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11023441 • Rev AA • Jan 2009 1 PLUS+1 TM Guide PLUS+1 TM Inverter Function Block Library

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11023441 • Rev AA • Jan 2009 1

PLUS+1TM Guide PLUS+1TM Inverter Function Block Library

PLUS+1TM Guide PLUS+1 TM Inverter Function Block Library

2 11023441 • Rev AA • Jan 2009

Revisions

History of Revisions

Table of Revisions

Date Page Changed ECO No. Rev.

09.03. 2007 All valid since software version 1.00 - Rev A

04.09.2007 Rev B

26.10.2007 Rev C

26.05.2008 - Rev D

10.06.2008 Rev D

08.09.2008 Rev E

22 Jan, 2009 All Released AA

Sauer-Danfoss welcomes suggestions for improving our documentation. If you have suggestions for improving this document, please contact Sauer-Danfoss at [email protected].

© 2009, Sauer-Danfoss Sauer-Danfoss can accept no responsibility for possible errors in catalogs, brochures and other printed material. Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provides that such alterations can be made without affecting agreed specifications. All trademarks in this material are properties of the respective owners. Sauer-Danfoss ,the Sauer-Danfoss logotype, the Sauer-Danfoss S-icon, PLUS+1TM, what really matters is inside® and Know-How in MotionTM are trademarks of the Sauer-Danfoss Group.

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Contents

Analog Input 4 Analog Input............................................................................................................................................................ 4

Calibration .......................................................................................................................................................... 4 Manual Calibration.......................................................................................................................................... 4 Semi-Automatic Calibration ........................................................................................................................ 4 Semi-Automatic Calibration with enable input.................................................................................... 5 Set Defaults ........................................................................................................................................................ 5 Inputs/Outputs ................................................................................................................................................. 5 Basic Function ................................................................................................................................................... 7

Battery Discharge Indicator 8 Battery Discharge Indicator (BDI)..................................................................................................................... 8

Discharge Characteristic, Voltage per Cell ............................................................................................. 8 Inputs/Outputs ................................................................................................................................................. 9

Brake and Power 10 Brake and Power ..................................................................................................................................................10

Inputs/Outputs ...............................................................................................................................................11 Derating 13

Derating ..................................................................................................................................................................13 Inputs/Outputs ...............................................................................................................................................13

Direction Signals 14 Direction Signals ..................................................................................................................................................14

Inputs/Outputs ...............................................................................................................................................14 Dynamic Drive Curve Generator 15

DDCG........................................................................................................................................................................15 Inputs/Outputs ...............................................................................................................................................15

Error History 20 Error History...........................................................................................................................................................20

Inputs/Outputs ...............................................................................................................................................20 Error Status Handler 22

Error Status Handler............................................................................................................................................22 Inputs/Outputs ...............................................................................................................................................22

Hour Counter 25 Hour Counter.........................................................................................................................................................25

Inputs / Outputs .............................................................................................................................................25 Main Contactor 26

Main Contactor.....................................................................................................................................................26 Inputs/Outputs ...............................................................................................................................................26

Roll Off 27 Roll Off .....................................................................................................................................................................27

Inputs/Outputs ...............................................................................................................................................27 Seat Switch 30

Seat Switch.............................................................................................................................................................30 Inputs/Outputs ...............................................................................................................................................30

Service Counter 31 Service Counter ....................................................................................................................................................31

Inputs/Outputs ...............................................................................................................................................31 Shunting 32

Shunting..................................................................................................................................................................32 Inputs/Outputs ...............................................................................................................................................32

Solenoid Chopper 33 Solenoid Chopper................................................................................................................................................33

Inputs/Outputs ...............................................................................................................................................33

