SECU Control Unit SECU Control Unit: Programming Instructions

SECU Control Unit
PROGRAMMING
INSTRUCTIONS
Via Enrico Toti, 4 - 44042 Cento (FE) ITALY
Printed 04/2009 Ver. 3.09 Tel. +39-0516836502 Fax +39-0516836799

Page 1/28 USE and INSTALLATION INSTRUCTIONS for SECU CONTROLLERS
3.08 software version
Use and installation instructions

for controllers series
SECU-10
SECU-20
SECU-40
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
web site: www.elektrosistem.com
INDEX
INDEX.....................................................................................................................................................2
DESCRIPTION ........................................................................................................................................3
Description of a separately excited motor................................................................................................3
Operation of the SECU control unit .........................................................................................................3
Technical specifications .........................................................................................................................4
INSTALLATION.......................................................................................................................................6
Fixing holes and power connections........................................................................................................6
SECU-10 ..............................................................................................................................................6
SECU-20 and SECU-40...........................................................................................................................6
Main warnings and precautions ..............................................................................................................8
Installation procedure ...........................................................................................................................8
Description of connectors ......................................................................................................................9
12-pin A connector for SECU-10, SECU-20 and SECU-40...........................................................................9
8-pin B connector for SECU-10 .............................................................................................................10
8-pin B connector for SECU-20 and SECU-40 .........................................................................................10
Standard configuration ........................................................................................................................11
Wiring diagrams..................................................................................................................................13
Forward, reverse and auxiliary switches ................................................................................................13
Tiller / parking brake switch.................................................................................................................13
Emergency reverse belly button switch .................................................................................................13
Speed control by means of potentiometer .............................................................................................14
Speed control by means of potentiometer with neutral in the middle position...........................................14
Speed control by means of 0-5V and 0-10V signal .................................................................................15
Speed control by means of +/-5V, +/-10V and 0-10V signal without external resistors..............................15
Coils for contactors .............................................................................................................................16
External status LED .............................................................................................................................16
Battery disconnecting switch ................................................................................................................17
Shutdown from external device ............................................................................................................17
Wiring diagram for the UMP terminal ....................................................................................................18
FIRST STARTING .................................................................................................................................19
SPECIAL FUNCTIONS...........................................................................................................................19
Field auto-calibration...........................................................................................................................19
Potentiometer auto-calibration .............................................................................................................19
Speed reduction with low battery voltage..............................................................................................19
PROGRAMMING ...................................................................................................................................20
FACTORY-SET FUNCTIONS ..................................................................................................................23
DIAGNOSTICS ......................................................................................................................................24
Main warnings ....................................................................................................................................24
LED OFF.............................................................................................................................................24
LED steadily ON..................................................................................................................................24
LED rapidly flashing – Not serious errors ...............................................................................................24
LED slowly flashing - Serious errors ......................................................................................................25
Display of parameters during operation.................................................................................................26
Trouble shooting.................................................................................................................................27
Notes.................................................................................................................................................27
Voltages on logic card connector in normal conditions ............................................................................27
Checks on the motor ...........................................................................................................................27
Check for chassis insulation .................................................................................................................27
Checks on contactors ..........................................................................................................................27
Checks on the potentiometer ...............................................................................................................28
Wrong programming ...........................................................................................................................28
FAQ (frequently asked questions).......................................................................................................28
DESCRIPTION
The SECU control unit features bidirectional operation and regenerative braking and has been designed
to control the speed of DC separately excited motors. High frequency static control allows reversing without
the use of direction contactors and offers silent operation.
The main contactor guarantees reverse polarity protection and compliance with the safety standards in
force.
A microprocessor controls operation and calculates in real time field and armature current according to
the parameters programmed and to load conditions.
Programming is made through personal computer or terminal: the operator can modify parameters to
obtain a smooth and seamless control of the vehicle and to adapt the application to all kind of separately
excited motors.
Description of a separately excited motor

The motor is made up of an armature winding and a field winding that must be supplied separately.
Reversing is obtained acting on current direction in one of the windings.
In general, in a separately excited motor, the torque is proportional to the field and armature current;
the rotation speed of the shaft is proportional to the voltage applied to the armature and inversely
proportional to the field current. The system acts as a mechanical transmission. Armature and field
parameters can be adjusted to obtain a high torque with low rpm and a high power at max. speed.
Operation of the SECU control unit

