DMC SuperSigma2 Service manual

SuperSigma2 QRM for
Permanent Magnets Synchronous motors
Quick Reference Manual V01.02.02
This user manual details the features of the standard controller range:
(for more detailed information contact DMC)
PMS range for Permanent Magnet Synchronous Motors 24-96V, 250-600Arms
Modification History:

SuperSigma2 QRM PMS –V01.02.02 17-1-2020 Page 2 (58) ©2019 DMC GmbH Herten Germany
Revision
Issue Date
Author
Changes
01.00.09
20-04-2016
RP
Match Firmware V02.06.01
01.01.00
23-01-2017
FM
Match Firmware V02.07.01
01.01.01
14-02-2017
FM
Match Firmware V02.07.02
01.01.02
16-02-2017
FM
Fix pms motor error code list
01.01.03
10-04-2017
FM
Match Firmware V02.07.03
01.01.04
17-11-2017
YS
Match Firmware V02.08.00
01.01.05
19-02-2018
RP
Corrected mechanical drawing Size 1
01.01.06
13-03-2018
FM
V02.08.01. Improved the inching in traction, added Shared Line contactor
compatible with Control Via CAN HMI, enable the creep ramp time for traction
and pump, add serial numbers visible in About menu of calibrator.
01.01.07
15-05-2018
FM / RP
Updated error code tables, EMC and Layout
01.01.08
04-06-2018
FM
V02.08.02 Improved F30 (overspeed) management (pump-traction). Increased
available output voltage for AC motor(pump.traction). For traction: improved
inching, footbrake operation, scale of accel pot in traction speed mode. Added
adj 17 in traction for torque mode 3 for better end of braking in footbrake
operation. Changed some default values. Included Park Icon for display..
Improved F12 and F13 management. Improved PC interface settings download.
Improved the function inhibit of change of direction.
01.01.09
24-08-2018
FM
Update Layout and Cross-references. Minor textual errors corrected
01.01.10
15-01-2019
FM
Update Nominal RMS motor current for tuning
01.02.00
04-11-2019
AvB
Match tables to ADVANCED MANUAL V 1.5.3
01.02.01
15-01-2020
SM
Match tables to ADVANCED MANUAL V1.5.5
01.02.02
17-01-2020
SM
Match tables to ADVANCED MANUAL V1.5.6

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CONTENTS
1DMC PHILOSOPHY –INTRODUCTION ..................................................................................................................... 5
2SUPERSIGMA2 VARIANTS ...................................................................................................................................... 6
3CONTROLLER FEATURES......................................................................................................................................... 7
4TECHNICAL SPECIFICATIONS................................................................................................................................... 8
4.1 ELECTRICAL ..............................................................................................................................................................8
4.1.1 Voltage specifications: .....................................................................................................................................8
4.1.2 Current specifications: .....................................................................................................................................8
4.2 ENVIRONMENTAL ......................................................................................................................................................8
4.3 MECHANICAL ...........................................................................................................................................................9
5INSTALLATION INSTRUCTIONS ............................................................................................................................. 10
5.1 SAFETY..................................................................................................................................................................10
5.2 MECHANICAL INSTALLATION AND COOLING ..................................................................................................................10
5.3 POWER WIRING ......................................................................................................................................................10
5.4 LIGHT WIRING.........................................................................................................................................................10
5.5 SPEED SENSOR CABLING............................................................................................................................................10
5.6 CONTACTORS .........................................................................................................................................................11
5.7 FLASHING NEW SOFTWARE........................................................................................................................................11
5.8 POWER UP DELAY ...................................................................................................................................................11
6EMC GUIDELINES.................................................................................................................................................. 12
6.1 POWER CABLES.......................................................................................................................................................12
6.2 SIGNAL CABLES.......................................................................................................................................................12
6.3 CONTROLLER..........................................................................................................................................................12
7CALIBRATOR ........................................................................................................................................................ 13
7.1 THE CALIBRATOR.....................................................................................................................................................13
7.2 CALIBRATOR MAP....................................................................................................................................................14
7.3 DMC PC PROGRAMMER..........................................................................................................................................14
8DASHBOARD DISPLAY .......................................................................................................................................... 15
8.1 GENERAL INFORMATION ...........................................................................................................................................15
8.2 DISPLAY SETUP MENU ..............................................................................................................................................15
8.3 DISPLAY FEATURES SETUP.........................................................................................................................................16
8.4 DISPLAY ICONS .......................................................................................................................................................17
9PARAMETERS....................................................................................................................................................... 18
9.1 MENU 1“ADJUSTMENT”..........................................................................................................................................18
9.2 MENU 1“TRACTION ADJUSTMENTS”..........................................................................................................................18
9.2.1 Neutral braking setup options .......................................................................................................................20
9.2.2 Neutral braking setup in speed control mode (control mode 0) ....................................................................20
9.2.3 Neutral braking setup in torque control mode (control mode 1) ...................................................................20
9.2.4 Neutral braking setup in torque control mode (control mode 2) ...................................................................20
9.2.5 Hill Hold..........................................................................................................................................................20
9.3 MENU 1“PUMP ADJUSTMENTS”...............................................................................................................................21
9.4 MENU 2“STATUS”..................................................................................................................................................22
9.4.1 Status tables...................................................................................................................................................23
M2-3 BDI States table..............................................................................................................................................23
M2-6 Drive and brake status table ..........................................................................................................................23
M2-7 Speed limits table...........................................................................................................................................23
M2-8 Torque limits table .........................................................................................................................................23
M2-9 Motor limits table ..........................................................................................................................................23
9.5 MENU 3“CONTROLLER SETUP”.................................................................................................................................24

