PG Drives Technology I-DRIVE Series User manual

I-DRIVE CONTROLLER FAMILY
TECHNICAL MANUAL
SK76977-07

©PG Drives Technology 2009
All rights reserved.
This manual is furnished under copyright and may only be used in accordance with the terms laid out by PG Drives Technology.
The information in this manual is furnished for informational use only, is subject to change without notice, and should not be
construed as a commitment by PG Drives Technology.
Except as permitted by such terms, no part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means electronic, mechanical, recording, or otherwise - without the prior written permission of PG Drives
Technology. [phone].

PG DRIVES TECHNOLOGY I-DRIVE TECHNICAL MANUAL
TABLE OF CONTENTS
8.1.5 Status Indicator Flashes Rapidly And Continuously
(even with throttle released)................................... 16
About this manual..................................................... 8
Icons ..................................................................... 8 8.2 TruCharge Indicator............................................... 17
8.2.1 TruCharge Indicator Steady................................... 17
Chapter 1 – Operation ................................................................9 8.2.2 TruCharge Indicator Flashing 1 Bar Slowly And
Continuously .......................................................... 17
1Introduction................................................. 11
8.2.3 TruCharge Indicator Flashes Slowly, Pauses, Then
Flashes Slowly Again (even with throttle released) .17
2General....................................................... 11
8.2.4 TruCharge Indicator Blinks On Every 3½ Seconds.. 17
2.1 Handling ................................................................11
8.2.5 TruCharge Indicator Flashing Rapidly .................... 17
2.2 Operating Conditions ............................................11
8.3 Self-Help Guide...................................................... 18
3 Controls....................................................... 11
8.4 Slow or Sluggish Movement ................................... 18
3.1 On/Off Switch......................................................... 11
9Battery Gauge .............................................19
3.2 Status Indicator ......................................................12
9.1 How To Read A Single Bulb (or LED) Battery Gauge19
3.3 Throttle ...................................................................12
9.2 How To Read A TruCharge Battery Gauge............. 19
3.3.1 Wig-wag Throttle ....................................................12
3.3.2 Single-ended Throttle............................................. 12 10 Pushing your Machine .................................19
3.3.3 Unipolar Throttle .....................................................12
11 Programming...............................................20
3.4 Tiller Switch .............................................................12
12 Warranty ......................................................20
3.5 Direction Switches..................................................12
3.6 Reverse Switch.......................................................12 13 Servicing......................................................21
3.7 Speed Limiting Potentiometer ...............................12
3.8 Belly Button ............................................................12 Chapter 2 – Installation ....................................................... 23
3.9 Slow/Fast Switch .....................................................13
1Documentation............................................25
3.10 Audible Alarm ........................................................ 13
1.1 i-Drive Versions ....................................................... 25
4Getting Ready to Drive ............................... 13
1.2 i-Drive Operation.................................................... 25
5Tips for Using Your Controller ....................... 13 1.3 Dimensions ............................................................ 26
5.1 Driving - General....................................................13 1.3.1 i-Drive 45A and 70A Controllers ............................. 26
5.2 Driving Technique ..................................................13 1.3.2 i-Drive 140A and 180A Controllers ......................... 27
1.4 Program Settings.................................................... 27
6Precautions for Use...................................... 14
1.5 Soft-Stop ................................................................ 28
6.1 Hazards.................................................................. 14
1.6 Other Information .................................................. 28
7Safety Checks ............................................. 15 2Immobilizing the Machine ...........................28
7.1 Daily Checks..........................................................15
2.1 Prevention of Unauthorized Use ............................. 28
7.2 Weekly Checks ...................................................... 15
2.2 Charger Interlock ................................................... 28
7.3 Servicing ................................................................15
3Connections ................................................28
8Status Indication ......................................... 16
3.1 General ................................................................. 28
8.1 Single Lamp and LED Status Indicators.................. 16
3.1.1 Wiring Configuration i45 & i70 ............................... 29
8.1.1 Status Indicator Steady ..........................................16
3.1.2 Wiring Configuration i140 & i180 ........................... 30
8.1.2 Status Indicator Flashes Slowly and Continuously ..16
3.2 Connectors & Connector Kits ................................ 30
8.1.3 Status Indicator Flashes Slowly, Pauses, Then
Flashes Slowly Again (even with throttle released)..16 3.2.1 Motor And Battery .................................................. 30
3.2.1.1 i45 & i70 .............................................................. 30
8.1.4 Status Indicator Blinks On Every 3½ Seconds .........16
3.2.1.2 i140 & i180 .......................................................... 31
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3.2.2 Aux 1 Connector ...................................................31 5Drive Motors.................................................49
3.2.3 Tiller Interface Connector.......................................31 5.1 Gradient Performance .......................................... 49
3.2.4 Programming Connector ......................................31 5.2 Freewheeling ......................................................... 50
3.3 Crimping................................................................32
6Programming Connection ...........................50
3.4 Wire Gauge and Types .......................................... 32
7Batteries.......................................................50
3.5 Battery Connection................................................33