The SECU control unit applies voltage to the armature through a half bridge and allows reversing and
field current setting through a full bridge. The power part is made with MOSFETs.
Changing the position of the accelerator from min. to max., the SECU applies to the armature a voltage
from 0 to battery one and adjusts at the same time field current from the rated value (Code 0160) to the
min. value (Code 0162). If the required torque causes the armature current to be higher than the value for
compensation start (Code 0166), the field current increases and reaches the max. value (Code 0164) when
the armature current reaches the compensation end value (Code 0168).
The field current supplied is calculated according to the required torque and to the voltage applied.
When the vehicle is “at full speed” in normal conditions, the armature current should not exceed the
rated current declared by the manufacturer to avoid overheating of the motor.
The max. speed must be reached with 100% voltage applied to the armature, that is without speed
reduction enabled, and with a min. field current that must not be lower than the min. value indicated by the
motor manufacturer.
In order to program the function of “electronic transmission” described above it is necessary to obtain
min., max. and rated field current from the motor manufacturer.
During parameter setting it is advisable to refer to the data supplied by the motor manufacturer. Any
operation with current values different from those indicated can cause efficiency loss, operation anomaly and
in some cases even damage.
For special requirements it is possible to obtain a customized mapping of armature and field curves.
Technical specifications
• Full bridge power MOSFET design for the motor field and half bridge design for the armature with high
frequency components, offering:
o A rapid speed control.
o Silent operation.
o High efficiency.
o Regenerative braking (always enabled) with adjustable intensity.
• Self diagnostics with anomaly signalling through:
o LED on the control unit.
o External LED.
o Programming terminal or computer.
• Control by means of:
o 5KΩ 3-wire potentiometer.
o 5KΩ 3-wire potentiometer with neutral in the middle position.
o 0-5V signal or 0-10V signal with resistor card in the wiring.
o +/-5V and +/-10V signal with interface card (on request).
• Automatic calibration of potentiometer travel for forward and reverse directions.
• Battery voltage setting from 24V to 48V for SECU-10 and from 24V to 80V for SECU-20 and SECU-40
control units, in 1V steps. Max. voltage depends on the model.
• Overvoltage and undervoltage cutback, with values that can be customized.
• Reverse polarity protection by means of the main contactor.
• Protection for potentiometer failure.
• Protection for MOSFET short circuit.
• Overtemperature protection limits the current supplied or shuts down the controller. Active from 70 to
80 °C.
• Voltage can be applied to the field even with accelerator in idle position to brake the motor.
• An acceleration ramp with 2 different speeds can be programmed.
• Protection to prevent the vehicle from moving if the controller is turned on with the potentiometer not
in neutral position.
• 24V coils for contactors for all battery voltages.
• 3 outputs (2 for SECU-10 model) rated at 3 Amps, with coil overheating and short circuit protection to
control the following functions:
o Main contactor.
o Electromagnetic brake (supplied with battery voltage).
o Power steering contactor.
o Auxiliary contactor supplied by external device
o Reverse buzzer (supplied with battery voltage).
• Reverse and release braking current can be set.
• Braking current during emergency reverse can be set.
• The field value can be increased to obtain a higher torque.
• Timing for electromagnetic brake locking can be programmed.
• Timing for power steering contactor opening can be programmed.
• Max speed in backward direction can be limited.
• An option is available to open the main contactor after a programmable time when the operator is not
seated.
• Fault history file.
• 5 input lines for SECU-10 and 4 for SECU-20 and SECU-40 to control:
o Seat switch.
o Tiller switch.
o Parking brake switch.
o Brake pedal switch.
o Auxiliary contactor.
o Emergency reverse switch.
o 3 speed reductions acting on field and armature.
o 1 speed reduction acting on field (min. field current 2).
o SECU shutdown from external device.
• Advanced communication protocol for connection with other control units, with programming terminal,
display or computer.
• Possibility to customize parameters to optimise the vehicle’s operation.
• Operation frequency (armature/field) 17KHz.
• Weight: 800g for SECU-10 – 2,5Kg for SECU-20 – 3,5Kg for SECU-40.
Models available
Model Field current Armature current Voltage

SECU 10 160/25 25A 160A 48V
SECU 10 220/40 40A 220A 24-36V
SECU 20 200/25 25A 200A 60-80V
SECU 20 350/50 50A 350A 24-48V
SECU 40 350/40 40A 350A 96V
SECU 40 400/50 50A 400A 60-80V
SECU 40 600/70 70A 600A 24-48V
INSTALLATION
Fixing holes and power connections

All dimensions are in millimetres.
SECU-10
+Vb: battery positive after the main contactor.

- Vb: battery negative.
F1: field connection.
E+: armature connection.
E-: armature connection.
F1 F2 E+ E-
The dimensions of the aluminium base are referred to the single controller without contactors. According
to the customer’s needs bases with different dimensions complete with main and pump contactors can be
supplied. Special dimensions can be requested for special requirements.
In max. height also consider the contactors and the connectors.
SECU-20 and SECU-40 F1 F2 E1 E2

+Vb: battery positive after the main contactor.
-Vb: battery negative.
E1: armature connection.
E2: armature connection.
The dimensions of the aluminium base are referred to the single controller without contactors. According
to the customer’s needs bases with different dimensions complete with main and pump contactors can be
supplied. Special dimensions can be requested for special requirements.
In max. height also consider the contactors and the connectors.
Main warnings and precautions

• Do not connect SCR systems (controllers, inverters, etc…) to the same battery used for the SECU,
interferences could shut down or even damage the control unit.
• Do not use a battery voltage other than the rated one indicated for the control unit by the
manufacturer.
• Do not use a converter or a battery charger to apply voltage to the unit. During braking the SECU
control unit generates a current and a battery is necessary to absorb it.
• Always contact Elektrosistem’s engineers for special applications.
Installation procedure
• Fix the control unit on a clean, smooth and not painted metal surface. Use conductive paste for a better
heat disposal.
• Choose a location to protect the controller from water and dust.
• Do not use the vehicle’s chassis as electrical conductor. Use cables and plugs suitable to motor power
for battery and motor connection.
• Keep cables as short as possible and one near the other from the battery to the control unit.
• The battery must be disconnected from the control unit during battery charging, leave the space
necessary for this operation.
Description of connectors
12 11 10 9 8 7 6 5 4 8 7 6 5
6 5 4 3 2 1 3 2 1 4 3 2 1
12 pin 6 pin 8 pin

