MOTION TECH BLDC450 Series Brushless motor controller Manual

MANUAL

BLDC450

Brushless motor controller

BLDC450 - Series

BLDC/PMAC motor controller

V2.0 Oct. 2013

Specifications subject to change without notice

1

OVERVIEW

BLDC450 motor controllers are programmable DC brushless motor speed controller. BLDC450 – series motor controllers are designed to control 3-phase permanent magnet brushless BLDC/PMAC motor in battery power traction and pump applications. The applications include high power motorcycle, pallet truck, scissor lift, stackers, sweeper/scrubber machines, industrial vehicles, person carrier, electric tricycle, golf car, electric boats and light electric car.

The controllers are designed in high end driving technology and reliable hardware which provide the silent and smooth operation for the brushless motor.

This high performance motor controller is simple to install, light weigh, high efficient and cost effective.

BLDC450 brushless motor controller

BLDC450-Series Motor Controller Manual 1

The controllers are manufactured with high quality materials and professional workmanship for high end users. The casing is completely sealed to meet IP65 protection.

The controllers have many intelligent protection functions, includes real-time motor and controller current protect, motor temperature protect, controller temper protect, Over/Low voltage protect, motor sensor protect...etc.

General Features include:

•

Suitable for BLDC and PMAC motor

•

Low noise, high efficient and newest driving technology

•

Simple size and high weight/power density

•

Three half bridge design which provide smooth and silent operation

•

Four quadrant motor control technology

•

Regenerative braking allows shorter stopping distances, increases battery charge, and reduces motor heating

•

Anti-roll-back/Anti-roll-forward function

•

Real time current control

•

IP65 protection

•

Tyco waterproof 35-pin AMPSEAL connector

•

I/O protect

•

Main contactor and electronic magnetic brake control by motor controller

•

EMR/Belly switch available

•

Available for 0-5KΩ, 0-5V, switch, wig-wag throttles

•

Over/Low voltage protection

•

Motor temperature protect

•

Hall sensor detect

•

Controller Over/Under temperature protection

•

Motor stall protection

•

High pedal disable function

BLDC450-Series Motor Controller Manual 2

•

Real time status LED

•

Compatibility with Stars HP80 handheld programmers for quick and easy testing, diagnostics, and parameter adjustment.

•

Build in status monitor message

•

Operator timer – Save the vehicle operation time

Caution:

RUNAWAYS

— Some fault conditions could cause the vehicle to run out of control. Jack up the vehicle, get the drive wheels off the ground or disconnect the motor before attempting these procedures or any other work on the motor control circuitry.

HIGH CURRENT ARCS

— Electric vehicle batteries can supply very high power, and arcs can occur if they are short circuited. Always open the battery circuit before working on the motor control circuit. Wear safety glasses, and use properly insulated tools to prevent shorts.

BLDC450-Series Motor Controller Manual 3

2

INSTALLATION AND

WIRING

The outline and mounting holes dimensions for the

BLDC450 controller are shown in Figure. BLDC450 motor controllers meet the IP65 requirements for environmental protection against dust and water.

Even the controllers casing meet the IP65, the mounting location should be carefully chosen to keep the controller as clean and dry as possible. It is recommended that the controller be fastened to a clean, flat metal surface with four 6mm (1/4") diameter bolts, using the holes provided.

Mounting dimensions of the

BLDC450 motor controller, dimensions in millimeters.

BLDC450-Series Motor Controller Manual 4

CONNECTORS:

Five copper terminals and one Tyco 35 position, vertical

AMPSEAL connector (Tyco p/n 776231) on the top side of the controller.

There are five high current terminals, identified on the controller housing as B+, B-, U, V, and W.

Terminal

B+

B-

U

V

W

Function

Positive battery to controller

Negative battery to controller

Motor phase U

Motor phase V

Motor phase W

BLDC450-Series Motor Controller Manual 5

Caution:

► Please make sure each power terminal is fix reliable and correct.

M8 BOLT

HIGH LOAD

SAFETY WASHER

LUG

M8 TERMINAL

POWER TERMINAL ASSEMBLY :

Five copper M8 terminals are provide. Lugs should be installed as follows, using M8 bolts sized to provide proper engagement (see diagram):

• Place the lug on top of the brass terminal, followed by a high-load safety washer with its convex side on top.

