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
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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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I-DRIVE TECHNICAL MANUAL PG DRIVES TECHNOLOGY
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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I-DRIVE TECHNICAL MANUAL PG DRIVES TECHNOLOGY
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
SK76977-0710