Conn. A Conn. C Conn. B
SECU-10
12 11 10 9 8 7 8 7 6 5 6 5 4
6 5 4 3 2 1 4 3 2 1 3 2 1
12 pin 8 pin 6 pin

Conn. A Conn. B Conn. C
SECU-20/40
12-pin A connector for SECU-10, SECU-20 and SECU-40
Pin Function Direction Colour

1 For factory tests only
2 Reverse in Pink
3 Forward in White/Black
4 Status LED negative out Yellow/Black
5 Power supply positive (key switch) in White/Green
6 Main contactor out Orange/Black
7 Potentiometer positive out White/Blue
8 Potentiometer wiper in White/Yellow
9 Potentiometer negative out Red/Black
10 Status LED positive out Yellow
11 Power supply positive for contactors/brake coils out White
• Electromagnetic brake Black/Blue
• Power steering contactor Yellow/Grey
12 (1) out
• Auxiliary contactor (for SECU-10 only) Orange/Green
• Buzzer (for SECU-10 only) (1) Pink/Green
(1) In the SECU-20 and SECU-40 use pin 5 of 8-pin B connector for this function.
8-pin B connector for SECU-10

• Emergency reverse (NC contact) White/Brown
2 • Pedal brake in White/Brown
• 1st speed reduction Yellow/Brown
• 3rd speed reduction Red/Blue
3 • shutdown from external device in Blue/Grey
• min. field current 2 Brown/Black
7 Pump contactor in Green/Red
• seat switch Green/Sky blue
(2)
• tiller switch Green/Sky blue
8 in
• parking brake switch Brown (2)
• 2nd speed reduction Green/Brown
8-pin B connector for SECU-20 and SECU-40

1 Supply positive for contactors’ coil. out White
• Pedal brake White/Brown
2 • Emergency reverse (NC contact) in White/Brown
• 1st speed reduction Yellow/Brown
• pump contactor Orange/Green
5 out
• buzzer Pink/Green
• 3rd speed reduction Red/Blue
6 • shutdown from external device in Blue/Grey
• min. field current 2 Brown/Black
7 Pump contactor in Green/Red
• seat switch Green/Sky blue
(2)
• tiller switch Green/Sky blue
8 in
• parking brake switch Brown (2)
• 2nd speed reduction Green/Brown
(2) The colour indicated for the function is to be used when a positive signal is given to pin 8 in B connector
on the control unit. If the pin is already used, the function can be obtained interrupting the positive to the
common of running switches. In this case the colour to be used will be White/Green on both connections of
the tiller switch.
Standard configuration
Battery Power
fuse
Main
contactor
Motor Aux. fuse
Key switch
Potentiometer
5K
F2 F1 -Vb E- E+ +Vb
SECU-10
Conn. A
Conn. C Conn. B
Signalling
led
Reverse switch
Forward switch
General wiring diagram for the SECU-10 control unit.

Always refer to the wiring diagram enclosed with the material which is specific for the application.
Battery Power
fuse
Main
contactor
Motor Aux. fuse
E2 F1 +Vb
F2
-Vb
E1
Key switch
Potentiometer
SECU-20/40
5K
Signalling
led
Conn. C Conn. B Conn. A
Reverse switch
Forward switch
General wiring diagram for SECU-20 and SECU-40 control units.

Always refer to the wiring diagram enclosed with the material which is specific for the application.
Wiring diagrams
Forward, reverse and auxiliary switches
The following indications concern:
• Forward and reverse switches.
• Seat switch.
• Brake pedal switch.
• Auxiliary contactor.
• Speed reductions.
When one function is not active the circuit should be open; to enable the function apply battery voltage
to the pin using NORMALLY OPEN switches, as indicated in the diagrams concerning running switches.
Take the positive common to all switches from the key switch (WHITE/GREEN).
Note for the seat switch function: when the operator is on the seat, battery voltage must be applied
to pin 8 in 8-pin B connector.
Tiller / parking brake switch
Key positive
WHITE/GREEN
(WHITE/GREEN)
Key positive
Tiller / 12 pin Conn. A 12 11 10 9 8 7 (WHITE/GREEN)
parking brake switch SECU-10/20/40 6 5 4 3 2 1
GREEN/SKY-BLUE Tiller / parking
BROWN PINK brake switch
8 7 6 5 8 pin Conn. B Reverse switch
WHITE/BLACK
4 3 2 1 SECU-10/20/40
Forward switch WHITE/GREEN
Config. 1 Config. 2 WHITE/GREEN
The functions can be obtained in two ways:

