SECU Control Unit SECU Control Unit: Programming Instructions
SECU Control Unit SECU Control Unit: Programming Instructions
PROGRAMMING
INSTRUCTIONS
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
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3.08 software version
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
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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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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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.
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• 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
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INSTALLATION
SECU-10
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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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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.
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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
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
SECU-20/40
12-pin A connector for SECU-10, SECU-20 and SECU-40
(1) In the SECU-20 and SECU-40 use pin 5 of 8-pin B connector for this function.
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(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.
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Standard configuration
Battery Power
fuse
Main
contactor
Key switch
Potentiometer
5K
F2 F1 -Vb E- E+ +Vb
SECU-10
Conn. A
Conn. C Conn. B
Signalling
led
Reverse switch
Forward switch
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Battery Power
fuse
Main
contactor
E2 F1 +Vb
F2
-Vb
E1
Key switch
Potentiometer
SECU-20/40
5K
Signalling
led
Reverse switch
Forward switch
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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.
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
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.
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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
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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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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.
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WHITE
Power steering /
Aux. Contactor Main contactor brake coil
coil coil
BLACK/BLUE
YELLOW/GREY
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.
YELLOW
12 11 10 9 8 7 12 pin Conn. A
6 5 4 3 2 1 SECU-10/20/40
YELLOW / BLACK
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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.
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.
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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).
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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.
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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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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(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.
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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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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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.
ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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ELEKTROSISTEM s.r.l. – Via Enrico Toti, 4 – 44042 Cento (FE) ITALY – Tel. +39 051 683 65 02 – Fax +39 051 683 67 99
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The UMP terminal can display some controller’s parameters during operation (refer to the UMP manual).
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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.
• 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.
• 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 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.
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
Page 28/28 USE and INSTALLATION INSTRUCTIONS for SECU CONTROLLERS
3.08 software version
• 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.
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..
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
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