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9.5.1 Controller Setup for Traction..........................................................................................................................24
9.5.2 Controller Setup for Pump..............................................................................................................................26
9.6 PMS MOTOR AUTO TUNING ....................................................................................................................................28
9.6.1 Setting up auto tuning ...................................................................................................................................28
9.7 MENU 4“PMS MOTOR AUTO TUNING”.....................................................................................................................29
9.7.1 Initiating auto tuning .....................................................................................................................................30
9.7.2 Auto tuning errors..........................................................................................................................................31
9.7.3 Recalculation..................................................................................................................................................32
9.8 MENU 5“PMS MOTOR SETUP”................................................................................................................................33
9.9 MENU 6“PMS MOTOR ADVANCED”.........................................................................................................................34
9.10 MENU 7“LIMITS SETUP”.........................................................................................................................................35
9.11 MENU 8“BDI” BATTERY DISCHARGE INDICATOR..........................................................................................................36
9.12 MENU 9“CAN BUS SETUP”.....................................................................................................................................37
9.13 MENU 10 “FAULT LOG”...........................................................................................................................................38
9.14 MENU 11 “TEST”...................................................................................................................................................39
9.14.1 Test menu for Traction ..............................................................................................................................39
9.14.2 Test menu for Pump ..................................................................................................................................40
9.15 MENU 12 “DEBUG”................................................................................................................................................41
9.16 MENU 13 “ABOUT”................................................................................................................................................41
9.17 THERMAL MOTOR MANAGEMENT &PERFORMANCE TABLE............................................................................................42
9.17.1 Current roll back on motor temperature ...................................................................................................42
9.17.2 Option to disable current roll back functions.............................................................................................42
10 DIAGNOSTICS.................................................................................................................................................. 43
10.1 ERROR CODES ........................................................................................................................................................43
10.2 PMS MOTOR SUB ERROR CODES................................................................................................................................48
11 GRAPHICS & SCHEMATICS............................................................................................................................... 49
11.1 ACCELERATOR CHARACTERISTICS ................................................................................................................................49
11.2 CONTROLLER THERMAL CUTBACK CHARACTERISTIC........................................................................................................49
11.3 LIGHT WIRING OF PMS CONTROLLER..........................................................................................................................50
11.3.1 Connectors’ pin assignment for Traction ...................................................................................................50
11.3.2 Light wiring example for traction ..............................................................................................................51
11.3.3 Connectors’ pin assignment for Pump .......................................................................................................52
11.3.4 Light wiring example for pump..................................................................................................................53
11.4 CAN BUS WIRING....................................................................................................................................................54
11.4.1 CAN bus wiring example with DMC Display: .............................................................................................54
11.4.2 CAN bus wiring example without DMC Display: ........................................................................................54
11.5 IGAUGE DISPLAY –CONNECTION DIAGRAM ..................................................................................................................55
11.6 POWER WIRING......................................................................................................................................................55
12 MECHANICAL DRAWINGS ............................................................................................................................... 56
12.1 SUPERSIGMA2CONTROLLERS....................................................................................................................................56
12.2 DMC ADVANCED DISPLAY........................................................................................................................................56
13 AVAILABLE APPLICATION NOTES..................................................................................................................... 57
14 CONTACT INFORMATION ................................................................................................................................ 58

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1DMC PHILOSOPHY –INTRODUCTION
DMC (Digital Motor Control) GmbH, is a company with a dedicated team of individuals with many years’ experience in the design,
manufacture, sales and aftermarket support of controllers predominately utilised in the electric vehicle industry. The Company has
been formed with enthusiasm and professionalism to create and develop unique products for this particular "niche" industry where
specialist knowledge and experience are essential for success.
A full range of associated accessories and support infrastructure completes the DMC service. To conclude, a fusion of creative
thinking, collective experience and latest state of the art technology, has produced what we believe to be the most flexible and
thermally advanced controller ranges available in the market place to date.
Next Generation: The SuperSigma2 Controller Range
After the success of the Sigmadrive controller range, DMC has developed a new controller range, specially designed to control AC
induction and PMAC (PMS/IPM) motors, running on nominal battery voltages in the range of 24V up to 120V, at nominal powers up
to 30kW and peak powers up to 60kW.
The power board design fundamentals are similar to the previous Sigmadrive design, combining superior heat sinking of components
and connections with unmatched vibration protection. The mechanical design is improved to IP65 and we incorporated the industry
standard 35 way AMP-seal connector.
Nonetheless we had to leave the single PCB design philosophy in favour of a separate logic PCB to utilise state of the Art 32bit
microcontroller technology that enables us to offer features required for today’s vehicle control. A completely new motor control
module is introduced, using flux vector motor control for both AC induction and PMAC.
New Features on SuperSigma2 are for example fully automated tuning of AC induction motors and PMS without the need for manual
fine tuning or using a PC. The advanced auto tuning algorithms allow motor tuning even if the motor is installed on the vehicle. Just
entering the motor name plate data into the controller tuning menu is enough to obtain optimal tuning results. Even when the motor
name plate data is unknown it is possible to get the system running smoothly!
On PMAC we introduce automated motor sensor setup for 8bit sin/cos absolute position encoders and hall sensors, which
significantly eases the production of PMAC motors, eliminating the costly need for adjusting sensor offsets.
Vehicle constructers now have the choice to use control via CAN or use the flexibility of software selectable active high or active low
inputs. Optimized interfacing with battery management systems completes the SuperSigma2 controller range, allowing limiting
battery current, especially useful for vehicles using Lithium batteries.
Sigmadrive Controller Range
The first generation of DMC controllers, today known as the ‘Sigmadrive controller range’ was designed in the year 2000. Utilising
revolutionary power heat sinking technology called IMS (Insulated Metal Substrate) a new generation of highly efficient controllers
for all popular motor types is offered from a single core design, in the 24V - 96V, 1KW - 24KW power range. Using 'flash memory' in
the control electronics coupled with a unique design architecture, all powers and motor types including AC, PMS (PMAC), SEM, PM4
and Series, can be accommodated within 3 standard power frames. Particular attention has been placed on providing high-resolution
control circuitry and software, to provide fully optimised, highly efficient motor control.
The principle advantage of IMS technology (which can be visualised as a metal PCB) is that cost effective SMD Mosfet power devices
can be mounted and soldered directly onto the IMS PCB, which provides immediate and excellent 'integral' heat sinking.
Consequently, reliability and efficiency are significantly enhanced due to the power switching devices running cooler and therefore
inherently more efficiently. This approach also leads to significantly improved continuous power delivery (1 hour current rating), as a
ratio to peak power, with the controllers continuous rating normally being one of the most important aspects in determining the
vehicles performance.
By using an innovative patented technique, DMC has fully exploited IMS technology to realise a unique controller design. The
construction provides manufacturing simplicity and reliability by removing the need for any interconnections and using a minimal
number of mechanical and electronic components. This gives a totally robust and environmentally sealed, space efficient controller.
©2015 DMC GmbH

