a released firmware file would be RMS_20150724_1953_Group_1.hex Where, ‘20150724’ is the date code, July 24, 2015 ‘19’ is the major release number ‘53’ is the minor release number Important: Starting with firmware 1900+, users will be provided with two (2) executable files. The hex file with the tag “Group_1” in the filename should be used for motor types between 0 and 59. The hex file with the tag “Group_2” in the filename should be used for motor types starting from 60 and onward. RMS Firmware is released on a continuous basis. The time to release firmware depends on the new feature requests, change requests, and bug reports discovered internally at RMS or by the external customers. Each firmware release has an accompanying ‘Firmware Release Notes’ document that provides the following information: (a) Important notices regarding the new firmware (b) New features and/or change requests (c) Bug fixes 1/5/2016 RMS PM100 Software User Manual 6 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 1.1 Firmware Release Package In addition to the document, Firmware Release Notes, the firmware release package contains the following directories/folders: (a) Firmware (b) Tools (c) Documentation The complete RMS firmware package is uploaded to an online repository. To access the repository navigate to the RMS web site, www.rinehartmotion.com Go to the Support page. If customers need to access a previous release, many previous releases are available online at the same repository, or contact RMS. 1.1.1 Firmware This folder contains the firmware file. The firmware file can be downloaded to the PM unit over the serial port (RS-232). The program C2Prog is used to download the firmware to the controller. Please see section, ‘C2Prog - Firmware Programming Guide’ for more details. The SCI (serial communication interface) is used for three purposes. It is used for firmware download, graphical user interface (GUI) communication, and for SCI data acquisition. The default communication method is SCI at power up. SCI data is transmitted in hexadecimal format. This data can be captured on a PC by using any standard communications software such as Hyper-terminal or Real-term. The data can also be captured on any type of device that has a standard serial port. The data can be used to plot specific graphs to understand vehicle performance. The GUI is used to reprogram EEPROM parameters and also to monitor data using MS Windows platform. In order to activate GUI, disconnect the SCI communication device and hook up the PC to PM unit. Start GUI application. GUI then tries to establish communication with PM unit. This may take a few seconds. Once the communication is established, GUI will show all parameters that can be monitored and reprogrammed. Refer to the section, ‘RMS GUI – EEPROM Parameter Programming Guide’ for details on programming EEPROM parameters into the PM unit. 1.1.2 Tools This folder contains several tools to program the firmware, monitor and program several parameters, and capture data stream for a more in-depth analysis. 1.1.2.1 RMS GUI The sub-folder ‘GUI Files’ contains the GUI application and all the needed files to install and run this application properly. The GUI program allows the user to monitor various variables and to 1/5/2016 RMS PM100 Software User Manual 7 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com reprogram EEPROM parameters. EEPROM parameters must be programmed before the controller is operated. Refer to the section, ‘RMS GUI –EEPROM Parameter Programming Guide’ for more information. Following file can be located in the sub-folder GUI Files: • RMS GUI.exe: This provides the main application to monitor data and also to reprogram EEPROM parameters. There is not setup file. Simply copy this application to an appropriate location. • defsyms_yyyymmdd.txt: This is the default symbols file that includes the parameters to be monitored and reprogrammed. This is a firmware-specific file which means that each firmware has its own default symbols file. The two files can be matched through the date code in yyyymmdd format. The default symbols file is also located under the ‘Firmware’ folder. • gtk+-2.8.9-setup-1.exe: This is a one-time installed library file. The computer needs to be rebooted after the installation. • gui_config.txt: This file is no longer required for RMS GUI version 1.3.0 or above. This file is used to set the correct serial port to communicate between GUI and controller box. However, the new GUI application automatically detects and stores the COM port information. This file can be opened with any text editor, such as Notepad.exe. 1.1.2.2 C2Prog C2Prog is a flash programming tool for TI C2000™ MCUs. Rather than using JTAG as the communication interface between the programming tool and the MCU, C2Prog utilizes RS-232, RS-485 and CAN (Controller Area Network). The programmer is, therefore, well suited for deployment in the field where the JTAG port is typically not accessible. C2Prog Flash Programmer uses the boot-loader feature of the MCU for rapid Flash programming over the serial line. Please download a version from the RMS’ online repository. The link has been provided in the above section, ‘Firmware Release Package’. For the latest version of the application and more details, please visit http://www.codeskin.com 1.1.2.3 Realterm Realterm is a terminal program specially designed for capturing, controlling and debugging binary and other data streams. It has more features for debugging communication ports than a Hyper-terminal. However, it has no support for dialing modems. RMS uses this application to develop SCI features and collect the streaming data during bench testing. However, most of the on-vehicle testing has been done using PDA Palm-V. Palm-V is much smaller in size than any laptop computer and can be easily carried in RMS’ electric vehicle during test drives. 1/5/2016 RMS PM100 Software User Manual 8 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Some of the features of this application include command line control, ability to capture to file, arbitrary baud rates, etc. For more details, please refer to http://realterm.sourceforge.net/ 1.1.3 Documentation There are a number of documents that are useful for setting up and operating the RMS products. • RMS Getting Started Guide • RMS PM Hardware User Manual, description of hardware features of RMS inverters. • RMS PM Software User Manual (this manual) • Resolver Calibration Manual, all PM motors must have the resolver calibrated. • Download Diagnostic Data, a manual covering high speed data download from the inverter. • Inverter Discharge Process • PM100 HV Connection Manual • And others, see www.rinehartmotion.com/support for more This RMS Software Manual includes details on: o PM Programming using C2Prog (in this document, section ‘C2Prog – Firmware Programming Guide’) o Programming EEPROM Parameters using GUI (in this document, section ‘RMS GUI – EEPROM Parameter Programming Guide’) o RMS SCI Data Acquisition (previously known as SCI Data Stream Parameters) o Shudder Compensation Manual (now a sub-section in this document) 1/5/2016 RMS PM100 Software User Manual 9 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 1.2 Saving Firmware Release Package It is highly recommended that each firmware release package is downloaded and kept separate from each other. This allows a better referencing during debugging. Also, save files directly under the C:\ drive instead of ‘Desktop\My Documents’. Following is a suggested folder structure to keep track of RMS firmware versions: High level view of RMS folder structure Files under subfolder ‘GUI’ Files under subfolder ‘Firmware’ 1/5/2016 RMS PM100 Software User Manual 10 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This page is intentionally left blank 1/5/2016 RMS PM100 Software User Manual 11 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 2. C2Prog – Firmware Programming Guide 2.1 Required Hardware RS232 cable or RS232-USB Adapter (based on PC’s port availability) 2.2 Required Software (a) New firmware for the PM unit will be provided by Rinehart Motion Systems. (b) The reprogramming requires the use of the C2Prog software. • Home page: http://www.codeskin.com/ • C2Prog page: http://www.codeskin.com/c2prog-download 2.3 Programming Steps (a) After starting the software make sure that the screen looks similar to the one below. If necessary press the expansion button next to “Hex File Configuration”. (b) Make sure the proper COM selected. First click “Configure Ports” and then “Scan Ports” to see the available COM ports. Then select the proper port from the pull-down. (c) Using the “Target:” pull-down menu select the correct target from the list. RMS firmware requires one of the two options: • 28335_30MHz (only used with rare units that contain floating point support) • 28234_30MHz (this is the most common) 1/5/2016 RMS PM100 Software User Manual 12 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com e c a d f b IMPORTANT: If the HW Version number starts with 234 then the Target is 28234, 30MHz. 1/5/2016 RMS PM100 Software User Manual 13 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com (d) Make sure that the “Smart Selector Selection” box is checked. (e) Click the “Select File…” button on the top right hand corner and browse to the correct firmware file provided by RMS. The file will have a .hex extension. (f) Now click the “Program” button near the bottom. (g) Make sure that Program Enable switch in the inverter harness is closed. Then power-on the inverter. Programming will then begin. The C2Prog software will show the status of the programming. (h) When the programming is completed, click OK to close the Status screen. If going to step ‘b’ above. 1/5/2016 RMS PM100 Software User Manual 14 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This page is intentionally left blank 1/5/2016 RMS PM100 Software User Manual 15 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 3. RMS Data Acquisition Guide 3.1 Required Hardware RS232 cable or RS232-USB Adapter (based on PC’s port availability) 3.2 Required Software This section defines parameters that are transmitted by the PM unit using SCI over RS232 serial cable. In order to receive the data, RS232 port should be configured as follows: Baud Rate Parity Data Bits Stop Bits Hardware Flow Control 57600 None 8 1 None 3.2.1 Data Records Each parameter is 16-bits long and each nibble (4-bits) in a parameter is sent as an ASCII character. A ‘record’ consists of total five characters, that is, the four nibbles in a parameter and a space character. After sending all records, two additional characters, a carriage return and a linefeed, are sent. 0 0 6 8Figure 5.1 – Data Record Data Record 1 Data Record 2 Data Record 3 Data Record N Figure 5.2 – A complete set of data records 3.2.2 Update Rate The update rate of one complete set of data records depends on the total number of records in each set: For example, if there are 21 data records in one set: Time to send 5 characters (1 data record) = 3 msec Time to send 21 records = 21 records x 3 msec = 63 msec Plus last two characters = 63 + 3 = 66 msec 1/5/2016 RMS PM100 Software User Manual 16 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 3.3 Data Acquisition Parameters The following data records are transmitted over the serial bus: Count 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Parameter Slow Interrupt Counter Filtered Accel-pot Blended Torque Vehicle Torque Command DC Voltage DC Current Omega Tach Flux Weakening Regulator Output FB Voltage Magnitude IQ Command IQ Feedback ID Command ID Feedback Modulation Module A Temperature Motor Temperature Run Fault Low Word Run Fault High Word Torque Shudder Filtered Brake pot 3.3.1 Data Capture Tools In order to save the data on the serial bus, a terminal program such as Realterm ( http://realterm.sourceforge.net/ ) can be used. Most of the data capture at RMS has been done using a Palm or a similar device. HU UH 3.3.2 Utilizing the Captured Data: Once the data is captures in a text file, it should be imported into a Microsoft Excel spreadsheet as space delimited data. After importing all data, it can be copied into SCI Template.xls spreadsheet which provides conversion formulae for each data record and allows the user to plot graphs to analyze the vehicle performance in more detail. 