how to program a sevcon gen4

General Discussion about large electric scooters and motorcycles and other things with no pedals.
ceibnu   1 µW

1 µW
Posts: 2
Joined: Jul 09 2014 11:27pm

Re: how to program a sevcon gen4

Post by ceibnu » Jul 10 2014 4:43pm

querlenker wrote:There are different models of the PMS 120, I could share the manufactory standard values of a 72/80v 10,5kw water cooled version.
I have the one that is 7kw air cooled, 72v. Even though, I would apresiate if you could send me the dcf
Thanks

tomaj   10 W

10 W
Posts: 72
Joined: Nov 12 2010 5:01pm
Location: Slovenia

Re: how to program a sevcon gen4

Post by tomaj » Jul 28 2014 7:03am

I still have not manage to set sevcon to operate with ME1302 motor. Motor spins up to 1000RPM and starts to oscillate. I have uploaded dcf file for this motor. Settings are for 80V nominal voltage but I run it on 105,6V.

Firstly I have to set encoder offset in DVT. I have no idea how to do that. There is nothing about this in the manual. Heeeelp! :mrgreen:

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Jul 28 2014 8:51am

tomaj wrote:I still have not manage to set sevcon to operate with ME1302 motor. Motor spins up to 1000RPM and starts to oscillate. I have uploaded dcf file for this motor. Settings are for 80V nominal voltage but I run it on 105,6V.

Firstly I have to set encoder offset in DVT. I have no idea how to do that. There is nothing about this in the manual. Heeeelp! :mrgreen:

Thomas, PM me your email I will send you the document for that :wink:

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

e-vektor   10 W

10 W
Posts: 97
Joined: Sep 22 2013 10:30am
Location: Spain

Re: how to program a sevcon gen4

Post by e-vektor » Sep 16 2014 4:32am

Dear All

I bought a sevcon gen4 from ebay (the one which was advertised in other post), the problem now is that of course my local distributor will not provide the DVT software.
Have any of you managed to communicate with the sevcon using some open-source CANopen software?
any ideas?

I am trying to configure an induction motor/alternator from a Buick Lacrosse. Have any of you managed to control this motor?
(first problem is the resolver, I am preparing a resolver to encoder pulses converter PCB with an Analog Devices chip)

thanks

buddhafragt   1 µW

1 µW
Posts: 2
Joined: Oct 15 2014 3:33am

Re: how to program a sevcon gen4

Post by buddhafragt » Oct 15 2014 3:39am

Hallo,
anyone know how to get the Sevcon DVT Software?
Sevcon Germany is exreamly unfriendly, although the software is free,
they dont like to send me a copy :cry:

Gruß
Michael

BigHolly   1 µW

1 µW
Posts: 1
Joined: Oct 15 2014 4:22pm
Location: Bedfordshire UK

Re: how to program a sevcon gen4

Post by BigHolly » Oct 15 2014 4:34pm

Hello all
I have a GEN4 controller stuck in BOOTLOADER mode and I need the DLD file for a GEN4 80V 350A controller.
Can any one help

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Oct 15 2014 10:12pm

Hi Guys,

Send me a PM with your email, i'll see if i can help both of you:wink:

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

EEDan1010101   100 µW

100 µW
Posts: 9
Joined: Oct 22 2014 1:02pm

Re: how to program a sevcon gen4

Post by EEDan1010101 » Oct 28 2014 8:32pm

Hi Guys,

I have a Motenergy ME1115 Motor and I'm using a sevcon gen4 size4 motor controller. I bought the USB-CAN and have the DVT software, but I'm wondering if there is a dcf for this motor.

tomaj   10 W

10 W
Posts: 72
Joined: Nov 12 2010 5:01pm
Location: Slovenia

Re: how to program a sevcon gen4

Post by tomaj » Oct 29 2014 5:07pm

Winter is coming and time to deal with lovely Sevcon :D

I have dcf file for Size 4, 80V. I uploaded file to my Size 6, 105V nominal. Well, it kinda works. But motor spins only to around 2000RPM and starts to oscilate. Decreasing RPMs is also not smooth, actually it is impossible to reduce RPM gradually. Motor is ME1302.

Which values I have to change due to higher system voltage?

I have already change battery pack voltages, raise the RPM limits,set encoder, contactor and throttle.

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Oct 29 2014 10:01pm

tomaj wrote:Winter is coming and time to deal with lovely Sevcon :D

I have dcf file for Size 4, 80V. I uploaded file to my Size 6, 105V nominal. Well, it kinda works. But motor spins only to around 2000RPM and starts to oscilate. Decreasing RPMs is also not smooth, actually it is impossible to reduce RPM gradually. Motor is ME1302.