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2SUPERSIGMA2 VARIANTS
Model Nr.
Power
AC Traction
PAC960T4-**
60-96V 600Arms
PAC945T3-**
60-96V 450Arms
PAC927T2-**
60-96V 270Arms
PAC914T1-**
60-96V 140Arms
PAC460T3-**
24-48V 600Arms
PAC445T2-**
24-48V 450Arms
PAC425T1-**
24-48V 250Arms
AC Pump
PAC960P4-**
60-96V 600Arms
PAC945P3-**
60-96V 450Arms
PAC927P2-**
60-96V 270Arms
PAC914P1-**
60-96V 140Arms
PAC460P3-**
24-48V 600Arms
PAC445P2-**
24-48V 450Arms
PAC425P1-**
24-48V 250Arms
PMS Traction
PMS960T4-**
60-96V 600Arms
PMS945T3-**
60-96V 450Arms
PMS927T2-**
60-96V 270Arms
PMS914T1-**
60-96V 140Arms
PMS460T3-**
24-48V 600Arms
PMS445T2-**
24-48V 450Arms
PMS425T1-**
24-48V 250Arms
PMS Pump
PMS960P4-**
60-96V 600Arms
PMS945P3-**
60-96V 450Arms
PMS927P2-**
60-96V 270Arms
PMS914P1-**
60-96V 140Arms
PMS460P3-**
24-48V 600Arms
PMS445P2-**
24-48V 450Arms
PMS425P1-**
24-48V 250Arms
Example:
PAC960T4-01
Model Number Description
Motor Technology
PAC = 3 phase AC Induction
PMS = Permanent Magnet Synchronous
IPM = Interieur Permanent Magnet
Nominal Battery Voltage:
4 = 24/48V
9 = 60/96V
1 = 120V (future)
Maximum Current (Arms)
14 = 140 Arms
25 = 250 Arms
27 = 270 Arms
45 = 450 Arms
60 = 600 Arms
Frame Size
1 = Size 1 (160x200x72mm) (small)
2 = Size 2 (200x200x72mm) (medium)
3 = Size 3 (250x200x72mm) (medium+)
4 = Size 4 (320x200x72mm) (large)
Firmware Number
Configuration
T = Traction
P = Pump
E = Power steer

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3CONTROLLER FEATURES
Feature
Number of digital switch inputs.
7
Number of digital inputs, sensor related
3
Number of analogue inputs
6
Number of contactor driver outputs (2.5 Amps as limited by interconnect current carrying capability)
(build in contactor coil suppression)
3
Number of low power output (Can be amplified with a DMC external driver module 830/DRV)
1
✓24V - 120V Operation
✓
✓100% on Mosfet technology
✓
✓IMS power PCB for superb thermal conduction
✓
✓Cooled power terminals
✓
✓Updatable firmware / flash memory, easy software updates
✓
✓Environmental protection IP65
✓
✓Powerful, State of the art 32 bit microprocessor control
✓
✓High frequency 16kHz (Silent Operation)
✓
✓Internal watchdog monitoring microprocessor operation
✓
✓Arc less contactor switching and built in coil suppression
✓
✓Low impedance, active low inputs switched to B-ve
✓
✓Active high inputs available on request
✓
✓Thermally compensated current limit
✓
✓Selectable accelerator characteristics
✓
✓Adjustable creep speed
✓
✓Seat switch timer
✓
✓Power steer timer
✓
✓Electro brake timer
✓
✓Belly switch operation
✓
✓Regenerative braking
✓
✓Direction braking proportional to accelerator position
✓
✓Braking in neutral
✓
✓Braking with brake pedal –proportional or switched
✓
✓Under and Over-voltage protection
✓
✓Accelerator wire off detect
✓
✓Inching facilities
✓
✓Short circuit and open circuit contactor detect
✓
✓3 traction cutback speeds
✓
✓6 Pump speeds with Additive & Priority
✓
✓Input to disable pump operation
✓
✓Independent power steer speed and compensation settings
✓
✓Hardware and Software fail-safe systems
✓
✓+ 12V or +5V selectable output pin supply
✓
✓Diagnostics with LED indication
✓
✓Remote diagnostic LED
✓
✓Adjustments made via a calibrator or PC programmer
✓
✓CAN Open compatible
✓
✓Hours count displaying key & pulsing hours on calibrator
✓
✓BDI on Calibrator
✓
✓Dashboard display connectable
✓
✓Easy to use ‘icons’ for display information
✓
✓Resettable Service and Fault logs
✓
✓Setup menu on calibrator to enable various options
✓