• If two lugs are used on the same terminal, stack them so the lug carrying the least current is on top.

• Tighten the assembly to 9.6 ±0.9 N·m (85 ±8 in-lbs).

Note: The lug may rotate up to ±5° in the cover.

HIGH CURRENT WIRING

RECOMMENDATIONS:

Battery cables (B+, B-)

These two cables should be run close to each other between the controller and the battery. Use high quality copper lugs and observe the recommended torque ratings.

Motor wiring (U, V, W)

The three phase wires should be close to the same length and bundled together as they run between the controller and the motor. The cable lengths should be kept as short as possible. Use high quality copper lugs

BLDC450-Series Motor Controller Manual 6

Caution:

► Low current signal wires should not be run next to the motor cables. and observe the recommended torque ratings. For best noise immunity the motor cables should not run across the center section of the controller.

All low power connection are through a Tyco 35-pin

AMPSEAL connector (Tyco p/n 776231). The mating plug is AMP p/n 776164-1 and the contact pins are

AMP p/n 770520-3. The connector will accept 20 to 16

AWG wire with a 1.7 to 2.7mm diameter thin-wall insulation.

PIN NAME

1 Serial TX

2 Serial RX

3

4

5

HP Ground

HP +12V

Not used

6 Not used

7 Not used

8 KSI

9 Not used

10 Not used

11 Not used

12 Main

13 +5V Out1

14 Ground 1

15 Hu

16 Hv

BLDC450-Series Motor Controller Manual

DESCRIPTION

Serial transmit line for display or flash update.

Serial receive line for flash update.

Handheld programmer ground reference.

Handheld programmer +12V power sourse.

Internally disconnected.

Internally disconnected.

Internally disconnected.

Keyswitch input. Provide logic power for the controller, switches and power for the coil drivers.

Internally disconnected.

Internally disconnected.

Internally disconnected.

Typical used for main contactor, Ipeak < 3A.

Hall sensor/Encoder Positive Supply (+5 Vdc).

Negative of the Hall sensor/Encoder.

Motor Hall sensor U input.

Motor Hall sensor V input.

7

17 Hw

18 Not used

19 Not used

20 Not used

21 Not used

22 Not used

23 Not used

24 Pot Wiper

25 5V signal

26 +5V Out2

Motor Hall sensor W input.

Internally disconnected.

Internally disconnected.

Internally disconnected.

Internally disconnected.

Internally disconnected.

Internally disconnected.

Pot wiper connection for the throttle pot.

Electric throttle signal input, accept range form 0 to 5V

+5V power source for electric throttle.

27 I/O ground Ground reference for electric throttle.

28 Motor TEMP Motor temperature switch input.

29 Not used Internally disconnected.

30 Forward

31 Reverse

32 Not used

33 EMR

34 Not used

35 Interlock

Forward switch signal input.

Reverse switch signal input.

Internally disconnected.

Emergency reverse switch signal input.

Internally disconnected.

Interlock switch input.

BLDC450-Series Motor Controller Manual 8

PART NO.

REV B

ST-500-012

11/11/2013

KEY SWITCH

KEY

J1-8

EMERGENCY

FORWARD

REVERSE

INTERLOCK

J1-33

J1-31

J1-30

J1-35

SWITCH 1

SWITCH 2

SWITCH 3

SWITCH 4

5A POLARITY

PROTECTION DIODE

5A MAX CONTROL FUSE

MUST ADD THIS FUSE

MAIN CONTACTOR

DRIVE 1

J1-12

B+

MOTOR

TEMPERATURER

SENSOR

J1-28

THROTTLE 0-5K OHM

PRECHARGE RESISTOR

PRECHARGE RESISTOR

250 OHM 5W 24-36V

470 OHM 5W 48V

1000 OHM 5W 72V

POWER FUSE

ANN 250A

WIGWAG

POT LOW

J1-24

J1-27

THROTTLE WIPER

THROTTLE LOW

U

V

W

BLDC

MOTOR

EMERGENCY

DISCONNECT

SWITCH

0-5V THROTTLE

POWER +5V

0-5V

THROTTLE

0-5V SIGNAL

GROUND

J1-26

J1-25

J1-27

Red

Yellow

Green

Blue

Black

HALL SENSOR

+5V

SENSOR 1 (U)

SENSOR 2 (V)

SENSOR 3 (W)

GROUND

J1-13

J1-15

J1-16

J1-17

J1-14

B-

+12V

Rx

Tx

I/O GROUND

J1-4

J1-2

J1-2

J1-3

BLDC - SERIES BLDC MOTOR CONTROLLER

NOTE:

1. FUSE REQUIRE FOR ALL INSTALLATIONS

2. PRE-CHARGE RESISTOR REQUIRED

3.