Which values I have to change due to higher system voltage?

I have already change battery pack voltages, raise the RPM limits,set encoder, contactor and throttle.

Ahh it seem you have to play with these proportional integral and Ke value witch is a real nightmare :P

I actually get this oscillation problem when WOT until hitting 50mph.. if i reduce the throttle(acceleration) it goes well... but going WOT make the motor to cut and oscillate slowly at 80+km/h

It's a real engineering degree that ia required to fully understand the parameters.. and without a dyno it is even worst!

Sevcon are great quality and performance but a real nightmare to tune!

Doc

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

tomaj   10 W

10 W
Posts: 72
Joined: Nov 12 2010 5:01pm
Location: Slovenia

Re: how to program a sevcon gen4

Post by tomaj » Oct 30 2014 3:15am

Thanks for the answer.
Yes it is a pain in the ass to tune the controller :roll: :lol:

Do you perhaps have any manual or explanation of those parameters?
I do not have dyno but I have time 8)

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Oct 30 2014 10:11am

tomaj wrote:Thanks for the answer.
Yes it is a pain in the ass to tune the controller :roll: :lol:

Do you perhaps have any manual or explanation of those parameters?
I do not have dyno but I have time 8)

Send me a Pm with your email, i'll see what i can do.. it might take some days i am really busy now.

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

User avatar
etlaare   1 µW

1 µW
Posts: 3
Joined: Nov 02 2013 4:12am

Re: how to program a sevcon gen4

Post by etlaare » Dec 08 2014 3:34pm

Oh oh, running a gen4 size 4 with a ME0913 it looks fine until I throttle up above 2000 rpm the motor spins out of control stops brutally and gives these two messages on the DVT:

0 : 0x52c3 Current Control Fault
1 : 0x51319 Mtr Slv in Wrong State

I did not setup any master slave as it's a single motor configuration.

Any ideas anyone ??

Biff   100 W

100 W
Posts: 192
Joined: May 26 2008 10:58am
Location: Kelowna, BC

Re: how to program a sevcon gen4

Post by Biff » Dec 16 2014 7:35pm

etlaare wrote:Oh oh, running a gen4 size 4 with a ME0913 it looks fine until I throttle up above 2000 rpm the motor spins out of control stops brutally and gives these two messages on the DVT:

0 : 0x52c3 Current Control Fault
1 : 0x51319 Mtr Slv in Wrong State

I did not setup any master slave as it's a single motor configuration.

Any ideas anyone ??
Mtr Slv in wrong state has to do with the state machine inside the softare of the controller, not a master / slave relationship. They occur quite often after a current control, or a motor over current fault

I suspect that your encoder offset is not setup properly.

Try spinning your motor at around 1000 RPM while recording a trace (ensure you have Ud and Uq in a TPDO) for about 10 seconds then use the PMAC encoder window to plot the voltage vectors and adjust the encoder offset.

-ryan

User avatar
Arlo1   100 GW

100 GW
Posts: 8115
Joined: Apr 26 2009 10:36pm
Location: Nanaimo
Contact:

Re: how to program a sevcon gen4

Post by Arlo1 » Jan 22 2015 9:07pm

I have one stuck in the IM motor control and won't let me set it up to run a PMAC. Anyone else order any of the cheep sevcons from ebay and get them running a PMAC? It is one of these ones.

It looks like they programed them to run some induction motors but now I need to set it up to run a Zero motor and I can't figure out how to swtich it from IM settings to PMAC settings.

I tried the setting under RPDOs and TPDOs "setup PMAC default TPDO" and every time I get this error code and then the progress bar freezes.
Attachments
John (800 x 411).jpg
John (800 x 411).jpg (47.74 KiB) Viewed 5043 times
JOHNS size 4 2 (600 x 297).jpg
JOHNS size 4 2 (600 x 297).jpg (33.98 KiB) Viewed 5043 times
JOHNS SIZE 4 (600 x 400).jpg
JOHNS SIZE 4 (600 x 400).jpg (40.8 KiB) Viewed 5043 times
My Leaf motor controller build. http://endless-sphere.com/forums/viewto ... 27#p963227
My YSR build http://www.youtube.com/watch?v=BRo8r5g4NBg
RC and most types of Lithium batteries you MUST know your individual cell voltages charging and discharging.
Don't keep them were you cant afford smoke or fire!
Never above 4.2v never below 2.7v EVER!!!
Support me on Patreon. https://www.patreon.com/user/posts?u=6842045
http://www.undergroundelectrics.ca/

Elstrat   1 µW

1 µW
Posts: 1
Joined: Feb 18 2015 4:11am

Re: how to program a sevcon gen4

Post by Elstrat » Feb 18 2015 4:15am

Hi

does anyone here have the Drive wizard software? I would need it for self configuring
a Gen 2 size 4. Losing my mind here with an induction motor.

rea tu rd @ gmail com

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Feb 18 2015 8:56pm

OK sorry guys but let's be clear.. I am not your Sevcon software life saver! :lol:

I get so many email requesting dvt and dcf and how to.... :shock: :shock:

Please if you get sevcon stuff ask your seller for these qustions.. you pay less for used parts.. but take note that you will have to spend time learning on the "how to" but i am not the "here it is"....