3.6 Motor Connection .................................................33 8Mounting .....................................................51
3.7 Auxiliary 1 Output ................................................... 33 8.1 Mounting the i-Drive............................................... 51
3.7.1 Solenoid Brake .......................................................33 8.1.1 i45 & i70 ................................................................ 51
3.7.2 Auxiliary 1 Other Modes ......................................... 33 8.1.2 i140 & i180 ............................................................ 52
4Tiller Interface.............................................. 35 8.1.3 Orientation............................................................. 52
8.1.4 Position .................................................................. 52
4.1 Throttle Potentiometer Configuration ..................... 35
8.1.5 Cables................................................................... 53
4.2 Speed Limiting Potentiometer / Belly Button Input.. 36
8.2 Mounting the i-Drive & i-Cover............................... 53
4.2.1 Speed Limiting Potentiometer Configuration......... 36
8.2.1 i45 & i70 + i-Cover ................................................ 53
4.2.2 Belly Button Configuration...................................... 37
8.2.2 i140 & i180 + i-Cover ............................................ 54
4.3 Fused B+ Supply....................................................38
8.2.3 Orientation............................................................. 54
4.4 On/Off Switch......................................................... 38
8.2.4 Position .................................................................. 54
4.5 Status Indicator ......................................................38
8.2.5 Cables................................................................... 54
4.5.1 Status Indicator Diagnostic Setting ........................39
4.6 Slow/Fast Switch .....................................................40 9 Battery Gauge .............................................55
4.7 Reverse Switch / Auxiliary 3 Input / Reverse Direction
Switch ....................................................................40 10 Electromagnetic Compatibility (E.M.C.).......55
10.1 Emissions................................................................ 55
4.7.1 Reverse Switch.......................................................40
10.1.1 Motor Suppression ................................................ 55
4.7.2 Auxiliary 3 Input ......................................................40
10.1.2 Cables.................................................................. 55
4.7.3 Reverse Direction Switch........................................ 41
10.2 Immunity................................................................ 56
4.8 Auxiliary 2 Output ................................................... 41
4.8.1 Diagnostic/Reverse Alarm......................................41 11 Electro-Static Discharge (E.S.D.) ...................56
4.8.2 Brake Light .............................................................42
11.1 Electrical Masses ................................................... 56
4.8.3 Auxiliary 2 Other Modes ......................................... 42
11.2 Prevention of Flashover.......................................... 56
4.9 Auxiliary 3 Output ................................................... 43
11.2.1 Control Panels....................................................... 57
4.10 0 Volts ....................................................................44
11.2.2 Electrical System to Chassis Paths ........................ 57
4.11 Inhibit 1 / Forward Direction Switch ........................44
11.2.3 Electrical Components......................................... 57
4.11.1 Inhibit 1 ................................................................. 44
11.2.4 Ensuring Repeatability .......................................... 58
4.11.2 Inhibit 1 Debounce............................................... 44
11.2.5 Drain Path Components ....................................... 58
4.11.3 Inhibit 1 Mode....................................................... 44
12 Production Tests ...........................................59
4.11.4 Inhibit 1 Target ......................................................45
4.11.5 Inhibit 1 Speed .....................................................45 12.1 Mounting ............................................................... 59
4.11.6 Inhibit 1 Operation................................................45 12.2 Cables and Connectors........................................ 59
4.11.7 Forward Direction Switch....................................... 46 12.3 Preset Settings........................................................ 59
4.12 Inhibit 2 / Tiller Switch.............................................. 46 12.4 Operational Test .................................................... 59
4.12.1 Inhibit 2 ................................................................. 46 12.5 Test Drive................................................................ 59
4.12.2 Inhibit 2 Debounce............................................... 47 12.6 Soft-Stop Test ......................................................... 59
4.12.3 Inhibit 2 Mode....................................................... 47
4.12.4 Inhibit 2 Target ......................................................47 Chapter 3 – Programming....................................................61
4.12.5 Inhibit 2 Speed...................................................... 48 1Introduction .................................................63
4.12.6 Inhibit 2 Operation ................................................ 48
1.1 SP1a & DTT ............................................................. 63
4.12.7 Tiller Switch ............................................................ 48
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1.2 PC Programmer..................................................... 63 7.5 Diagnostic Flash Sequence................................... 73
1.3 Parameters ............................................................63 7.6 Reverse Alarm........................................................ 74
7.7 Pulsed Reverse Alarm ............................................ 74
2Speed Parameters ...................................... 65
7.8 Diagnostic Alarm ................................................... 74
2.1 Forward Acceleration ............................................65
7.9 Brake Disconnected Alarm .................................... 74
2.2 Forward Deceleration ............................................65
7.10 Brake Fault Detect ................................................. 74
2.3 Reverse Acceleration ............................................65
7.11 Brake Light ............................................................. 75
2.4 Reverse Deceleration ............................................66
7.12 Freewheel Speed Limit .......................................... 75
2.5 Max. Forward Speed ............................................. 66
8Motor Parameters ........................................75