1/5/2016 RMS PM100 Software User Manual 17 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 4. Data Formats Throughout this document, all parameters will adhere to the data formats mentioned in this section, unless specified otherwise. The column, Variable Type follows the standard computer programming data types. These data types are defined as follows: • Byte (char): an 8-bit value ranging from 0 – 255 for unsigned and -128 – 127 for signed characters. • Integer (int): a 16-bit value ranging from 0 – 65535 for unsigned and -32768 – 32767 for signed integers. • Long Integer (long): a 32-bit value ranging from –(231+1) to 231. All EEPROM data is broadcast with a multiplication factor. In order to get the actual value, divide it by the value in the column ‘Multiplier’ (may also be referred to as ‘Prescalar’). Format Variable Type Range Temperature Signed Integer ± 3000.0 °C 10 Low Voltage Signed Integer ± 300.00 Volts 100 High Voltage Signed Integer ± 3000.0 Volts 10 Torque Signed Integer ± 3000.0 N.m. 10 Current Signed Integer ± 3000.0 Amps 10 Angle Signed Integer 0 to ±359.9 Degrees 10 Angular Velocity Signed Integer ± 30000 RPM N.A. Boolean Unsigned Byte 0 OR 1 Binary N.A. Frequency Signed Integer ± 3000.0 Hz 10 Power Signed Integer ± 3000.0 kW 10 Flux Signed Integer 0 to 30.000 Webers 1000 Proportional Gain Unsigned Integer 0 - 655.00 OR 0 - 6.5535 N.A. 100 OR 10000 Integral Gain Unsigned Integer 0 - 6.5535 N.A. 10000 Derivative Gain Unsigned Integer 0 - 655.35 N.A. 100 Low-pass Filter Gain Unsigned Integer 0 - 6.5535 N.A. 10000 Time Unsigned Long Integer OR Unsigned Integer See Parameter Description See Parameter Description See Parameter Description See Parameter Description See Parameter Description See Parameter Description See Parameter Description Per-unit Value 1/5/2016 Unit RMS PM100 Software User Manual Multiplier 18 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This page is intentionally left blank 1/5/2016 RMS PM100 Software User Manual 19 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 5. RMS GUI – EEPROM Parameters Guide RMS GUI is a Windows application developed by RMS. This application communicates over a RS232 port. The primary purpose of this application is to be able to monitor a specific set of parameters in real time. However, the application also provides the ability to program certain EEPROM parameters. The set of EEPROM parameters need to be modified based on each motor and other system set up by the customer. EEPROM parameters must be programmed correctly before the PM controller is operated. This section provides the user with a process of updating EEPROM parameters for the PM1 unit using the GUI application. 5.1 Required Hardware RS232 cable or RS232-USB Adapter (based on PC’s port availability) 5.2 Required Software Following software applications/files are needed to program EEPROM parameters: RMS GUI Application: This application is part of the RMS Firmware Release Package and can be downloaded using the link provided in the above section, ‘Firmware Release Package’. Default symbols file (defsyms_yyyymmdd.txt): Each released firmware requires a specific default symbols file. Please refer to section 1.1.2.1 ‘RMS GUI’ for more details. Firmware file: Please refer to section 1.1.1 ‘Firmware’ for more details. 5.3 Programming Steps (a) Start the GUI. Make sure it is version 1.2.7 or above. Confirm the GUI version number, Firmware date code and firmware version on the title of the GUI window. The latest RMS GUI application also displays the COM port information. (b) Click on the EEPROM View tab (labeled ‘Tab 2’ in figure 5.2). This will display all EEPROM parameters that can be programmed by the user. (c) In order to change any value, click on the value under the VALUE column. Enter a new value and then click ENTER key on your keyboard. (d) When all values are changed, click on the Program EEPROM button (labeled ‘Button 3’ in figure 5.2). (e) A status message will confirm whether the programming was successful or not. Follow the on-screen instructions. 1/5/2016 RMS PM100 Software User Manual 20 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Figure 5.1 5.4 Saving EEPROM values EEPROM values can be saved by using the Save button (labeled ‘Button 4’ in figure 5.2). You will be prompted for a filename to save the data to. After selecting the file you will be prompted to press “OK” to start the download. 5.5 Uploading EEPROM values You can also load a predefined set of values by using the Load EEPROM Values button (labeled ‘Button 2’ in figure 5.2). GUI version, Firmware Date-code & Version Tab 1 Tab 2 Button 1 Button 2 Button 3 Button 4 Figure 5.2 1/5/2016 RMS PM100 Software User Manual 21 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 5.6 Switching back to SCI mode Once in the GUI mode, the user has the option to switch back to the SCI data acquisition mode. However, it requires the RMS GUI application to be completely shut down. In other words, the GUI application must release the serial port. Once the serial port is released, another terminal application such as Realterm can be started. Open the serial port and click anywhere in the window where the serial data appears. Press ‘+’ and then . The SCI broadcast data should start to appear again. Realterm, in particular, also has an option to send out the ASCII characters as shown below. You can enter ‘+’ in the first box and check the +CR and +LF options for carriage return and linefeed respectively. Then press the “Send ASCII” button. The SCI broadcast data should start to appear again. 1/5/2016 RMS PM100 Software User Manual 22 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 6. EEPROM Parameter Setup (via GUI EEPROM View) There are a number of internal parameters (may be considered as “calibrations”) that must be set in the controller before it is ready to operate a vehicle. All of these values must be adjusted to suit the vehicle and motor you are using. These adjustments are part of personalizing the drivability and vehicle dynamics to suit the final application of the vehicle. Parameter setup is accomplished using custom software provided by RMS. Refer to section 8, “RMS GUI – EEPROM Parameters Guide” for more information on how to update and program these parameters in non-volatile memory. Refer to the following appendices for different categories of EEPROM parameters (each appendix is hyper-linked, press CTRL-CLICK to go to a specific table): Appendix A: Motor Configuration Parameters Appendix B: System Configuration Parameters Appendix C: CAN Configuration Parameters Appendix D: Current Parameters Appendix E: Voltage & Flux Parameters Appendix F: Temperature Parameters Appendix G: Accelerator & Torque Parameters Appendix H: Speed Parameters Appendix I: PID Regulator Parameters Appendix J: Shudder Compensation Parameters Appendix K: Brake Parameters 1/5/2016 RMS PM100 Software User Manual 23 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 7. Monitored Parameters View (via GUI Memory View) The GUI provides the ability to monitor several operation parameters of the controller. It is also helpful for checking connections to the controller. Items can be added or removed from the Memory Window to the Watch window to view the parameter. Refer to the following appendix for a complete list of parameters that can be monitored through RMS GUI (each appendix is hyper-linked, press CTRL-CLICK to go to a specific table): Appendix L: GUI Display Parameters No Faults/Check Faults button: This button allows the user to check the fault status when the ‘Auto’ box is check for ‘Continuous Refresh’ or by clicking on this button. ‘No Faults; status in blue indicates that there are no faults currently present. ‘Check Faults’ status indicates the presence of one or more faults. To check which faults are present, click on this button. Clear Faults button: This button allows the user to clear all faults with the exception of a few mentioned in Appendix N (table of Run Faults). Download Diagnostic Data button: This button allows the user to download SCI Diagnostic Data. Please refer to the user manual ‘Download Diagnostic Data’ for details. Load Default Symbols button: This button allows the user to load the default symbols file for the firmware in the PM unit. 1/5/2016 RMS PM100 Software User Manual 24 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This page is intentionally left blank 1/5/2016 RMS PM100 Software User Manual 25 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 8. Calibration Processes Before the RMS inverter can be used successfully, it is very important to make sure that it is calibrated properly. There are several calibrations that are performed before each unit is shipped to the customer. However, some of these calibrations depend on the specific environment in which the unit is used. User Manuals for following calibration processes are provided to customers. The calibrations can be performed as many times as needed. Calibration Process Current Offset DC Voltage Hall Sensor Encoder SIN/COS Encoder Resolver RTD 1/5/2016 User Manual (PDF format) Current Offset Calculation (only used with certain units, not common) RMS DC Voltage Calibration Process (factory calibrated thus not normally needed) Encoder Hall Sensor Calibration (not normally needed) RMS Encoder Calibration for SIN_COS Encoder (only necessary with certain motors that have a sin/cos encoder) RMS Resolver Calibration Process (this process is necessary for all motors that use a resolver) RMS RTD Calibration Process (factory calibrated thus not normally needed) RMS PM100 Software User Manual Factory Calibrated? No Yes No No No Yes 26 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This page is intentionally left blank 1/5/2016 RMS PM100 Software User Manual 27 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 9. Vehicle State Machine The drive has an internal state machine that steps through a series of actions at startup, at shutdown, and generally whenever operation “transitions” from one mode or state to another. The particular state that the drive is in can be tracked via the RMS GUI software. The state is monitored via the VSM_State symbol. This symbol will take on the following values: VSM_State 0 1 2 3 4 5 6 7 14 15 Name Start State Pre-charge sequence initial state – Turn on the pre-charge relay Pre-charge sequence active state – Waiting for capacitor to finish charging. Pre-charge sequence finish state – Completes the final checks before proceeding to Wait State. Wait State – waiting for activation of forward or reverse. Ready State – Activates the inverter state machine to begin energizing the motor. Motor Running State – Normal motor running Fault State – The controller has faulted Shutdown in Process – In key switch mode 1, user has turned key switch to off position. Recycle Power State – This indicates that the power to the controller needs to be recycled after EEPROM Programming is complete. 