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Analog Input

Analog Input

Notes: The two calibration points must be connected to s16 memory locations. By default, they are connected using the dynamic memory inside the Local_Para page. To use with static memory, delete the Local_Para page and use the Para bus to route the signals to the static memory. If multiple Sensor_2Pt_AC function blocks are to be used in one application then the Namespace feature will have to be used or the memory names will have to be changed. The Fault timer is an up/down counter. This allows faults to be detected if they occur in more than 50% of program cycles. StorePara and SetDef are outputs intended to control the EE_PROM blocks in the parameters pages. Calibration When using the local parameters included inside, the block, calibration can be accomplished by one of the three methods outlined below. Manual Calibration CalLo and CalHi are stored in an EE memory location with a distinguishable alias for easy updating. Use the PLUS +1TM GUIDE Service and Diagnostic Tool to update CalLo and CalHi. Semi-Automatic Calibration The two calibration points are stored in the same EE memory locations as in Manual Calibration. The Calibration Command must be set to one (Enable Semi-automatic Calibration). When the values stored for CalLo and CalHi are zero, the function is not calibrated and the input is used for semi-automatic calibration. The Expected Calibration Point specifies the center of the window size of Calibration Window. When the input falls within the window for a specific calibration point for Calibrate Time, the last value is captured and stored for that calibration point. After completing this for both calibration points, semi-automatic calibration will be complete. Force the function block into a calibrated mode by either setting the Calibration Command input to equal 4 or when the Input at Zero fault is declared if the Calibration Command equals 1.

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Analog Input

Analog Input (continued) Semi-Automatic Calibration with enable input The two calibration points are stored in the same EE memory locations as in Manual Calibration. The Calibration Command must be set to two (Enable Semi-automatic Calibration with enable input). When the values stored for CalLo and CalHi are zero, the function is not calibrated and the input is used for semi-automatic calibration with enable input. The Expected Calibration Point specifies the center of the window size of Calibration Window. When the input falls within the window for a CalHi calibration point for Calibrate Time, the last value is captured and stored for that calibration point. When the input falls within the window for a CalLo calibration point and the Enable Input has a rising edge (0 -> 1) the value is captured and stored for that calibration point. After completing this for both calibration points, semi-automatic calibration will be complete. Force the function block into a calibrated mode by either setting the Calibration Command input to equal 4 or when the Input at Zero fault is declared if the Calibration Command equals 1 Set Defaults When the Calibration Command equals tree, the Set Defaults variable in the parameter bus is TRUE. If this is used as the SET_DEF inputs for the CalLo and CalHi memory blocks, then the DEF_VALUE will be stored into memory. Inputs/Outputs Inputs

Item Description/Range

Cal Cmd (0 - 4) 0: Manual calibration

1: Semi Auto Cal

2: Semi Auto Cal with enable input

3: Set Calibration values to defaults

4: Clear Calibration

Rst Para Flt (BOOL) T: Fault is not latched

F: Fault is latched until fixed and power is cycled

Rst In Flt (BOOL) T: Fault is not latched

F: Fault is latchet until fixed and power is cycled

Snsr Pwr (0 - 65535) Sensor Power in mV

Used for ratiometric calculations of calibration

points, deadbands and faults

Input (0 – 65535) Input mV

Enable (BOOL) If true and In is in CalLo win, value is saved.

Note: Only available if calibration mode = 2

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Analog Input

Inputs/Outputs (continued) Output

Item Description/Range

Status (U16) Standard Bitwise pattern

Fault (U16) Standard Bitwise pattern

Active (BOOL) HIGH if output is not 0

In % (U16) Percentage of input value from SnsrPwr

Out (S32) Output value scaled from LoOut to HiOut

Out % (U16) 0 to 10000 in .01%

Parameter

Item Description/Range

StorePara (BOOL) Signal used to store calibration values

SetDef (BOOL) Signal used to set default calibration values

CalLo (0 – 9999) Input value associated with output = 0

Specified by units of .01% of Snsr Pwr

CalHi (0 – 9999) Input value associated with output = 10000

Specified by units of .01% of Snsr Pwr

Fault % (0 to 10000) Input Fault Percent in .01%

A fault is declared when the input is either above

Hi Cal or below LoCal by at least

(Hi Cal-Lo Cal) * (SnsrPwr) * (Fault %)

LoOut (S32) Is the calibrated minimum value of “Out”

HiOut (S32) Is the calibrated maximum value of “Out”

DbndLo (0 – 5000) The output = 0 when the input is below

(SnsrPwr)*[Dbnd_1 + (Dbnd_1)*(CalHi - CalLo)]

Specified by units of .01% of Snsr Pwr

DbndHi (0 – 5000) The output = 10000 when the input is above

(SnsrPwr)*[CalHi – (Dbnd_2)*(CalHi – CalLo)]

Specified by units of .01% of Snsr Pwr

ExpCalLo (0 – 10000) Expected value used to determine center of

acceptable calibration window. Specified by units

of .01% of Snsr Pwr

ExpCalHi (0 – 10000) Expected value used to determine center of

acceptable calibration window. Specified by units

of .01% of Snsr Pwr

CalWin (0 – 5000) Amount +/- expected calibration points used to

determine acceptable calibration window.