1. apply a positive signal to the corresponding pin (pin 8 in 8-pin B connector).
2. interrupt the common wire in forward and reverse switches.
If the pin is free the first solution is to be preferred. The diagram shows both possibilities.
NOTE: the two functions are identical, in the PROGRAMMING section only the “Tiller input enabling”
parameter is listed.
Emergency reverse belly button switch
Key positive
(WHITE/GREEN)
WHITE/GREEN
Emergency
reverse switch
WHITE/BROWN
8 pin Conn. B 8 7 6 5
SECU-10/20/40 4 3 2 1
Use a NORMALLY CLOSED switch, that is in standard conditions battery voltage must be applied to the
pin and the function is activated when no voltage is applied.
Speed control by means of potentiometer
WHITE/BLUE
WHITE/YELLOW
RED/BLACK
12 11 10 9 8 7 12 pin Conn. A
max. min. 6 5 4 3 2 1 SECU-10/20/40
5K
Use a 5KΩ 3-wire potentiometer connected according to the diagram above. Min speed is supplied when
the voltage of the Red/Black wire is present (0V) on the White/Yellow wire.
If a 4-wire potentiometer is used follow the connection shown in the diagram below.
WHITE/BLUE
WHITE/YELLOW
RED/BLACK
min. 12 11 10 9 8 7 12 PIN Conn. A

max. max. 6 5 4 3 2 1 SECU-10/20/40
10K 10K
Please note that this is NOT a configuration for a potentiometer with neutral in the middle position as
the control unit considers it as a standard 5KΩ potentiometer and supplies min. speed when the voltage of
the Red/Black wire (0V) is present on the White/Yellow wire.
The potentiometer to be used must have two 10KΩ tracks connected inside as per our diagram.
Speed control by means of potentiometer with neutral in the middle position

The electric wiring is the same described in the section about the standard three-wire potentiometer.
The potentiometer is mechanically fixed so that with accelerator in neutral position, the voltage on the wiper
(White/Yellow) is 2.5V, that is half the voltage applied to the potentiometer. Turn the potentiometer to apply
a value lower or higher than 2.5V and to enable forward or reverse directions.
Carry out potentiometer calibration to set the potentiometer travel and running directions (see the
POTENTIOMETER AUTO-CALIBRATION section). If necessary it is possible to change the values calibrated
(Codes 0242, 0244, 0702 and 0704).
Running switches are necessary to enable operation in case of speed control by means of potentiometer
with neutral in the middle position.
Speed control by means of 0-5V and 0-10V signal
WHITE/YELLOW
RED/BLACK
0-5V PLC +
0-5V - 12 11 10 9 8 7
12 pin Conn. A
control 6 5 4 3 2 1 SECU-10/20/40
18K-1/4W WHITE/YELLOW
0-10V PLC
+ RED/BLACK
22K-1/4W
control 0-10V
-
12 11 10 9 8 7 12 pin Conn. A
SECU-10/20/40
6 5 4 3 2 1
In case of speed control by means of 0-5V signal the two wires can be connected directly to the pins; for
0-10V signal add one 18KΩ and one 22KΩ 1/4W resistors as indicated in the wiring above.
On request a control unit already pre-set for 0-5V or 0-10V signal can be supplied, that is with resistors
already fitted for 0-10V signal, and with the “Check for potentiometer failure” parameter disabled. On the
contrary contact Elektrosistem’s engineers to obtain information about the procedure to disable this
parameter or the control unit will signal the error with 6 flashes.
For speed control by means of 0-10V signal without external resistors a special interface card can be
used; refer to the following section for information about input configuration.
NOTE: to avoid damage to the control unit, the input signal must not exceed:
• 5V for 0-5V signal.
• 10V for 0-10V signal.
Speed control by means of +/-5V, +/-10V and 0-10V signal without external
resistors
WHITE/BLUE
WHITE/YELLOW
RED/BLACK
+ Interface
PLC
- card 12 11 10 9 8 7
12 pin Conn. A
6 5 4 3 2 1 SECU-10/20/40
Please note that this is a special application and the control unit must be pre-set in our factory for the
connection with our interface card and programmed according to the output voltage requested.
NOTE: do not follow this diagram if the control unit has not been pre-set for this application
with interface card.
Coils for contactors
WHITE
Power steering /
Aux. Contactor Main contactor brake coil
coil coil
BLACK/BLUE
YELLOW/GREY
8 pin Conn. B 8 7 6 5 12 11 10 9 8 7 12 pin Conn. A

SECU-20/40 4 3 2 1 6 5 4 3 2 1 SECU-10/20/40
ORANGE/BLACK
The voltage of coils does not depend on battery voltage, but must always be 24V except for the model
SECU-10 12V, in this case the coil voltage must be 12V; once the operating voltage has been programmed
the suitable voltage will be applied to the coils.
Take battery positive from pin 11 in A connector for all coils and brake (WHITE).
Do not install a peak extinguishing diode in parallel to the coil.
Do not use devices to interrupt control lines of coils.
External status LED
YELLOW
12 11 10 9 8 7 12 pin Conn. A
6 5 4 3 2 1 SECU-10/20/40
YELLOW / BLACK
Do not connect other devices than a LED diode.

