High Power BLDC Controller User Guide

HPCSeriesBrushlessDCMotorControllerUserGuide

GoldenMotorHPCseriesmotorcontrollersarespeciallydesignedforhighpower,highreliability brushlessDCmotordriveforelectricvehicles,boats,andindustrialapplications.Thecontrolleris usingthecuttingedgetechnologiestodeliversmoothandrobustcontrolexperiences. Thecontrollersaremanufacturedwithhighqualitycomponentsandmaterialsforhighendusers. ThecasingiscompletelysealedtomeetIP66protection. Theoptionalprogrammingkit(usingPCUSBport)isavailableforexpertuserstosetupcontrol parametersfortheirspecialapplications. KeyFeatures: Suitable for brushless DC motors Low noiselittle torque fluctuation Maximum efficient >98%high reliability IP66 Protection 23-pin waterproof Connector Regenerative Braking Slope holding control Cruise speed control Over heat protection for both motor and controller Programmable via USB of PC/Laptops Programmable motor temperature limit DSP control

Support CAN port (optional) Dual controller synchronous drive

HPC300HSeries HPC500HSeries

HPC700HSeries

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High Power BLDC Controller User Guide

Product Specifications
Model HPC300H Series HPC500H Series HPC700H Series HPC300H48360 HPC300H72300 HPC300H96240 HPC500H48600 HPC500H72500 HPC500H96400 HPC700H48840 HPC700H72700 HPC700H96560 Peakinput current 180A 150A 120A 300A 250A 200A 420A 350A 280A PeakOutput current(1min) 360A 300A 240A 600A 500A 400A 840A 700A 560A

Voltageof BatteryPack 48V 72V 96V 48V 72V 96V 48V 72V 96V

Cooling Condition

External cooling

Product functions
HPCSeries

70~90C:limitcurrentoutputtopreventthecontrollerfrom overheatanddamage. >90C:controllerwillselfshutdown Motortemperatureprotection Programmabletemperaturelimit.Ifthemotortemperaturehit thelimit,controllerwilllowertheoutputcurrenttomotorto preventmotorfromoverheatordamagemotorparts. (Itworksonlywhenmotortemperaturesensorispresented) RegenerativeBraking(Energy Transformingkineticenergyofvehicleintoelectricitytocharge feedback) thebatterywhenBrakeisshortedtoGNDorBrakeis12V, chargingcurrentandvoltageareprogrammableviaUSB programmableinterface. Brakecontrol Stopmotordrive,regenerativebrakingstarts. FWD/REVcontrol Controlthemotorrotationdirectionbetweenforwardand reverse Cruisecontrol Buttonswitch: Depresstheswitchtostartcruisespeedmode Releasethebuttontocancelcruisemode,orcruisecontrol functioniscancelledwheneverbrakeisONorFWD/REV switchchanges. Note: Ifacceleratorcontrolspeedishigherthancruisecontrolspeed, acceleratorcontrolisineffect.Ifacceleratorcontrolspeedis lowerthancruisecontrolspeed,acceleratorcontrolisnotin
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Item Controllertemperature protection

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Slopeholdingcontrol

effect. Optional: Whenparkingorstartonslope,thevehicledoesnotslip.

Alarm status output by USB or CAN Alarmstatusdisplay HighVoltageShutdown Actionstorectify Checkandresetparameter<VoltageHigh Shutdown>valuesetting,thenrestart controller Checkandreset<VoltageLowShutdown> valuesetting,orchargebatterypack Checkandreset<VoltageLow1>value setting,orchargebatterypack. Checkandreset<VoltageLow2>value setting,orchargebatterypack. Coolingcontrollerorcheckheatsink,then restartcontroller. Coolingcontrollerorcheckheatsink. Checkandadjust<motoroff(C)>valueor coolthemotor CheckLinecontractorcoil(PIN2,PIN3) Checkfancontractorcoil(PIN2,PIN4) Checkreversecontractorcoil(PIN2,PIN5)

LowVoltageShutdown Voltagelowlimitedspeedto50% Voltagelowlimitedspeedto15% Controllershutdownathightemperature Controllerlimitscurrentoutputathigh temperatureofcontroller Controllerlimitscurrentoutputathigh temperatureofmotor CurrentShutdownofDCContactor1(PIN3) CurrentShutdownofDCContactor2(PIN4) CurrentShutdownofDCContactor3(PIN5) MotorHallError

