HBC - SERIES V7 Low Voltage (63V), small types Programmable brushless controllers for industry using Operating Manual – firmware version 3.8 or higher Development, manufacture, service: MGM COMPRO, Ing. G. Dvorský Sv. Čecha 593, 760 01 Zlín, Czech Republic Tel.: +420 577 001 350 E-mail: mgm@mgm-compro.cz Info: www.mgm-compro.
/ 60 HBC-series V7 small power Small programmable brushless controllers for industry using TMM® xxxx – 3 HBC-series V7 These motor speed controllers provide very quality, smooth motor controls for electric cars, karts, bikes, scooters, boats, aircrafts, gliders, UAV, etc.. Great application is located in many industrial drives for pumps, winches, robots, production lines, …. Controller uses the best available power MOSFET and synchronous PWM for achieve very high efficiency.
/ 60 HBC-series V7 LV small types Table of content: Table of content: ........................................................................................................................................... 3 First steps ..................................................................................................................................................... 4 Basic Recommendations ..............................................................................................................
/ 60 HBC-series V7 LV small types First steps First, before you start run controller, we recommend read Basic Recommendations and make these steps: solder (mounted) suitable connectors select basic of driving type (car, boat, aircraft / PWM, constant rpm, constant torque).
/ 60 HBC-series V7 LV small types Technical data (valid for 25°C environment temperature) (valid for control board EF5) Temperature of the environment: Motor controlling: Suitable for motors: 0°C to 40°C PWM: from 8 up to 32 kHz Number of regulation steps: Max.
/ 60 HBC-series V7 LV small types *) Maximal continuous (nominal) current: Maximal continuous current, without any time limits, is defined as current with full switching (100% motor PWM) with environment temperature 25°C and with corresponding cooling (air flow, fan or water cooling). Another important criterion is the phase currents in the full switch. Requested are practically identical (as relates to the current value) as the current from the battery.
/ 60 HBC-series V7 LV small types Available versions of HBC-series TMM xxxxx-3 V7 and basic dimension (specification in chapter „Technical data “) Basic dimensions.
/ 60 HBC-series V7 LV small types Version with cooler (heatsink) for controllers 4526-3, 6026-3, 5035-3, 5063-3 WR version Version with 2 coolers (heatsinks) and fans for controllers 9026-3, 12026-3, 21026-3, 10035-3, 18035-3, 4545-3, 9045-3, 10063-3 WR version
/ 60 HBC-series V7 LV small types Basic description of the controllers RxD data to controller (orange) TxD data from controller (red) GND (minus), brown to electromotor to electromotor C C cable #34 communication Control pulses (orange) +5 V for servos and receiver (red) GND (minus), brown Indication LED abeam B B Indication LED abeam ) A cable #2 control voltage A Connector ICS-2: Connecting brake lights + programming + ext.
/ 60 HBC-series V7 LV small types Marking and Specification of the HBC controllers / allowed combination Marking of HBC_AAAVV_V7 HBC-series Controllers - specification of options for ordering Meaning of the specifications: AAA – nominal current/ VV – max. feeding voltage Sample: TMM 10063-3 V7 HBC AAA = 100 max. continuous current 100A (nominal) VV = 63 max.
/ 60 HBC-series V7 LV small types Basic controller connection Power connectors Power connectors Traction battery (supply) or direct motor connection to the controller (without power connectors) Controller HBC- series A AKU B Braking resistors Výkonová část - řízení motoru C Sensors feeding Motor temperature BLDC motor with or without sensors +5V Sensor A Sensor B Sensor C (GND) GND FET driver Switching element Connector EFRA for sensors Braking resistors driving Control board EF5 Swi
/ 60 HBC-series V7 LV small types Connecting controller to the traction supply and turning on Auxiliary connector External antispark resistor (50Ω /1W) Controller HBC- series AC2 Traction battery PC2 To Power stage Closed contact = BATT Power connectors Electronics feeding 330F - Motor cut-off - Internal electronics cut-off - outputs cut-off 330F Switch V1 PC1 GND Filtering capacitors Note: BATT Power connectors and auxiliary connector can be replaced by corresponding contacts of the p
/ 60 HBC-series V7 LV small types Control signals specification Controller can be driven (depend on the customer specification) by some other modes (type of driving signals): - By input PWM, width of driving pulse is 1 – 2 ms, pulses period 3.5 – 30 ms, can be galvanic isolated By voltage 0 up to +3.3V (resp.