Respect the polarity indicated in the drawing without adding other components.
Battery disconnecting switch
Main Battery disconnecting

contactor switch
RED
Pin 5 WHITE/GREEN
Conn. A
Key switch Aux. contact
Battery
The SECU control unit features regenerative braking; if a battery disconnecting switch is used, it is
extremely important to have an auxiliary contact that opens before the power contact when the battery
disconnecting switch is pushed. The positive applied to pin 5 of 12-pin A connector must pass through this
contact. This connection is necessary to avoid damage to the control unit due to excessive voltage increase
when this switch is used to disconnect the battery during braking.
Shutdown from external device
Key positive Key positive

(WHITE/GREEN) (WHITE/GREEN)
10K If necessary
10K
If necessary 1W 1W
BLUE/GREY
8 7 6 5 8 pin Conn. B
4 3 2 1 SECU-10 8 7 6 5 8 pin Conn. B
4 3 2 1 SECU-20/40
BLUE/GREY
x SECU-10 x SECU-20/40
To shut down the SECU control unit from an external device battery voltage must be applied to the input
and the function must be programmed On (Code 0378). In standard conditions 0 volt (-Vb) must be
measured on this pin.
If the system controlling the shutdown has a line controlling the two operation levels, that is supplies
both battery positive and negative, connect this line to the pin.
If on the contrary the device has only one contact free or connected to the negative (–Vb), follow the
connection in the diagram above. Connect a 10KΩ 1W resistor as near as possible to the SECU connector
between the control line (BLUE/GREY) and the positive after the key switch (WHITE/GREEN); the external
system must keep the control line connected to –Vb (battery negative) in normal conditions and leave it free
when it must activate the shutdown function. In this case the 10KΩ resistor applies the battery positive to
the pin and shuts down the control unit.
It is important to connect the 10KΩ resistor as near as possible to the SECU connector, or the function
will be bypassed in case of interruption of the control line. Using the resistor, when the control line is
accidentally interrupted the controller is shut down.
NOTE: During the shutdown the status LED indicates the error flashing 22 times. Also refer to the
section concerning errors.
Wiring diagram for the UMP terminal
Connect the 6-pin connector on the controller (C connector) and apply voltage to the controller and to
the terminal (a 2-pin connector is on the unit).
FIRST STARTING
During the first starting the control unit carries out a field calibration, that is reads the features of the
motor connected. The battery must be charge and connections must be tight.
NOTE: If running directions are reversed exchange the field wires or the armature wires. Do not
exchange the wires of running switches.
SPECIAL FUNCTIONS
Field auto-calibration
The field calibration procedure reads motor features. It is necessary each time the motor is replaced.
The function can be enabled programming Code 017A On. During the procedure the main contactor closes
and the LED remains On for less than a minute. Then if the procedure has been correctly carried out the
LED becomes off and the vehicle is ready to operate. On the contrary, in case of error the LED starts
flashing (refer to the section concerning errors to find the problem).
Potentiometer auto-calibration
The potentiometer auto-calibration can be enabled programming Code 0700 On (refer to the section
concerning PROGRAMMING).
Follow the procedure below.
Please note that the first running switch enabled will be considered as FORWARD.
1. enable forward switch (for the handle unit rotate the throttle switch for forward direction).
2. reach max. speed in forward direction, wait for a few seconds, and return to zero.
3. enable reverse switch (for the handle unit rotate the throttle switch for reverse direction).
4. reach max. speed in reverse direction, wait for a few seconds, and return to zero.
During this procedure the status LED stays on. If the procedure lasts more than 1 minute the LED will signal
the error flashing 12 times; it is necessary to switch the key controller off to resume operation. After re-
starting the controller the LED is on to signal that the potentiometer auto-calibration has to be repeated.
Speed reduction with low battery voltage

When the battery voltage is reaching the min. level allowed for operation, instead of causing the vehicle
to stop, a progressive speed reduction enables the operator to bring the vehicle to the charging location
avoiding damage to the battery.
PROGRAMMING
During programming the vehicle must be stopped with all switches in off position.
To modify parameters always refer to the manual concerning the programming device
necessary (display, terminal or computer and serial interface).
When loading a parameter the following message could be displayed “Archive’s parameters version does
not match device’s parameters version !” to signal that the programming device has found a software
version not compatible. We suggest not to proceed with this procedure to avoid problems.
Due to the sophisticated technology used and the high performance of the control unit, programming
includes a lot of parameters. A special attention is therefore required during this operation.
Always refer to the current values supplied by the motor manufacturer to avoid efficiency loss and
operation anomaly.
In the following table parameters are listed per Code. If the programming software version available is
not updated (both on computer and on the terminal) some parameters are not displayed; refer to the Code
to avoid confusion.
Always check that only those functions used are programmed and only necessary pins are connected.
For further information contact Elektrosistem’s engineers.
Code Parameter Description Calculation Notes

Duration of the acceleration 0 = no acceleration
0100 Acceleration 60/ramp in seconds
ramp without load 239 = max. acceleration(1)
Duration of the braking ramp 0 = no braking
0102 Deceleration 60/ramp in seconds
without load 239 = max. braking (1)
Max acceleration Max. armature current during Current desired x 255 / This parameter determines
0120
current acceleration armature current max. torque.
Release braking Max. armature current during Current desired x 255 / The value must be lower than
0124
current release braking armature current that in Code 0126
Reverse braking Max. armature current during Current desired x 255 / The value must be higher than
0126
current reverse braking armature current that in Code 0124
Field current at startup
Current desired x 255 /
0160 Rated field current without current on the
field current
armature
Field current at max speed
Current desired x 255 / This parameter determines
0162 Min field current without current on the
field current max. speed.
armature
Field current at startup with
Current desired x 255 / This parameter determines
0164 Max field current max. current on the
field current max. torque.
armature
A new auto-calibration of
Enable field current
017a motor features will be carried Enabled/Disabled
acquisition
out. (2)
Max. modulation applied in 0 = vehicle stopped
0200 Max forward speed
forward direction 255 = max. speed
Max backward Max. modulation applied in 0 = vehicle stopped
0202
speed reverse direction 255 = max. speed
When voltage is applied to