PRECHARGE RESISTOR REQUIRED

4. POLAR DIODE REQUIRED

5. CONATCTORS COIL DIODE REQUIRED

> ANY DOUBTS PLEASE CONTACT STARS

HALL

SENSOR

HIGH CURRENT WIRING IN BOLD

}

HANDHELD

PROGRAMMER

BATTERY

(24-72V)

POWER WIRE GAUGE

300AMP

400AMP

500AMP

650AMP

6 AWG

4 AWG

4AWG - 2AWG

2AWG - 1/0

DWG

JONES CHO

CHECK

SHIN WANG

APPROVED

JONES CHO

DATE

11/11/13

DATE

11/11/13

DATE

11/11/13

PROPRIETARY

TITLE

BLDC450 STANDARD WIRING DIAGRAM

DOCUMENT NO.

REV.

ST-500-012

FILE: BLDC450 -STANDARD-20131111 SHEET 1 OF 1

INSTALLATION CHECKOUT :

A. Jack up the electric vehicle to get the wheels off the ground.

B. Make sure the wiring is connected correctly.

C. Keep the Forward/Reverse switch is in neutral and the throttle in zero.

D. Connect the battery power.

E. With the forward/reverse switch in neutral, turn the key switch. If the motor runs without the throttle being applied, turn the key switch off and recheck the wiring.

F. Select a direction and slowly apply the throttle, the motor should now respond.

E. Check the HPD (High pedal disable). Turn off the key switch and direction switch. Apply the throttle, turn the key switch on, and then select a direction. The motor should not run. Release the throttle and re-apply it – the motor should run now.

F. Take the vehicle down off the blocks and drive it in clear area. It should have smooth acceleration and good top speed.

Caution:

►Put the vehicle up on blocks to get the drive wheels off the ground before beginning these tests.

►Don’t let anyone stand in front of or behind the vehicle during the checkout.

►Make sure the key switch is off and the vehicle is in neutral before beginning.

►Wear safety glasses and use well-insulated tools.

BLDC450-Series Motor Controller Manual 10

3

MOTOR SELECTION

GUIDE

BLDC motor can match with BLDC/PMAC motor from voltage 48 to 72VDC and motor power from 2.0kw to

5.5kw. The follow table shows the motor specifications and drawing for the BLDC motors.

BLDC450-Series Motor Controller Manual 11

特性規格(Performace Spec.)

額定電壓(Rated Voltage) 48VDC

無載轉速(No Load Speed)

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

相電流( two-phase Current)

額定轉速(Rated Speed)

3000RPM

T.B.D.

C.W.

2.0KW

T.B.D. N-m

60A

2000RPM

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

8.8m

Ω

1000VAC/2mA/1sec.

500VDC/50M

Ω

min.

3- M8xP1.25

2

18 18 18

W V U

1

25

線色定義

(UL3266/AWG24)

名稱

H+

H-

S1

S2

S3

線色

黃

綠

棕

紅

橙

銘版型式

MOTION TECH MOTOR

BLDC motor

TYPE:BLJ0S48R8R00120202

48VDC

S/N:

2000Watt 2000R.P.M

工號 序號

碩陽

參考圖

2013-07-26

3

79

±0.3

75

55

4- 13.5

P.C.D.

200

5

45°

180

45°

R114

19.77

M8xP1.25,深20mm

0 0.

25

172

20

圖 名

型 號

圖

BLJ0S48R8R00120202

號

外型圖

BL180_S(48VDC/2000RPM)

件 數 * *

比 例

1:3

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS CO.,LTD

MOTION TECH MOTORS

01 邱義章

07-26-'13

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖 邱義章 07-18-'12

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

特性規格(Performace Spec.)

額定電壓(Rated Voltage)

無載轉速(No Load Speed)

48VDC

3000RPM

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

額定電流(Rated Current)

額定轉速(Rated Speed)

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

1

T.B.D.