9.1 Start State (VSM_state = 0): 9.1.1 12V Power-up: When the vehicle is powered up, this is the default state. If the program enable input is held low at power up it will not execute the RMS software and will not proceed into the Vehicle State Machine. Default Initialization: This is the processor setup and initialization process, including setting all I/O pins to the correct state (in/out, pull-up or –down, weak or strong, etc). At this point, the initialization process sets up a default list of parameters with pre-assigned default values. 9.1.2 Load from EEPROM: This state will load the application parameters to configure the unit for the actual application. This also loads FACTORY CALIBRATIONS from memory, as these are just a class of EEPROM parameters. 9.1.3 Power on Self-Test (POST): A number of tests are to be performed in this state. Each test will have an associated fault flag. Following is a list of parameters checked: 1/5/2016 RMS PM100 Software User Manual 28 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Test Area Current sensors Accelerator input PCB Temperature Sensor GDB Temperature Sensor Module Temperature Sensors 5V power 12V power 2.5V power 1.5V power HW Faults (Saturation and over current) Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Description Check current sensors reading to be within a valid range Check accelerator input data is within a valid range Check PC temperature is in valid range Check gate drive board temperatures in range Check substrate temperatures for module A, module B, and module C in range Check internal 5V and external transducer power in range Check 12V power in range Check internal 2.5V reference voltage in range Check internal 1.5V reference voltage in range If exist, attempt to clear faults and then report If a power-on self-test fault occurs it will blink the fault indicator followed by two quick blinks to differentiate POST faults from RUN faults. The number of blinks gives a general indication of the particular fault. A particular fault code can be found by clicking on the “Check Faults” button on the “Memory View” page of RMS GUI. Parameters, “post_fault_hi and post_fault_lo have been removed from the parameter list and are not available anymore. The list on the next page shows all POST faults: 1/5/2016 RMS PM100 Software User Manual 29 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Byte 3 Byte 2 Byte 1 Byte 0 CAN Byte CAN Bit POST Fault Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com CAN Byte Value 1 Fault Word 0 Hardware Gate/Desaturation Fault 1 HW Over-current Fault 2 00000001 00000002 2 Accelerator Shorted 4 00000004 3 Accelerator Open 8 00000008 4 Current Sensor Low 16 00000010 5 Current Sensor High 32 00000020 6 Module Temperature Low 64 00000040 7 Module Temperature High 128 00000080 8 Control PCB Temperature Low 1 00000100 9 Control PCB Temperature High 2 00000200 10 Gate Drive PCB Temperature Low 4 00000400 11 Gate Drive PCB Temperature High 8 00000800 12 5V Sense Voltage Low 16 00001000 13 5V Sense Voltage High 32 00002000 14 12V Sense Voltage Low 64 00004000 15 12V Sense Voltage High 128 00008000 16 2.5V Sense Voltage Low 1 00010000 17 2.5V Sense Voltage High 2 00020000 18 1.5V Sense Voltage Low 4 00040000 19 1.5V Sense Voltage High 8 00080000 20 DC Bus Voltage High 16 00100000 21 DC Bus Voltage Low 32 00200000 22 Pre-charge Timeout 64 00400000 23 Pre-charge Voltage Failure 128 00800000 24 EEPROM Checksum Invalid 1 01000000 25 EEPROM Data Out of Range 2 02000000 26 EEPROM Update Required (warning) 4 04000000 27 Reserved 8 08000000 28 Reserved 16 10000000 29 32 20000000 30 Reserved Brake Shorted 64 40000000 31 Brake Open 128 80000000 Please refer to Appendix M for description of power-on self-test faults. 1/5/2016 RMS PM100 Software User Manual 30 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 9.2 Pre-charge Sequence: 9.2.1 Pre-charge Initialization (VSM_State = 1) This state declared VDC Out-of-range high fault if DC voltage is above the software overvoltage threshold. The value of software over-voltage threshold is hard-coded and can only be changed through RMS firmware release process. If DC voltage is below the software over-voltage threshold, Pre-charge output is activated. State machine goes to Pre-charge Active State. 9.2.2 Pre-charge Active (VSM_State = 2) This state controls the charging of the capacitors internal to the controllers. If the rate of charge stays within range, Main output is activated and Pre-charge output is deactivated. During the pre-charge process: If DC voltage exceeds software over-voltage threshold, VDC Out-of-range high fault is declared. After 3 seconds that is, the maximum pre-charge time, - If DC voltage is less than the value of EEPROM parameter, DC Under-voltage threshold VDC Out-of-range low fault is declared. - If DC voltage is still charging, pre-charge timeout fault is declared. 9.2.3 Pre-charge Complete (VSM_State = 3) This state checks if the capacitor charge is stable, that is, it is not over-charged or undercharged, or there is no quick change in voltage since the pre-charge output was deactivated. If any of the conditions is true, a relevant fault is declared. 1/5/2016 RMS PM100 Software User Manual 31 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 9.3 Wait State (VSM_state = 4): This state checks for the Key Switch Mode. Based on that value, the inverter can be powered to run the motor as follows: 9.3.1 Key Switch Mode 0 This mode allows for a simple on/off ignition switch functionality. To power up the PM unit, turn the ignition to ON position. This state then checks to see that the brake switch is active and only one of /FORWARD and /REVERSE switches is active. If both switches, /FORWARD and /REVERSE, are active, the state shall declare a FWD_RVS_INVALID_STATE_FAULT. If a correct direction and the brake are active then the motor will be enabled. 9.3.2 Key Switch Mode 1 This mode allows for traditional ignition switch functionality. To power up the PM unit, turn the ignition to ON position. This state then checks to see that the brake switch has been active and start signal pulse has been received. While keeping the brakes on, only one of /FORWARD and /REVERSE switches needs to be activated. If both switches, /FORWARD and /REVERSE, are active, the state shall declare a FWD_RVS_INVALID_STATE_FAULT. 1/5/2016 RMS PM100 Software User Manual 32 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 9.4 Ready State (VSM_State = 5): The READY state shall send out the Enable Inverter Command and wait for Inverter Ready Flag to be set. The Inverter Ready Flag will be set if the inverter successfully performs a series of actions necessary to stat the motor. If inverter does not enable the motor within a specific amount of time, the state shall declare an inverter state timeout fault. This state automatically transitions to the next state if there are not faults. The following table lists several inverter states: Inverter States (inv_mode) 0 1 2 3 4 5 6 7 8 9 10 11 12 15 Description Precharge, power-up state Stop - Inverter is not running and is in “STOP” state. Open Loop State - for testing purposes Closed Loop state – normal state Start Time Delay – small delay before starting the inverter Current Sensor Test – flux ramp and flux regulators enabled Closed Loop Torque – iorque regulator is enabled Torque Ramp – start torque ramp Idle Run – inverter running normally Idle Stop – inverter is stopped Ramp Off Torque – ramps down the torque command Ramp Off Flux – ramps down the flux command All Ramps Off – shutoff inverter Default – Stop state 9.5 Motor Running State (VSM_State = 6): This is the normal motor running operation of the vehicle state machine. While running the drive can be switched from torque command to speed command mode, and may be exercised within the full operating envelope of the machine / drive combination. 9.6 Fault State (VSM_State = 7): If a fault occurs either during power-On self-test, or while the drive is running, the drive will go to the fault state. If the drive has a fault during the running state a fault code will be set and the fault indicator will begin blinking. At any given time, the fault indicator will blink only one fault. A particular fault code can be found by clicking on the “Check Faults” button on the “Memory View” page of RMS GUI. Parameters, “run_fault_hi and run_fault_lo have been removed from the parameter list and are not available anymore. 1/5/2016 RMS PM100 Software User Manual 33 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Byte 6 Byte 5 Byte 4 CAN Byte CAN Bit CAN Byte Value 1 RUN Fault Fault Word 32 Motor Over-speed Fault 33 Over-current Fault 2 00000002 34 Over-voltage Fault 4 00000004 35 Inverter Over-temperature Fault 8 00000008 36 Accelerator Input Shorted Fault 16 00000010 37 Accelerator Input Open Fault 32 00000020 38 Direction Command Fault 64 00000040 39 Inverter Response Time-out Fault 128 00000080 40 Hardware Gate/Desaturation Fault 1 00000100 41 Hardware Over-current Fault 2 00000200 42 Under-voltage Fault 4 00000400 43 CAN Command Message Lost Fault 8 00000800 44 Motor Over-temperature Fault 16 00001000 45 Reserved 32 00002000 46 Reserved 64 00004000 47 Reserved 128 00008000 48 Brake Input Shorted Fault 1 00010000 49 Brake Input Open Fault 2 00020000 50 Module A Over-temperature Fault1 4 00040000 51 Module B Over-temperature Fault7 8 00080000 Module C Over-temperature Fault7 16 00100000 32 00200000 52 Fault7 53 PCB Over-temperature 54 Gate Drive Board 1 Over-temperature Fault 00000001 64 00400000 Gate Drive Board 2 Over-temperature Fault7 128 00800000 56 Gate Drive Board 3 Over-temperature Fault7 1 01000000 57 Current Sensor Fault 2 02000000 58 Reserved 4 04000000 59 Reserved 8 08000000 60 Reserved 16 10000000 61 Reserved 32 20000000 62 Resolver Not Connected 64 40000000 63 Inverter Discharge Active (warning) 128 80000000 55 Byte 7 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Please refer to Appendix N for the table of run faults. 1 This is a new fault used only for Gen-3 board which is used in all PM150 units. 1/5/2016 RMS PM100 Software User Manual 34 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 9.6.1 Fault Priority: Fault indicator will blink faults in the following priority: POST Faults (Higher priority) RUN Faults (Lower priority) POST faults are followed by two quick blinks to distinguish from RUN faults. For each type of fault (POST or RUN), the highest priority of a fault is based on the number of blinks. The fault with 1 blink is the highest priority and the fault with the highest number of blinks is the lowest priority fault. The fault blinking will occur such that if the highest priority fault goes away, the lower priority fault will start blinking and this pattern will continue till all faults are removed. 