2.6 Min. Forward Speed............................................... 66
2.7 Max. Reverse Speed.............................................. 67 8.1 Current Limit........................................................... 75
2.8 Min. Reverse Speed...............................................67 8.2 Boost Drive Current and Boost Drive Time .............. 75
2.9 Speed Limit Pot. Enabled ......................................67 8.3 Current Foldback Threshold, Current Foldback Time,
Current Foldback Level and Motor Cooling Time .. 76
3Operation Parameters................................. 68
8.4 Current Foldback Temperature ............................. 77
3.1 Sleep Timer ............................................................68 8.5 Controlling a Machine on a Slope ........................ 77
3.2 Throttle Invert.......................................................... 68 8.5.1 Motor Compensation ............................................ 77
8.5.2 Slope Factor .......................................................... 78
4Throttle Parameters...................................... 68
8.5.3 Anti-Rollback Level................................................. 78
4.1 Throttle Type........................................................... 68
8.6 Set-up Procedure................................................... 78
4.2 Throttle Deadband ................................................ 68
8.7 Pull-Away Delay ..................................................... 79
4.3 Throttle Gain ..........................................................68
8.8 Anti-Rollback Velocity ............................................ 79
4.4 Throttle Operated At Power-Up ..............................69
4.5 Throttle Reference Test........................................... 69 9 Belly Button ..................................................79
4.6 ISO Tests Resistor ....................................................69 9.1 Belly Button Switch Type ......................................... 79
4.7 Direction Switches..................................................70 9.2 Belly Button Speed................................................. 79
9.3 Belly Button Time .................................................... 79
5Battery Parameters...................................... 70
5.1 Cable Resistance .................................................. 70 10 Factory ........................................................80
5.2 Calibration Factor..................................................70 10.1 Safety Fences ........................................................ 80
5.3 Battery Lockout Parameters ...................................70 10.2 Supply Voltage ...................................................... 80
5.3.1 Battery Lockout Voltage.........................................71
11 Auxiliary Outputs ..........................................80
5.3.2 Battery Lockout Voltage 2......................................71
11.1 Auxiliary 1 Output Mode ........................................ 80
5.3.3 Battery Lockout Time..............................................71
11.2 Auxiliary 1 Output Off Delay ................................... 81
5.3.4 Battery Lockout Type.............................................. 71
11.3 Auxiliary 2 Output Mode ........................................ 81
5.3.5 Battery Lockout Input Select ..................................71
11.4 Auxiliary 2 Output Off Delay ................................... 82
5.4 Low Battery Alarm .................................................. 72
11.5 Auxiliary 3 Output Mode ........................................ 82
6Inhibit Parameters ....................................... 72
11.6 Auxiliary 3 Input Type.............................................. 82
6.1 Inhibit 1 Debounce, Mode, Operation, Speed &
Target.....................................................................72 11.7 Auxiliary 3 Output Voltage ..................................... 82
11.8 Auxiliary 3 Output Off Delay ................................... 83
6.2 Inhibit 2 Debounce, Mode, Operation, Speed &
Target.....................................................................72 12 Memory Functions .......................................83
6.3 Tiller Switch .............................................................72 12.1 Diagnostic Logs ..................................................... 83
12.1.1 Read System Log.................................................. 84
7General Parameters.................................... 73
12.1.2 Clear System Log ................................................. 84
7.1 Soft-Stop ................................................................73
12.1.3 Read Control Log ................................................. 84
7.2 Brake Time .............................................................73
12.1.4 Clear Control Log ................................................. 84
7.3 Output Voltage ...................................................... 73
12.2 Timer...................................................................... 84
7.4 Status Output Type................................................. 73
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12.2.1 Read Timer ........................................................... 84 2.1 Surface Variant ...................................................... 96
12.2.2 Clear Timer ...........................................................84 2.2 Inset Variant ........................................................... 96
3Mounting .....................................................97
Chapter 4 – Diagnostics......................................................85 3.1 Handling ................................................................ 97
1Introduction................................................. 87 3.2 Surface Variant ...................................................... 97
3.2.1 Fixing...................................................................... 97
1.1 Diagnostic Procedure ............................................87
3.2.2 Sealing................................................................... 97
1.2 Detecting A Trip Has Occurred ..............................87
3.3 Inset Variant ........................................................... 98
2 Trip Types And Possible Causes ................... 88
3.3.1 Fixing...................................................................... 98
2.1 Trip Type 1 – Low Battery Voltage........................... 89 3.3.2 Sealing................................................................... 98
2.1.1 Low Battery Voltage ............................................... 89
4Wiring...........................................................99
2.1.2 Very Low Battery Voltage .......................................89
4.1 Wire Gauge ........................................................... 99
2.2 Trip Type 2 – Motor Open Circuit............................ 89
4.2 Connectors............................................................ 99
2.3 Trip Type 3 – Motor Wiring Trip ................................89
4.2.1 Surface Mount Variant ........................................... 99
