PG Drives Technology S45A User manual

S-DRIVE CONTROLLER FAMILY
TECHNICAL MANUAL
SK76745/10

©PG Drives Technology 2016
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 be any means electronic, mechanical, recording, or otherwise - without the prior written permission of PG Drives
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PG DRIVES TECHNOLOGY S-DRIVE TECHNICAL MANUAL
SK76745/10
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TABLE OF CONTENTS
About this manual ............................................... 8
Chapter 1 - Operation ..........................................................9
1Introduction..............................................11
2General....................................................11
2.1 Handling.....................................................11
3 Controls....................................................11
3.1 On/Off Switch .............................................11
3.2 Status Indicator...........................................11
3.3 Throttle ........................................................11
3.3.1 Wig-wag Throttle................................................ 12
3.3.2 Single-ended Throttle ........................................ 12
3.3.3 Unipolar Throttle................................................. 12
3.4 Reverse Switch............................................12
3.5 Speed Limiting Potentiometer....................12
3.6 Slow/Fast Switch..........................................12
3.7 Audible Alarm.............................................12
4Getting Ready to Drive ............................12
5Tips for Using Your Controller ....................13
5.1 Driving - General ........................................13
5.2 Driving Technique.......................................13
6.1 Hazards ......................................................13
7Safety Checks ..........................................14
7.1 Daily Checks...............................................14
7.2 Weekly Checks ...........................................14
7.3 Servicing .....................................................14
8Status Indication ......................................14
8.1 Single Lamp and LED Status Indicators......15
8.1.1 Status Indicator Steady ..................................... 15
8.1.2 Status Indicator Flashes Slowly .......................... 15
8.1.3 Status Indicator Blinks On Every 5 Seconds........ 15
8.1.4 Status Indicator Flashes Rapidly ...........................
(even with throttle released).............................. 15
8.2 TruCharge Indicator ...................................15
8.2.1 TruCharge Indicator Steady .............................. 15
8.2.2 TruCharge Indicator Flashing Slowly...................15
8.2.3 TruCharge Indicator Stepping Up ......................16
8.2.4 TruCharge Indicator blinks on every 3.5 secs ....16
8.2.5 TruCharge Indicator Flashing Rapidly ................16
8.3 Self-Help Guide ......................................... 16
8.4 Slow or Sluggish Movement....................... 17
9Battery Gauge......................................... 17
9.1 How To Read a Single Bulb (or LED) Battery
Gauge....................................................... 18
9.2 How To Read a TruCharge Battery Gauge 18
10 Pushing your Scooter ............................... 18
11 Programming .......................................... 18
12 Warranty.................................................. 19
13 Servicing.................................................. 19
Chapter 2 –Installation ................................................20
1Documentation ....................................... 22
1.1 S-Drive Operation ...................................... 22
1.2 Dimensions ................................................ 22
1.2.1 S45A, S70A and S90A Controllers.......................22
1.2.2 S120A and S140A Controllers ............................23
1.2.3 S200A Controller ................................................24
1.2 Program Settings ....................................... 24
1.3 Soft-Stop .................................................... 25
1.4 Other Information ...................................... 25
2Immobilizing the Scooter ......................... 25
2.1 Prevention of Unauthorized Use................. 25
2.2 Charger Interlock....................................... 25
3Connections............................................ 26
3.1 General ..................................................... 26
3.1.1 Wiring Configuration S45A, S70A & S90A ...........27
3.1.2 Wiring Configuration S120A & 140A...................27
3.1.3 Wiring Configuration S200A ...............................28
3.2 Connectors & Connector Kits.................... 28
3.2.1 Motor and Battery..............................................29