Specified by units of .01% of Snsr Pwr

CalDetTm (0 – 65535) Calibration capture time in ms

FltDetTm (0 – 65535) Fault detection time in ms. The time that a fault

needs to be present before it is declared

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Analog Input

Basic Function

Fault: The “Fault” output is the fault code of the function block.

Bit Position Value Range/Type

-- 0x0000 Block is OK

1 0x8001 Input value is too low

2 0x8002 Input value is too high

16 0xX000 Custom/Standard code bit

Status: The “Stat” output is the status code of the function block.

Bit Position Value Range/Type

-- 0x0000 Block is OK

1 0x8001 Block is not calibrated

4 0x8008 Invalid Setup/ Calibration

16 0xX000 Custom/Standard code bit

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Battery Discharge Indicator

Battery Discharge Indicator (BDI)

The Battery Discharge Indicator (BDI) is designed to cover lead acid battery only. There are 11 discharge and one charge characteristics stored in the function block. Each characteristic consists of 10 internal voltage values. All in all 120 different threshold values are available for the calculating algorithm. The different battery types can be handled by adjusting the parameter BDI_BatteryType for the discharge characteristics. A time counter increases if the actual battery voltage is higher than the actual charge threshold and decrease if the actual battery voltage is lower than the actual discharge threshold value. If the time counter = 0 the Level decrease one step. If the time counter reaches Tmax the level increase one step. The actual threshold values are calculated out of the actual level and battery type.

Discharge Characteristic, Voltage per Cell

Type0 Type1 Type2 Type3 Type4 Type5 Type6 Type7 Type8 Type9 Type10

Charge of

battery

Level %

1,950 1,963 1,974 1,986 1,997 2,006 2,010 2,014 2,021 2,026 2,030 10 100

1,903 1,922 1,938 1,954 1,970 1,982 1,989 1,995 2,005 2,011 2,018 9 90

1,855 1,880 1,901 1,922 1,943 1,959 1,968 1,976 1,988 1,997 2,005 8 80

1,808 1,838 1,864 1,890 1,915 1,936 1,946 1,957 1,972 1,982 1,993 7 70

1,760 1,797 1,827 1,858 1,888 1,913 1,925 1,937 1,956 1,968 1,980 6 60

1,713 1,755 1,790 1,826 1,861 1,890 1,904 1,918 1,939 1,953 1,968 5 50

1,665 1,713 1,754 1,794 1,834 1,866 1,883 1,899 1,923 1,939 1,955 4 40

1,618 1,672 1,717 1,762 1,807 1,843 1,861 1,879 1,906 1,924 1,943 3 30

1,570 1,630 1,680 1,730 1,780 1,820 1,840 1,860 1,890 1,910 1,930 2 20

1,523 1,588 1,643 1,698 1,753 1,797 1,819 1,841 1,874 1,896 1,918 1 10

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Battery Discharge Indicator

Inputs/Outputs Inputs

Item Description/Range

Level Init (U8) When the block is started up, this value is used to

initialize the charge level ( 1 … 10)

Note: These values need to be connected to an

EEPROM cell (NVRam Input), which is saved at

power down.

ChgCounter (U32) When the block is stated up, this value is used to

initialize the charge counter

Note: These values need to be connected to an

EEPROM cell (NVRam Input), which is saved at

power down.

RstEnblPwr (BOOL) Initiates a reset of the block at power on when the

following conditions are also fulfilled.

Level < 7

U-Batt > BDI-ResetVoltage_mV x cells

Power on

Reset (BOOL) Initiates a reset of the block

UBatt_mV (U32) Battery power in mV

Output

Item Description/Range

ChargeCount (U32) Current value of the discharge/charge timer

Note: These values need to be connected to an

EEPROM cell (NVRam Output), which is saved at

power down.

Level (U8) Current discharge level of the battery. (1 … 10)

Note: These values need to be connected to an

EEPROM cell (NVRam Output), which is saved at

power down. Parameter

Item Description/Range

NmbrCells (U8) Number of battery cells (^2 Volt/cell)

Default: 24

Tmax (U32) Time in Milliseconds between two levels.