2.3.1 Motor Shorted To Battery Positive ...........................89
4.2.2 Inset Variant ........................................................... 99
2.3.2 Motor Shorted To Battery Negative ........................89
2.4 Trip Type 4 – Not Used............................................89 5Connections ..............................................100
2.5 Trip Type 5 – Not Used............................................89 5.1 Surface Variant .................................................... 100
2.6 Trip Type 6 – Inhibit Active ......................................89 5.2 Inset Variant ......................................................... 100
2.6.1 Inhibit 1 Active .......................................................89 5.3 Controller Connections........................................ 101
2.6.2 Inhibit 2 Active .......................................................90 5.4 ESD Connection .................................................. 101
2.6.3 Blink – Sleep Mode................................................. 90 5.4.1 Surface Mount Variant ......................................... 101
2.7 Trip Type 7 – Throttle Trip......................................... 90 5.4.2 Inset Mount Variant .............................................. 101
2.7.1 Parallel Speed Pot. Wiper Error ............................... 90
6Electromagnetic Compatibility (EMC)........101
2.7.2 Throttle Reference Error..........................................90
6.1 Immunity and Emissions ...................................... 101
2.7.3 Series Speed Pot. Wiper Error .................................90
6.2 Electro-Static Discharge (ESD).............................. 101
2.7.4 Throttle Displaced At Start-Up.................................90
2.7.5 Belly Button Active At Start-Up ................................90 7Production Tests .........................................102
2.8 Trip Type 8 – Possible Controller Fault.....................91 7.1 Mounting ............................................................. 102
2.8.1 Possible Controller Fault ......................................... 91 7.2 Cables and Connections .................................... 102
2.8.2 Record Of Possible Controller Fault........................91 7.3 Operational Test .................................................. 102
2.9 Trip Type 9 – Solenoid Brake Trip............................. 91
2.9.1 Short Circuit In Solenoid Brake................................91
Chapter 6 – Warning Summary.................................. 103
2.9.2 Open Circuit In Solenoid Brake .............................. 91
1Introduction ...............................................105
2.10 Trip Type 10 – High Battery Voltage........................ 91
2.10.1 High Battery Voltage .............................................91 2Warnings....................................................105
2.10.2 Very High Battery Voltage .....................................91 2.1 Driving Technique ................................................ 105
2.11 Programmable Setting Changed .......................... 91 2.2 Hazards................................................................ 105
3 Servicing Of Defective Units ........................ 92 2.3 Safety Checks...................................................... 106
2.4 Pushing Your Machine ......................................... 106
2.5 Programming ...................................................... 106
Chapter 5 – TruCharge Module......................................93
2.6 Servicing .............................................................. 106
1Introduction................................................. 95
2.7 Program Settings.................................................. 106
1.1 Surface Mount Variant ...........................................95 2.8 Charger Interlock ................................................. 107
1.2 Inset Variant ...........................................................95 2.9 General ............................................................... 107
2 Dimensions.................................................. 96 2.10 Motor And Battery ................................................ 107
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PG DRIVES TECHNOLOGY I-DRIVE TECHNICAL MANUAL
2.11 i140 & i180 ..........................................................107
2.12 Programming Connector ....................................107
2.13 Crimping..............................................................107
2.14 Wire Gauge and Types ........................................ 108
2.15 Battery Connection..............................................108
2.16 Belly Button Configuration.................................... 108
2.17 Fused B+ Supply..................................................108
2.18 Inhibit 1 & 2 Speed ..............................................108
2.19 Drive Motors .........................................................108
2.20 Freewheeling .......................................................109
2.21 Programming Connection...................................109
2.22 Position.................................................................109
2.23 Production Tests ...................................................109
2.24 Introduction .........................................................109
2.25 Forward Acceleration ..........................................109
2.26 Forward Deceleration ..........................................110
2.27 Reverse Deceleration ..........................................110
2.28 Max. Forward Speed ........................................... 110
2.29 Speed Limit Pot. Enabled ....................................110
2.30 Throttle Operated At Power-Up ............................110
2.31 Soft-Stop ..............................................................110
2.32 Brake Fault Detect ...............................................110
2.33 Freewheel Speed Limit ........................................110
2.34 Current Foldback Temperature ...........................111
2.35 Motor Compensation ..........................................111
2.36 Pull-Away Delay ...................................................111
2.37 Belly Button Time ..................................................111
2.38 Safety Fences ......................................................111
Chapter 7 – Specifications..................................................113
1Electrical Specifications ............................ 115
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I-DRIVE TECHNICAL MANUAL PG DRIVES TECHNOLOGY
About this manual
This manual is divided into 7 chapters.
Chapter 1 – Operation
This chapter deals with the controls and functionality of the i-Drive controller.
Chapter 2 – Installation
This chapter deals with the mounting, connection, wiring and set-up procedures of the i-Drive controller.
Chapter 3 – Programming
This chapter provides an overview of the programmable parameters held within the i-Drive controller.
Chapter 4 – Diagnostics
This chapter provides an overview of the diagnostic capabilities of the i-Drive controller.