C.W.

1

2.1KW

9.5N-m

1

T.B.D.

2000RPM

1

T.B.D.

1000VAC/2mA/1sec.

500VDC/50M

Ω min.

25

25

172

碩陽

參考圖

45

101-02-13

4- 13.5

3

180

228

34

圖 名

型 號

圖

號

外型圖

BL180_S(48VDC/3600RPM)

BLJ0S48G8R00136352

件 數 * *

比 例

1:3

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS CO.,LTD

MOTION TECH MOTORS

.

.

20

P.C.D. 200

01

.

江俊瑯

.

02-13-'12

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖 江俊瑯 01-04-'12

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

特性規格(Performace Spec.)

額定電壓(Rated Voltage)

無載轉速(No Load Speed)

48VDC

3000RPM

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

額定電流(Rated Current)

額定轉速(Rated Speed)

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

1

T.B.D.

C.W.

1

3.2KW

14.3N-m

1

1

T.B.D.

2000RPM

T.B.D.

1000VAC/2mA/1sec.

500VDC/50M

Ω min.

25

25

232

碩陽

參考圖

45

101-02-13

4- 13.5

3

180

228

34

.

.

20

P.C.D. 200

圖 名

型 號

圖

號

外型圖

BL180_M(48VDC/3600RPM)

BLJ0M48G8R00136502

件 數 * *

比 例

1:3

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS CO.,LTD

MOTION TECH MOTORS

01

.

江俊瑯

.

02-13-'12

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖 江俊瑯 01-06-'12

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

特性規格(Performace Spec.)

額定電壓(Rated Voltage) 48VDC

無載轉速(No Load Speed) 2500RPM

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

相電流( two-phase Current)

額定轉速(Rated Speed)

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

W

180

V U

T.B.D.

C.W.

5.5KW

26N-m

135A

2000RPM

T.B.D. m

Ω

1000VAC/1mA/1sec.

B

M10牙條

76

38

1

6

5

10

Molex 5557-10R

(B-B VIEW)

2013-06-27

B

130

Molex 5557-10R腳位線色定義

PIN

1

2

3

4

5

6

7

8

9

10

名稱

H+

H-

S1

S2

S3

溫度

溫度

線色

黃

綠

棕

紅

橙

白

黑

空腳

空腳

編織網

碩陽

銀

參考圖

4- 13.5

45

銘版黏貼位置

(MTM朝出力軸)

MOTION TECH MOTOR

BLDC motor

TYPE:BLJ0L48G8R00120552

48VDC

S/N:

5500Watt 2000RPM

工號

銘版型式 u

序號

180 v

3

34 w

4- 13.5

34

228

3

20

P.C.D. 200

228

圖 名

型 號

圖

BLJ0L48G8R00120552

號

外型圖

BL180_L(48VDC/2000RPM)

件 數 * *

比 例

1:3

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS CO.,LTD

MOTION TECH MOTORS

20

.

.

289

P.C.D. 200

.

.

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖

江俊瑯 2013-06-28

邱義章 06-27-'13

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

特性規格(Performace Spec.)

額定電壓(Rated Voltage)

無載轉速(No Load Speed)

48VDC

3000RPM

T.B.D.

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

額定電流(Rated Current)

額定轉速(Rated Speed)

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

C.W.

1

1

5.5KW

26N-m

1

1

T.B.D.

2000RPM

T.B.D.

1000VAC/2mA/1sec.

500VDC/50M

Ω min.

25

25

292

碩陽

參考圖

101-02-13

45

4- 13.5

3

180

228

34

圖 名

型 號

圖

號

外型圖

BL180_L(48VDC/3600RPM)

BLJ0L48G8R00136652

件 數 * *

比 例

1:3

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS CO.,LTD

MOTION TECH MOTORS

.

.

20

01

.

江俊瑯

.

02-13-'12

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖 江俊瑯 01-06-'12

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

P.C.D. 200

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

特性規格(Performace Spec.)

額定電壓(Rated Voltage) 60VDC

無載轉速(No Load Speed)

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

額定電流(Rated Current)

額定轉速(Rated Speed)

4600RPM

2 A

C.W.

5 KW

T.B.D. N-m

T.B.D.

4000RPM

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

T.B.D.

1000VAC/2mA/1sec.