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4TECHNICAL SPECIFICATIONS
4.1 Electrical
4.1.1 Voltage specifications:
Model
Nominal battery
voltage
Absolute operating voltage
range
Reduced braking
voltage levels (F4)
High Voltage cut out
level (F22)
PXX4xx-XX
24 V –48 V
12.0 V –72.5 V
60.0 V –67.5 V
70 V
PXX9xx-XX
60 V –120 V
12.0 V –144.0 V
130.0 V –138.5 V
140 V
Note: These voltage levels are used to set the voltage levels in the Limits menu.
4.1.2 Current specifications:
Model
Power
Current limit
(1 min)
Continuous current 1 hour
rating. Unit mounted on
an sufficient heat sink, at
20C ambient.
Controller frame size
PXX425XX
24/48V 250A
250Arms
130A
Size 1
PXX445XX
24/48V 450A
450Arms
250A
Size 2
PXX460XX
24/48V 600A
600Arms
330A
Size 3
PXX914XX
60/96V 140A
140Arms
75A
Size 1
PXX927XX
60/96V 270A
270Arms
140A
Size 2
PXX945XX
60/96V 450A
450Arms
230A
Size 3
PXX960XX
60/96V 600A
600Arms
300A
Size 4
Switching Frequency: Controller frequency is 8KHz (centre aligned PWM switching). Motor frequency 16KHz.
Electrical Isolation: Enclosure to any live part = 1KV. Controller internal insulation specified at >10MΩ @500V DC.
Reverse Battery Polarity: If line contactor installed according to the manual, yes
I/O details: See light wiring diagram.
4.2 Environmental
Impact Protection (IP): The enclosure is protected to IP65 (when AMP seal Connector fitted)
Vibration: 6G, 40-200Hz for 1 hour, in x, y and z planes.
Operating Temperature: -30oC to +40oC ambient around controller.
Storage Temperature: -40oC to +70oC.
Humidity: 95% maximum, non-condensing.
Humidity Resistance: Ingress protected, watertight AMP seal connector
Safety: Designed to the requirements of machine directive 2006/42/EC, safety of industrial trucks
EN1175-1:1998+A1:2010, EN13849-1, UL94.
The vehicle manufacturer is responsible for the compliance of the complete system with the
appropriate regulations.
EMC: EN 12895 (2015), (Immunity tested at 30V/M)
EN 61000-6-3 (2007) +A1 (2011) + AC (2005) (Residential Emissions, Class B)
EN 61000-6-2 (2005) + AC (2005) (Industrial Immunity)
The machine manufacturer is responsible for the compliance of the complete system with the
appropriate regulations.

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4.3 Mechanical
Details: See mechanical drawings.
Enclosure: Aluminium heat sink with ABS plastic cover.
Power connections: Vertical Copper studs.
Hexagonal: Fixing torque 9.5Nm (Slot screws are recommended!)
Slot screw: Recommended, fixing torque 9.5Nm (Brass)
Bolt length: Max 20mm incl. washer and spring washer
Weight: Size1: 3.25kg; Size2: 4.1kg; Size3: 4.9kg; Size4: 6.2kg;
Always use a torque wrench when fixing the power terminals.
Exceeding the maximum specified torque can cause serious damage to the controller and warranty
might be void.
Too long bolts damage the controller.