Chapter 5 – TruCharge Module
This chapter deals with the mounting, connection and wiring of the TruCharge control panel module.
Chapter 6 – Warning Summary
This chapter summarizes the warnings shown throughout the manual.
Chapter 7 – Specifications
This chapter lists the electrical specifications of the i-Drive controller.
Icons
Throughout this manual, icons are used to draw the reader’s attention.
The icons used are:
Note – A general point for best practice.
Caution – A point of safety which if ignored could result in damage to the control system or the
vehicle.
Warning – A point of safety which if ignored could cause injury to the individual.
PG Drives Technology accepts no liability for any losses of any kind if these points are not followed.
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PG DRIVES TECHNOLOGY I-DRIVE TECHNICAL MANUAL – OPERATION
CHAPTER 1 – OPERATION
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I-DRIVE TECHNICAL MANUAL – OPERATION PG DRIVES TECHNOLOGY
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PG DRIVES TECHNOLOGY I-DRIVE TECHNICAL MANUAL – OPERATION
1 Introduction
The relevant contents of this chapter should be included in the machine operating guide. Further copies are available from PGDT
in either written or disk (Microsoft Word) format. Copies should not be made without the express permission of PG Drives
Technology.
Operation of the i-Drive controller is simple and easy to understand. The controller incorporates state-of-the-art electronics, the
result of many years of research, to provide you with ease of use and a very high level of safety. In common with other electronic
equipment, correct handling and operation of the unit will ensure maximum reliability.
This chapter covers all types of operation. It is the responsibility of the machine manufacturer to ensure that only the relevant
sections of this chapter are included in the i-Drive’s operating manual.
Please read this chapter carefully - it will help you to keep your machine reliable and safe.
2 General
2.1 Handling
Avoid knocking your controller and especially the connectors. Be careful not to strike obstacles with the controller. Never drop the
controller.
When transporting your machine, make sure that the controller is well protected. Avoid damage to cables.
2.2 Operating Conditions
Your controller uses industrial-grade components throughout, ensuring reliable operation in a wide range of conditions. However,
you will improve the reliability of the controller if you keep exposure to extreme conditions to a minimum.
Do not expose your controller or its components to damp for prolonged periods.
3 Controls
Depending on the specification of the machine to which the i-Drive is fitted, some or all of the following controls will be used.
3.1 On/Off Switch
The On/Off switch applies power to the controller electronics, which in turn supplies power to the machine’s motor. Do not use the
On/Off switch to stop the machine unless there is an emergency. (If you do, you may shorten the life of the machine drive
components).
Some machines may have a keyswitch in addition to the normal On/Off switch; the function of the
keyswitch is the same as the On/Off switch.
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3.2 Status Indicator
Depending on the machine model, the status indicator may be a single bulb (or LED) or a PGDT TruCharge battery and
diagnostics indicator.
The status indicator shows you that the machine is switched on. It also indicates the operating status of the machine. Details are
given in Section 8.
3.3 Throttle
The throttle controls the speed of the machine. The further you push the throttle, the faster your machine will move. When you
release the throttle, the brake is automatically applied.
Depending on the machine model, the throttle configuration may be one of three types – wig-wag, single-ended or unipolar.
3.3.1 Wig-wag Throttle
In this configuration, the throttle controls both the speed and the direction of the machine. To drive forwards, push the throttle in
one direction; to drive in reverse, push the throttle in the other direction.
3.3.2 Single-ended Throttle
In this configuration, the throttle controls just the speed of the machine. When the throttle is pushed, depending on the position of
the reverse switch (refer to Section 3.6), the machine will drive in either the forward or reverse direction.
3.3.3 Unipolar Throttle
In this configuration, the throttle controls just the speed of the machine. When the throttle is moved, in either direction, depending
on the position of the reverse switch (refer to Section 3.6), the machine will drive in either the forward or reverse direction.
3.4 Tiller Switch
A tiller switch is generally fitted on ‘walkie’ type machines to provide a safety interlock. The tiller arm is usually sprung to the vertical
position and is pulled towards the horizontal to remove a drive inhibit.
3.5 Direction Switches
Direction switches are sometimes used in combination with the throttle to effect drive. After switching on the machine, either the
forward or reverse direction switch must be operated in conjunction with the throttle to enable drive.
3.6 Reverse Switch
This switch will be fitted to the machine if the throttle configuration is single-ended or unipolar (refer to Sections 3.3.2 & 3.3.3). The
switch is used to change between forward and reverse drive.
3.7 Speed Limiting Potentiometer
This control sets the maximum speed of the machine. Turn the knob clockwise to increase the maximum speed setting or anti-
clockwise to decrease the maximum speed setting.
3.8 Belly Button
This device is a safety feature that is activated each time the machine is placed in reverse. If the button is activated, the
machine will stop its reverse drive and immediately begin to move forwards at a programmed speed.
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3.9 Slow/Fast Switch
This switch selects the driving mode – either slow or fast – of the machine. You can use this switch to limit the machine’s driving
behavior in environments where that may be desirable or necessary, e.g. if you are driving in an enclosed space.