Default: 240000 ms [ms]

ResetVoltage_mV (U16) Voltage threshold per cell

Default: 2090

(0 … 4000)

Battery Type (U8) Selection of the discharge curve

Default: 3

(0 … 10)

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Brake and Power

Brake and Power

The “Brake and Power” function control the electromechanical brake and the power stage, at different driving conditions. Start: If the “Enbl” signal goes active (positive edge) the power stage shall be enabled immediately, but the brake shall be opened (powered) with a time delay (BrkOpen_ms). Emergency stop (Emc): The power stage shall be disabled and the brake shall be closed immediately. Emergency stop has the highest priority. Stop ramp (Mode = 0): If the “Enbl” signal goes inactive and the stop ramp is activated. The function has to wait until the actual speed is less than a threshold value (BrkThd_rpm1) and then a time (BrkClose_ms) shall be started. After this time the brake shall be closed immediately and a second time (PwrDsbl_ms) shall be started. During this time the brake has time to close and at the end of this time the power stage shall be disabled.

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Brake and Power

Brake and Power (continued) Coast (Mode = 1): If the “Enbl” signal goes inactive and the coast function is activated. The power stage shall be disabled immediately. Then the function has to wait unit the actual speed is less than a threshold value (BrkThd_rpm1) and then a time (BrkClose_ms) shall be started. After this time the brake shall be closed. At the beginning of this function, a safety time (SafTm_ms) shall be started. After this time the brake shall be disabled, in any case.

Inputs/Outputs Inputs

Item Description/Range

Enbl (BOOL) Drive enable input

Emc (BOOL) Emergency input

Spd_rpm1 (S32) Actual motor speed [0.1 rpm]

Output

Item Description/Range

Brk (BOOL) Mechanical brake output

Pwr (BOOL) Power stage enable output

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Brake and Power

Inputs/Outputs (continued)

Parameter

Item Description/Range

BrkOpen_ms (U16) Brake open delay time

Default 500 ms

(0…1000) [ms]

BrkClose_ms (U16) Brake open delay time

Default 10000 ms

(0…10000) [ms]

PwrDsbl_ms (U16) Power stage off delay time

Default 200 ms

(0…1000) [ms]

SafTm_ms (U16) Safety time

Default 5000 ms

(0…50000) [ms]

BrkThd_rpm1 (U16) Brake close threshold

Default 50 rpm

(0…2500) [0.1 rpm]

Mode (U8) Mode 0: ramp

Mode 1: coast

Default 0

(0…1)

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Derating

Derating

This function can be used for derating the max motor current dependant on the inverter temperature as well as for a derating dependant of the motor temperature. There are two separate derating curves, one for motor mode (acceleration) and one for generator mode (deceleration). If ActTemp is lower than Temp100perc, the output is at 10000 (100%) If ActTemp is higher than TempDerate the output is IDerateG (GenMode=1) or IDerateM (GenMode=0) If ActTemp is between Temp1 and Temp2 the output is reduced by a linear curve between 100% and IDerateM (GenMode=0) or IDerateG (GenMode=1) Inputs/Outputs Inputs

Item Description/Range

ActTemp [S16] Actual Temperature

GenMode [BOOL] 0/F = Motor Mode

1/T = Generator Mode

Output

Item Description/Range

Derating [U16] Derating factor (0.. 10.000) [0.01%]

Status [U8] Status of the function.

0 = Temperature ok

1 = Temperature High -> Derating starts

2 = Temperature too high -> Derating at max.

Parameter

Item Description/Range

Temp100perc [S16] Temperature at which the derating curve starts

TempDerate [S16] Temperature at which the derating curve ends

IDerateM [U16] Derated curve for motor mode [0.01%]

IDerateG [U16] Derated curve for generator mode [0.01%]

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Direction Signals

Direction Signals

Use the FNR Direction block to handle the forward, neutral and reverse logic of a vehicle. With the Precondition input it can be avoid, that the truck starts to move with out some start up sequence and that a rising edge (0->1) is necessary on the FWD or RWD Switch. Inputs/Outputs Inputs

Item Description/Range

PreCond (BOOL) Must be TRUE to enable Fwd and Rvs switch. Fwd

and Rvs must be FALSE to enable PreCond. If

PreCond goes to FALSE Fwd and Rvs will be

disabled

Fwd SW (BOOL) Forward switch signal

Rvs SW (BOOL) Reverse switch signal

Fdbk (S32) Must be zero before output direction can change

Fault (U16) Standard Bitwise pattern

Output

Item Description/Range

Direction (S16) -1 = Reverse

0 = Neutral

+1 = Forward

Drv Enbl (BOOL) T = Exactly one direction input is true

F = neutral or Fault

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Dynamic Drive Curve Generator

DDCG

Function: To obtain a comfortable drive feeling the speed curve is generated with a drive curve generator dependant on the variation of the set value. Beside the actual speed, it is also considered how far and how fast the set value is changed. According to the variation of the set value a very sensible and smooth drive feeling can also performed as well as a dynamic driving.