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3.2.1.1 S45A, S70A & S90A........................................... 29
3.2.1.2 S120A & S140A................................................. 29
3.2.1.3 S200A ...............................................................29
3.2.2 Brake Connector ...............................................29
3.2.3 Tiller Interface Connector..................................30
3.2.4 Charger/Programming Connector....................30
3.3 Crimping ....................................................30
3.3.1 Brake, Tiller Interface & Charger/Programming
Connectors .......................................................30
3.3.2 Motor and Battery Connectors.......................... 30
3.4 Wire Gauge and Types ..............................31
3.5 Battery Connection ....................................31
3.6 Motor Connection......................................31
3.7 Solenoid Brake Connection .......................32
4Tiller Interface ..........................................32
4.1 Throttle Potentiometer Configuration .........33
4.2 Speed Limiting Potentiometer Config........33
4.3 ISO-Test Resistor Configuration ...................34
4.4 On/Off Switch .............................................34
4.5 Status Indicator...........................................34
4.5.1 Status Indicator Diagnostic setting .................... 35
4.6 24V .............................................................35
4.7 Slow/Fast Switch..........................................36
4.8 Reverse Switch ...........................................36
4.9 Audible Alarm.............................................36
4.9.1 Brake Light......................................................... 37
4.10 0 Volts.........................................................37
4.11 Inhibit 2....................................................38
4.11.1 Inhibit 2 Mode ...................................................38
4.11.2 Inhibit 2 Speed ..................................................39
4.11.3 Inhibit 2 Operation ............................................ 39
4.12 Inhibit 3.......................................................39
4.12.1 Inhibit 3 Mode ...................................................40
4.12.2 Inhibit 3 Speed ..................................................40
4.12.3 Inhibit 3 Operation ............................................ 40
4.13 Auxiliary Output ..........................................41
5Drive Motors .............................................41
5.1 Gradient Performance ...............................42
5.2 Freewheeling..............................................42
6Charger/Programming Connections
(Off-board & On-board) .......................... 43
6.1 Inhibit 1.......................................................43
6.1.1 Inhibit Mode...................................................... 44
6.1.2 Inhibit 1 Speed.................................................. 44
6.1.3 Inhibit 1 Operation............................................ 44
7Batteries .................................................. 45
8Mounting................................................. 45
8.1 Mounting of the S-Drive..............................45
8.1.1 S45A, S70A & S90A ........................................... 45
8.1.2 S120A + S140A................................................. 45
8.1.3 S200A ............................................................... 46
8.1.3 Orientation........................................................ 46
8.1.4 Position.............................................................. 46
8.1.5 Cables.............................................................. 46
8.2 Mounting the S-Drive + S-cover system .....47
8.2.1 S45, S70A & S90A + S-cover............................. 47
8.2.2 S120A & S140A + S-cover ................................ 48
8.2.3 S200A + S-cover............................................... 48
8.2.3 Orientation........................................................ 48
8.2.4 Position.............................................................. 49
8.2.5 Cables.............................................................. 49
9Production Tests ...................................... 49
9.1 Mounting ....................................................49
9.2 Cables and Connectors ............................49
9.3 Preset Settings.............................................49
9.4 Operational Test .........................................49
9.5 Test Drive ....................................................50
9.6 Soft-Stop Test ..............................................50
10 Electromagnetic Compatibility (E.M.C.) . 50
10.1 Emissions ....................................................50
10.1.1 Motor Suppression ............................................ 50
10.1.2 Cables.............................................................. 50
10.2 Immunity ....................................................51
10.3 Electro-Static Discharge (E.S.D.) .................51