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5INSTALLATION INSTRUCTIONS
5.1 Safety
Electric vehicles can be dangerous. All testing, fault-finding and adjustment should be carried out by competent
personnel. The drive wheels should be off the floor and free to rotate during the following procedures.
•THE VEHICLE MANUFACTURER’S MANUAL SHOULD BE CONSULTED BEFORE ANY OPERATION IS
ATTEMPTED.
•THE BATTERY MUST BE DISCONNECTED AND THE INTERNAL CAPACITORS MUST BE DISCHARGED
BEFORE REPLACING, MODIFYING OR ATTEMPTING ANY REPAIRS OF THE CONTROLS
Before working on the controls disconnect the battery and connect the B+ and B- controller terminals via a 10 ohm 25
watt resistor to discharge the internal capacitors.
Never connect the controller to a battery with its vent caps removed as an arc may occur due to the controller’s internal
capacitance when it is first connected.
5.2 Mechanical installation and Cooling
The controller should be bolted down to a flat (0.2mm max. Deviation) paint free surface, eventually lightly coated with
a thermal transfer compound, by the 4 fixing holes provided. Care should be taken not to trap any wires, etc., under the
controller. The mounting surface MUST be a substantial metal section of the vehicle for the full controller ratings to be
achieved. If there is no sufficient cooling surface available, then we advise to use a ripped aluminium heat sink
supported by a fan, or mount the heat sink in such a way that the driving wind cools the system.
5.3 Power wiring
Power connections should be made with flexible heat resisting cables of suitable cross-sectional area for the current to
be carried. These should be terminated in crimped lugs attached to controller and the contactors. Note that bolts and
washers are supplied for the connections on the controller. Be careful not to use to long bolts, as they can damage the
PCB. A battery-disconnect switch should be used (EC Directive).
Fixing torque for power connectors M8 terminals is 9,5Nm, for M6 power connectors 9,5Nm.
The controller wiring must be completely isolated from the chassis, NEVER CONNECT B- OR B+ TO THE CHASSIS OF THE
VEHICLE. On road vehicles with an 12 Volt on-board electrical system, the 12 Volt system MUST be galvanic separated
from the drive power system. This can be done via a DC-DC converter that charges the 12 Volt system from the drive
battery system. Always use a line contactor, controlled by the DMC controller, to enable the controller to switch off in
unsafe situations.
5.4 Light wiring
The controller may be supplied as a stand-alone unit or pre-wired onto a base-plate with contactors etc.
Control wiring connections should be made using 0.56mm² (AWG#20) or equivalent stranded wire. The correct pressure
release crimping tools MUST be used for long term connection reliability.
The main battery cable should be fused with a suitable air-break fuse. The key switch line must also be fused at a level
not exceeding 10 A when using the specified Ametek or Albright contactors.
The return wiring for the accelerators should be connected to pin A10 on the controller to guarantee wire off
detection..
5.5 Speed sensor cabling
Avoid routing the sensor cabling along with high power motor or battery cables.
Special care should be taken when connecting the screen of the motor speed sensor cable. Be sure only to connect the
screen on the controller side @ pin A31). When connected also to the motor side, current will flow over the screen,
disturbing the signal from the sensor to the controller, this can result in dangerous situations.

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5.6 Contactors
The contactor mounting plane can affect performance; contactors should never be mounted with their terminal studs
vertically down. For further applications information on contactors, please consult DMC GmbH in Herten.
As blow-out magnets are fitted to contactors (except 24V) ensure that no magnetic particles can accumulate in the
contact gaps and cause malfunction. Ensure that contactors are wired with the correct polarity to their power terminals
as indicated by the + sign on the top moulding.
The SuperSigma2 can be used with permanently-connected on-board chargers, as long as the maximum allowed voltage
of the particular controller model is not exceeded. If the batteries should not be charged during operation, a change-
over contactor as line contactor is a good solution to fit both the charger and the controller in the truck.
5.7 Flashing new software
When flashing the controller with a new software version, ALWAYS carefully check ALL parameters after flashing to be
correct. Only qualified engineers are allowed to update the controllers firmware.
5.8 Power up Delay
At first power up the internal capacitor bank needs to be charged. The controller has a build in pre-charge resistor, and
is monitoring the capacitor bank voltage. As soon as the voltage is at the required level, the line contactor will pull in.
Specially at 24V systems using a Large size controller, the time delay to charge the capacitor bank can by longer.

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6EMC GUIDELINES
The following guidelines are intended to help vehicle manufacturers to meet the requirements of the EC directive
Electromagnetic Compatibility. The SuperSigma2 controller range is designed to meet EN61000-6-2 (industrial
immunity), EN61000-6-3 (residential emissions, Class B).
Any high speed switch is capable of generating harmonics at frequencies that are many multiples of its basic operating
frequency. It is the objective of a good installation to contain or absorb the resultant emissions.
All wiring is capable of acting as a receiving or transmitting antenna. Wiring should be arranged to take maximum
advantage of the structural metal work inherent in most vehicles. Vehicle metalwork should be electrically linked with
conductive braids.
6.1 Power Cables
All cables should be routed within the vehicle framework and kept as low in the structure as is practical –a cable run
within a main chassis member is better screened from the environment than one routed through or adjacent to an
overhead guard. Power cables should be kept short to minimize emitting and receiving surfaces. Shielding by the
structure may not always be sufficient –cables run through metal shrouds may be required to contain emissions.
Parallel runs of cables in common circuits can serve to cancel emissions –the battery positive and negative cables
following similar paths is an example.
Tie all cables into a fixed layout and do not deviate from the approved layout in production vehicles. A re-routed battery
cable could negate any approvals obtained.
6.2 Signal Cables
All wiring harnesses should be kept short. Wiring should be routed close to vehicle metalwork. All signal wires should be
kept clear of power cables or made from screened cable. When using screened cable, make sure only to earth it to one
point! Control wiring should be kept clear of power cables when it carries analogue information –for example,
accelerator wiring. Tie all wiring securely and ensure wiring always follows the same layout.
6.3 Controller
Thermal and EMC (emissive) requirements tend to be in opposition. Additional insulation between the controller
assembly and the vehicle frame work reduce capacitive coupling and hence emissions but tend to reduce thermal
ratings. A working balance needs to be established by experiment. The complete installation should be documented, in
detail, and faithfully reproduced on all production vehicles. When making changes, consider their effect on compliance
ahead of any consideration of cost reduction or other “improvement”.