Inputs/Outputs Inputs

Item Description/Range

SpdStptln_rpm1 (S32) Speed set value.

(-SpdMax_rpm1….SpdMax_rpm1) [0.1 rpm]

SpdAct_rpm1 (S32) Actual speed value (motor)

(-200000….200000 ) [0.1 rpm]

Init (BOOL) Init. function of the dynamic correction.

(see DeacDynCor)

(0….1; pos. transition)

DeacDynCor (BOOL) Dynamic correction of drive curve output value:

At inversion from acceleration to deceleration or

at a pos. transition at “Init” input, a correction of

the drive curve is made, the drive curve output

value is immediately set to the actual speed value

(SpdAct_rpm1).

(Graph DDCG_1 and Graph DDCG_2)

(0 = dynamic correction; 1 = no dynamic

i ) AcelMax (S32) Acceleration:

Specifies the max. acceleration, without rounding

and without progression (R=0, P=0). The

maximum acceleration is achieved, if the set value

escalates from zero to maximum speed.

(1….500000) [0.1 rpm/s]

DecelMax (S32) Deceleration:

Specifies the max. deceleration, without rounding

and without progression (R=0, P=0). The

maximum deceleration is achieved, if the set

value jumps down from maximum speed to zero.

(1….500000) [0.1 rpm/s]

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Dynamic Drive Curve Generator

DDCG (continued) Graph DDCG_1

without correction

0

20

40

60

80

100

120

0 1 2 3 4 5 6

t/s

spee

d/%

drive curve actual speed

Decel. Delay

Graph DDCG_2

with correction

0

20

40

60

80

100

120

0 1 2 3 4 5 6t/s

spee

d/%

drive curve actual speed

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Dynamic Drive Curve Generator

Inputs/Outputs (continued)

Output

Item Description/Range

SpdStptOut_rpm1 (S32) Calculated speed set value.

(-20000….200000) [0.1 rpm]

Parameter

Item Description/Range

Progression (U8) Specifies the influence of the set value variation to

the value of acceleration or deceleration.

Progression = 0: Independently of the set value

variation always the maximum acceleration or

deceleration is active. (Graph DDCG_3)

Progression = 100: The value of acceleration or

deceleration depends on the variation of the set

value on a linear characteristic. (Graph DDCG_4)

Default: 0 (0…100)

Roundness (U8) Specifies the strange of the roundness (0: no

rounding; 90: max. rounding).

The speed curve is always rounded before

reaching the final value. A rounding at the

beginning of acceleration or deceleration

becomes effective only if the set value changes

slowly. With a slowly change of the set value a

smoothly drive reaction is performed, as

acceleration is increased continuously. In case of a

fast change of the set value an aggressive drive

reaction results, as acceleration achieves it’s

maximum value precipitously. (Graph DDCG_5)

Default: 0 (0…90)

SpdMax_rpm1(U32) Max. speed value of the application.

Default 1500 rpm

(1…200000) [0.1 rpm]

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Dynamic Drive Curve Generator

Inputs/Outputs (continued) Graph DDCG_3

Speed curve

0

20

40

60

80

100

120

0 0,5 1 1,5 2 2,5 3 3,5 4

t/s

v/

%

Graph DDCG_4

Speed curve

0

20

40

60

80

100

120

0 0,5 1 1,5 2 2,5 3 3,5 4

t/s

v/

%

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Dynamic Drive Curve Generator

Inputs/Outputs (continued) Graph DDCG_5

0

20

40

60

80

100

120

0 0,5 1 1,5 2 2,5 3 3,5 4

t/s

v/%

drive curve Set Value

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Error History

Error History

Function: In the error history memory, the last 8 errors are stored together with a time stamp (HC_h4) and a error counter. If the same error has appeared, consecutively several time, the error will be shown only once, but with the latest time stamp and with an increased error counter. Inputs/Outputs Inputs

Item Description/Range

Clr (BOOL) If the “Clr” input goes active (positive edge), the

complete error history memory, shall be cleared.