PG DRIVES TECHNOLOGY S-DRIVE TECHNICAL MANUAL
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11 Battery Gauge .........................................51
Chapter 3 –Programming .......................................... 52
1Introduction..............................................54
1.1 SP1a Programmer ......................................54
1.2 PC Programmer .........................................54
1.3 Parameters.................................................54
1.4 Safety Fences.............................................55
2Speed Parameters ...................................56
2.1 Forward Acceleration.................................56
2.2 Forward Deceleration.................................56
2.3 Reverse Acceleration .................................56
2.4 Reverse Deceleration.................................56
2.5 Max Forward Speed ...................................57
2.6 Min Forward Speed ....................................57
2.7 Max Reverse Speed ...................................57
2.8 Min Reverse Speed ....................................58
2.9 Speed Limit Pot. Enabled...........................58
3Operation Parameters..............................58
3.1 Throttle Invert ..............................................58
3.2 Sleep Timer.................................................58
4Throttle Parameters...................................59
4.1 Throttle Type................................................59
4.2 Throttle Deadband.....................................59
4.3 Throttle Gain ...............................................59
4.4 Throttle Operated At Power-up...................59
4.5 Throttle Reference Test ...............................60
4.6 ISO Tests Resistor.........................................60
5Battery Parameters ...................................60
5.1 Low Battery Flash Level...............................60
5.2 Cable Resistance.......................................60
5.3 Calibration Factor ......................................60
5.4 Low Battery Alarm.......................................60
5.5 Low Battery Alarm Tone ..............................61
5.6 TruCharge Reset Level................................61
6Inhibit Parameters ....................................61
6.1 Inhibit 1 Mode, Inhibit 1 Speed,
Inhibit 1 Latch ............................................ 61
6.2 Inhibit 2 Mode, Inhibit 2 Speed,
Inhibit 2 Latch ............................................ 61
6.3 Inhibit 3 Mode, Inhibit 3 Speed,
Inhibit 3 Latch ............................................ 61
6.4 Aux Output Mode...................................... 61
7General Parameters ................................ 62
7.1 Soft-Stop .................................................... 62
7.2 Brake Time ................................................. 62
7.3 Output Voltage.......................................... 62
7.4 Status Output Type .................................... 62
7.5 Diagnostic Flash Sequence ...................... 62
7.6 Reverse Alarm ........................................... 63
7.7 Reverse Alarm Tone...........................................63
7.8 Pulse Reverse Alarm .................................. 63
7.9 Diagnostic Alarm ....................................... 64
7.10 Diagnostic Alarm Tone ......................................64
7.11 Brake Disconnected Alarm........................ 64
7.12 Brake Disconnected Alarm Tone .......................64
7.13 Brake Fault Detect ..................................... 64
7.14 Brake Light ................................................. 64
7.15 Push Too Fast Threshold ............................. 65
7.16 Push Too Fast Timeout ............................... 65
7.17 Freewheel Enable...................................... 65
7.18 Inhibit 2 Horn Input Enable ........................ 65
7.19 Inhibit 2 Horn Input Enable Tone ........................66
8Motor Parameters .................................... 66
8.1 Current Limit .............................................. 66
8.2 Boost Drive Current and Boost Drive Time . 66
8.3 Current Foldback Threshold,
Current Foldback Time,
Current Foldback Level,
Motor Cooling Time................................... 66
8.4 Current Foldback Temp. ........................... 67
8.5 Motor Compensation................................ 67
8.6 Motor Stall Timeout .................................... 68
8.7 Braking Current .......................................... 68