9.6.2 Clear Faults Command: Once a fault is acknowledged, it can be cleared using the Clear Faults Command from the GUI. In order to clear a fault, set the Clear Faults Command to 0. This command clears all active faults including POST Faults. The only exception is the POST Fault, EEPROM Update Required (refer to section 10.1.4 above). This fault is set after programming a new firmware in the PM controller. The purpose of this fault is to have the user accept all previous EEPROM parameters and update the new ones. If there are no EEPROM parameters to update, user should still enter the Access Code and Program EEPROM Command to accept all EEPROM parameters. Please refer to “RMS GUI – EEPROM Parameters Guide” for more details on how to program EEPROM parameters. In CAN mode, before sending out the Clear Faults Command, make sure that the inverter is disabled. If inverter is enabled and the command is sent out, the motor may start running based on the mode and commanded Torque/Speed. 9.7 Shutdown in Process State (VSM_State = 14): This state indicates that the inverter “Shutdown in Process”. In key switch mode 1, user has turned key switch to off position by holding the ignition input low. 9.8 Recycle Power State (VSM_State = 15): This state indicates that the EEPROM Programming has been successfully completed. For new EEPROM values to take effect, the controller must be re-powered. 1/5/2016 RMS PM100 Software User Manual 35 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix A Motor Configuration Parameters RMS GUI Parameter Motor_Type_EEPROM Resolver_PWM_Delay_EEPROM_(Counts) Gamma_Adjust_EEPROM_(Deg)_x_10 Sin_Offset_EEPROM_(Voltsx100) Cos_Offset_EEPROM_(Voltsx100) GUI ADDRESS Value Range 0x0119 0 - 255 This parameter is used to select the motor that will be connected to the inverter. If you do not know the motor type number for your motor please contact RMS. 0 - 6250 This parameter adjusts a delay that is used to synchronize the resolver feedback to the PWM cycle. It is only used with motors that use resolvers. See RMS Resolver Calibration Process for more information on resolver calibration. 0 - ±3599 This is a calibration parameter used in the alignment of the magnetic field of the motor with the resolver. This parameter is only used with PM type motors. See RMS Resolver Calibration Process for more information on resolver calibration. 0x0118 0x011A Description Please refer to the manual, “RMS Encoder Calibration for SIN_COS Encoder”. Sin_Offset_EEPROM_(ADC_Counts) 0x0163 0 – 4096 Cos_Offset_EEPROM_(ADC_Counts) 0x0164 0 – 4096 1/5/2016 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This feature is dependent on the hardware version of the PM unit. In some cases, the resolver sine and cosine outputs may require adjustments for improved signals. These offsets are added as ADC counts to calibrate the sin and cosine signals directly. RMS PM100 Software User Manual 36 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix B Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com System Configuration Parameters RMS GUI Parameter Serial_Number_EEPROM Precharge_Bypassed_EEPROM Run_Mode_EEPROM GUI ADDRESS 0x0113 Value Range 0 to 65535 0x0115 0 or 1 0x0116 0 or 1 Description Used for storage of the unit serial number. Set to 1: Setting this to a 1 will bypass the pre-charge sequence. When the drive is powered it will go directly to state “Wait State”. Set to 0: Setting this to a 0 will enable the pre-charge sequence as described above. Default is 0. Set to 1: Setting this to a 1 will force the drive into speed control mode. This mode is only recommended for demonstration purposes when the motor is not connected to a high inertia load such as a vehicle. The Accelerator input will command a speed. Contact the factory for more information. For speed mode to operate correctly the Regen Torque Limit must be greater than 0. It should be set to at least 10% of the Motor Torque Limit. Set to 0: Setting this to a 0 will place the drive into torque mode. This is the normal operating mode for the drive. Default is 0. This parameter sets the operating mode of the inverter. Inv_Cmd_Mode_EEPROM(CAN = 0_VSM=1) 0x011B 0 or 1 Set to 0: Operate under control of the CAN bus. The CAN bus is responsible for enabling and disabling the motor. The brake, forward, and reverse switches are not used. Set to 1: Operate under control of accelerator input and switches (VSM Mode). 1/5/2016 RMS PM100 Software User Manual 37 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com This parameter provides alternate key switch modes. This allows different types of ignition for vehicles. Key_Switch_Mode_EEPROM Discharge_Enable_EEPROM Relay_Output_State_EEPROM 0x012B 0x016D 0x012C 0 or 1 0,1,2 0 - 255 0 = Allows a simple on/off switch for powering up the inverter. 1 = Provides the functionality of a more traditional ignition switch with momentary START signal that powers up the inverter and keeps it powered until the ignition switch is turned off. This configuration must use the IGNITION and START inputs. Key Switch Mode is only effective in VSM Mode. CAN mode remains unaffected. However, the parameter can be updated through both GUI and CAN. Controls the Active Discharge process. Can be used to discharge the internal high voltage capacitors quicker than the passive discharge. See the RMS Inverter Discharge Process Manual for more information. 0 = discharge disabled 1 = discharge is enabled without any faults 2 = discharge is enabled with faults This parameter controls all relays. To keep the compatibility with previous versions (prior to firmware version 1909), this parameter should be set to 0x000C which will maintain the functionality of OK and fault outputs. Bit 0: Relay 1 - (Precharge output) Bit 1: Relay 2 - (Main Output) Bit 2: Relay 3 - (OK Output) Bit 3: Relay 4 - (Fault Output) Bit 4: Relay 5 Bit 5: Relay 6 Bit 6: Relay 7 Bit 7: Relay 8 Please see the table below for detailed behavior of each relay. 1/5/2016 RMS PM100 Software User Manual 38 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 1/5/2016 RMS PM100 Software User Manual Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 39 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Precharge Output Options Command Precharge Output Relay CAN Output Precharge Mode Bypass Config Command State Final Relay # States 0: CAN 0: No 0: CAN Control 0: Turn off 0: Off Active? 1: VSM 1: Yes 1: Normal Mode 1: Turn on 1: ON Precharge 1/5/2016 1 Function 0 0 0 0 Y 0 CAN Control 0 0 0 1 Y 1 CAN Control 0 0 1 0 Y 1 Normal Function 0 0 1 1 Y 1 Normal Function 0 0 0 0 1 1 1 1 0 0 1 1 0 1 0 1 N N N N 0 1 1 1 CAN Control CAN Control Normal Function Normal Function 1 0 0 x Y 0 Normal Function 1 0 0 x Y 0 Normal Function 1 0 1 x Y 0 Normal Function 1 0 1 x Y 0 Normal Function 1 1 1 1 1 1 1 1 0 0 1 1 x x x x N N N N 0 0 1 1 Normal Function Normal Function Normal Function Normal Function RMS PM100 Software User Manual Description Output will toggle during prechrage. Afterwards, goes to CAN control Output will toggle during prechrage. Afterwards, goes to CAN control Output will toggle during prechrage. Afterwards, goes to output configuration Output will toggle during prechrage. Afterwards, goes to output configuration Output directly goes to CAN control Output directly goes to CAN control Output directly goes to output configuration Output directly goes to output configuration Output will toggle during prechrage. Afterwards, goes to output configuration Output will toggle during prechrage. Afterwards, goes to output configuration Output will toggle during prechrage. Afterwards, goes to output configuration Output will toggle during prechrage. Afterwards, goes to output configuration Output directly goes to output configuration Output directly goes to output configuration Output directly goes to output configuration Output directly goes to output configuration 40 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Main Output Options Command Precharge Output Relay CAN Output Precharge Mode Bypass Config Command State Final Relay # States 0: CAN 0: No 0: CAN Control 0: Turn off 0: Off Active? 1: VSM 1: Yes 1: Normal Mode 1: Turn on 1: ON Main 1/5/2016 2 Function 0 0 0 0 Y 1 Normal Function 0 0 0 1 Y 1 Normal Function 0 0 1 0 Y 1 Normal Function 0 0 1 1 Y 1 Normal Function 0 0 0 0 1 1 1 1 0 0 1 1 0 1 x x N N N N 0 1 0 1 CAN Control CAN Control Normal Function Normal Function 1 0 0 x Y 1 Normal Function 1 0 0 x Y 1 Normal Function 1 0 1 x Y 1 Normal Function 1 0 1 x Y 1 Normal Function 1 1 1 1 1 1 1 1 0 0 1 1 x x x x N N N N 0 0 1 1 Normal Function Normal Function Normal Function Normal Function RMS PM100 Software User Manual Description Ouptut under precharge control. ON at the end of pecharge. Ouptut under precharge control. ON at the end of pecharge. Ouptut under precharge control. ON at the end of pecharge. Ouptut under precharge control. ON at the end of pecharge. Output directly goes to CAN control. Output directly goes to CAN control. Output is ON. No precharge function. Output is ON. No precharge function. Ouptut under precharge control. ON at the end of pecharge. Ouptut under precharge control. ON at the end of pecharge. Ouptut under precharge control. ON at the end of pecharge. Ouptut under precharge control. ON at the end of pecharge. Output directly goes to output configuration Output directly goes to output configuration Output directly goes to output configuration Output directly goes to output configuration 41 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Other outputs Command Precharge Output Relay CAN Output Precharge Mode Bypass Config Command State Final Relay # States 0: CAN 0: No 0: CAN Control 0: Turn off 0: Off Active? 1: VSM 1: Yes 1: Normal Mode 1: Turn on 1: ON Fault OK Unused Unused Unused Unused 1/5/2016 Function 0 x 0 0/ 1 x 0/ 1 CAN Control 1 x 1 x x 1 Normal Function 0 x 0 0/ 1 x 0/ 1 CAN Control 1 x 1 x x 1 Normal Function 0 x 0 0/ 1 x 0/ 1 CAN Control 1 x 1 x x 1 Normal Function 0 x 0 0/ 1 x 0/ 1 CAN Control 1 x 1 x x 1 Normal Function 0 x 0 0/ 1 x 0/ 1 CAN Control 1 x 1 x x 1 Normal Function 0 x 0 0/ 1 x 0/ 1 CAN Control 1 x 1 x x 1 Normal Function 3 4 5 6 7 8 RMS PM100 Software User Manual Description This output can be toggled by CAN Parameter command This output will toggle a fault code of a fault exists This output can be controlled by CAN Parameter command This output will be ON to indiciate 12-V on the inverter This output can be controlled by CAN Parameter command This output will be ON to indiciate 12-V on the inverter This output can be controlled by CAN Parameter command This output will be ON to indiciate 12-V on the inverter This output can be controlled by CAN Parameter command This output will be ON to indiciate 12-V on the inverter This output can be controlled by CAN Parameter command This output will be ON to indiciate 12-V on the inverter 42 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix C Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com CAN Configuration Parameters RMS GUI Parameter GUI ADDRESS Value Range Description CAN_ID_Offset_EEPROM CAN_Extended_Msg_ID_EEPROM(0=N_1=Y) CAN_J1939_Option_Active_EEPROM CAN_Term_Res_Present_EEPROM CAN_Command_Message_Active_EEPROM CAN_Bit_Rate_EEPROM_(kbps) Please refer to the document, RMS CAN Protocol for a detailed description of all CAN parameters. CAN_ACTIVE_MSGS_EEPROM_(Lo_Word) CAN_ACTIVE_MSGS_EEPROM_(Hi_Word) CAN_Diag_Data_Tx_Active_EEPROM 1/5/2016 RMS PM100 Software User Manual 43 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix D Current Parameters RMS GUI Parameter IQ_Limit_EEPROM_(Amps)_x_10 ID_Limit_EEPROM_(Amps)_x_10 Ia_Offset_EEPROM Ib_Offset_EEPROM Ic_Offset_EEPROM Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com GUI Value ADDRESS Range 0x0101 See motor setup manual This parameter sets the Q-axis current limit. The Q-axis current is an industry term for the torque producing portion of the motor current. The current level is set in terms of peak amps. For example, to set a level of 400 amps peak use a parameter setting of 4000. See motor setup manual This parameter sets the D-axis current limit. The D-axis current is an industry term for the flux producing portion of the motor current. For induction motors it is necessary to provide flux current to the motor. For PM motors the flux is provided by the magnets. However, at high speeds it is necessary to weaken the flux. D-axis current will be used with PM motors to reduce the magnet flux. The current level is set in terms of peak amps. For example, to set a level of 400 amps peak use a parameter setting of 4000. 