HC_h4 (U32) Time stamp [0.001h]

Err (U16) An error is detected, if the “Err” input is unequal

zero.

New error is detected:

“Err” is not equal to the latest error in the memory

and the error level is enabled to store.

- A new entry is made in the error history

memory

- The oldest entry is deleted

An error is detected again:

“Err” is equal to the latest error in the memory and

the error level is enabled to store.

- The time stamp of the latest entry is

updated.

- The error counter is increased.

(0…9999)

ErrStatAct (Bus) The error active- and status active variables are

located in the “ErrStatAct” bus. This variables

indicates, whether the attendant error level is

active.

ErrLev0Act … ErrLev6Act (BOOL) Error level 0…6

is active

StorLev (U8) The “StorLev” input define, whether an error level

can be stored.

StorLev (Bit 0...6) Error level 0…6 is enabled to

store

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Error History

Inputs/Outputs (continued) Output

Item Description/Range

ErrStor (Array [8]; U16) Error storage (Err0….Err7)

HCStor (Array[8]; U32) Time stamp storage (HC0_h4….HC7_h4) [0.001h]

ErrCStor (Array[8]; U16) Counter storage (ErrC0….ErrC7)

The element 0 from the array is the latest element.

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Error Status Handler

Error Status Handler

The error and status handler collect and administrated all errors and status events. Inputs/Outputs Inputs

Item Description/Range

ClrErr (BOOL) A positive edge at the “ClrErr” input clears all error

levels, which are select with the “ClrLev” input.

The error levels can only cleared, if the input value

of this error variable equal to zero.

ClrLev (U8) The “ClrrLev” input define, whether an error level

variable can be cleared with the “ClrErr” input.

ClrLev (Bit0...6) Error level 0…6 is enabled,

to clear with the “ClrErr” input

HldErrLev (U8) The “HldErrLev” input define, whether an error

variable is held after the first occurrence of the

error.

HIdErrLev (Bit0… 6 ) Error level 0…6 is held

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Error Status Handler

Inputs/Outputs (continued)

Inputs

Item Description/Range

ErrStat (Bus) The error and status variables are located in the

“ErrStat” bus.

Error variable:

ErrLev0 (U16) 0…9999; level 0 (highest priority)

ErrLev1(U16) 0…9999; level 1

ErrLev2(U16) 0…9999; level 2

ErrLev3 (U16) 0…9999; level 3

ErrLev4 (U16) 0…9999 ; level 4

ErrLev5 (U16) 0…9999 ; level 5

ErrLev6 (U16) 0…9999 ; level 6 (lowest priority)

The error variable with the level 0 has the highest

priority and the error variable with the level 6 has

the lowest priority. If the error variables are equal

to zero, no error is triggered. If an error variable is

set to an error number, an error is triggered, with

the attendant error level.

Status variable:

StatLev0 (U16) 0…9999; level 0 (highest priority)

StatLev1 (U16) 0…9999; level 1

StatLev2 (U16) 0…9999; level 2

StatLev3 (U16) 0…9999; level 3 (lowest priority)

The status variable with the level 0 has the

highest priority and the status variable with the

level 3 has the lowest priority. If the status

variables are equal to zero, no status report is

triggered. If a status variable is set to a status

number, a status report is triggered, with the

attendant status level.

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Error Status Handler

Inputs/Outputs (continued) Output

Item Description/Range

ErrStatAct (Bus) The error active- and status active variables are

located in the “ErrStatAct” bus. This variables

indicates, whether the attendant level is active.

Error active variables:

ErrLev0Act (BOOL), Error level 0 is active

ErrLev1Act (BOOL), Error level 1 is active

ErrLev2Act (BOOL), Error level 2 is active

ErrLev3Act (BOOL), Error level 3 is active

ErrLev4Act (BOOL), Error level 4 is active

ErrLev5Act (BOOL), Error level 5 is active

ErrLev6Act (BOOL), Error level 6 is active

Status active variables:

StatLev0Act (BOOL), Status level 0 is active

StatLev1Act (BOOL), Status level 1 is active

StatLev2Act (BOOL), Status level 2 is active

StatLev3Act (BOOL), Status level 3 is active

Err (U16) The “Err” output displays the value of the active

error variable, with the highest priority. If the

output is equal to zero, no error is active.

(0…9999)

Stat (U16) The “Stat” output displays the value of the active

status variable , with the highest priority. If the

output is equal to zero, no status report is active.