S-DRIVE TECHNICAL MANUAL PG DRIVES TECHNOLOGY
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8.8 Timed Foldback Braking Current................68
8.9 Timed Foldback Speed..............................68
8.10 Enhanced Motor Compensation (Up),
Enhanced Motor Compensation (Down),
Enhanced Motor Comp (Up) Gain, ...........69
9Memory Functions ...................................69
9.1 Read System Log .......................................69
9.2 Clear System Log .......................................69
9.3 Read Timer.................................................69
9.4 Clear Timer.................................................69
Chapter 4 –Tiller Module............................................ 70
1Introduction .............................................72
1.1 Surface Variant...........................................72
1.2 Inset Variant................................................73
2 Dimensions ..............................................73
2.1 Surface Variant...........................................73
2.2 Inset Variant................................................74
3Mounting .................................................74
3.1 Handling.....................................................74
3.2 Surface Variant...........................................74
3.2.1 Fixing .................................................................74
3.2.2 Sealing ..............................................................75
3.3 Inset Variant................................................75
3.3.1 Fixing .................................................................75
3.3.2 Sealing ..............................................................76
4Wiring.......................................................76
4.1 Wire Gauge................................................76
4.2 Connectors ................................................76
4.2.1 Surface Mount Variant....................................... 76
4.2.2 Inset Variant.......................................................77
5Connections ............................................77
5.0.1 Surface Variant.................................................. 77
5.0.2 Insert Variant...................................................... 78
5.1 Controller Connections ..............................78
5.2 ESD Connection .........................................78
5.2.1 Surface Mount Variant....................................... 78
5.2.2 Inset Mount Variant ...........................................78
6Electromagnetic Compatibility (EMC) ..... 79
6.1 Immunity and Emissions.............................79
6.2 Electro-Static Discharge (E.S.D.) .................79
7Production Tests ...................................... 79
7.1 Mounting ....................................................79
7.2 Cables and Connections ..........................79
7.3 Operational Test .........................................79
Chapter 5 –Warning Summary........................... 80
1Introduction............................................. 82
2Warnings ................................................. 82
2.1 Driving Technique.......................................82
2.2 Hazards ......................................................82
2.3 Safety Checks ............................................83
2.4 Status Indicator Flashes Slowly....................83
2.5 TruCharge Indicator Flashes Slowly ............83
2.6 Pushing Your Scooter..................................83
2.7 Programming .............................................83
2.8 Warranty .....................................................83
2.9 Servicing .....................................................83
2.10 Program Settings ........................................84
2.11 Charger Interlock........................................84
2.12 Connections - General ..............................84
2.13 Battery and Motor Connections.................84
2.14 Crimping ....................................................85
2.15 Wire Gauge and Types ..............................85
2.16 Battery Connection ....................................85
2.17 ISO-Test Resistor Configuration ...................85
2.18 24V .............................................................85
2.19 0 Volts.........................................................85
2.20 Inhibit 2 Speed ...........................................85
2.21 Inhibit 3 Speed ...........................................86
2.22 Drive Motors................................................86
2.23 Freewheeling..............................................86
2.24 Charger Connections ................................86
2.25 Inhibit 1 Speed Limit Value.........................87

PG DRIVES TECHNOLOGY S-DRIVE TECHNICAL MANUAL
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2.26 Position .......................................................87
2.27 Production Tests..........................................87
2.28 Program Settings ........................................87
2.29 Introduction ................................................87
2.30 Safety Fences.............................................87
2.31 Forward Acceleration.................................87
2.32 Forward Deceleration.................................88
2.33 Reverse Deceleration.................................88
2.34 Max Forward Speed ...................................88
2.35 Speed Limit Pot. Enabled...........................88
2.36 Throttle Operated At Power-up...................88
2.37 Soft-Stop .....................................................88
2.38 Brake Fault Detect......................................88
2.39 Push Too Fast Threshold &
Push Too Fast Time-out...............................88
2.40 Motor Compensation.................................89
Chapter 6 –Specifications ........................................90
1Electrical Specifications ...........................92
Appendix –A............................................................................ 93
Compliance of the S-Drive range of Scooter
Controllers with ISO 7176-14: 2008 ....................95
Conformity of the S-Drive product family with
ISO 7176-14:2008 ..............................................95
Annex A - wiring guidance...............................100
Summary ............................................................100
Annex —S-Drive command signal leakage ....101
Appendix –B..........................................................................104
Set Up Procedure .............................................106

S-DRIVE TECHNICAL MANUAL PG DRIVES TECHNOLOGY
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About this manual
The Technical Manual gives an introduction to the S-Drive ‘Mark 2’ range of scooter controllers. These are identified by part
number D51270 onwards.
Throughout the 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 accept no liability for any losses of any kind if the points are not followed.

PG DRIVES TECHNOLOGY S-DRIVE –OPERATION
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CHAPTER 1 - OPERATION

S-DRIVE –OPERATION PG DRIVES TECHNOLOGY
SK76745/10
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