0x0102 Description Please refer to the document, Current Offset Calibration for a detailed description on these parameters. It is not normally necessary to make any change to these parameters. The total motor current is the vector determined by the Q-axis current and the D-axis current. So the total current is the square root of IQ^2 + ID^2. 1/5/2016 RMS PM100 Software User Manual 44 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix E Voltage & Flux Parameters RMS GUI GUI Value Parameter ADDRESS Range DC_Volt_Limit_EEPROM_(V)_x_10 0x0104 0 - 10000 DC_Volt_Hyst_EEPROM_(V)_x_10 0x0105 300 DC_UnderVolt_Thresh_EEPROM_(V)_x_10 Veh_Flux_EEPROM_(Wb)_x_1000 1/5/2016 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 0x0117 0x0100 Description This parameter is used to implement a DC Bus voltage limiting feature. The parameter should be set higher than the maximum battery voltage. Used with the above parameter. 0 - 10000 This is the under-voltage fault threshold voltage. If it is desired that the drive does not detect under-voltage faults the value can be set to 0. 0 - 30000 This parameter sets the back EMF (flux) constant for the motor. It will automatically default to the correct value when the motor type is changed. Most of the time, the default value is sufficient and this value seldom needs to be changed. The flux value is set in units of Webers. For example to set a value of 0.1 Webers set the parameter to 100. RMS PM100 Software User Manual 45 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix F Temperature Parameters RMS GUI GUI Value Parameter ADDRESS Range Inv_OverTemp_Limit_EEPROM_(C)_x_10 Mtr_OverTemp_Limit_EEPROM_(C)_x_10 Full_Torque_Temp_EEPROM_(C)_x_10 Zero_Torque_Temp_EEPROM_(C)_x_10 RTD_Selection_EEPROM_(BITS_1_0)2 2 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Description -40 – 125 C This parameter sets the Inverter temperature limit. The temperature is measured from three sensors that are mounted inside the power module. Generally the module temperature will be about 0 – 20°C higher than the water temperature. The temperature is set is degrees Celsius times 10 (85°C is set as 850). If the temperature exceeds this value then the inverter will turn off and declare a fault. 0x0121 -40 – 250 C This parameter sets the Motor temperature limit (if the motor has a temperature sensor). The temperature is set is degrees Celsius times 10 (150°C is set as 1500). If the temperature exceeds this value then the inverter will turn off and declare a fault. - - Please refer to the table in Appendix G. - - Please refer to the manual, “RMS PM User Manual - Gen3 Features”. 0x0106 This is a new feature used only for Gen-3 board which is used in all PM150 units. Please refer to the manual, “RMS PM User Manual - Gen3 Features”. 1/5/2016 RMS PM100 Software User Manual 46 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com G3_RTD1_100_Ohm_Gain_EEPROM_x_10000 G3_RTD1_100_Ohm_Offset_EEPROM_x_100 G3_RTD2_100_Ohm_Gain_EEPROM_x_10000 Please refer to the manual, “RMS RTD Calibration Process”. G3_RTD2_100_Ohm_Offset_EEPROM_x_100 G3_RTD1_1K_Ohm_Gain_EEPROM_x_10000 - - It is not normally necessary to make any changes to these parameters. G3_RTD1_1K_Ohm_Offset_EEPROM_x_100 G3_RTD2_1K_Ohm_Gain_EEPROM_x_10000 G3_RTD2_1K_Ohm_Offset_EEPROM_x_100 1/5/2016 RMS PM100 Software User Manual 47 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix G Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Accelerator & Torque Parameters X COAST_LO MOTOR TORQUE LIMIT ACCEL_MIN TORQUE_CMD PEDAL_LO The accelerator pedal input provides a torque command to the motor. The graph below details the relationship between the accelerator input voltage and the torque command: 0 PEDAL_HI X ACCEL_MAX REGEN TORQUE LIMIT COAST_HI ACCEL Input Below is a list of the parameters that effect how the accelerator input works. The accelerator input has a range of 0 to 500. This corresponds to a physical range of 0 to 5.00 volts on the input. The parameters are designed for a pedal that provides a low input voltage when the pedal is released and a higher voltage as the pedal is pressed. If the vehicle has a pedal that operates in the opposite direction use the ACCEL PEDAL FLIPPED parameter as described below. 1/5/2016 RMS PM100 Software User Manual 48 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com For initial setup and calibration, the accel pedal voltage can either be monitored by a volt meter, or it can be monitored by the GUI software over the serial port. RMS GUI GUI Value Parameter ADDRESS Range Accel_Pedal_Flipped_EEPROM_(0=N_1=Y) Pedal_Lo_EEPROM_(V)_x_100 Accel_Min_EEPROM_(V)_x_100 0x0114 0x0107 0x0108 0 or 1 Description If the pedal increases in voltage as it is pressed use a value of 0 (not flipped). If the pedal decreases in voltage as it is pressed use a value of 1 (flipped). When this parameter is 1, the pedal voltage will first be processed by the equation new_pedal_voltage = 5.00 – old_pedal_voltage. Thus will make the pedal act the same as a pedal that normally increases in voltage. 1 – 500 For accelerator inputs less than this value the torque command is zero. This value should be set to a value that is lower than the lowest possible accelerator position, but higher than zero. If the accelerator input were to be shorted to ground the desired torque command is zero. 1 – 500 For accelerator inputs between PEDAL_LO and ACCEL_MIN the torque command is set to a constant value of REGEN TORQUE LIMIT. Depending on the desired characteristics of the vehicle this range could be very small. Coast_Lo_EEPROM_(V)_x_100 0x0109 1 – 500 For accelerator inputs between ACCEL_MIN and COAST_LO the torque command is linearly from REGEN TORQUE LIMIT to zero. If desired this range allows the operator to control the amount of regen torque. Coast_Hi_EEPROM_(V)_x_100 0x010A 1 – 500 For the range between COAST_LO and COAST_HI the torque command is zero. Normally this range would be fairly small. 1 – 500 For the range between COAST_HI and ACCEL_MAX the torque is linearly increased from zero to the MOTOR TORQUE LIMIT. This would be the normal driving range. Accel_Max_EEPROM_(V)_x_100 1/5/2016 0x010B RMS PM100 Software User Manual 49 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Pedal_Hi_EEPROM_(V)_x_100 Motor_Torque_Limit_EEPROM_(Nm)_x_10 0x010C 0x0110 Regen_Torque_Limit_EEPROM_(Nm)_x_10 0x0111 Braking_Torque_Limit_EEPROM_(Nm)_x_10 0x0112 Torque_Rate_Limit_EEPROM_(Nm)_x_10 0x014B 1/5/2016 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 1 – 500 For the range between ACCEL_MAX and PEDAL_HI the torque command is held constant at MOTOR TORQUE LIMIT. PEDAL_HI should be set above the normal range of pedal motion, but below 500. See Motor Manual This parameter sets the maximum torque that can be commanded by the controller in motoring mode. It is active in both VSM mode and CAN mode. However, if the current limit of the drive is reached before the torque command has been achieved the controller will limit on the current first. If this happens the operator will feel an additional amount of unused pedal range at the top end. The motor torque limit should always be set at a torque that would be lower than or equal to the current limit. Torque value is set in Nm times 10. For example to set 300 Nm use a value of 3000. See Motor Manual This parameter sets the maximum regen torque that can be commanded by the controller. It is active in both VSM mode and CAN mode. In VSM mode this parameter is the maximum regen torque that is commanded when the pedal is fully released. Torque value is set in Nm times 10. For example to set 300 Nm use a value of 3000. This parameter sets the amount of the torque applied when the brake is active. Torque value is set in Nm times 10. For example to set 300 Nm use a value of 3000. 0.1 – 25.0 Nm This parameter adjusts how quickly the torque command is allowed to change. The parameter is set in terms of torque increment every 3 milliseconds. Torque value is set in Nm times 10. RMS PM100 Software User Manual 50 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Full_Torque_Temp_EEPROM_(C)_x_10 0x015D -40 – 250 ⁰C Below this temperature threshold where the full torque is available. As the motor temperature is increased from Full_Torque_Temp_EEPROM_(C)_x_10 to Zero_Torque_Temp_EEPROM_(C)_x_10, the allowed torque capability is linearly decreased. This parameters should be less than Zero_Torque_Temp_EEPROM_(C)_x_10 which should be less than Mtr_OverTemp_Limit_EEPROM_(C)_x_10. Zero_Torque_Temp_EEPROM_(C)_x_10 0x015E -40 – 250 ⁰C Temperature threshold where the torque is zeo. This value should be less than Mtr_OverTemp_Limit_EEPROM_(C)_x_10. The Motor_Torque_Limit_EEPROM_(Nm)_x_10 and Regen_Torque_Limit_EEPROM_(Nm)_x_10 parameters set the maximum value of commanded torque. They will be modified internally based on motor speed as the motor cannot put out full torque over the entire speed range. The accelerator should be designed so that in its normal range of operation it is greater than 0 volts and less than 5 volts. The parameters Pedal_Lo_EEPROM and Pedal_Hi_EEPROM should be set so that if the input goes to 0 or 5 the torque command goes to zero. These parameters allow the controller to be setup to command a pedal off amount of regen torque. This regen torque would mimic the engine compression feel that vehicles often have. Example Setup: As an example let’s assume that assume that the accelerator input comes from a potentiometer. That is, the one end of the pot is connected to AGND. The other end is connected to XDCR_PWR (+5V), and the wiper is connected to AIN1. This setup is shown in the example application schematic. First we need to determine the range of travel of this potentiometer. With the controller 12V turned on measure the voltage on the wiper of the pot (AIN1). Note how the voltage changes as the pedal is pushed and released. If the voltage increases as the pedal is pressed then the ACCEL_PEDAL_FLIPPED_EEPROM parameter needs to be set to 0. If the voltage decreases then the ACCEL_PEDAL_FLIPPED_EEPROM parameter needs to be set to 1. Whenever the parameter is set to 1 all of the other parameter 1/5/2016 RMS PM100 Software User Manual 51 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com settings must be calculated as follows (parameter = 500 – actual voltage*100). For example if you desire a parameter to be set to 1.20 volts then the actual parameter setting will be 500 – 1.20*100 = 380. For this example we will assume that the voltage increases as the pedal is pressed. So Accel_Pedal_Flipped_EEPROM will be set to 0. First measure the wiper voltage (AIN1) when the pedal is in the fully off position. For this example let’s assume the measured value is 0.83 volts. The Pedal_Lo_EEPROM parameter should be set to a value that is lower than this measured value. In this example let’s set it to 0.40 volts (this corresponds to Pedal_Lo_EEPROM = 40). We want to set the parameter Accel_Min_EEPROM to be equal to this measured value (Accel_Min_EEPROM = 83). This will cause the torque to start increasing as soon as the pedal begins to be pressed. Now measure the value of the wiper voltage (AIN1) when the pedal is fully pressed. For this example let’s assume that measured value is 4.75 volts. When the pedal is fully pressed we want to be commanding full torque so set the Accel_Max_EEPROM parameter to this measured value (Accel_Max_EEPROM = 475). The Pedal_Hi_EEPROM parameter should be set to a value that is above this measured value but less than 5.00 volts. In this example let’s set the value to 4.90 volts (Pedal_Hi_EEPROM = 490). The Coast_Lo_EEPROM and Coast_Hi_EEPROM parameters define a range of pedal position where the torque command will be zero. For this example we’ll define this range to be fairly narrow and with the pedal only slightly depressed. So we will set Coast_Lo_EEPROM to 1.10 volts (110) and Coast_Hi_EEPROM to 1.20 volts (120). 