500VDC/50M

Ω

min.

3- M8xP1.25

2

W V U

2

18 18 18

線色定義

(UL3266/AWG24)

名稱

H+

H-

S1

S2

S3

線色

黃

綠

棕

紅

橙

MOTION TECH MOTOR

BLDC motor

TYPE:BLJ0M60R8R00140502

60VDC

S/N:

5000Watt 4000R.P.M

工號 序號

銘版型式

碩陽

參考圖

2013-07-26

413.5

P.C.D.Φ200

79

±0.3

75

3

55 5

45°

180

45°

R 114

38

66

25

M8xP1.25深20mm

0 -

20

232

圖 名

型 號

圖

BLJ0M60R8R00140502

號

外型圖

BL180_M(60VDC/4000RPM/5KW) 件 數 * *

比 例

1:3

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS CO.,LTD

MOTION TECH MOTORS

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖 邱義章 07-26-'13

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

特性規格(Performace Spec.)

額定電壓(Rated Voltage) 72VDC

無載轉速(No Load Speed) 4500±5%RPM

無載電流(No Load Current)

轉向(Direction of Rotation)

額定功率(Rated Power)

額定轉矩(Rated Torque)

額定電流(Rated Current)

額定轉速(Rated Speed)

線間電阻(L-L Resistance)

耐壓測試(Hi-Pot)

絕緣測試(Insulation Test)

T.B.D.

C.W.

5KW

T.B.D.N-m

T.B.D.

T.B.D.RPM

T.B.D.

1000VAC/2mA/1sec.

500VDC/50M

Ω

min.

驅動時序表（8P/從導線側看,C.C.W.)

馬達出口線 Hall訊號線

U V W

X Low Hi

S1

1

S2

1

S3

0

Hi Low X

Hi

X

Low

Low

X

Hi

Hi

X

Low

Low

X

Hi

0

0

0

1

1

1

1

0

0

0

0

1

1

1

0

線色定義

(UL3266/AWG24)

名稱 線色

H+

H-

S1

S2

S3

黃

綠

棕

紅

橙

TYPE: BLJ0M72G8R00145502

Motion Tech Motors

BL180 MOTOR

72VDC 5000W 4500 R.P.M

*工號(8碼)序號(4碼)*

銘版型式

碩陽

參考圖

2013-08-27

W V U

M10牙條

Ucom

Vcom

Wcom

60

25

105

130

47.5

±0.3

3

-

0

0.1

25有效長

4- 13.5

P.C.D.

200

1.5

30

°

66

45°

180

45°

20

25 232

R114

圖 名

型 號

圖

號

外型圖

BL180_M(72VDC/4500RPM/5KW)

BLJ0M72G8R00145502

件 數 * *

比 例

1:4

第 三 角 法

單 位 mm

碩陽電機股份有限公司

MOTION TECH MOTORS

MOTION TECH MOTORS CO.,LTD

版 數 設變單號 簽 名 月-日-'西元

核 定

審 查

校 對

製 圖

江俊瑯 2013-09-02

邱義章 08-19-'13

簽 名 月-日-'西元

材 質

**

標準無註明公差

0.5-6

0.1

120-315

6-30

30-120

0.2

0.3

315-1000

1000-2000

0.5

0.8

1.2

APPENDIX A :

SPECIFFICATIONS:

BLDC450 Brushless motor controller

► Nominal input voltage: 24V ; 36V ; 48 ; 60 ; 72VDC

► PWM operation frequency: 16KHz

► Programmable system, program by HP80 handheld programmer

► Electrical isolation to heatsink: 500 V ac (minimum)

► 7 types of throttle support.

► Storage ambient temperature range : -40 o

C to 95

o

C

► Internal heatsink operating temp. range : -40 o

C to 95

o

C

► Package environmental rating : IP65

► Casing : Black Plastic、Aluminum base

► Dimensions : 159 X 194 X 78.2 mm

► Weight : 2.9kg

BLDC450

Family Model

Nominal battery voltage (Volts)

Rating current

(amps)

Current

Limit (amps)

BL24400

BL36400

BL48400

BL60350

BL72300

24V

36V

48V

60V

72V

200A

200A

200A

200A

150A

400A

400A

400A

350A

300A

Cooling

Air cooling

BLDC450-Series Motor Controller Manual A