Enable speed the input the max. speed
0204 Enabled/Disabled
reduction value becomes the one set in
Code 0206 (3)
Value for the first speed 0 = vehicle stopped
0206 Speed reduction
reduction (absolute) 255 = max. speed
Enable speed the input the max. speed
reduction II value becomes the one set in
Code 020a (3)
Value for the second speed 0 = vehicle stopped
020a Speed reduction II
reduction (absolute) 255 = max. speed
Enable speed the input the value set for
020c Enabled/Disabled
reduction III speed is diminished from the
value set in Code 020e (3)
Value for the third speed 0 = max. speed
020e Speed reduction III
reduction (differential) 255 = vehicle stopped
The control unit starts When set at 0 max modulation
modulating when the input is supplied when the running
0242 Min. pot. voltage Voltage in volts x 51,2
reaches this value (in switch is enabled, ignoring the
forward direction). potentiometer position.
The control unit applies max.
armature voltage when the
0244 Max. pot. voltage Voltage in volts x 51,2
input reaches this value (in
reverse direction).
Rated battery
0300 Voltage in volts
voltage
Enable power
Voltage is applied to the
0324 steering/motor Enabled/Disabled
output to obtain the function.
brake
The auxiliary contactor is
Enable auxiliary
032A closed when voltage is Enabled/disabled
relay
applied to the input.
Emergency reverse function
0362 Enable fast reverse is activated when voltage is Enabled/disabled
Main contactor is closed and
control unit operation is Enabled/Disabled
036a Enable seat switch
allowed when voltage is
Control unit operation is
036e Enable helm switch allowed when voltage is Enabled/Disabled
Acceleration current is halved

and braking current passes
0372 Enable brake switch to the value set in reverse Enabled/Disabled
braking current when voltage
is applied to the input.
The control unit is shut down
from an external device (22
Enable external
0378 flashes, code 2e) when Enabled/Disabled
fault input
voltage is applied to the
input.
Enable Backing the input, the motor starts
Mode turning with a fixed speed
for a max. time.
A new measure of
potentiometer travel is
Enable pot.
0700 made. Parameters 0242, Enabled/Disabled
acquisition
0244, 0702 and 0704 (4) are
reprogrammed.
The control unit starts
Min. pot. If set at 0 the ref. value is the
0702 modulating when the input Voltage in volts x 51,2
voltage BW one in Code 0242
reaches this value (reverse)
The control unit applies max.
Max. pot. armature voltage when the If set at 0 the ref. value is the
0704 Voltage in volts x 51,2
Voltage BW input reaches this value one in Code 0244
(reverse)
(1) (ref. Code 0100 and 0102). In standard applications higher values are not useful and can be dangerous
for the control unit. Please contact Elektrosistem’s engineers to program higher values.
(2) (ref. Code 017A) After programming, calibration starts immediately, status LED remains on and the
control unit operation will be inhibited until the end of the procedure. Make sure the battery is charge and
the connections are tight. This operation determines the correct control of the motor.
(3) If both first and second speed reductions are active the one with higher reduction will prevail.
Third speed reduction is never bypassed and can stop the vehicle.
(4) (ref. Code 0700) When programming is finished, the LED stays ON and the control unit waits for the
operator to carry out a complete travel of the potentiometer for both forward and reverse directions (max.
one minute). If the travel between min. and max. is higher than 1.28 Volts in both forward and reverse
directions the measure will be considered valid and parameters 0242, 0244, 0702 and 0704 will be updated.
FACTORY-SET FUNCTIONS
The following options are available. Contact Elektrosistem’s engineers for further information.
It is also possible to enable or design special functions to meet specific requirements.
• It is possible to modify the vehicle’s operation features according to the input.

• In addition to field parameters’ programming it is also possible to carry out a further field and armature
mapping according to the requirements of the application, to motor efficiency and to the type of
vehicle.
• It is possible to enable a serial communication to control the unit with a serial protocol made by
Elektrosistem.
• When required by safety standards it is possible to modify the system to use NORMALLY CLOSED or
NORMALLY OPEN switches.
• Standard programming includes safety functions to comply with standards requiring shutdown in case
of potentiometer not in neutral position and/or switches already on when the key is turned
on. When the standard does not require this function and the customer in not interested in it, the
function can be disabled.
• It is possible to use the SECU control unit for two traction motors with power steering control.
• Voltage control filters short changes, but reads the instantaneous value. According to standard
programming:
o Undervoltage is set at 1.5V/cell.
o Overvoltage is set at 2.35V/cell.
It is possible to customize these voltage values.
• It is possible to program operation without potentiometer: when the running switch is activated the
vehicle operates with max speed.
DIAGNOSTICS
It is possible to check the control unit state through the status LED, programming console or software.
Main warnings
• When the battery is connected do not touch contactors with your hands, in particular when an error
condition is present.
• Before any operation on the equipment always check that the key switch is off and the battery plug is
disconnected.
• Filter capacitors on the SECU control unit can remain charged for some time after switching off. Before
any maintenance operation on the unit always discharge them, that is connect a 10Ω resistor between
–Vb and +Vb terminals on the SECU control unit for approx. 5 seconds.
• Get the drive wheels off the ground before doing any work on the vehicle, in particular during voltage
checks.
LED OFF
The control unit is off or is operating without signalling anomalies.
LED steadily ON
The control unit is connected to the programming terminal or interface and the operator is setting
parameters.
Or, immediately after switching on:
Code Status Notes