1/5/2016 RMS PM100 Software User Manual 52 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Motor Over-temperature Torque Reduction This feature allows the Torque Capability to take motor temperature into consideration. Figure G-2 shows the relationship between Torque Capability and Motor Speed. Based on the calculation of the slope and offset of the line from Full_Torque_Temp_EEPROM_(C)_x_10 to Zero_Torque_Temp_EEPROM_(C)_x_10, the new torque capability is reduced by a factor of (slope * Motor Temperature + offset). Zero_Torque_Temp_EEPROM_(C)_x_10 should be less than Zero_Torque_Temp_EEPROM_(C)_x_10, which should be less than Mtr_OverTemp_Limit_EEPROM_(C)_x_10. Figure G-2 1/5/2016 RMS PM100 Software User Manual 53 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix H Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Speed Parameters Torque Capability Curve is a function of Motor Speed, a feedback parameter from the Motor Control. Figure H-1 shows the relationship between Torque Capability and Motor Speed: REGEN Torque Motor Torque REGEN_TRQ_LM T MOTOR_TRQ_LM T Motor Speed BREAK_SPEED MAX_SPEED FADE_SPEED BREAK_SPEED MAX_SPEED Figure H-1 – Torque Capability vs. Motor Speed There are two types of Torque Capability curves, Motor Torque Capability and REGEN Torque Capability. The two quantities MOTOR_TRQ_LMT and REGEN_TRQ_LMT (see previous section) define the maximum values for these curves. When motors exceed a certain speed the amount of torque that they can produce will drop. The BREAK_SPEED parameter defines a curve that represents this drop in torque. The curve is defined BREAK_SPEED divided by actual speed time the torque limit. The purpose of this curve is to reduce the torque limit so that the accel input does not try and command torque that the motor cannot deliver. If CAN mode is used or other torque limit means the BREAK_SPEED parameter can be set equal to MAX_SPEED to eliminate this effect. 1/5/2016 RMS PM100 Software User Manual 54 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com The following table lists the calibration parameters that pertain to the above graphs. The values of these parameters come from the EEPROM and are set via the DSPGui software. RMS GUI GUI Value Parameter ADDRESS Range Max_Speed_EEPROM 0x010F Regen_Fade_Speed_EEPROM 0x010D Break_Speed_EEPROM 0x010E Speed_Rate_Limit_EEPROM_(RPM/sec) 1/5/2016 0x014E 1 - 30000 RPM 1 - 30000 RPM 1 - 30000 RPM 100 – 5100 RPM/sec Description This parameter sets the maximum allowable speed. If the speed is above this value the torque command will be reduced to zero. (Default value: 10,000 RPM) This parameter sets at which the amount of regen torque available is reduced. (Default value: 200 RPM) This parameter sets the speed at which the maximum torque command is reduced to compensate for a reduction of available torque due to field weakening. (Default value: 3000 RPM) This parameter adjusts how quickly the speed command is allowed to change. The parameter is set in terms of speed increment every second. Default value is set to 100 RPM/sec. This parameter has no effect on torque mode operation. RMS PM100 Software User Manual 55 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Max Speed Torque Reduction This feature allows the Torque Capability to take maximum speed into consideration. Figure H-2 shows the relationship between Torque Capability and Motor Speed. When the speed goes above the Max Speed, it begins a linear reduction in the torque towards zero. The slope of the reduction is such that at (Max Speed * 1.02) the torque is zero. The torque slope would be calculated based on the available torque at max speed. This reduction of torque is applied to motoring as well as regen. Motor Torque Capability MOTOR_TRQ_LMT 1.02 x MAX_SPEED BREAK_SPEED MAX_SPEED Figure H-2 1/5/2016 RMS PM100 Software User Manual 56 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix I Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com PID Regulator Parameters The motor controller is some instances use a torque regulator and a speed regulator. For non IPM type motors the torque regulator is used all of the time. The speed regulator is only used if the controller is in Speed Mode (see Run Mode parameter). The regulators are both based on the classic PID architecture. Each of these regulators has 4 gain values associated with them. They are: Kp – Proportional Gain Ki – Integral Gain Kd – Derivative Gain Klp – Low Pas filter gain Generally it is not necessary to adjust these gains. In some instances if the torque regulator seems unstable it may be necessary to adjust the value. Please contact RMS if this situation arises. RMS GUI Parameter GUI ADDRESS Value Range Kp_Torque_EEPROM_x_10000 0x12D 0 – 6.5535 Ki_Torque_EEPROM_x_10000 0x012E 0 – 6.5535 Kd_Torque_EEPROM_x_100 0x012F 0 – 655.35 Klp_Torque_EEPROM_x_10000 0x0130 0 – 6.5535 1/5/2016 Description Torque Regulator proportional gain. This is a times 10000 value. Multiply the value within the valid range by 10000 before programming it using RMS GUI application. Torque Regulator integral gain. This is a times 10000 value. Multiply the value within the valid range by 10000 before programming it using RMS GUI application. Torque regulator derivative gain. This is a times 100 value. Multiply the value within the valid range by 100 before programming it using RMS GUI application. Torque regulator low pass filter gain. This is a times 10000 value. Multiply the value within the valid range by 10000 before programming it using RMS GUI application. RMS PM100 Software User Manual 57 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Kp_Speed_EEPROM_x_100 0x122 0 – 655.35 Ki_Speed_EEPROM_x_10000 0x0123 0 – 6.5535 Kd_Speed_EEPROM_x_100 0x0124 0 – 655.35 Klp_Speed_EEPROM_x_10000 0x0125 0 – 6.5535 1/5/2016 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Speed regulator proportional gain. This is a times 100 value. Multiply the value within the valid range by 100 before programming it using RMS GUI application. Speed regulator integral gain. This is a times 10000 value. Multiply the value within the valid range by 10000 before programming it using RMS GUI application. Speed regulator derivative gain. This is a times 100 value. Multiply the value within the valid range by 100 before programming it using RMS GUI application. Speed regulator low pass gain. This is a times 10000 value. Multiply the value within the valid range by 10000 before programming it using RMS GUI application. RMS PM100 Software User Manual 58 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix J Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Shudder Compensation Parameters Using an electric motor in a vehicle can expose driveline resonances (shudder) that might not normally be noticed in an ICE vehicle. Typically these resonances occur at very low speeds and moderate torque levels. The shudder compensation system implemented on the PMxxx family converters provides a mechanism for the user to try and counteract the resonance. The basic idea is to provide a compensating torque that tries to drive any AC components of the speed to zero. That is if the speed is found to be varying (oscillating) and additional torque is added to the command that attempts to remove the oscillation. Torque Command From VSM or CAN Shudder Torque in per unit + + Torque Command to Main Control Loop Figure 1: Shudder Torque Implementation Figure 1 shows the mechanism for including the shudder compensation torque into the torque command. If shudder compensation is enabled the shudder torque value will be added to the normal torque command that comes from the VSM (vehicle state machine) or from a CAN command. The mechanism for calculating the correct value of shudder torque compensation is shown in Figure 2. The compensation algorithm compares the electrical speed of the motor to a filtered version of the speed. The output of the comparison is then clamped to a value between +TCLAMP and –TCLAMP. This value is then phased out based on two speed parameters, Shudder Speed Lo and Shudder Speed Hi. 1/5/2016 RMS PM100 Software User Manual 59 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 - Electrical speed in per unit Kp_ shudder Low-Pass Filter Shudder Filter Frequency - Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Shudder Torque in per unit + TCLAMP Shudder Speed Lo & Shudder Speed Hi Figure 2: Shudder Compensation Algorithm 1/5/2016 RMS PM100 Software User Manual 60 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 RMS GUI GUI Value Parameter ADDRESS Range Shudder_Compensation_Enable_EEPROM 0x0134 0, 1 Kp_Shudder_EEPROM_x_100 0x0135 0.1 – 50 TCLAMP_Shudder_EEPROM_(Nm)_x_10 0x0136 0 – 100 Nm Shudder_Filter_Freq_EEPROM_(Hz)_x_10 0x0137 Shudder_Speed_Fade_EEPROM_(RPM) 0x0140 Shudder_Speed_Lo_EEPROM_(RPM) 0x0138 Shudder_Speed_Hi_EEPROM_(RPM) 0x0139 1/5/2016 0.1 – 20 Hz 0 – 32000 RPM Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Description This parameter is used to enable or disable the shudder compensation system. The default value is 0 for disabled. To enable the system change the value to a 1. This parameter defines the gain of the shudder compensation controller. This parameter has a scaling factor of 100. Thus a setting of 100 gives a gain of 1.00. The default value of the gain is 20 (or a parameter setting of 2000). Testing of the vehicle system will be necessary to determine the best gain setting. This parameter defines the maximum amount of compensation torque that will be added to the commanded torque. The parameter has a scaling factor of 10. Thus a setting of 10 gives a torque of 1.0 Nm. The default value is 19.9 Nm. This parameter determines the frequency of the low-pass filter used in the shudder compensation algorithm (See Figure 2). The parameter has a scaling factor of 10. Thus a setting of 10 gives a frequency of 1.0 Hz. The default value of the parameter is 3.0 Hz (setting of 30). The filter frequency should be lower than the frequency of resonance of the drive-line. Again it may be necessary to perform testing on the vehicle to determine the correct value. This parameters is used to define the linear phase in of the shudder torque compensation at lower speeds starting from 0 RPM. Between this value and Shudder_Speed_Lo, full value of shudder torque is used. This value must be lower than Shudder_Speed_Lo