Checkhallsensorwireofmotorand connectorormotorhallsensor PhaseCurrentOverShutdown Checkphasewireofmotor Checkcoilwireofmotor Checkcontrolleroutputcurrent StallofMotorShutdown Resetphasecurrentvalue Checkpositionsensorofmotor Motorshaftisbraked AcceleratorOutputVoltageHighShutdown(PIN7) CheckacceleratorGND(PIN8)wire, connectororaccelerator

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Wiringdiagram
HPCHSeriesMotorControllerWiringDiagram

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23PINConnectorPinNumbering

PINConnectorPinDefinitionandDescription Function PIN Symbol Numericalvalue Powerinput 1 PWR BatteriesVoltage Contractor+ 2 CON BatteriesVoltage Linecontactor 3 CON1 24~48Vwindingofline control contactor Fancontactor 4 CON2 24~48Vwindingofcontactor control2 Reservecontactor 5 CON3 24~48Vwindingofcontactor control3 PWR 6 +5VPWR +5V Accelerator 7 Acc Acceleratorsignal Sensor GND 8 GND GND FWD/REV 9 FWD/REV GNDFWD Brake 10 BAK GNDTrue Cruisecontrol 11 Cruisecontrol GNDTrue Hybridcontrol 12 Hybridcontrol GNDTrue Brake 13 BAK 12VTrue RXD 14 RXD RXD TXD 15 TXD TXD CANH 16 CANH CANH CANL 17 CANL CANL Motorsensor 18 Ha/SIN Halla/SIN Motorsensor 19 Hb/COS Hallb/COS Motorsensor 20 Hc/AGND Hallc/AGND PWR 21 +5VPWR +5V GND 22 GND GND MotorTEMP 23 Motor MotorTEMP temperature
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Remarks Precharge Ipeak<10A Ipeak<10A Ipeak<10A Ipeak<1A Buttonswitch 0~15VInput Ipeak<1A Silicontemperature sensors: KTY84130

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HPC300HseriesMotorControllerDimensions(weight2.2kg):

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HPC500HseriesMotorControllerDimensions(weight2.9kg):

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High Power BLDC Controller User Guide

HPC700HseriesMotorControllerDimensions(weight5.7kg):

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High Power BLDC Controller User Guide

z Connectwithaccelerator
Acceleratoroutputvaluecanbewithlinearoutputorindexoutput,useUSBprogrammer softwaresetup. 1. ConnectwithHallSensorAccelerator 2. Connectwith3wireResistorSensorAccelerator 3. Connectwith2wireResistorSensorAccelerator Initialvalue(mv) Finalvalue(mv) Threshold(mv) Typicalvalue 100 4100 4500 range 50~1200 2000~4100 4500~4900 Initialvalue(mv) Finalvalue(mv) Threshold(mv) Typicalvalue 100 4100 4500 range 50~1200 2000~4100 4500~4900 Initialvalue(mv) Finalvalue(mv) Threshold(mv) Typicalvalue 800 4500 4900 range 650~1200 2000~4500 4600~5000

Note:Externalresistor(1Kohms)topreventGND disconnectautomaticallyrunofthevehicle.

Note:Externalresistor(1Kohms)topreventGND disconnectautomaticallyrunofthevehicle.

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Connectwithmotortemperaturesensor Motortemperaturesensor Type:KTY84130 Range:40~300C

z Connectwithmotorhallpositionsensors
Controller Pin18 Pin19 Pin20 Pin21 Pin22 Motor Halla/sin Hallb/cos Hallc/AGND +5V GND MotorColor Blue Green Yellow Red Black
U V W
Motor Controller 18
19

Blue

Motor

Green

M
Motor Sensor Ha/sin Hb/cos + Hc/agnd

Yellow

20 21 22
+5V GND

z Connectwithcontractor
contactorcoilvoltage contactorcoilvoltagesetup 36Vdc 24Vor36V 48Vdc 36or48V 72Vdc 48V WhenthePowerOn,SelfTestisnormal,about 600ms,afterthecontrollerstartlinecontractor. Whenthecontrollertemperature>30,after thecontrollerstartFancontractor.
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WhentheFWD/REVisREV,afterthecontroller startReversecontractor. ConnectwithBrakeorBrake

z Brake: Whenthebrakeswitchisclosed,themotor feedbackenergytothebatteryaccordancewith setupvoltageandcurrent.

Brake: Whenthebrakeswitchisclosed,themotor feedbackenergytothebatteryaccordancewith setupvoltageandcurrent. or

Brake switch 13
12V

Motor Controller

GND

Brake: Whenthebrakesignalchanges,themotorfeedback energytothebatteryaccordancewithsetupcurrent scaledchanges.

+5V

Brake signal 5K
GND

13
8

Motor Controller

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