30 Field calibration See the specific section
33 Potentiometer calibration for forward See the specific section
34 Potentiometer calibration for reverse See the specific section
LED rapidly flashing – Not serious errors

A not serious anomaly is signalled. The control unit can operate only when the problem is corrected.
Code Error Possible causes and solutions

1C Potentiometer not in neutral position Speed voltage was higher than “min. pot.” value
(Code 0242) when the direction switch has been
activated.
26 Forward and reverse switches enabled at the Put running switches in off position and
same time potentiometer at min. value.
70 Seat switch off The running switch is on but the seat switch is
open.
LED slowly flashing - Serious errors

Errors are signalled with the flashing of the status LED. According to the number of flashes it is possible
to identify the cause for the error. The LED continues flashing until the key switch is turned off.
Flashes Code Error Possible causes and solutions

The motor was turning when the key has been
switched on. If the error is repeated power
1 1f Moving motor on start
components could be damaged. Contact
Elektrosistem’s engineers.
Check the main contactor according to the
2 08 Relay contact fault procedure described in the troubleshooting
section.
Battery voltage is decreased below the min.
3 1d Too low supply voltage
value.
Battery voltage has exceeded the max. voltage
4 1e Too high supply voltage
or the max. value allowed for the control unit.
Follow the procedure described in the
5 10 Relay driver fault troubleshooting section concerning contactors for
all contactors controlled by the SECU control unit.
Refer to the troubleshooting section concerning
6 1b Broken pot.
the potentiometer.
Check mounting of the control unit. If the error is
7 18 Temperature fault
repeated contact Elektrosistem’s engineers.
The control unit has been switched off while the
8 23 Fault on turn off vehicle was still moving. Always switch the
control unit off when the vehicle is stopped.
Some parameters have not been correctly
9 27 Fault on parameters’ setting programmed. Refer to the troubleshooting
section concerning programming.
Programming procedure has been interrupted.
10 2d Fault on checksum
Repeat it.
The control unit is not able to reach the field
desired current. Refer to the troubleshooting
11 2a Field not correctly connected
section concerning the motor and check the field
parameters programmed.
The auto-calibration has not been correctly
carried out. Refer to the troubleshooting sections
12 22 Fault on acquisition
concerning potentiometer and motor and check
the field parameters programmed.
13 20 Incoherent field current Contact Elektrosistem’s engineers
14 2c Too high field current Contact Elektrosistem’s engineers
15 1a Field fault Contact Elektrosistem’s engineers
16 2b Too high rotor current Contact Elektrosistem’s engineers
17 19 Rotor fault Contact Elektrosistem’s engineers
18 21 Rotor voltage fault Contact Elektrosistem’s engineers
19 28 Program memory CRC fault Contact Elektrosistem’s engineers
20 29 Parameters memory CRC fault Contact Elektrosistem’s engineers
21 2f Device not registered Contact Elektrosistem’s engineers
The control unit shutdown has been activated
22 2e External fault through the input or via serial communication
from an external device
Check serial communication wiring (C connector).
23 40 Serial communication fault If the error is repeated contact Elektrosistem’s
engineers.
Display of parameters during operation
The UMP terminal can display some controller’s parameters during operation (refer to the UMP manual).
The parameters displayed are shown in the table below:
Page Parameter Unit of measurement

1 Digital input for potentiometer (pin 8A) Volt
Digital input for potentiometer 2 (pin 6B) Volt
Set speed %
Actual speed %
2 Digital input for forward (pin 3A) On / Off
Digital input for reverse (pin 2A) On / Off
Digital input aux 1 (pin 2B) On / Off
3 Digital input aux 3 (pin 3B, if present) On / Off
4 Set speed %
Actual speed %
Armature current Ampere
Field current Ampere
5 Control unit temperature °C
Key switch voltage (pin 5A) Volt
Power circuit voltage (+Vb terminal) Volt
Trouble shooting
Notes
• All voltage measures are referred to battery negative and must be carried out with the key switch in on
position and running switches in off position.
• All resistance and continuity measures on components must be carried out with battery disconnected
and capacitors discharged (connect a 10Ω resistor between +Vb and –Vb terminals of the SECU control
unit for at least 5 seconds) to avoid damage to the instrument; also motor cables must be
disconnected.
Voltages on logic card connector in normal conditions