/ 60 HBC-series V7 LV small types Control by data transfer. When controlling is realized by data transfer, following possibilities can be choice: - standard line RS 232 or bus RS 485 or CAN (also optically insulated – see specification) - or RS 232 line with TTL level (advantage fr direct communication processor – processor). Controller cooperates with 3.3V systems, as well as with 5V systems. In this case line is defined like this: frame 1 byte +2.4 up to +3.3V (5.
/ 60 HBC-series V7 LV small types Control by potentiometer. In case, potentiometer is connect by longer cable (>20 cm), we recommend use shielding cable. Shielding connects to input GND point of the controller: Controller HBC- series +3.3V +3.3V Source of 3.3V 1 kΩ 1 kΩ to AD convertor GND GND Cable shielding Control by voltage. Source of control voltage must have low impedance << 1kΩ.
/ 60 HBC-series V7 LV small types Control and additional control by logic signals Control by logic signal (function A). The controller can be operated only by logic signal (on / off), applied to the control input "INP_1". Speed (power, torque, etc.) in the on position can be defined by setting the parameters P19, P20, P50 (various limits) or the engine goes to the full power. The speed of acceleration ramp is again given by parameter P16 “Acceleration”.
/ 60 HBC-series V7 LV small types Cooperation with RC Remote Control When you need or is necessary used industry version of the controller in the model or you want only use transfer path of RC equipment: Receiver and antenna should be placed as far as possible from the motor, controller, the batteries and power leads. Controller’s cable #1 connect to the receiver, throttle channel.
/ 60 HBC-series V7 LV small types Control signal – correct limits and emergency conditions Controller monitors presence of driving signal continuously (input PWM, voltage range, potentiometer connections, data transfer). When find not correct driving signal range, absence of driving signal, potentiometer defect etc., activates emergency stop regime, with parameters P38 (Masking time for signal lost) and P39 (Brake intensity for signal lost), which defines all the emergency stop process.
/ 60 HBC-series V7 LV small types Control by input PWM: Here is similar situation. When lost signal from driving PWM generator or signal parameters go outside from limit range, or cut signal wires or shorting of these wires (together or to GND), after time "masking signal drop" P38 is activated emergency stop procedure, as in previous cases.
/ 60 HBC-series V7 LV small types Back data transfer, telemetry (only for controllers marking „BC“). If you need some information or data to monitor in traffic in real time, at a distance (i.e. cannot be used "Monitoring"), it is possible to use some sets of modules for remote control and the data transfer and display their help with. Controllers with „BC“ modification has not only general servocable #1, but also second cable #34.
/ 60 HBC-series V7 LV small types Sensor motors and controllers Sensor motors (BLDC motors with sensors) can have generally different connector and variously connected. If you have a motor with any sensor connector or if you are not 100% sure of connecting the motor sensor wires and/or motor power cables on separate phases, it is necessary make to first "Automatic sensor settings".
/ 60 HBC-series V7 LV small types SENSOR MOTORS: Sensor motor according to EFRA specification: Phase C Phase B - must have 6-pin JST ZH connector model ZHR-6 or equivalent, marked as SZH-002TP0.5 26-28 awg.
/ 60 HBC-series V7 LV small types Optimal and allowed motor sensor position Next picture displayed correct relative position all phases voltage (back EMF) and sensors. Phase voltage, as well as sensor signals, is offset by 120°. Optimal sensor position is such that sensor signal edge correspond with “zero crossing” moment (marking by red ring on the phase voltage).
/ 60 HBC-series V7 LV small types Basic operating modes - mode choice and basic type of behavior The regulator has a preset several basic modes (or types) of behavior that can be combined with PWM, constant speed, constant torque.
/ 60 HBC-series V7 LV small types Divided control BRAKE / THROTTLE Mode CAR: one way mode ●► Mode CAR: one way mode One-way Car brake is on a separate channel »●► THROTTLE BRAKE Braking intensity P11 = P10 P9 P8 P7 STOP P6 . fig. 9 fig. 10 The throttle is controlled by the main control channel, brake by auxiliary. If the brake is activated (brake driver / activator is out of neutral, i.e.