I dont have time to share everything to all of you so please dont contact me for that.

this is not because i acept helping one person that i can help everyone :lol: :roll: think about it!.. it's my free time and i preffer sharing it with the E-S for VARIOUS subject rather than sending emails with DVT etc... and explain how that not easy Sevcon programming job is..

Thanks for understanding! :wink:

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

stealthhack   100 µW

100 µW
Posts: 8
Joined: Jul 18 2014 6:45am

Re: how to program a sevcon gen4

Post by stealthhack » Feb 24 2015 9:56am

Guys can you help me with configuring the sevcon gen 4 80V size 6 to AD AC24LS motor, i'm new with these inverters and my knowing is very limited, i manage to spin the motor, but the parameters are mess, so pls help with configuring!
I also have Sevcon SCWiz which is a auto-tune wizzard for these contollers but can't make it work for now, don't know the reason(it says Access Denied).
Here is my DCF file, dumped from the controller:
https://drive.google.com/file/d/0B-uUzk ... sp=sharing
And that's the Sevcon SCwiz control panel, which i can't make it work for unknown reasons:
https://drive.google.com/file/d/0B-uUzk ... sp=sharing
https://drive.google.com/file/d/0B-uUzk ... sp=sharing
If you want the Sevcon SCwiz software, just tell me i will upload it here! :wink:
And that's the motor which is wired in Delta(40V 89A per phase)!
http://endless-sphere.com/forums/downlo ... &id=160155
EDIT: sorry if my english is rusty. :oops:
Attachments
DSC_0007.jpg

toukanar   1 mW

1 mW
Posts: 15
Joined: Sep 20 2014 12:56pm
Location: Nantes
Contact:

Re: how to program a sevcon gen4

Post by toukanar » Jul 04 2015 3:11pm

To Arlo1 :
Have you been able to setup your controller ? I'm using 2 of these with cheap PMAC MOTENERGY motors, and I haven't had much problems so far:
http://endless-sphere.com/forums/viewto ... 34&t=67388

Yannick

User avatar
Arlo1   100 GW

100 GW
Posts: 8115
Joined: Apr 26 2009 10:36pm
Location: Nanaimo
Contact:

Re: how to program a sevcon gen4

Post by Arlo1 » Jul 04 2015 7:05pm

toukanar wrote:To Arlo1 :
Have you been able to setup your controller ? I'm using 2 of these with cheap PMAC MOTENERGY motors, and I haven't had much problems so far:
http://endless-sphere.com/forums/viewto ... 34&t=67388

Yannick
Yup a super awesome helpful person helped me out. :)
Yes I had to load new firmware :)
Then a DCF and set it up I got all 5 set up:)
My Leaf motor controller build. http://endless-sphere.com/forums/viewto ... 27#p963227
My YSR build http://www.youtube.com/watch?v=BRo8r5g4NBg
RC and most types of Lithium batteries you MUST know your individual cell voltages charging and discharging.
Don't keep them were you cant afford smoke or fire!
Never above 4.2v never below 2.7v EVER!!!
Support me on Patreon. https://www.patreon.com/user/posts?u=6842045
http://www.undergroundelectrics.ca/

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Oct 19 2015 1:06am

It is official, my old 2012 ZF9 is now using the SR size 6 controller as well as the 75-7 motor of all 2013+ 8)... Oh.. and with boostpack to bring it to ZF15! ;)

ONe of the most complicated part was to rebuild the DCF file for the controller that match all these parameters together from other DCf files from the 2014 SR, 2012 S with 75-7 motor.

I have used Winmerge and isolated every single variable that a reuncommon to both files from the 2014 SR and 2012 S 75-7.

for exemple, setting the new torque to 180Nm, new max current 660A insteaf of 420, etc

I have preserved all voltage parameters from the 2012 S file to keep all compatible settings that are made for the 66V battery of teh 2012 and have transfered all parametres like torque, current, gain, torque curves etc...

