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.