• Key switch (5A): check that battery voltage is present on pin 5 in A connector.
• Potentiometer: check that the voltage between the White/Yellow wire (8A) and the Brown/Black wire
(9A) is lower than the value set in Code 242 in rest conditions; turning the potentiometer the voltage
must reach approx. 5V.
• Check that between pin 7 and pin 9 in A connector a value slightly lower than 5V is present.
• Running switches: check whether battery voltage is present:

o on pin 2 in A connector when reverse direction is enabled
o on pin 3 in A connector when forward direction is enabled.
On the pin of the direction not enabled and on the pins of both directions in idle position, 0V must be
measured.
• Main contactor: check whether battery voltage is present on pin 11 in A connector. To keep the
contactor closed between pin 11 (positive) and pin 6 (negative) in A connector 11V must be present
(coil overheating protection).
Checks on the motor

• Check for electric continuity between armature and field terminals.
• Check for motor insulation from the vehicle’s chassis and battery positive or negative.
Check for chassis insulation

• No voltage must be measured between the chassis and battery positive or negative.
• No voltage must be measured between the chassis and motor terminals.
Checks on contactors
• Contactors must be in good conditions and the mobile part should be able to move.
• The coil resistor value (when cold) must be higher than 9Ω.
• Coil wires should not be damaged or stripped.
• Pellets should not be worn out nor show important signs of burning.
• The voltage measured on coil ends in all contactors controlled by the SECU system must be approx. 24V
for the first seconds and then 11V.
• Battery voltage must always be present on the coil positive (White) when the key switch is in on
position.
Checks on the potentiometer
• Check that the wires connected to the potentiometer are not interrupted.
• If potentiometer calibration lasts more than 1 minute Error 12 is signalled.
Wrong programming
• This error is signalled when battery voltage (Code 0300) is higher than the max. voltage allowed for the
control unit.
Models Max. voltage allowed

SECU-10 160/25 60V
SECU-10 220/40 55V
SECU-20 350/50 – SECU-40 600/70 60V
SECU-20 200/25 – SECU-40 400/50 100V
FAQ (frequently asked questions)

Q: The control unit does not signal any error, but the vehicle does not move and the main
contactor does not close.
R: if the seat function is enabled, check whether battery voltage is present on pin 8 in B connector when the
operator is seated. If not check the wiring and the switch.
Q: The control unit does not signal any error but the vehicle does not move and the main
contactor is closed.
R:
• If the tiller switch function is enabled, check whether battery voltage is present on pin 8 in B
connector when the tiller is down. If not check the wiring and the switch.
• If the emergency reverse function is enabled, check whether battery voltage is present on pin 2 in B
connector in normal conditions. If not check the wiring and the switch.
• In case of speed reductions check that:
o They are not on, that is on corresponding pins (2B, 8B and 3B for SECU-10 or 2B, 8B and 6B
for SECU-20) no voltage is present.
o They are not programmed at min..
s. r. l.
ELEKTROSISTEM s.r.l. - Via Enrico Toti,4 - 44042 Cento (FE) ITALY - Tel. +39-0516836502 (4 linee r.a.) - Fax +39-0516836799

SECU Control Unit SECU Control Unit: Programming Instructions

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SECU Control Unit SECU Control Unit: Programming Instructions

Uploaded by

Copyright:

Available Formats

SECU Control Unit

Via Enrico Toti, 4 - 44042 Cento (FE) ITALY

Printed 04/2009 Ver. 3.09 Tel. +39-0516836502 Fax +39-0516836799

Use and installation instructions

3.08 software version

Description of a separately excited motor

Operation of the SECU control unit

Model Field current Armature current Voltage

Fixing holes and power connections

+Vb: battery positive after the main contactor.

SECU-20 and SECU-40 F1 F2 E1 E2

Main warnings and precautions

12 pin 6 pin 8 pin

12 pin 8 pin 6 pin

Pin Function Direction Colour

8-pin B connector for SECU-10

Pin Function Direction Colour

8-pin B connector for SECU-20 and SECU-40

Pin Function Direction Colour

Motor Aux. fuse

General wiring diagram for the SECU-10 control unit.

Motor Aux. fuse

Conn. C Conn. B Conn. A

General wiring diagram for SECU-20 and SECU-40 control units.

Tiller / parking brake switch

Config. 1 Config. 2 WHITE/GREEN

The functions can be obtained in two ways:

Emergency reverse belly button switch

Speed control by means of potentiometer

min. 12 11 10 9 8 7 12 PIN Conn. A

Speed control by means of potentiometer with neutral in the middle position

Speed control by means of 0-5V and 0-10V signal

Coils for contactors

8 pin Conn. B 8 7 6 5 12 11 10 9 8 7 12 pin Conn. A

External status LED

Do not connect other devices than a LED diode.

Battery disconnecting switch

Main Battery disconnecting

Shutdown from external device

Key positive Key positive

Wiring diagram for the UMP terminal

Speed reduction with low battery voltage

For further information contact Elektrosistem’s engineers.

Code Parameter Description Calculation Notes

When voltage is applied to

Acceleration current is halved

• It is possible to modify the vehicle’s operation features according to the input.

Or, immediately after switching on:

Code Status Notes

LED rapidly flashing – Not serious errors

Code Error Possible causes and solutions

LED slowly flashing - Serious errors

Flashes Code Error Possible causes and solutions

Display of parameters during operation

The parameters displayed are shown in the table below:

Page Parameter Unit of measurement

Voltages on logic card connector in normal conditions

• Running switches: check whether battery voltage is present:

Checks on the motor

Check for chassis insulation

Checks on the potentiometer

Models Max. voltage allowed

FAQ (frequently asked questions)