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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

DSHF-B CONTROL UNIT - 2.47.2 version

The four quadrant DSHF-B control unit is a bidirectional, microprocessor aided controller featuring
regenerative braking and high frequency . Designed to control a permanent magnet motor it is fully
programmable by a hand -held device . The DSHF-B control unit is built with MOSFET technology
according to the safety standards for use on EC marked vehicles. Thanks to the acceleration limit the
vehicle gradually reaches maximum speed for a smooth control.
The max. current applied to the
motor can be controlled through a limiter. The control unit performs a regenerative braking that can
be set by the customer, acting during deceleration, when the running control is released and during
reversal.
The DSHF-B control unit offers high performance thanks to the microprocessor technology and to
the wide range of parameters that can be set according to the specific requirements of the customer.

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

TECHNICAL FEATURES
Parameters setting by means of the ITS programmer or the PC-LINK serial interface.
Slow starting through adjustable acceleration slope.
Adjustable limit for max. current applied to the motor.
Thermal limit with proportional action.
Adjustable limit for max. braking current.
Control by three-wire 5K potentiometer.
Control by two-wire potentiometer with angle on request.
Protection against reverse polarity by means of main relay inside the controller.
Safety device in case of short circuit of MOSFETs.
Safety device in case of potentiometer failure.
Safety device in case of potentiometer not at 0 at start up. Reset is made putting potentiometer
to 0.
- Driver for electromagnetic brake (max. current 1 Amp)

TECHNICAL SPECIFICATIONS
-

Voltage rating
Peak current
Allowed power supply variation
Operation frequency
Operation temperature
Relative humidity at 25C
Thermal limiter action
Weight for 45-60A
90/140A

*not available at 48V

12 - 24 - 36 - 48 Volts
45* - 60 - 90 - 140 Amps
85-125%
16Khz
from -20C to +40C
90%
70-80C
350g
800g

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

WARNINGS FOR A PROPER USE OF

THE DSHF-B CONTROL UNIT

Never disconnect the battery during running.

Never switch off and then on the key switch during running.

Never enable the key switch when the vehicle is pushed or downhill.

Never connect micro switches stopping the vehicle (for instance the seat switch) in series to the
key switch; they must be connected in series with the common running contact.

The electric contact of the key switch must be in good conditions to avoid bounces or
contacts.

Always check that the contact between connectors is good; a lways check that power connections
are tightened and use deoxidising spray on connectors.

Always disconnect the key switch during battery charging.

Always use cables with a suitable section to connect motors and batteries.

The path between power cables and the unit must be as shorter as possible; we suggest to use
different paths for power and auxiliary wiring harness.

Fasten the control unit in a proper position, protected against dust and water.

During cleaning disconnect the battery, never wash the equipment with water or solvents, avoid
pressure jets and before re-starting the vehicle check that the equipment is dry.

Always contact engineers to supply power to the vehicle with systems other than
a battery.

Never modify the original wiring diagram.

false

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

PROGRAMMING
Access to programming mode
To enter programming mode remove the jumper near the LED and power the unit (the LED remains
off). Connect the PC or the programming terminal to the control unit and carry out programming. At
the end of programming fit again the jumper.
Important: changes can cause anomalies in the equipment operation !

LOCATION
0
1
2
3
4
5
6
7
8
9
10

12
13
14

DESCRIPTION

bit
bit
bit
bit
bit
bit
bit
bit

0
1
2
3
4
5
6
7

Acceleration slope (44.7 / duration of the slope in seconds)

Max. acceleration current (desired current x 255 / peak current)
Max. braking current (desired current x 255 / peak current)
Min. battery voltage (102 x V/cell)
Max. battery voltage (102 x V/cell)
Braking slope (44.7 / duration of the slope in seconds)
Min level for potentiometer (V x 51.2)
Max. level for potentiometer (V x 51.2)
Max. forward speed (0-255)
Max. reverse speed (0-255) (VIII)
Enabling of special functions (active at 1) (See example)
(1)
Virtual potentiometer with central zero (ref. loc 12)
(2)
Autocalibration of potentiometer
(4)
Autocalibration of current zero values
(8)
Slope at 2 levels
(16)
Virtual logarithmic potentiometer
(32)
IR Compensation
(64)
Running controls active when not connected to -VB
(128)
Filtering of digital inputs
Potentiometer centre when in simulation of pot. at central zero (V x 51.2)
Max. current of braking end (desired current x 255 / peak current)
Function associated with auxiliary input (to be connected with -VB)
function is enabled with closed contact
function is enabled with open contact

01-20
02-3
04-5
07-6
09-8
11-10
12-13

Speed reduction (I)