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7CALIBRATOR
7.1 The Calibrator
General
The DMC Calibrator is designed for Setting up the SuperSigma2 controller
range. It also has a build-in interface calibrator software updates via USB.
This guarantees maximum flexibility and no waste of hardware when only
the software must be updated.
CAN Node Setup
When connecting the Calibrator to a controller it will ‘scan’ the CAN bus for
all available Nodes, to enable calibration of all DMC controllers on the same
bus. All controllers are by factory default set to Node 0. Therefore before
using this feature, give all controllers on the bus a unique Node number. To
do this, the calibrator must be plugged in to the controller you want to adjust
the Node number on (menu item 9.1)
Adjustments
The calibrator is easy to use. The up and down buttons are used for scrolling
up and down. Selections can be made with the SEL-button. The plus- and
minus-buttons are used to increase or decrease the parameters.
Firmware updates
On the top-right-hand side a 3-way switch is used to select the operating
mode. For normal operation it must be in position 2.
For flashing new calibrator firmware the switch must be moved to position 3.
To be able to update the calibrator firmware it is necessary to have a PC
software package installed and a copy of the calibrator firmware.
For detailed information on updating firmware please contact your DMC
supplier. SuperSigma2 controller firmware updates are done with a separate
dongle, please contact DMC for details.

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7.2 Calibrator map
•Press and hold the select button for 3 seconds to return to the first screen.
•The calibrator remembers the cursor position in the submenus until key-off.
•When connecting more than 1 node to the CAN bus, the calibrator will react slightly slower.
7.3 DMC PC Programmer
The PC programmer is available for download from our website in the download section (register first).
To be able to use the PC programmer software, the latest version of the DMC calibrator with USB connectivity is
required. The PC programmer let you edit, store and print controller parameters on a windows based PC running XP,
Vista or Windows7. All SuperSigma2 controllers are compatible with the PC programmer.
The installation package includes a manual describing the features and functionality.
The PC programmer updates it’s data dictionary automatically when new parameters are available. For the automatic
update of the data dictionary on Windows Vista, 7 and 8, the DMC PC programmer must be started as administrator.

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8DASHBOARD DISPLAY
The DMC dashboard display is specially
designed to be as flexible as possible to meet
customer requirements.
The display is CAN-Bus driven and gets its
information from the DMC controllers and
eventually from auxiliary equipment.
In the future the membrane buttons will allow
selecting different performance settings to be
selected.
Faults are indicated with Icons.
The Icons can be modified and even the
customer’s brand name and logo can be
displayed to match the truck-identity.
8.1 General information
<1> Brand name window. When required DMC can fit the customer’s name and logo here during production.
<2> Membrane buttons. Used for setting functions as Service interval timer, Hours counter and the Customer
information field <6>.
<3> Battery Discharge Indicator. Indicates the battery discharge state set by CAN-Node 0 (master)
<4> Fault indication fields. Indicates the status of the traction- and pump controllers and other CAN-Nodes.
The CAN node number is displayed in the Icons to indicate which controller has a problem.
When a fault is indicated it replaces the ‘OK’ below the CAN-Node indicator with a fault icon.
Via the calibrator it is possible to select what failure types are displayed or ignored.
<5> General indication field. Calibrator selectable indicators for speed, motor voltage, accelerator demand and
steering (from master)
<6> Free 2x9 character field to show a text. The text can be edited with the display buttons.
<7> Hours counter. Here either Work or Key hours are displayed, selectable with the display buttons.
The hours counter value is stored in the display. The controllers have their own separate counter.
8.2 Display setup menu
To access the display setup menu, hold the select button for 3 seconds.
Features as the Service interval timer, Hours counter and the Customer information field can be adjusted and optionally
protected with a pin code.
Use the up and down arrows (↑↓)to choose the option, press SEL, then use the +and –buttons to change the
value.
1
2
3
4
5
6
7

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8.3 Display Features Setup
Ref
Parameter
Submenu ref.
Sub menu description
Range & Action
1
Service timer
1. Svc interval
Set the time interval for next service.
(40 Hours before service is needed a
spanner icon is shown at power up
indicating service is required)
0–32767 Hr.
2. Count hours
Set to count work or key hours
Work / Key Hrs.
3. Reset timer
Resets the service interval timer
To confirm press SEL
4. Svc time
Indication of the actual counter
value
Indication only
2
Hours counter
1.=Key, 2.=Work
Select to indicate work or key hours
Select ↑↓ and confirm
SEL
3
Information field
1. Adjust field
Free 2x9 character field to show a
customised text.
↑↓ for position, + / –
change value, SEL to
return to menu
4
Pin codes
1. Service timer
Sets pin code for service timer access
2. Information field
Sets pin code for information field
access
3. Reset all pin
codes
Reset all pin codes
(Only with DMC master
code)
5
About
SW version & date
Indication of the software version &
date
Indication only
6
Return to main
screen
-
Select to return to the main menu
Select ↑↓ and confirm
(SEL)

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8.4 Display Icons
LED
code
Calibrator Message
Display Icon
0
None (lowest
priority)
1
Handbrake on
2
Voltage getting low
3
Pump inhibit
4
Voltage getting high
5
Motor hot
6
Controller hot
7
Adjustments out of
range
8
Default settings
restored
9
E-eprom cannot be
accessed
10
2 Direction fault
11
Seat- or tiller switch
open
12
Sequence fault
13
Accelerator high at
first power up
14
Inching or belly
fault
15
Voltage too low
16
N/A
17
Voltage too low
18
High sided Mosfet
short circuit
19
N/A
20
Hardware over
current
21
Contactor coil short
circuit
22
Voltage too high
23
Low sided Mosfet
short circuit
(neutral)
24
HWFS not working
25
Contactor fault
26
Thermal shutdown
fault
27
Low side Mosfet
short circuit
28
Wire off detected
29
CAN Node time out
30
Over speed
31-40
Motor fault

