Sensata M700 Series Manuel utilisateur

| M700

HYDRAULIC PUMP MOTOR CONTROLLER

INTERFACE MANUAL

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| M700 SERIES 
HYDRAULIC PUMP MOTOR CONTROLLER 
 2
 
Copyright © 2021 Sensata Technologies, Inc. 
 
CONTENTS 
 
 
OVERVIEW ........................................................................................................................................3
INSTALLATION AND WIRING.............................................................................................................5
MOUNTING THE CONTROLLER.....................................................................................................5
CONNECTIONS ..............................................................................................................................7
High current connections.............................................................................................................8
Low current connections..............................................................................................................8
CONTROLLER WIRING:    TYPICAL CONFIGURATION...................................................................9
KSI Wiring ...................................................................................................................................10 
Main Contactor...........................................................................................................................10 
Interlock Switch..........................................................................................................................11 
Circuitry Protection Devices.......................................................................................................11 
Throttle Wiring ...........................................................................................................................11 
PROGRAMMABLE PARAMETERS....................................................................................................16 
VOLTAGE MENU..........................................................................................................................17 
CURRENT MENU .........................................................................................................................18 
SPEED MENU...............................................................................................................................18 
THROTTLE MENU........................................................................................................................19 
MISCELLANEOUS PARAMETERS .................................................................................................23 
MONITOR MENU............................................................................................................................24 
DIAGNOSTICS AND TROUBLESHOOTING .......................................................................................25 
PC APP DIAGNOSTICS.................................................................................................................25 
LED DIAGNOSTICS.......................................................................................................................27 
    MAINTENANCE .......................................................................................................................28 
CLEANING....................................................................................................................................28 
FAULT HISTORY ...........................................................................................................................29 
 
 
 

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

OVERVIEW

M700 is a high-power hydraulic pump controller that provides

fully programmable control of DC series wound motors. It

features microprocessor-based logic with programmable

parameters and offers maximum flexibility for minimum cost.

This means the controller can be tailored to the needs of

specific applications. In addition to configuration flexibility,

use of the programmer offers diagnostics and test capability. It

is the ideal solution for hydraulic pump motor control on

aerial work platform (AWP) equipment.

Fig. 1 M700-VR1

hydraulic pump motor

controller.

The M700 controller offers superior operator control of motor

speed and torque.

Controllable Power

➢Pulse Width Modulation (PWM) control with programmable

speed, acceleration rate, and current limit.

➢Short duration boost capability (10 sec, 110% of 2 min current

rating). Allows clearing of obstacles, climbing ramps.

➢16 kHz PWM frequency for near silent operation.

➢High efficiency, silent operation. Operating costs, heat-sinking

requirements, motor and battery losses reduced. Low-end

torque, range, and battery life maximized.

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

Programmable and Flexible

➢Fully programmable via Sensata PC programming software.

➢Supports multiple throttle types and High Pedal Disable (HPD)

options.

➢LED output for easy system troubleshooting via flash codes.

➢Fully programmable analog throttle input for precise speed

control with a variety of signal sources.

➢Programmable under voltage cutback caters to different

battery types.

➢CAN type input for throttle function

➢Interlock function with a digital signal input that can be easily

disabled/enabled by setting.

➢Two-driver output with max 2A.

Robust Safety and Reliability

➢Redundant hardware and software watchdog timers.

➢MOSFET short-circuit protection functions.

➢Programmable HPD function prevents controller operation if

throttle is applied before key is turned on.

➢Contactor fault detection: controller shuts down safety if the

main contactor opens.

➢Contactor protection functions minimize high current arcing to

prevent contact pitting and thus prevent contactor weld

failures.

➢Undervoltage cutback and shutdown functions protect against

low battery voltage, including low voltage caused by external

loads.

➢Electrical isolation to heat sink: 500VAC.

➢Rugged housing meets IP54 environmental ratings.

➢Full power operation over -40°C to 50°C environment

temperature range.

Familiarity with the controller will help you install and operate it

properly. We encourage you to read this manual carefully. If you have

questions, please contact the Sensata service ofﬁce nearest you.

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

INSTALLATION AND WIRING

MOUNTING THE CONTROLLER

The M700 controller can be oriented in any position and meets

the IP54 ratings for environmental protection against dust and

water. However, the location should be carefully chosen to

keep the controller clean and dry. If a clean and dry mounting

location cannot be found, a cover must be used to shield the

controller from water and contaminants.

The controller’s outline and mounting hole dimensions are

shown in Figure 2. When selecting the mounting position, be

sure to also take into consideration that access is needed at the

end of the controller to plug the programming cable into its

connector. To ensure full rated power, the controller should be

fastened to a clean, flat metal surface with four 6 mm (1/4")

diameter screws, using the holes provided. Although not

usually necessary, a thermal joint compound can be used to

improve heat conduction from the controller heatsink to the

mounting surface. You will need to take steps during the design

and development of your application product to ensure that its

EMC performance complies with applicable regulations;

suggestions are presented in Appendix A.