/ 60 HBC-series V7 LV small types Programmable parameters Parameters setting by user, including default values for all memory banks (type of driving): parameter range step Bank #1 Default settings P1 P3 P2 P69 P5 P4 P33 P90 Memory bank Basic type of behavior Direction mode Control type Controller start behavior Control signal Control signal limits setting lock Signal limits monitoring 1 4 Bank #2 Default settings Bank #3 Default settings Bank #4 Default settings H H H H Bank #1 Car Bidirect
/ 60 HBC-series V7 LV small types Parameter Table continue parameter range step Bank #1 Default settings Bank #2 Default settings Bank #3 Default settings Bank #4 Default settings P16 Acceleration (time from 0% to 100%) 0,1 sec. 60 sec. 0,1 0,5 sec. 0,5 sec. 0,5 sec. 0,5 sec. P17 Acceleration from STOP position (only for constant rpm mode) 0,1 sec. 60 sec. 0,1 0,5 sec. 0,5 sec. 0,5 sec. 0,5 sec. 0,1 sec. 0 sec. 0% 60 sec. 60 sec. 100% 0,1 0,1 1% 0,5 sec.
/ 60 HBC-series V7 LV small types Description of all parameters P1 : Memory bank – memory choice (choice of pre-defined parameters) This special parameter makes possible choice of one of four pre-defined settings.
/ 60 HBC-series V7 LV small types P4: Control signal Driving signal can be: - input PWM (pulse width 1 ÷ 2 ms, period 3.5 ÷ 30 ms, signal pulse level 0 ÷ 3,3V or 0 ÷ 5V) - voltage 0 up to +3,3V resp. 0 up to +5,0V (or other range) - potentiometer 1kΩ (resp. 5kΩ or 10kΩ) - logic signal, value 0 to +3,3V resp. 0 to +5,0V, read contact, etc.
/ 60 HBC-series V7 LV small types P6, P7, P8: Joystick limits, range of control signal – values for Main channel (values in µs (microseconds) or mV (millivolts)) Full throttle Forward 100% (= 2.0ms for driving PWM or +3.3V (+5.0V / +10V) for driving voltage) STOP (Neutral) 0% (~ 1.5ms for driving PWM or ~1.65V (~2.5V resp. ~5.0V) for driving voltage) Full throttle Backward -100% (= 1.0ms for driving PWM or 0.
/ 60 HBC-series V7 LV small types P42: Controller feeding (Type of cells / switching-off voltage) Parameter set type of cells, include standard switch-off voltage. Monitoring each cell is possible select for some type of cells. Also is possible set switch-off voltage as 78% of value in moment of connection battery.
/ 60 P87: "Empty battery" in advance warning by charge (alarm when battery charge drops below that …) (value specified in% of battery capacity specify in P78) HBC-series V7 LV small types In some cases it is preferable to monitor the quantity of residual battery energy by integration of discharging current. The system alerts to residual amount of fuel (energy in the battery) when reach the set value of the residual capacity in %.
/ 60 HBC-series V7 LV small types P52: Motor timing (value in ° (angle in degrees)) Automatic timing or 0° is recommended settings for most of the motors. We recommend this setting also in cases when motor producers recommend some concrete angel, for example 10° (this is necessary for some other controllers, not MGM compro). Automatic timing cannot be the best for some sensorless motors working on the border of its power possibility – they can lose synchronization.
/ 60 HBC-series V7 LV small types P16: Acceleration, increasing of the power (rpm), time from 0% power to 100% (values in milliseconds) Sets the time (speed) stopped the engine acceleration from 0 to 100% power. Apply in proportion anytime between any levels. P18: Deceleration, decreasing of the power (rpm), time from 100% power to 0 (values in milliseconds) Time necessary for decrease rpm from full value to zero (from 100% to 0) when move throttle (joystick) from full throttle position to STOP.
/ 60 HBC-series V7 LV small types P82: Cruise controls Ramp (values in seconds) Sets the rate of reaction speed at which the cruise control tries to maintain a set speed. P22: Brake intensity (for car control type only) (value in %) Function enables to set the maximal force of proportional brake in the maximal deflection of the joystick (braking intensity) + possibility “no brake” (suitable for systems with mechanical brake). Set according to your needs.