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9PARAMETERS
9.1 Menu 1 “Adjustment”
This menu includes all the adjustments for a more comfortable driving experience.
Please notice that the adjustment menu’s parameters are visible and adjustable on the calibrator according to the
settings in Menu 3 “Controller Setup“.
For example the dual motor parameters 61) Dual motor cut out “DMcut” to 67) Dual motor speed 3 “DMspd3” (Menu 1
Traction Adjustments) will be visible only if parameter 13) dual motor control ”Si/DL/DR” (Menu 3 Traction) is enabled.
It is therefore important to properly set up and configure Controller’s settings in Menu 3 “Controller Setup“, recycle the
key and then move to Adjustment menu, where only active parameters will be visible.
DMC PC programmer interface is displaying always all parameters.
9.2 Menu 1 “Traction Adjustments”
Cal.
Ref.
Parameter
Calibrator
text
Min.
adjust
Max.
adjust
Step
size
Default
1
Acceleration delay
Accel
0.1 s
20.0 s
0.1 s
2.0 s
2
Deceleration delay
Decel
0.1 s
20.0 s
0.1 s
2.0 s
3
Creep speed
Creep
0.0 %
20.0 %
0.1 %
0.0 %
4
Creep speed ramp time
CreepRmp
0.1 s
20.0 s
0.1 s
2.5 s
5
Maximum speed forward
SpdMaxF
0.0 Hz
600.0 Hz
0.1 Hz
100.0 Hz
6
Maximum speed reverse
SpdMaxR
0.0 Hz
600.0 Hz
0.1 Hz
100.0 Hz
7
Neutral brake torque (torque mode only)
NBrake
0 %
100 %
1 %
10 %
8
Neutral brake ramp time
NBrkRamp
0.1 s
20.0 s
0.1 s
8.0 s
9
Neutral brake end delay
NBrkEnd
0.0 s
10.0 s
0.1 s
0.0 s
10
Direction brake torque (torque mode only)
DBrake
1 %
100 %
1 %
100 %
11
Direction brake ramp time
DBrkRamp
0.1 s
20.0 s
0.1 s
1.0 s
12
Max. direction change speed
MxDbrkSp
1 %
100 %
1 %
100 %
13
Foot brake torque (torque mode only)
FBrake
0 %
100 %
1 %
50 %
14
Foot brake ramp time
FbrkRamp
0.1 s
20.0 s
0.1 s
1.0 s
15
Speed threshold to enter end of braking
mode
SpdThEbM
0.1 %
50.0 %
0.1 %
15 %
16
Ramp time from the speed threshold to
zero
SpdRmpTm
0.1 s
20.0 s
0.1 s
3.0 s
17
Ramp time from the speed threshold to
zero low TH
SpdRTmFB
0.1 s
20.0 s
0.1 s
0.4 s
18
Zero Speed threshold to enter hill hold or
neutral brake end
ZSpdTh
0.1 %
10.0 %
0.1 %
0.2 %
19
Hill hold time
HHTime
0 s
60 s
1 s
5 s
20
Restraint hill hold speed
HHspeed
0.0 Hz
5.0 Hz
0.1 Hz
3.0 Hz
21
Restraint hill hold torque threshold
HHTrqTH
0.1 %
35.0 %
0.1 %
1.5 %
22
Cutback speed 1 (I/O 5-6 set to Speed)
Speed1
0.0 Hz
600.0 Hz
0.1 Hz
100.0 Hz
23
Inching speed (I/O 5-6 set to Inching)
InchSpd
0.0 Hz
25.0 Hz
0.1 Hz
10.0 Hz
24
Acceleration delay 1
Accel1
0.1 s
20.0 s
0.1 s
3.0 s
25
Deceleration delay 1
Decel1
0.1 s
20.0 s
0.1 s
3.0 s
26
Maximum Drive Torque 1 (Torque Mode
Only)
MxDrTrq1
0 %
100 %
1 %
100 %
27
Neutral Brake Torque 1 (Torque Mode
Only)
NBrkTrq1
0 %
100 %
1 %
10 %
28
Neutral brake ramp time 1
NBrkRmp1
0.1 s
20.0 s
0.1 s
3.0 s
29
Direction Brake torque 1 (Torque Mode
Only)
DBrkTrq1
0 %
100 %
1 %
100 %
30
Direction brake ramp time 1
DBrkRmp1
0.1 s
20.0 s
0.1 s
3.0 s
31
Foot Brake Torque 1 (Torque Mode Only)
FBrkTrq1
0 %
100 %
1 %
50 %
32
Foot brake ramp time 1
FBrkRmp1
0.1 s
20.0 s
0.1 s
3.0 s
33
Cutback speed 2 (I/O 5-6 set to Speed)
Speed2
0.0 Hz
600.0 Hz
0.1 Hz
100.0 Hz
34
Inching time (I/O 5-6 set to Inching)
InchTime
0.1 s
10.0 s
0.1 s
2.5 s
35
Acceleration delay 2
Accel2
0.1 s
20.0 s
0.1 s
4.0 s