After couple hours i finaly got the file and tested it.... and IT WORKED !! 8).. Well with the bike on the stand the rear wheel spin no prob and is very fast!!!.. but not tested yet on the road, it's 1am now and it's -3 degree outdoor with ice on road at some place!!! :o...

I'm watching carefully mother nature predictions so i can test it fully!

btw just by holding the rear brake to apply torque i twisted teh throttle and saw 35.5kW already and was not full torqu and speed yet !! and battery was at 66V...

I call this encouraging!!!! 8)



I have attached the DCF file i rebuilt for you guys!
Attachments
20151019_013422 (Medium).jpg
20151019_013422 (Medium).jpg (200.67 KiB) Viewed 712 times
20151019_013614_Richtone(HDR) (Medium).jpg
MY12 75-7 SR rebuilt from MY14SR and MY12 75-7 .zip
(36.63 KiB) Downloaded 161 times
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

User avatar
Arlo1   100 GW

100 GW
Posts: 8115
Joined: Apr 26 2009 10:36pm
Location: Nanaimo
Contact:

Re: how to program a sevcon gen4

Post by Arlo1 » Oct 19 2015 9:07am

Oh yeah... I took a 2011 DS and I've converted it into a DSLR for my wife with a 75-7 and a size 4 (for now)... :)
Attachments
034.jpg
034.jpg (100.7 KiB) Viewed 3798 times
011.jpg
011.jpg (140.58 KiB) Viewed 3798 times
038.jpg
038.jpg (77.6 KiB) Viewed 3798 times
099.jpg
099.jpg (85.52 KiB) Viewed 3798 times
144.jpg
144.jpg (92.45 KiB) Viewed 3798 times
171.jpg
171.jpg (123.67 KiB) Viewed 3798 times
174.jpg
174.jpg (131.27 KiB) Viewed 3798 times
My Leaf motor controller build. http://endless-sphere.com/forums/viewto ... 27#p963227
My YSR build http://www.youtube.com/watch?v=BRo8r5g4NBg
RC and most types of Lithium batteries you MUST know your individual cell voltages charging and discharging.
Don't keep them were you cant afford smoke or fire!
Never above 4.2v never below 2.7v EVER!!!
Support me on Patreon. https://www.patreon.com/user/posts?u=6842045
http://www.undergroundelectrics.ca/

User avatar
Doctorbass   100 GW

100 GW
Posts: 7425
Joined: Apr 08 2007 2:24am
Location: Quebec, Canada East
Contact:

Re: how to program a sevcon gen4

Post by Doctorbass » Oct 19 2015 9:13am

Arlo1 wrote:Oh yeah... I took a 2011 DS and I've converted it into a DSLR for my wife with a 75-7 and a size 4 (for now)... :)
Nice work!.. From what I see you don't use the BMS of the ZF2.8 right?
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

User avatar
Arlo1   100 GW

100 GW
Posts: 8115
Joined: Apr 26 2009 10:36pm
Location: Nanaimo
Contact:

Re: how to program a sevcon gen4

Post by Arlo1 » Oct 19 2015 10:17am

Doctorbass wrote:
Arlo1 wrote:Oh yeah... I took a 2011 DS and I've converted it into a DSLR for my wife with a 75-7 and a size 4 (for now)... :)
Nice work!.. From what I see you don't use the BMS of the ZF2.8 right?
I will add a BMS later. I find you can go 3-6 months then manually balance them.
My Leaf motor controller build. http://endless-sphere.com/forums/viewto ... 27#p963227
My YSR build http://www.youtube.com/watch?v=BRo8r5g4NBg
RC and most types of Lithium batteries you MUST know your individual cell voltages charging and discharging.
Don't keep them were you cant afford smoke or fire!
Never above 4.2v never below 2.7v EVER!!!
Support me on Patreon. https://www.patreon.com/user/posts?u=6842045
http://www.undergroundelectrics.ca/

User avatar
h0tr0d   1 kW

1 kW
Posts: 460
Joined: Apr 28 2012 5:17pm

Re: how to program a sevcon gen4

Post by h0tr0d » Oct 23 2015 10:46am

Doctorbass wrote: I have attached the DCF file i rebuilt for you guys!
Doc,

A few questions, according to the DVT sw:
1 - Why is the "Battery Current Limit Data Source" disabled in the "Master Battery Current limit parameters"?
Set up like that you don't have any current limit, at all! I guess the controller will pump 660A from 0 to 6000 rpm, the rev limiter you have.
(the torque curve is irrelevant if you have this set to disable, IMO)

2 - Max allowable motor temp to 195 ºC?

3 - why do write 195 Nm if the motor will only produce 165 @ 660A?
Doc.JPG
Doc.JPG (54.05 KiB) Viewed 1461 times

Post Reply