value. These two parameters are used to define the phase out of the shudder torque compensation at higher speeds. Both parameters are in RPM. Below Shudder_Speed_Lo the full value of the shudder torque is used. Between Shudder_Speed_Lo and Shudder_Speed_Hi the shudder torque is linearly decreased. Above Shudder_Speed_Hi the shudder torque value is 0. At higher speeds drive-line compensation may not be necessary. These two parameters allow the system to be phased out at higher speeds. The default values are 300 rpm for Shudder_Speed_Lo and 400 rpm for Shudder_Speed_Hi. Shudder_Speed_Lo must be less than Shudder_Speed_Hi. RMS PM100 Software User Manual 61 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix K Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Brake Parameters The Brake input works in two modes. These modes include Switch mode and Brake Pot mode. The switch mode allows for only a single value of braking torque (regen). The Brake Pot mode allows for a variable amount of braking torque. Normally, the Brake Pot would be connected to the brake pedal of a vehicle and would change in voltage relative to the amount of brake pedal applied. Brake Switch Mode: In this mode, the digital input DIN3 is used. When entering braking mode, the controller ramps the torque according to the regen_ramp_rate parameter. The graph below explains the relationship between time and REGEN torque when the brake input is pressed: Torque1 Torque0 T0 = 0 T1 Where T0 is the start time (in seconds) which is always 0 in this case, T1 is the ramp period indicated by the equivalent EEPROM parameter in seconds, Torque0 is value of torque that is currently produced, and Torque1 is the VSM Braking Torque Limit In order to use the brake in switch mode, following parameters need to be set as follows: 1/5/2016 RMS PM100 Software User Manual 62 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 RMS GUI Parameter GUI ADDRESS Value Range Brake_Mode_EEPROM_(0=SWITCH_1=POT) 0x013A 0 or 1 Regen_Ramp_Rate_EEPROM_(Sec)_x_1000 0x0133 3 - 20000 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Description This parameter selects the mode for the brake input. 0: Brake Switch Mode 1: Brake Pot Mode This value of time is entered in milliseconds. This is the time in which REGEN torque value ramps down to the braking torque limit. This time can also be represented as |T1 – T0|. Brake Pot Mode: The graph below details the relationship between the brake input voltage and the REGEN torque command: BRAKE_LO BRAKE_MIN TORQUE_CMD BRAKE_MAX BRAKE_HI 0 BRAKE Input Regen Torque Limit BRAKE_THRESH_HI Braking Torque Limit 1/5/2016 BRAKE_THRESH_LO RMS PM100 Software User Manual 63 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com The brake input has a range of 0 to 500. This corresponds to a physical range of 0 to 5.00 volts on the input. The parameters are designed for a pedal that provides a low input voltage when the pedal is released and a higher voltage as the pedal is pressed. If the vehicle has a pedal that operates in the opposite direction use the BRAKE PEDAL FLIPPED parameter as described below. For initial setup and calibration, the brake pedal voltage can either be monitored by a volt meter, or it can be monitored by the GUI software over the serial port. Below is a list of the parameters that effect how the brake input works. RMS GUI GUI Value Parameter ADDRESS Range Description This parameter selects the mode for the brake input. Brake_Mode_EEPROM_(0=SWITCH_1=POT) 0x013A 0 or 1 0: Brake Switch Mode 1: Brake Pot Mode This parameter decides if the brake input should be ignored or not in VSM mode: Brake_Switch_Bypassed_EEPROM 0x15F 0–2 0: Do not ignore brake input (process as usual) 1: Ignore brake input for starting the vehicle and for regen 2: Ignore brake input only for starting the vehicle Brake_Pedal_Flipped_EEPROM Brake_Lo_EEPROM_(V)_x_100 1/5/2016 0x013F 0x013B 0 or 1 If the pedal increases in voltage as it is pressed use a value of 0 (not flipped). If the pedal decreases in voltage as it is pressed use a value of 1 (flipped). When this parameter is 1, the pedal voltage will first be processed by the equation new_pedal_voltage = 5.00 – old_pedal_voltage. Thus will make the pedal act the same as a pedal that normally increases in voltage. 1 – 500 For brake inputs less than this value the torque command is zero. This value should be set to a value that is lower than the lowest possible brake position, but higher than zero. If the brake input were to be shorted to ground the desired torque command is zero. Below this value, Brake Input Short Fault is set. RMS PM100 Software User Manual 64 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Brake_Min_EEPROM_(V)_x_100 0x013C 1 – 500 For brake inputs less than this value, the torque command is held at 0. Brake_Max_EEPROM_(V)_x_100 0x013D 1 – 500 For brake inputs between BRAKE_MIN and BRAKE_MAX, the torque command is linearly decreased from 0 to Braking Torque Limit. 1 – 500 For the range between BRAKE_MAX and BRAKE_HI the torque command is held constant at Braking Torque Limit. BRAKE_HI should be set above the normal range of pedal motion, but below 500. Above this value, Brake Input Open Fault is set. 1 – 500 This value is supposed to be between Brake_Lo_EEPROM_(V)_x_100 and Brake_Min_EEPROM_(V)_x_100. Below this threshold, brake is considered inactive (OFF). 1 – 500 This value is supposed to be between Brake_Lo_EEPROM_(V)_x_100 and Brake_Min_EEPROM_(V)_x_100. This value should be greater than Brake_Thresh_Lo_EEPROM_(V)_x_100 to provide some hysteresis for turning the brake switch on and off. Above this threshold, brake is considered active (ON). Brake_Hi_EEPROM_(V)_x_100 Brake_Thresh_Lo_EEPROM_(V)_x_100 Brake_Thresh_Hi_EEPROM_(V)_x_100 1/5/2016 0x013E 0x0161 0x0162 RMS PM100 Software User Manual 65 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix L Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com GUI Display Parameters The GUI provides the ability to monitor several operation parameters of the controller. It is also helpful for checking connections to the controller. Items can be added from the Item list to the Watch window to view the parameter. RMS GUI Parameter Description Run_Command(Trq=0_Spd=1) Displays the current command mode (Torque control or Speed control). Commanded_Speed_(RPM) Shows the Commanded speed if the controller is in Speed mode. Feedback_Speed_(RPM) Shows the motor speed as calculated from particular motor position feedback sensor used for the motor type (e.g. encoder/resolver). Commanded_Torque_(Nm)_x_10 The commanded torque is displayed if the controller is in torque control mode Feedback_Torque_(Nm)_x_10 This is the motor torque as calculated by the controller. The torque is calculated based on motor currents and the parameters of the motor. If the motor is running in reverse the Feedback Torque will have the opposite sign to the Commanded Torque. Voltage_Feedback_Speed_(RPM) This parameter shows the motor speed as calculated from measuring the back EMF of a PM motor. This parameter will only be valid if there is sufficient back EMF to generate a measurable voltage and the motor is not enabled. It is useful to ensure that motor phasing matches the resolver feedback (same direction/speed). Torque_Shudder_(Nm)_x_10 Amount of torque compensation that is being applied when using the Shudder compensation feature. V_DC_Filtered_(Volts)_x_10 DC Bus Voltage measurement. V_MAG_Filtered_(Volts)_x_10 The magnitude of the output voltage being applied to the motor. This is represented in line to neutral peak volts. SW_Over_Voltage_(Volts)_x_10 A hard-coded value for over-voltage threshold this is used during pre-charge process and during normal operation for over-voltage detection. I_DC_Filtered_(Amps)_x_10 The DC Bus current. The controller can only calculate this value as it does not actually measure the DC bus current. The calculation is based on an estimate of the motor power and the DC Bus voltage. I_MAG_Filtered_(Amps)_x_10 The motor phase current magnitude. This is the peak value of the current (not RMS). SW_Over_Current_(Amps)_x_10 A hard-coded value for over-current threshold this is used during normal operation for over-current detection. 1/5/2016 RMS PM100 Software User Manual 66 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Motor_Temp_(C)_x_10 Shows the motor temperature if available. The sensor used is selected automatically via the motor type. Some motors do not have a sensor selected and this will display 0 then. Mod_A_Temp_(C)_x_10 The temperature of the sensor embedded in Phase A of the power module. Mod_B_Temp_(C)_x_10 Phase B Mod_C_Temp_(C)_x_10 Phase C PCB_Temp_(C)_x_10 Temperature of the control board PCB. GDB_Temp_(C)_x_10 Temperature of the gate driver board PCB (Gen-2 boards only). GDB_1_Temp_(C)_x_10 Temperature of the gate driver board PCB 1 (Gen-3 boards only). GDB_2_Temp_(C)_x_10 Temperature of the gate driver board PCB 2 (Gen-3 boards only). GDB_3_Temp_(C)_x_10 Temperature of the gate driver board PCB 3 (Gen-3 boards only). RTD1_Temp_(C)_x_10 Temperature of the sensor hooked to the RTD1 input. RTD2_Temp_(C)_x_10 Temperature of the sensor hooked to the RTD2 input. RTD3_Temp_(C)_x_10 Temperature of the sensor hooked to the RTD3 input (Gen-2 board only). RTD4_Temp_(C)_x_10 Temperature of the sensor hooked to the RTD4 input (Gen-2 board only). RTD5_Temp_(C)_x_10 Temperature of the sensor hooked to the RTD5 input (Gen-2 board only). ID_Bits 3 =Gen-2 board 2 =Gen-3 board Inverter_Mode The Inverter State, see description in section 11.4 VSM_State The VSM State, see description in section 11 Inverter_Enable Displays a 1 when the inverter is enable, 0 if disabled. Vehicle_Direction Shows the commanded vehicle direction, 1 = Forward, 0 = Not commanded, -1 = Reverse Ignition_Input Shows the state of DIN5, 1 = asserted, 0 = deasserted. Start_Input Shows the state of DIN6, 1 = asserted, 0 = deasserted. Brake_Switch Shows the state of DIN3, 1 = asserted, 0 = deasserted. Forward_Switch Shows the state of DIN1, 1 = asserted, 0 = deasserted. Reverse_Switch Shows the state of DIN2, 1 = asserted, 0 = deasserted. Regen_Disable_Switch Shows the state of DIN4, 1 = asserted, 0 = deasserted. 