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

Fig 2 Mounting dimensions,

M700-VR1 controller

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

caution

CONNECTIONS

The controller’s connectors are all conveniently located on one end:

Working on electrical systems is potentially dangerous. You should

protect yourself against uncontrolled operation, high current arcs, and

outgassing from lead acid batteries.

UNCONTROLLED OPERATION — Some conditions could cause the

hydraulic pump system to run out of control. Disconnect the motor or

make sure the pump system has enough room to operate before

attempting any work on the motor control circuitry. Note: If the wrong

throttle input signal type is selected with the programming device, the

pump system may suddenly begin to operate.

HIGH CURRENT ARCS — Batteries can supply very high power, and arcs

can occur if they are short circuited. Always open the battery circuit

before working on the motor control circuit. Wear safety glasses and

use properly insulated tools to prevent shorts.

LEAD ACID BATTERIES — Charging or discharging generates hydrogen

gas, which can build up in and around the batteries. Follow the battery

manufacturer’s safety recommendations. Wear safety glasses.

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

High current connections

This controller has three high-current busbars: B+, B- and M-. The

busbars are tin-plated solid copper.

Cables used for the battery and motor connections must be heavy

enough to carry the high current required. A minimum size of 25 mm2 (#4

AWG) is recommended.

Connections to the controller busbars should be made with lugs

suitable for the cable used, fastened by M8 bolts and nuts. When

tightening the bolts, two opposing wrenches should be used. Failure to

use the double-wrench technique could cause undue strain to be placed

on the internal connections, and could also result in cracked seals around

the busbars.

Low current connections

This controller has six low-current connections: four 6.35 mm push-on

terminals (J1, J2, J3, and J5), and two 4-pin connectors (J4 and J6).

Table 2 Low Current Connections

Keyswitch

Wire 1 of 2-wire throttle; Pot High of 3-wire.

Wire 2 of 2-wire throttle; Pot Wiper of 3-wire throttle.

4-pin connector: see Table 3.

Reverse signal output / main contactor coil driver.

4-pin connector: see Table 4.

For the control wiring, 0.75 mm2 (#18 AWG) vinyl insulated stranded wire

is recommended.

The mating connector for J4 is a 4-pin Molex Mini-fit Jr. or equivalent.

Either an external Status LED or a USB2UART programmer can be

connected to J4. The pinout is as follows.

Table 1 High Current Connections

B+

Battery+ and motor armature

B-

M-

Motor field (controller output)

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

Note: When J4 is used for a Status LED, a jumper must be added between

pins J4-1 and J4-4 as shown in the basic wiring diagram (Figure 3).

The mating connector for J6 is a 4-pin TE Mini-Universal MATE-N-LOK or

equivalent. The pinout is as follows.

CONTROLLER WIRING: TYPICAL CONFIGURATION

Figure 3 shows the typical wiring conﬁguration for most applications. The

interlock switch is typically a seat switch, tiller switch, or foot switch, the

interlock function can be disable in the setting. The throttle shown is a 3-

wire pot; other types of throttles can also be used.

PIN PROGRAMMER STATUS LED

J4-1 Data input from programmer (Rx). Status LED enable.

J4-2 GND GND

J4-3 Data output to programmer (Tx). Status LED output.

J4-4 +12.7V +12.7V

Table 3 J4 connector pinout

Table 4 J6 connector pinout

PROGRAMMER

J6-1

Driver output

J6-2

Interlock

J6-3

CANL

J6-4

CANH

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| M700 SERIES

HYDRAULIC PUMP MOTOR CONTROLLER

KSI

THROTTLE POT

WIPER

J3 THROTTLE POT

LOW

+12V

GND

CANH

CANL

INTERLOCK

Reserved

B+

M-

B-

Main Contactor

Driver J5

MAIN

PRECHARGE RESISTOR

J6-4

J6-3

J6-2

J6-1

MAIN CONTACTOR

POLARITY

PROTECTION

DIODE

FUSE

THROTTLE POT

Fig.3 Typical wring diagram

KSI Wiring

The keyswitch input (KSI) circuit includes input from the keyswitch and from

the various interlocks. The controller KSI is used to turn the controller on and

off. KSI is turned on by connecting it to battery B+. Any positive voltage greater

than about 16 volts will turn on the controller, but usually the full vehicle battery

voltage is used. KSI draws up to 120 mA with the programmer connected.

In its simplest form, KSI is operated by a keyswitch that turns the vehicle off and

prevents unauthorized use. The keyswitch should also turn off the main contactor

This will act as a safety feature by removing power from the motor control system

when the keyswitch is turned off.

Main Contactor

A main contactor should be used with the controller. Otherwise, the controller’s

fault detection will not be able to fully protect the controller and hydraulic system

from damage in a fault condition. The main contactor allows the controller and

motor to be disconnected from the battery. This provides a signiﬁcant safety

feature, because it means the battery power can be removed from the hydraulic

system if a controller or wiring fault results in battery power being applied to the

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