/ 60 HBC-series V7 LV small types Freewheel and Brake, control type Car bidirectional, freewheel active: Unloaded motor rpm go slowly down bay inertia (freewheel) +100% Braking with 40% intensity Control signal Joystick (throttle) moving Braking with 70% intensity Braking with 40% intensity motor PWM Motor is stopped 0% (STOP) 0,5 sec.
/ 60 HBC-series V7 LV small types P71: BB data logging period (Internal BlackBox record period) / real time Monitoring The standard write speed is 100 ms. With this rhythms are stored in the memory averaged measured values. Recording time is about 12 minutes. If you want to write faster (each 10 ms), averaging is faster (fewer samples), rapid of the details are better drawn, but recording time is 10 times shorter. You can select a record from the beginning or end (last 12 minutes).
/ 60 HBC-series V7 LV small types P36: Calibration of the battery temperature sensor (value in °C) For easy replacement of the temperature sensor you can make its calibration at any time. If you specify this parameter in the current ambient temperature in which the sensor is calibrated (of course after stabilization of temperature), write them into the controller and turn-off and back turnon the controller.
/ 60 HBC-series V7 LV small types Parameters setting / Data reading from controller To set parameters or reading data from the controller, you need to connect your PC and the controller module USBCOM 4 or USBCOM 4i (for the controller feeding from the mains power supply), the PC software "Controller 2", which is free to download from our web and on CD and need connecting cable CC_11. .
/ 60 HBC-series V7 LV small types Locks of parameters If you need for parameters that you set (only some or even all) the user could not change value for any reason, you can use a system of locks parameters. If the window "Settings" click on "Lock settings", you open the window where you can choose which parameter remains open and which not. Mark all the parameters you want locked against overwriting (here P1, P2, P3 and P4), enter " Lock code " and select "Write settings"“.
/ 60 Locked parameters are displayed, but they cannot be changed (up to unlock using the correct code).
/ 60 HBC-series V7 LV small types Internal Black Box (flying recorder) – data logger For correct using of controller’s Black Box, set requested value for „Record period“ (P71). You can choice more quickly record with more details but shorter record time (each 10 ms, i.e. 100× per second, record time ca 1,2 minutes) or slower and longer record (each 100 ms, i.e. 10× per second, record time ca 12 minutes).
/ 60 HBC-series V7 LV small types Read History Export to Excel file Setting the properties of curves, assigning to the left or right scale, appearance chart A new area selected to zoom The left vertical axis (scale) „Switch-on“ and „switch-off“ selected variables The right vertical axis (scale) Time axis Enlarged selected area
/ 60 HBC-series V7 LV small types Evaluation (interpretation) parts of the record: For greater clarity, the color and scale are changed to images on the previous page. Here is shows a throttle (input command), the output power in % and current from about 11 to 40 second.
/ 60 HBC-series V7 LV small types Data stored in the record to an internal Black Box / The data displayed in real time (Monitoring): storage / display data comment Data: D1 D2 D3 D4 D5 D6 D7 Time Input command The supplied power % Motor speed (×100) Speed of system (× 100) sec.
/ 60 HBC-series V7 LV small types Monitoring (display data in real time) If you need monitor the values of individual variables and data in real time on a PC monitor (not telemetry, which currently has limited options for imaging), it is appropriate to use the "Monitoring" data. This allows you to watch all the variables as in the graph (as well as for reading data recorded Black Box) and the numerical values in separate box also.
/ 60 HBC-series V7 LV small types Throttle limits settings (range of joystick, range of control signals) To respond the controller to control signal (joystick) exactly by your image, it is necessary to unify end points of the control signal (control signal limits) generated by the control equipment (potentiometer, etc.) with the values entered or stored in the controller. There are two ways. I. To the parameter P4 "control signal" set " PWM pulse - Automat" (default setting).
/ 60 b) HBC-series V7 LV small types By control signal source - set corresponding limits at any time direct by the signal source (even without connection to PC). Parameter P33 "Setting from transmitter" must be set to "Enabled“. Parameter P4 "Control signal" is set to „Programmed“. Neutral=STOP STOP position (NEUTRAL) +1.65 V (1.