3.10 Audible Alarm
This provides an audible warning when the machine is being driven in the reverse direction. The alarm may also be used to signal
other conditions, such as when the machine is in freewheel.
4 Getting Ready to Drive
Check that the speed limiting control is turned to a position that suits you.
Operate the On/Off switch. Either:
A TruCharge type status indicator will blink and remain on after half a second.
A single bulb (or LED) type status indicator will blink and remain on after half a second.
During the first half-second after the machine is switched on, the controller is performing important safety checks within itself and
the rest of the machine’s electrical system. Therefore, if you push the throttle during this time, you will not be able to drive until you
have returned the throttle to the rest position and switched the controller off and on again.
If the machine has a single-ended or unipolar throttle, use the reverse switch to select the direction you want to drive in and then
push the throttle to control the speed. If the machine has a wig-wag throttle, push the throttle in the direction you want to drive.
Depending on the configuration of the machine, you may also have to operate a direction switch and/or a tiller switch before
drive commences.
If you do not push the throttle as you switch the machine on and the status indicator flashes rapidly, then there may be a trip.
Refer to Section 8 for details.
5 Tips for Using Your Controller
5.1 Driving - General
Make sure that all the controls are within easy reach and are comfortable to operate.
5.2 Driving Technique
The controller interprets the throttle movements and reverse switch setting (if fitted) and drives the machine in the correct direction
at the appropriate speed. You will need very little concentration to control the machine, which is especially useful if you are
inexperienced.
The further you push the throttle away from the rest position, the faster the machine will go.
The intelligent speed controller minimizes the effects of slopes and different types of terrain.
The machine user must be capable of driving a machine safely. PGDT accepts no liability for
losses of any kind arising from failure to comply with this condition.
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I-DRIVE TECHNICAL MANUAL – OPERATION PG DRIVES TECHNOLOGY
6 Precautions for Use
In the event of the machine moving in an unexpected way, RELEASE THE THROTTLE. This action
will stop the machine under any circumstances.
6.1 Hazards
Do not drive the machine:
Beyond restrictions indicated in your machine user manual, for example inclines, curb heights etc.
In places or on surfaces where a loss of wheel grip could be hazardous, for example on wet grassy slopes.
If you know that the controller or other crucial components require repair.
Although the i-Drive is designed to be extremely reliable and each unit is rigorously tested during
manufacture, the possibility of system malfunction always exists (however small the probability).
Under some conditions of system malfunction the controller must (for safety reasons) stop the
machine instantaneously. If there is any possibility of the user falling out of the machine as a
result of a sudden braking action, it is imperative that a restraining device such as a seat belt is
supplied with the machine and that it is in use at all times when the machine is in motion. PGDT
accepts no liability for losses of any kind arising from the unexpected stopping of the machine, or
arising from the improper use of the machine or controller.
Do not operate the i-Drive if the machine behaves erratically or shows abnormal signs of heating,
sparks or smoke. Turn the i-Drive off at once and consult your service agent. PGDT accepts no
liability for losses of any kind arising from failure to comply with this condition.
Electro Magnetic Interference (EMI) can affect electronic equipment. Such interference may be
generated by radio stations, TV stations, other radio transmitters and cellular phones. If the
machine exhibits erratic behavior due to EMI, turn the controller off immediately and consult your
service agent. PGDT accepts no liability for losses of any kind arising from failure to comply with
this condition.
It is the responsibility of the machine manufacturer to ensure that the machine complies with
appropriate National and International EMC legislation. PGDT accepts no liability for losses of
any kind arising from failure to comply with this condition.
The machine user must comply with all machine safety warnings. PGDT accepts no liability for
losses of any kind arising from failure to comply with this condition.
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7 Safety Checks
The electronic circuits in the i-Drive have been designed to be extremely safe and reliable. The on-board microprocessor carries
out safety checks at up to 100 times per second. To supplement this safety monitoring you should carry out the following periodic
checks.
If the controller fails any of these checks, do not use the machine and contact your service agent.
These checks should be conducted in an open space and a restraining device such as a seat belt
should always be used. PGDT accepts no liability for losses of any kind arising from failure to
comply with this condition.
7.1 Daily Checks
Throttle:
• With the machine switched off, check that the throttle mechanism is not bent or damaged and that it returns
to the rest position when you push and release it. If there is a problem, do not continue with the safety
checks and contact your service agent.
7.2 Weekly Checks
Throttle:
• Put the throttle to the full speed forward position and switch the machine on. The machine should not move.
To show you that you have switched the machine on with the throttle already pushed, a TruCharge type
status indicator may flash seven bars, whereas a single bulb (or LED) type status indicator will flash seven
times in sequence.
• If the machine does move, contact your service agent.
Parking brake:
• This test should be carried out on a level surface with at least one meter clear space around the machine.
• Switch the machine on.
• Check that the status indicator remains on, or flashes slowly, after half a second.
• Go to drive the machine slowly in the forward direction until you hear the parking brake operate (if fitted).
The machine may start to move.