Emergency reverse (II)
Emergency reverse without micro switch release control (II)
Replacing of acceleration slope value (III)
Replacing of braking slope value (III)
Replacing of acceleration current value (III)
Immediate stop (including brake control when enabled)

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15
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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

14-15 Special operation mode with repeated stops and starts (IV)
17-16 Replacing of braking current (III)
18-19 Delay in running controls release (VII)
Register 0 for auxiliary input
Function associated with the auxiliary output (to be connected with -VB)

function is enabled with closed pin

function is enabled with free pin

Electromagnetic brake control (V)

Electromagnetic brake control without current control at zero (V)
Enabling of external logic card
17
Register for auxiliary output
18
Compensation level R x I (when enabled)
19
Starting delay (seconds x 10)
20
Delay in reverse engagement (seconds) when not at central zero
21
Enabling of special functions second part (active at 1) (See example)
bit 0 (1)
Control of potentiometer at zero before starting
bit 1 (2)
Control of current limitation duration (ref. loc. 22)
bit 2 (4)
Rapid reading of potentiometer
bit 3 (8)
High performance with max. speed
bit 4 (16)
Stop with one limit switch when in simulation of pot. at central 0
bit 5 (32)
Check for jumper presence after starting
bit 6 (64)
Stop with both limit switches opened at central 0
bit 7 (128)
Time / 4 for values expressed in seconds (loc. 15, 17, 20 and 22)
22
Max. time of duration for current limitation (seconds)
23
Braking slope in reverse (44.7 / duration of the slope in seconds)
24
Register 1 for auxiliary input
25
Enabling of special functions third part (active at 1)
bit 0 Rapid passage to braking
28,29
Hour meter (h = 256 x loc28 + loc29) (VI)
02
03
04-5

(I)
(II)
(III)
(IV)
(V)
(VI)
(VII)
(VIII)

Reduction speed (0-255) in the register 0 for the auxiliary input (loc. 15)
The forward running time after emergency reversal (seconds) in the register 0 for the auxiliary input (loc. 15)
The value to replace in the register 0 for the auxiliary input (loc. 15)
The time for ON (seconds) in the register 0 for the auxiliary input (loc. 15) and time for OFF (seconds) in the
Register 1 for the auxiliary input (loc. 24)
The time (seconds) to wait before enabling the electromagnetic brake when the vehicle has stopped in the
Register for the auxiliary output (loc. 17)
Reading only locations
The time (in seconds) for the delay in the Register 0 for the auxiliary input (loc. 15)
Location 9 = 127 means a proportional 50% reduction, calculated in comparison with the speed in forward
direction

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

Example: setting of acceleration slope at 2.2 seconds

Procedure:
Look for the location referred to acceleration slope in the list of parameters:
0

Acceleration slope (44.7 : duration of the slope in seconds)

where 0 (zero) refers to the location and in brackets

formula helps to rapidly calculate the desired value.
The result of a simple division:

(44.7 : duration of the slope in seconds) a

44.7 : 2.2 = 20.3

that will be rounded up to 20

is the value to program in the control unit.

In short, to obtain an acceleration slope of 2.2 seconds (current limitation excluded) t he following is
to be programmed:
location 0, value 20

Example: binary setting

Enabling of "slope at 2 levels" and "simulation of logarithmic potentiometer" parameters.
Procedure:
Look for the parameters in the list:
10
bit
bit
bit
bit
bit
bit
bit
bit

0
1
2
3
4
5
6
7

Enabling of special functions (active at 1) (See example)

(1)
Virtual potentiometer with central zero (ref. loc 12)
(2)
Autocalibration of potentiometer
(4)
Autocalibration of currents zeros
(8)
Slope at 2 levels
(16)
Virtual logarithmic potentiometer
(32)
RI Compensation
(64)
Running controls active when not connected to -VB
(128)
Filtering of digital inputs

The single items are the location bits (in binary), the value to put is the sum of the values in brackets
of the functions to be enabled.
In this case:

bit 3 + bit 4 = 8 + 16 = 24

To enable the "slope at 2 levels" and "simulation of logarithmic potentiometer" functions, the
following is to be programmed:
location 0, value 24

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

FAULTFINDING
Error type according to the number of flashes of the signalling LED
1
2
3
4
5
6
7
9
10

The motor is not in standstill position at starting

The motor is not in standstill position at starting
Battery voltage is too low
Battery voltage is too high
The potentiometer is not in zero position at starting
The potentiometer is interrupted
Overheating
EPROM wrong programming
Power error

USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

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ITS PROGRAMMING TERMINAL

The four keys enable the operator to use the different options available. Use the [ESC] key to cancel the choice
and the [ENTER] key to confirm the displayed option. The [-] and [+] keys enable the operator to move among
the different options and to change numerical values.
The options on the ITS terminal are the following:
1)
2)
3)
4)
5)
6)