1/5/2016 RMS PM100 Software User Manual 67 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com OK_Output_Status Shows the state of RLY3, 1 = asserted, 0 = deasserted. Precharge_Output_Status Shows the state of RLY1, 1 = asserted, 0 = deasserted. Main_Output_Status Shows the state of RLY2, 1 = asserted, 0 = deasserted. Fault_Output_Status Shows the state of RLY4, 1 = asserted, 0 = deasserted. Hall_Input_1_Status Shows the status of Hall Input 1 Hall_Input_2_Status Shows the status of Hall Input 2 Hall_Input_3_Status Shows the status of Hall Input 3 Encoder_Input_A_Status Shows the status of Encoder Input A Encoder_Input_B_Status Shows the status of Encoder Input B Encoder_Input_Z_Status Shows the status of Encoder Input Z SAT_Fault_Output_Status Shows the status of HW Desaturation fault, 0=asserted, 1=deaaserted OC_Fault_Output_Status Shows the status of HW Over-current fault, 0=asserted, 1=deaaserted VSM_Accel_Filtered Shows the voltage applied to AIN1, 0 = 0 volts, 500 = 5.0 volts VSM_Brake_Filtered Shows the voltage applied to AIN3, 0 = 0 volts, 500 = 5.0 volts Power_on_Timer_3ms_(Hi_byte) The controller keeps a count of how many 3ms intervals have occurred since power was applied. It is represented as a 32 bit number. Power_on_Timer_3ms_(Lo_byte) See above. Sin_corr_(V)_x_100 If used, the reading of the resolver SIN input. Display shows the peak value of the input. Cos_corr_(V)_x_100 If used, the reading of the resolver COS input. Display shows the peak value of the input. Motor_Angle_(DEG)_x_10 Shows the rotational position of the motor shaft. Can be used to verify encoder or resolver operation. Delta_Resolver_In_Fil_(DEG)_x_10 This parameter is used for calibration of the resolver offset. It shows the offset between the back EMF angle and the resolver angle. Only valid if the motor is not enabled. Gamma_Adjust_(Deg)_x_10 This is a command parameter. The value can be adjusted by typing the new data in the GUI. This parameter is used with the resolver calibration procedure. This parameter is an offset angle added to the resolver feedback angle. The parameter will reset to the EEPROM whenever the power is cycled to the controller. Go back to the section (CTRL + Click), “Monitored Parameters View (via GUI Memory View)” 1/5/2016 RMS PM100 Software User Manual 68 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix M Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com POST Faults POST Fault Fault Indicator Number of Blinks Fault Description Hardware Gate/Desaturation Fault 5 A hardware de-saturation fault occurs for any of the following conditions: The current exceeds normal level and causes short-circuit in an IGBT An IGBT circuit is bad An over-voltage condition occurs on DC bus Currently, this fault cannot be cleared using the ‘Clear Fault Command’. In order to clear this fault, inverter power must be recycled. HW Over-current Fault 5 This fault occurs when any of the current sensors detect an over-current condition which could be positive or negative. All six over-current faults are ORed together to cause the HW over-current fault. Accelerator Shorted 4 Accelerator input voltage is less than the value in EEPROM parameter, Pedal_Lo_EEPROM_(V)_x_100. Accelerator Open 4 Accelerator input voltage is more than the value in EEPROM parameter, Pedal_Hi_EEPROM_(V)_x_100. Current Sensor Low 3 Current sensor reading is lower than the hard-coded value (-22.5 Amps) set for this fault. Current Sensor High 3 Current sensor reading is higher than the hard-coded value (22.5 Amps) set for this fault. Module Temperature Low 1 This fault is currently not active. Module Temperature High 1 One or more of the three module temperatures are above 125 C. Control PCB Temperature Low 1 PCB temperature is below -24 C. Control PCB Temperature High 1 PCB temperature has exceeded 125 C. Gate Drive PCB Temperature Low 1 GDB temperature is below -24 C. Gate Drive PCB Temperature High 1 GDB temperature has exceeded 125 C. 5V Sense Voltage Low 2 5V Sense reading is too low 5V Sense Voltage High 2 5V Sense reading is too high 1/5/2016 RMS PM100 Software User Manual 69 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 12V Sense Voltage Low 2 12V Sense reading is too low 12V Sense Voltage High 2 12V Sense reading is too high 2.5V Sense Voltage Low 2 2.5V Sense reading is too low 2.5V Sense Voltage High 2 2.5V Sense reading is too high 1.5V Sense Voltage Low 2 1.5V Sense reading is too low 1.5V Sense Voltage High 2 1.5V Sense reading is too high DC Bus Voltage High 6 During pre-charge, DC voltage is above the hard-coded SW over-voltage limit. SW over-voltage limit can be checked from the monitored parameter list by adding SW_Over_Voltage_(Volts)_x_10 to the watch list. DC Bus Voltage Low 6 DC bus voltage is below 100-V. Pre-charge Timeout 6 DC bus voltage is not charging at the rate of 2.7 V/50 msec and 3 seconds have elapsed. Pre-charge Voltage Failure 6 After pre-charge is complete, DC voltage has changed by more than 10-V within 15 msec. EEPROM Checksum Invalid 7 EEPROM checksum is not valid. EEPROM Data Out of Range 7 This fault is currently not active. EEPROM Update Required 7 The number of EEPROM parameters has changed (most of the time increased), check the new parameters and set appropriate values. Brake Shorted 8 Brake input voltage is less than the value in EEPROM parameter, Brake_Lo_EEPROM_(V)_x_100. Brake Open 8 Brake input voltage is more than the value in EEPROM parameter, Brake_Hi_EEPROM_(V)_x_100. Go back to the section (CTRL + Click), “Power on Self-Test (POST):” 1/5/2016 RMS PM100 Software User Manual 70 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Appendix N Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Run Faults RUN Fault Fault Indicator Number of Blinks Fault Description Motor Over-speed Fault 6 Motor speed is above the value in EEPROM parameter, Motor_Overspeed_EEPROM_(RPM) Over-current Fault 3 One or more of the three phase currents is above the hard-coded SW overcurrent limit. SW over-current limit can be checked from the monitored parameter list by adding SW_Over_Current_(Amps)_x_10 to the watch list. Over-voltage Fault 2 Filtered value of DC voltage is above the hard-coded SW over-voltage limit. SW over-voltage limit can be checked from the monitored parameter list by adding SW_Over_Voltage_(Volts)_x_10 to the watch list. Inverter Over-temperature Fault 1 One or more of the three module temperatures are above the value in EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. Accelerator Input Shorted Fault 4 Accelerator input is below the value in EEPROM parameter, Pedal_Lo_EEPROM_(V)_x_100. Accelerator Input Open Fault 4 Accelerator input is above the value in EEPROM parameter, Pedal_Hi_EEPROM_(V)_x_100. Direction Command Fault 7 Both directions forward and reverse are active at the same time. This fault has been de-activated. Inverter Response Time-out Fault 8 Inverter has not been enabled within 2 minutes of receiving the inverter enable command either through VSM or CAN. Hardware Gate/Desaturation Fault 5 A hardware de-saturation fault occurs for any of the following conditions: The current exceeds normal level and causes short-circuit in an IGBT An IGBT circuit is bad An over-voltage condition occurs on DC bus Currently, this fault cannot be cleared using the ‘Clear Fault Command’. In order to clear this fault, inverter power must be recycled. Hardware Over-current Fault 5 This fault occurs when any of the current sensors detect an over-current condition which could be positive or negative. All six over-current faults are ORed together to cause the HW over-current fault. 1/5/2016 RMS PM100 Software User Manual 71 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 3 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Under-voltage Fault 2 DC bus voltage is below the value in EEPROM parameter, DC_UnderVolt_Thresh_EEPROM_(V)_x_10. CAN Command Message Lost Fault 9 The inverter is not able to see the heartbeat command message when in CAN mode. Motor Over-temperature Fault 1 The motor temperature value exceeds the value in the EEPOM parameter, Mtr_OverTemp_Limit_EEPROM_(C)_x_10. Brake Input Shorted Fault 10 Brake input is below the value in EEPROM parameter, Brake_Lo_EEPROM_(V)_x_100. Brake Input Open Fault 10 Brake input is above the value in EEPROM parameter, Brake_Hi_EEPROM_(V)_x_100. Module A Over-temperature Fault3 1 Module A temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault for Gen-3 boards only. Module B Over-temperature Fault3 1 Module B temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault for Gen-3 boards only. Module C Over-temperature Fault3 1 Module C temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault for Gen-3 boards only. PCB Over-temperature Fault3 1 PCB temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault for Gen-3 boards only. Gate Drive Board 1 Over-temperature Fault 1 GDB 1 temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault used only for Gen-3 boards (all RMS products are currently at Gen-3). 1/5/2016 RMS PM100 Software User Manual 72 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com 1 GDB 2 temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault for Gen-3 boards only. Gate Drive Board 3 Over-temperature Fault4 1 GDB 3 temperature has exceeded the value in the EEPROM parameter, Inv_OverTemp_Limit_EEPROM_(C)_x_10. This is a new fault for Gen-3 boards only. Current Sensor Fault 3 If current readings are not within a certain range, current sensor is assumed to be mal-functioning. Resolver Not Connected Fault 11 The resolver is not connected. Inverter Discharge Active 11 Inverter discharge is in process. Gate Drive Board 2 Over-temperature Fault4 Go back to the section (CTRL + Click), “Fault State (VSM_State = 7):” 4 This is a new fault used only for Gen-3 board which is used in all PM150 units. 1/5/2016 RMS PM100 Software User Manual 73 of 75 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Revision History Version 2.0 Description of Versions/ Changes This version has following manuals combined: . SW Release Package Description . PM Programming using Codeskin . RMS SCI Data Acquisition . Programming EEPROM using GUI . PM User Manual (Sections 9, 10, 11, 12, 13) Updated by Date Azam Khan 9/5/12 Also, updated several sections based on document, “Firmware 1700 Release Notes”. 2.1 Added “Shudder Compensation” manual to appendix. Azam Khan 9/10/12 2.2 Peer Reviewed Chris Brune 9/12/12 2.3 In Appendix D, provided reference of “Current Offset Calibration” manul for current offset parameters, Ia_Offset_EEPROM, Ib_Offset_EEPROM, and Ic_Offset_EEPROM. Azam Khan 9/13/12 2.4 In section 3.3, Removed unnecessary column from the table that lists SCI broadcast parameters. From the same table, removed parameters number 17 and 18, Run Fault High Word and Limit Flag Low Word, and replaced the two with Run Fault Low Word and Run Fault High Word. Azam Khan 10/25/12 2.5 Updated Appendix K: Brake Parameters Brake Input Bypassed EEPROM parameter can also be set to a value of 2 in addition to 0 and 1. If this parameter is set to 2, brake input will be ignored only for starting the vehicle. However, the user can continue to use it for regen. Azam Khan 11/20/2012 2.6 SWRP 1805: Added new faults, “Resolver Not Connected” and “Inverter Discharge Active”. Sections updated: Section 9.6 Appendix N Azam Khan 12/13/2012 1/5/2016 RMS PM100 Software User Manual 7929 SW Burns Way Suite B Wilsonville, OR 97070 Phone: 503-344-5085 Fax: 503-682-9014 sales@rinehartmotion.com Version Description of Versions/ Changes Updated by Date 2.7 SWRP 1818: Added a new feature “Max Speed Torque Reduction” Sections updated: Appendix H Azam Khan 4/23/2013 Azam Khan 4/15/2014 Azam Khan 6/18/2014 Azam Khan 7/17/2014 Azam Khan 8/12/2014 Chris Brune 8/26/2015 Chris Brune 1/05/2016 2.8 Changed all references to the term “C2ooo” to just “C2” in accordance with the application name update. Corrected the CAN byte numbers for Run Faults to be 4, 5, 6, and 7 and adjusted bit numbers accordingly. Updated the description for 2.9 3.0 3.1 Relay_Output_State_EEPROM_(0=OFF_1=ON) in Appendix B System Configuration Parameters In Appendix B, added detailed tables for each relay output describing it behavior based on other configuration parameters. Added a new section 5.6,’Switching back to SCI mode’, that describes how to switch between GUI and SCI modes. In Appendix B, updated tables for the relay outputs. Also updated the description for Relay_Output_State_EEPROM. Updated Firmware naming description. 3.2 3.3 Removed broken manual links, updated manual descriptions. Added Inverter Discharge EEPROM parameter to the list of parameters. Clarified list of calibrations. 1/5/2016 RMS PM100 Software User Manual
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