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Cal.
Ref.
Parameter
Calibrator
text
Min.
adjust
Max.
adjust
Step
size
Default
36
Deceleration delay 2
Decel2
0.1 s
20.0 s
0.1 s
4.0 s
37
Maximum Drive Torque 2 (Torque Mode
Only)
MxDrTrq2
0 %
100 %
1 %
100 %
38
Neutral Brake Torque 2 (Torque Mode
Only)
NBrkTrq2
0 %
100 %
1 %
10 %
39
Neutral brake ramp time 2
NBrkRmp2
0.1 s
20.0 s
0.1 s
4.0 s
40
Direction Brake torque 2 (Torque Mode
Only)
DBrkTrq2
0 %
100 %
1 %
100 %
41
Direction brake ramp time 2
DBrkRmp2
0.1 s
20.0 s
0.1 s
4.0 s
42
Foot Brake Torque 2 (Torque Mode Only)
FBrkTrq2
0 %
100 %
1 %
50 %
43
Foot brake ramp time 2
FBrkRmp2
0.1 s
20.0 s
0.1 s
4.0 s
44
Cutback speed 3 (I/O 7 set to speed3)
Speed3
0.0 Hz
600.0 Hz
0.1 Hz
100.0 Hz
45
Handbrake On maximum Speed (I/O 7 set
to Handbrake)
HandBrk
0.0 Hz
400.0 Hz
0.1 Hz
10.0 Hz
46
Maximum Drive Torque speed 3 (I/O 7 set
to Handbrake)
MxDrTrq3
0 %
100 %
1 %
10 %
47
Speed limit ramp (torque control only)
SpLimRmp
0.1 s
20.0 s
0.1 s
10.0 s
48
Drive torque reduction time
DTrqRtm
0.1
3.0 s
0.1
0.8 s
49
Brake torque reduction time
BTrqRtm
0.1
3.0 s
0.1
0.8 s
50
Power steer delay
PStrDly
0.0 s
50.0 s
0.1 s
5.0 s
51
Electric brake delay
EBrkDly
0.1 s
50.0 s
0.1 s
0.5 s
52
Accelerator pot minimum
AccMin
0.0 V
10.0 V
0.1 V
0.2 V
53
Accelerator pot maximum
AccMax
0.0 V
10.0 V
0.1 V
4.6 V
54
Brake pot minimum
BrkMin
0.0 V
10.0 V
0.1 V
0.4 V
55
Brake pot maximum
BrkMax
0.0 V
10.0 V
0.1 V
4.6 V
56
Steer pot minimum
StrMin
0.00 V
10.00 V
0.01 V
0.20 V
57
Steer pot middle point
StrMid
0.00 V
10.00 V
0.01 V
2.50 V
58
Steer pot maximum
StrMax
0.00 V
10.00 V
0.01 V
4.80 V
59
Wig/Wag fwd threshold
FwdTH
0.0 V
10.0 V
0.1 V
3.0 V
60
Wig/Wag rev threshold
RevTH
0.0 V
10.0 V
0.1 V
2.0 V
61
Dual motor cut out
DMcut
1 %
100 %
1 %
10 %
62
Dual motor angle 1
DMang1
1 %
100 %
1 %
60 %
63
Dual motor angle 2
DMang2
1 %
100 %
1 %
70 %
64
Dual motor angle 3
DMang3
1 %
100 %
1 %
85 %
65
Dual motor speed 1
DMspd1
0 %
100 %
1 %
10 %
66
Dual motor speed 2
DMspd2
0 %
100 %
1 %
5 %
67
Dual motor speed 3
DMspd3
0 %
100 %
1 %
30 %
68
Speed ratio (display Kph)
SpdRatio
1.0
999.9
0.1
120.0
69
Vehicle max. speed
VmaxSpd
0.0 KPH
999.9 KPH
0.1 KPH
20.0 KPH
70
Safe stop Torque (Torque mode only)
SfStTorque
0 %
100 %
1 %
20 %
71
Safe stop Ramp Time
SfStRmpTm
0.1 s
10.0 s
0.1 s
1.0 s
72
Belly switch speed
BellySpd
0 Hz
600 Hz
0.1 Hz
50 Hz
73
Belly switch time
BellyTim
0 s
3 s
0.1 s
0.5 s

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9.2.1 Neutral braking setup options
Neutral braking can be setup in three different modes, depending on the vehicle requirements.
The neutral braking mode can be selected in combination with the control mode setup in the controller setup menu:
•Control mode 0, speed control is selected with neutral braking operating in speed mode.
•Control mode 1, torque mode is selected with neutral braking operating in torque mode.
•Control mode 2, torque mode is selected with the end neutral braking operating in speed mode.
If the Hill-Hold feature is required, the choice for the end of neutral braking in speed mode is mandatory.
9.2.2 Neutral braking setup in speed control mode (control mode 0)
Refer to AC ADVANCED MANUAL (See 13 Available Application Notes) for description of this feature.
9.2.3 Neutral braking setup in torque control mode (control mode 1)
The following graph shows how the available neutral braking parameters work.
Use this graph as a reference to understand the meaning of the different parameters used to setup smooth neutral
braking to zero speed.
The neutral braking torque is set with parameter 1.7 (typical value between 10 and 25%). The torque is ramped with
parameter 1.8 Neutral brake ramp time (typical set to 2 to 4 seconds). When ‘speed threshold to enter end of braking
mode’ is reached (1.15) the neutral braking torque will be reduced with speed to give a smooth end of braking feel
(typical value 10 to 20%). Refer to AC ADVANCED MANUAL (See 13 Available Application Notes) for description of this
feature.
9.2.4 Neutral braking setup in torque control mode (control mode 2)
Refer to AC ADVANCED MANUAL (See 13 Available Application Notes) for description of this feature.
9.2.5 Hill Hold
If the Hill-Hold feature is required, the choice for ‘end of neutral braking in speed mode’ is mandatory.
Refer to AC ADVANCED MANUAL (See 13 Available Application Notes) for description of this feature.