/ 60 HBC-series V7 LV small types Start with Automatic throttle limits In the parameter P4, „Control signal” is set „Automat“, this is also default setting. Neutral=STOP STOP position (NEUTRAL) +1.65 V (1.5 ms) Very helpful information about how controller evaluates the current position of the throttle stick, give LEDs of the controller. forward backward Signal sources with NEUTRAL (with lock of STOP position) (position STOP is identical with the position „Neutral“ ) 0.
/ 60 HBC-series V7 LV small types Start with programmed throttle limits a) Type of controller’s start (parameter P5) is set to „Safety start“ (default value) or „Fast start“ . In the parameter P4 „Control signal“ is set “Programmed“ or some possibility of Programmed, parameters II ( under line ====== ) Controller remembers set throttle limits. STOP position 1) Turn on control signal source. Joystick (potentiometer, control voltage, …) is in position STOP: = neutral for joystick with neutral = min.
/ 60 HBC-series V7 LV small types Maximal revolution of the output shaft Settings For setting of Maximal revolution of unloaded motor (view from the motor, not mechanics of the system) necessary make following steps. Set these parameters values by program Controller 2 (obligatory data): Parameter P50 Parameter P47 Parameter P48 – max.
/ 60 HBC-series V7 LV small types Update SW inside the controller (firmware) When you want make update firmware in you controller to newest available version, you need USBCOM 4 module (or in case of feeding from power supply USBCOM 4i module – isolated version) and CC_11 cable (the same as for standard programming of parameters). Controller must be connected to internet. CC_11 0 Starting sequence for firmware updating follows: 0. Connect USBCOM 4(i) module to PC and Start program Controller 2 first.
/ 60 HBC-series V7 LV small types 7. Updating procedure start. 8b. when procedure corrupt (communication error etc.), is displayed this message Necessary start this update again. 7 8a. When procedure correctly finished, message will appear. Push OK. 8b 8a 9. Follow next instruction. 10. After restart device (your speed controller), newest version of its firmware is displayed. Update procedure is complete.
/ 60 HBC-series V7 LV small types Installation and run program Controller 2 Are very simply and intuitive. Details are described in manual „Installation and controlling of program Controller 2“, follow instructions in this manual please. Update of program Controller 2 Update SW version of your program Controller 2 is possible make by two ways. 1. After start program automatically advice to new version in left upper corner – start update by this way.
/ 60 Controller states indication, Error messages HBC-series V7 LV small types (firmware 3.8x and higher) Controller indicate states by 4 LED and also acoustic by motor beeping. In this example blue LED blinking, others lights continuously: ♪ short beep long beeeep / blue is light, other is off: ♪ ♪ ♪ melody Possible states: short blink of all LEDs after switch/on controller (check of LED) ………………. a) correct states (= blue LED lights continuously ): 1 - all is O.K.
/ 60 HBC-series V7 LV small types Sparking prevent when connect higher voltage When connecting a Li-xxx pack to the controller, strong sparking commonly occurs. Fast charging of the controller filter capacitors causes this. The higher battery voltage (for the higher the cell count) and/or the lower the internal battery resistance (and the better the quality of the pack) caused more intensive spark.
/ 60 HBC-series V7 LV small types Additional information Influence of the battery quality to controller behavior (automatic current reducing). If the peak current during start and acceleration loaded battery to the point that the voltage has dropped below the minimum controller voltage, i.e. below about 10V, the controller automatically reduce power (current) to the engine (i.e. the speed ramp-up) so that the battery voltage does not drop below the safe limit.
/ 60 HBC-series V7 LV small types ® Some of Protective and Safety mechanisms of TMM controllers Controllers mask interference and signal losses for up to defined time in parameters. Motor revolutions are gradually reduced for longer lasting signal drop outs or interference. When the signal is restored, the controller goes smoothly back to the required power. Long lasting signal drop out (or its absence) is indicated by LED.
/ 60 HBC-series V7 LV small types Accessories FAN 05 with screws Power connectors MPJET 2,5 – 3,5 – 5,0 Indication module BL_04D Indication module BL_04D - detail For mounting fan(s) to original cooler (on the controller) is possible use only enclosed screws.
/ 60 HBC-series V7 LV small types Content of delivery Controller in box 3 antispark resistors CD with program Controller 2, with manual and other information Printed basic (general) information Warranty certificate Product Warranty MGM COMPRO guarantees, this product to be free from factory defects in material and workmanship. Warranty period is of 24 months from date of purchase and purchase within the EU.