• Immediately release the throttle. You must be able to hear the parking brake operate within a few seconds.
• Repeat the test in the reverse direction.
Cables and connectors:
• Check that all connectors on the machine are securely mated and ensure that all cables are free from
damage.
7.3 Servicing
To ensure continued satisfactory service, we suggest you have your machine and controller inspected by your service agent after
a period of one year from commencement of service. Contact your service agent for details, when the inspection is due.
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8 Status Indication
Depending on the machine model, the status indicator may be a single lamp (or LED) or a TruCharge battery gauge and
diagnostics display. Both types indicate the status of the controller.
A number of supposedly faulty controllers returned to PGDT are subsequently found to operate correctly. This indicates that many
faults are due to problems on the machine rather than within the controller.
8.1 Single Lamp and LED Status Indicators
8.1.1 Status Indicator Steady
This indicates that all is well.
8.1.2 Status Indicator Flashes Slowly and Continuously
The controller is functioning correctly, but the battery voltage has fallen below the level set by either Battery Lockout Voltage or
Battery Lockout Voltage 2.
Do not operate the machine if the battery is nearly discharged.
8.1.3 Status Indicator Flashes Slowly, Pauses, Then Flashes Slowly Again (even with throttle released)
The controller safety circuits have operated and the controller has been prevented from moving the machine.
This indicates that there is a trip. Please follow this procedure:
• Switch off the machine.
• Make sure that all connectors on the machine are mated securely.
• Check the condition of the battery.
• If the fault persists, count the number of flashes after a pause and then try using the self-help guide in
Section 8.3.
• Switch the machine on again and try to drive. If the safety circuits operate again, switch off and do not try to
use the machine.
• Contact your service agent.
When a system trip occurs and the parameter Diagnostic Flash Sequence has been set to ‘PG’, a series of flashes will be
reproduced on the lamp or LED status indicator. The number of flashes will mimic the TruCharge Status Indicator Trip Types, e.g.
when the lamp or LED flashes 2 times, pauses, then flashes 2 times again etc., the controller has detected a bad motor
connection. Refer to Section 8.3 for the full list of trip types.
8.1.4 Status Indicator Blinks On Every 3½ Seconds
The controller has entered Sleep Mode. Recycle the power to reset.
8.1.5 Status Indicator Flashes Rapidly And Continuously (even with throttle released)
The controller safety circuits have operated and the controller has been prevented from moving the machine.
This indicates that there is a trip. Please follow this procedure:
• Switch off the machine.
• Make sure that all connectors on the machine are mated securely.
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• Check the condition of the battery.
• Switch the machine on again and try to drive. If the safety circuits operate again, switch off and do not try to
use the machine.
• Contact your service agent.
8.2 TruCharge Indicator
The way in which the TruCharge Indicator should be read depends on whether the controller is driving, is in Sleep Mode or is in Trip
Mode. Each case is explained below.
8.2.1 TruCharge Indicator Steady
If the TruCharge Indicator shows red, yellow and green, the batteries are charged.
If the TruCharge Indicator shows just red and yellow, then you should charge the batteries as soon as you can.
If the TruCharge Indicator shows just red then you should charge the batteries immediately.
8.2.2 TruCharge Indicator Flashing 1 Bar Slowly And Continuously
The controller is functioning correctly, but the battery voltage has fallen below the level set by either Battery Lockout Voltage or
Battery Lockout Voltage 2.
Do not operate the machine if the battery is nearly discharged.
8.2.3 TruCharge Indicator Flashes Slowly, Pauses, Then Flashes Slowly Again (even with throttle released)
The controller safety circuits have operated and the controller has been prevented from moving the machine.
This indicates that there is a trip. Please follow this procedure:
• Switch off the machine.
• Make sure that all connectors on the machine are mated securely.
• Check the condition of the battery.
• If the fault persists, count the number of flashes / bars and then try using the self-help guide in Section 8.3.
• Switch the machine on again and try to drive. If the safety circuits operate again, switch off and do not try to
use the machine.
• Contact your service agent.
When a system trip occurs and the parameter Diagnostic Flash Sequence has been set to ‘PG’, a series of flashes / bars will be
reproduced on the TruCharge Indicator. The number of flashes / bars will mimic the TruCharge Status Indicator Trip Types, e.g.
when the TruCharge Indicator flashes 2 times / bars, pauses, then flashes 2 times / bars again etc., the controller has detected a
bad motor connection. Refer to Section 8.3 for the full list of trip types.
8.2.4 TruCharge Indicator Blinks On Every 3½ Seconds
The controller has entered Sleep Mode. Recycle the power to reset.
8.2.5 TruCharge Indicator Flashing Rapidly
The controller safety circuits have operated and the controller has been prevented from moving the machine.
This indicates that there is a trip. Please follow this procedure:
• Switch off the machine.
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• Make sure that all connectors on the machine are mated securely.
• Check the condition of the battery.
• If you can’t find the problem, count the number of flashing bars and use the self-help guide in Section 8.3.