(0…9999)

The error and status variables can only be connected with the “Value Connect” component.

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Hour Counter

Hour Counter

Active: If the “Active” signal is true, the output “HCounter_h4” runs up. SetHC: After a rising edge (0->1) on the set value “SetHC”, the output “HCounter_h4” is set to the set value “HCVal_h4”. HCStart_h4: After the switching-on, the output “HCounter_h4” is set to the input value “HCStart_h4”. Inputs / Outputs

Inputs

Item Description/Range

Active (BOOL) Hour counter is active

HCStart_h4 (U32)* Hour counter value after switching-on [0.001h]

Note: These values need to be connected to an EEPROM cell (NVRam Input), which is saved at power down.

Output

Item Description/Range

HCounter_h4 (U32) Hour counter value [0.001h]

Set Values

Item Description/Range

HCVal_h4 (U32) Set value for the hour counter [0.001h]

Note: These values need to be connected to an EEPROM cell(NVRam Output), which is saved at power down.

SetHC (BOOL) Set the hour counter to the set value HCVal_h4

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Main Contactor

Main Contactor

Function: The intention of this block is to switch on the main contactor after power up if the V_DC_Link_mV is above a defined level. The function avoid a unnecessary high charge current of the DC link capacitors. This block compares the input at V_DC_Link_mV with an adjustable percentage of the voltage at VKey. If the voltage is above that certain level the output is set to TRUE. Once set to TRUE, the output is only reset if the power of the system is shut down. Inputs/Outputs

Inputs

Item Description/Range

Enable (Bool) This signal enable the function.

V_DC_Link_mV (U32) Voltage at power stage [mV]

Vkey (U32) Key voltage [mV]

Output

Item Description/Range

Out (BOOL) True if voltage at the power stage has reached a

certain level. The value is latched and only reset if

the power is shut off.

Parameter

Item Description/Range

MCThreshold_% (U16) Define the threshold value the function switch

on.

( 0… 10.000 ) [0.01%]

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Roll Off

Roll Off

Function: The intention of this block is to avoid unintentional acceleration of the vehicle by creating active a brake torque through the drive system. To achieve this, the set speed of the drive system is set to 0 while this function is active. Furthermore the integral value of the speed controller is overwritten with 0 to get a remaining system deviation. The influence of the integrator value of the speed controller appears through a permanent downhill-rolling in case the roll off function is active. The function is activated when the power stage is inactive and the actual speed of the motor is higher than the specified limit. Inputs/Outputs

Inputs

Item Description/Range

Enable [BOOL] Activates the roll-off function

PwrStageStat [BOOL] Status of the powerstage. Is needed as an

important switch on criteria. Must be false to

activate the function.

RPM_Stpt [S32] Requested speed setpoint. Is needed to pass the

speed setpoint request through the block in case

the function is inactive.

[0.1 rpm]

ActSpd [S32] The current speed of the motor. Is needed as an

important switch on criteria. The absolute value

must be > than SpeedRollOff value to activate the

function.

[0.1 rpm]

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Roll Off

Inputs/Outputs (continued)

Output

Item Description/Range

Status [U16] 0x8008 = Invalid setup/calibration

Hysteresis > RollOffSpd

Enable [BOOL] Activates the output enable in case roll off get

active. Activates the output enable in case the roll

off in inactive but the Input Enable = true

SpeedKI [U32] Integral gain of the speed controller.

[0.00001 Nm/rpm/s]

Note: Connect value to the Motor Control

Interface!

RPM_Stpt_Out [S32] Speed setpoint for the motor

[0,1 rpm]

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Roll Off

Inputs/Outputs (continued) Parameter

Item Description/Range

SpeedRollOff [U32] Value at which the function switches to active,

assumed other switch on conditions fulfilled.

[0,1 rpm]

RollOffHysteresis [U16] Defines how far the SpeedRollOff value has to be

under run to switch of the function.

SpeedKI [U32] Integral gain of the speed controller.

[0.00001 Nm/rpm/s]

Note: Delete value on the Motor Control Interface

Default parameter settings generate a “Invalid setup/calibration” status.