DECIMAL MODIFICATION
BINARY MODIFICATION
CTRL DATA ITS [Page 1]
ITS DATA CTRL [Page 1]
CTRL DATA ITS [Page 2]
ITS DATA CTRL [Page 2]

The first two options enable to modify adjusting parameters using the decimal or binary system.
We suggest to modify all parameters us ing the DECIMAL system , and to use the binary system only for those
parameters expressed in bits (locations 10 and 21).
The instructions contained in the present pages are referred to the decimal system.
Short use instructions for the option BINARY MODIFICATION
The system includes 8 bits
0 1 2 3 4 5 6 7
If you choose the BINARY MODIFICATION option, a page is displayed where each zero represents a bit
Bit

0
7

0
6

0
5

0
4

0
3

0
2

0 0
1 0

0 stands for disabled function, 1 stands for enabled function

If you want to enable bits 1 and 2 you need to change the page as follows
0

1 1 0

Correspondence between decimal and binary system

Bit
Decimal value

7
128

6
64

5
32

4
16

3
8

2
4

1
2

0
1

To enable bits 1 and 2 in decimal modification the value to be set is therefore 6 (2+4 = 6)
The higher value that can be set corresponds to the sum of all values and is to 255.
Options 3, 4, 5 and 6 enable to transfer all adjus ting parameters saved in a control unit to another control unit.
The ITS memory has two pages, it is therefore possible to save up to two parameter lists at the same time.
To transfer the data from one control unit to the ITS terminal select and confirm o ption 3 to store the data on
page 1 or option 5 to store the data on page 2.
To transfer the data from the ITS terminal to one control unit, select and confirm option 4 to transfer the data
saved on page 1 or option 6 to transfer the data saved on page 2.

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

PROGRAMMING
Preliminary instructions
Programming can be carried out by means of the yellow ITS programming terminal.
Procedure
1) - Disconnect the control unit from the power supply.
- Remove the small bridge on the control unit near the signalling LED.
- Connect the control unit with the power supply.
- Connect the ITS programming terminal with the control unit, that is the green plug of the terminal with the
two-pin green connector of the control unit.
2) - Connect the ITS programming terminal with the power supply: connect the red alligator clip of the terminal
with the positive pole and the black alligator clip with the negative pole.
Important: the power supply
source must be included between 10V and 80V.
- The following message will be displayed on the programming terminal:
PROGRAMMING
-CONSOLE 1.1In case the starting message does not appear, disconnect one of the alligator clips (if possible the red one),
wait for a few seconds and re-connect the clip with the power supply.
3) - Press any key on the programming terminal.
4) - Press the [+] or [-] key until the following option appears on the display:
DEC. MODIFICAT
Key [ENTER]: Enter
- Press the [ENTER] key to display the following message:
DEC. MODIFICAT
PLEASE WAIT!
After some seconds if the terminal is not able to become connected with the control unit, the anomaly is
signalled as follows:
DEC. MODIFICAT
Wrong Data!
In this case press any key in order to display the following message back:
DEC. MODIFICAT
Key [ENTER]: Enter
Now, press ag ain the [ENTER] key in order to try again to become connected. If the following message
appears again:
DEC. MODIFICAT
Wrong Data !
repeat the whole procedure from the beginning.

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

5) - If the terminal is able to become connected with the control unit, the following message is displayed:
LOC:00 Register
- Press the [+] and [-] keys to scroll registers up and down . During selection the message displayed is
usually the following:
LOC:NN Register
where NN indicates the number of selected register. Refer to the table with the parameters to find out the
register number referred to the parameter to modify.
6) - Use the [+] and [-] keys to display the parameter to be modified. Then press the [ENTER] key.
- If the terminal is able to receive the data from the control unit the following message is displayed:
LOC:NN Register
VALUE: XXX
where XXX indicates the numerical value stored in the NN register.
- Use the [+] and [-] keys to modify the numerical value. Then press the [ENTER] key to confirm the change
or the [ESC] key to cancel it.
- If the terminal is not able to receive the data from the control unit, the following message is displayed:
LOC:NN Register
Wrong Data !
press any key to display the following message:
LOC:NN Register
- Press again the [ENTER] key and try again.
Using the procedure described at points 5 and 6 it is possible to modify all parameters, without leaving the
DEC. MODIFICAT option.
7) - In order to save the modifications remove power from the control unit.
- Fit again the small bridge that has been removed.
- Unplug the programming terminal.
- Re-power the control unit.
Now changes are effective.

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

CONNECTION DIAGRAM for UMP PROGRAMMING TERMINAL

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USE INSTRUCTIONS for DSHF-B CONTROLLER 2.47.2 version

STANDARD WIRING DIAGRAM