• Switch the machine on again and try to drive. If the safety circuits operate again, switch off and do not try to
use the machine.
• Contact your service agent.
8.3 Self-Help Guide
Below is a list of self-help actions. Try to use the following table before you contact your service agent. Go to the number in the list
that matches the number of flashing bars and follow the instructions.
The battery needs charging or there is a bad connection to the battery. Check the connections to the
battery. If the connections are good, try charging the battery.
There is a bad connection to the motor. Check all connections between the motor and the controller.
The motor has a short circuit to a battery connection. Contact your service agent.
Not used.
Not used.
The controller is being inhibited from driving.
A throttle fault is indicated. Make sure that the throttle is in the rest position before switching on the
machine.
A controller fault is indicated. Make sure that all connections are secure.
The parking brakes have a bad connection. Check the parking brake and motor connections. Make
sure the controller connections are secure.
An excessive voltage has been applied to the controller. This is usually caused by a poor battery
connection. Check the battery connections.
8.4 Slow or Sluggish Movement
If the machine does not travel at full speed and the battery condition is good, check the position of the speed limiting control. If
adjusting the speed limiting control does not remedy the problem then there may be a non-hazardous fault.
Contact your service agent.
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9 Battery Gauge
Depending on the type of machine you have, the battery gauge may be a single bulb (or LED) or a TruCharge display. How to
read each type is described in the previous section.
The battery gauge is included to let you know how much charge is left in your batteries. The best way for you to use the gauge is
to learn how it behaves as you drive the machine. Like the fuel gauge in a car, it is not completely accurate, but it will help you
avoid running out of ‘fuel’.
Depending on the type of machine you have, the battery gauge may also show you the charging status of the batteries.
The battery gauge works in the following way.
When you switch on the controller, after half a second, the battery gauge shows an estimate of the remaining battery charge.
The battery gauge gives you a more accurate reading about a minute after you start driving the machine.
When you replace worn out batteries, fit the type recommended by the machine manufacturer. If
you use another type, the battery gauge may be inaccurate.
The amount of charge in your batteries depends on a number of factors, including the way you use your machine, the
temperature of the batteries, their age and the way they are made. These factors will affect the distance you can travel in your
machine. All machine batteries will gradually lose their capacity as they age.
The most important factor that reduces the life of your batteries is the amount of charge you take from the batteries before you
recharge them. Battery life is also reduced by the number of times you charge and discharge the batteries.
To make your batteries last longer; do not allow them to become completely flat. Always recharge your batteries promptly after
they are discharged.
If your battery gauge reading seems to fall more quickly than usual, your batteries may be worn out.
9.1 How To Read A Single Bulb (or LED) Battery Gauge
Refer to Section 8.1 for full details.
9.2 How To Read A TruCharge Battery Gauge
Refer to Section 8.2 for full details.
10 Pushing your Machine
The machine will be fitted with a freewheel mechanism which allows the machine to be pushed if there is a fault, the batteries
are disconnected or not fitted.
Depending on the type of freewheel mechanism, it may be possible for the machine to freewheel at
potentially dangerous speeds. Therefore, do not push the machine up or down inclines on which
you cannot stop or hold the machine. Never sit on the machine if the freewheel mechanism is
disengaged. PGDT accepts no liability for losses of any kind arising from the machine being
moved while the freewheel mechanism is disengaged.
Do not freewheel the machine faster than the programmed Maximum Speed, e.g. by towing. PGDT
accepts no liability for losses of any kind arising from failure to comply with this condition.
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11 Programming
If you cannot find a position on the speed limiting control that suits you, the controller can be programmed to meet your needs.
The controller can be programmed in three ways – with an SP1 programmer, a DTT Programmer or specialist PC software and
interface cable.
The SP1 is a small hand-held unit, which can be plugged into the controller to alter parameter values.
The DTT is PGDT’s latest hand-held programmer. With a larger LCD screen than the SP1, many parameters can be viewed at the
same time. The DTT can also be plugged directly into the controller to alter parameter values.
The PC Programmer contains a software CD and an interface cable. When the software is installed onto a PC, it can then be
connected to the controller by using the special programming cable. The i-Drive can then be programmed in a Windows™ type
environment.
The programming tools may be included with your machine. If they are not, your machine distributor or service agent or
machine manufacturer will be able to program your controller for you.
If you have a programmer, read the user guide before you use it.
If you re-program your controller, make sure that you observe any restrictions given in your machine user manual. Note any
changes you make for future reference.
Programming should only be conducted by electronic service professionals with in-depth
knowledge of PGDT controllers. Incorrect programming could result in an unsafe set-up of a
machine for a user. PGDT accepts no liability for losses of any kind if the programming of the
controller is altered from the factory preset values.
12 Warranty
The i-Drive controller is covered by a warranty period defined by the machine manufacturer. For details of the warranty period,
please contact your service agent.
The warranty will be void if the i-Drive has:
• Not been used in accordance with the i-Drive Technical Manual, SK76977.
• Been subject to misuse or abuse.
• Been modified or repaired by non-authorized persons.
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