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Seat Switch

Seat Switch

Function: This function block is a delayed on/off switch. The delay function is active on the negative transition. On a positive transition at the input signal SeatSwitch the output is activated immediately. On a negative transition at the input signal SeatSwitch the output is deactivated after an adjustable delay time. If during the delay time, the input is true again, the output stays true without any interrupts. Inputs/Outputs

Inputs

Item Description/Range

SeatSwitch (BOOL) Signal which will be off delayed

Output

Item Description/Range

Out (BOOL) Off-delayed input signal

Parameter

Item Description/Range

SeatSwDelay_ms (U16) Time after which the output follows the negative

transition on the input.

Default: 1000 ms

(0 … 10.000) [ms]

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Service Counter

Service Counter

Active: If the “Active” signal is true, the output “SHCounter_ha” runs down and stops at zero. SHCZero: If the output “SHCounter_h4” equal to zero, the output “SHCZero” goes to true. SetInterval: After a rising edge (0->1) on the set value “SetInterval”, the output “SHCounter_h4” is set to the parameter value “SHCInterval_h4”. SHCStart_h4: After the switching-on, the output “SHCounter_h4” is set to the input value “SHCStart_h4”.

Inputs/Outputs

Inputs

Item Description/Range

Active(BOOL) Service hour counter is active

SHCStart_h4 (U32) Counter value after switching-on [0.001h]

Note: These values need to be connected to an

EEPROM cell (NVRam Input), which is saved at

power down.

Output

Item Description/Range

SHCZero (BOOL) Service hour counter is invalid

SHCounter_h4 (U32) Service hour counter value [0.001h]

Note: These values need to be connected to an

EEPROM cell (NVRam Output), which is saved at

power down.

Parameter

Item Description/Range

SHCInterval_h4 (U32)

(default value: 500000)

Service interval

Default: 500 h

[0.001h]

SetInterval (BOOL) Set service hour counter to the service interval

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Shunting

Shunting

Function: This block allows to set a RPM setpoint for a specified short time. The function is typically used to move a tractor towards the load, by using two buttons at the back of the vehicle. The operator can move the machine fwd or rvs at a low speed by pushing one or the other shunting button. The speed and time period for this function is limited independent how long the buttons are pressed. To activate this function the “EnblStat” (Power stage ) needs to be low and the enable needs to be high.

Inputs/Outputs Inputs

Item Description/Range

EnblStat (BOOL) Status of the PowerStage (disabled/enabled)

Needs to be disabled to allow shunting to work

Enbl (BOOL) This signal enables the function

Fwd (BOOL) Activates shunting in forward direction

Rvs (BOOL) Activates shunting in reverse direction

Warning: These two inputs must not be high at

the same time!

Outputs

Item Description/Range

Active [Bool] This output is TRUE in case of shunting is currently

running.

RPM_Stpt (S32) Value speed set point.

[0,1 rpm]

Parameter

Item Description/Range

ShuntingSpeed (U32) Maximum rpm used when shunting is active

[0,1 rpm]

MaxShuntingTime (U16) Maximum time for which the output is set

[1 ms]

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Solenoid Chopper

Solenoid Chopper

Function: After a rising edge(0->1) on the input signal Activate the output PWM is calculated according to SettlingValue for the time Settling Time_ms and then according to SteadyValue. The PWM_Value is calculated dependant on the actual supply value: If the actual supply value changes the PWM_Value is calculated in order to reach a constant voltage at the load. In order to avoid oscillations at the load voltage the PWM_Value has a hysteresis of 2%. Means the output value only changes if the difference between the result of the calculation and the output value of the previous task is more than 2%. Note: The output value is always 4,99% higher the calculated value. The reason is that the Plus+1 inverters can only handle 10% steps.

Inputs/Outputs Inputs

Item Description/Range

SupplyPWR (U32) Supply power for the according output. Can be

volt or percentage.

Important: This value needs to be of the same

scaling and unit as SETTLING VALUE and STEADY

VALUE!

Activate (BOOL) This signal starts the sequence

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Solenoid Chopper

Inputs/Outputs (continued) Output

Item Description/Range

PWM (U16) Value defined by settling resp. steady value

calculated according to the supply power.

(0…10000) [0.01%]

Parameter

Item Description/Range

SettlingTime_ms (U16) Time while settling value is present at the output.

(0… 10.000) [1 ms]

SettlingValue (U32) Output value during settling time

Important: This value needs to be of the same

scaling and unit as SETTLING VALUE and STEADY

VALUE!

SteadyValue (U32) Output value when settling time is over and

Activate is still active

Important: This value needs to be of the same

scaling and unit as SETTLING VALUE and STEADY

VALUE!

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Note

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