PG Drives Technology SIGMADRIVE Series User manual

SIGMADRIVE AC TRACTION
TECHNICAL MANUAL
SK79646-01

©PG Drives Technology 2008
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 SIGMADRIVE TECHNICAL MANUAL – AC TRACTION
TABLE OF CONTENTS
Pin 6 – Speed Limit 2 / Inch Reverse ................................ 20
About this manual..................................................... 6
Pin 7 – Speed Limit 3 / Handbrake ................................... 20
Icons ..................................................................... 6
Pin 8 – Accelerator / Footbrake ....................................... 20
Pin 9 – Accelerator / Footbrake ....................................... 20
Chapter 1 – Installation............................................................. 7 Pin 10 – Keyswitch............................................................ 21
1Introduction................................................... 9 Pin 11 – Contactor Coil Supply ........................................ 22
Pin 12 – Line Contactor.................................................... 22
2Guidelines For Working On Electric Vehicles . 9
Pin 13 – Electric Brake Contactor..................................... 22
2.1 Precautions For Working On Electric Vehicles ..........9
Pin 14 – Power Steer Contactor ....................................... 22
2.1.1 Uncontrolled Operation ........................................... 9
Pin 15 – +12V Supply....................................................... 22
2.1.2 High Current Arcs ..................................................... 9
Pin 16 – +5V Potentiometer Supply ................................. 22
2.1.3 Lead Acid Batteries.................................................. 9
6.5 Connector ‘B’ – Communications (8-way) ............. 22
2.2 Precautions For Use..................................................9
Pin 1 – Not Used............................................................... 22
3Frame Dimensions....................................... 10 Pin 2 – Not Used............................................................... 22
3.1 Small Frame ..........................................................11 Pin 3 – Flash Programming Mode (+12V)........................22
3.2 Medium Frame......................................................12 Pin 4 – Flash Programmer I/O........................................... 22
3.3 Large Frame ..........................................................13 Pin 5 – CAN L ................................................................... 22
Pin 6 – CAN H................................................................... 23
4Mounting..................................................... 14
Pin 7 – +12V Supply......................................................... 23
4.1 Cable Routing .......................................................14
Pin 8 – 0V ......................................................................... 23
5Wiring Guidance......................................... 15 6.6 Connector ‘C’ – Motor Feedback (6-way) ............. 23
5.1 Battery and Motor Connections............................. 16 Pin 1 – Encoder Speed (A) ............................................... 23
5.1.1 Tightening Torque for Battery and Motor
Connections .......................................................... 16
Pin 2 – Encoder Direction (B) ............................................ 23
Pin 3 – Remote LED or Brake Light.................................... 23
5.2 Battery and Motor Wire Size and Type Selection ....17 Pin 4 – Thermistor or Steering Potentiometer .................... 23
5.3 Battery and Motor Connection Crimps
and Tooling............................................................ 17 Pin 5 – +12V Supply......................................................... 24
Pin 6 – 0V ......................................................................... 24
5.4 Control Connections ............................................. 17
7Electromagnetic Compatibility (E.M.C.).......24
5.5 Control Connection Wiring.....................................17
5.6 Control Connections Crimps and Tooling.............. 18 7.1 Emissions................................................................ 24
7.1.1 Power Cables ........................................................ 24
6Connections ............................................... 18
7.1.2 Signal Cables ........................................................ 24
6.1 Battery Connection................................................ 18
7.1.3 Controller ............................................................... 24
6.1.1 Power Fuse.............................................................18
6.1.2 Line Contactor & Pre-charge Resistor .................... 18
Chapter 2 – Adjustments ....................................................25
6.1.3 Discharge Resistor.................................................. 18
1Adjustments .................................................27
6.1.4 Emergency Disconnect Switch .............................. 18
6.2 Motor Connections................................................ 19 1.1 Acceleration – (Accel) ........................................... 28
6.3 Control Connections ............................................. 19 1.2 Deceleration – (Decel) .......................................... 28
6.4 Connector ‘A’ – Vehicle Interface (16-way) ........... 19 1.3 Creep Speed – (Creep)......................................... 28
Pin 1 – Forward Switch......................................................19 1.4 Maximum Forward Speed – (SpdMaxF) ................. 28
Pin 2 – Reverse Switch...................................................... 19 1.5 Maximum Reverse Speed – (SpdMaxR)................. 28
Pin 3 – Footswitch / Belly Button........................................ 19 1.6 Speed Limit 1 / Inching Speed
– (Speed 1/InchSpd) .............................................. 28
Pin 4 – Seat / Tiller............................................................. 19
Pin 5 – Speed Limit 1 / Inch Forward ................................ 19
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SIGMADRIVE TECHNICAL MANUAL – AC TRACTION PG DRIVES TECHNOLOGY
1.7 Speed Limit 2 / Inching Time
– (Speed 2/InchTime)............................................. 29 Chapter 4 – Controller Set-Up ...................................... 45
1Controller Set-up..........................................47
1.8 Speed Limit 3 – (Speed 3)...................................... 29
1.1 Accelerator Characteristic – (Lin/Curv) .................. 48
1.9 Direction Regen. Braking – (DBrake)....................... 29
1.2 Control Mode (Traction) – (Spd/Torq) ..................... 48
1.10 Neutral Regen. Braking – (NBrake) ......................... 29
1.3 Proportional Braking – (Off/Bpro)............................. 48
1.11 Footbrake Regen. Braking – (FBrake) ..................... 30
1.4 Anti Roll-off (Hill Hold & Restraint) – (Off/Arol) .......... 49
1.12 Direction Braking Ramp – (DBrkRamp) ................... 30
1.5 Connector A Pin 5 and 6 – (Spd/Inch) ................... 49
1.13 Neutral Braking Ramp – (NBrkRamp)......................30
1.6 Connector A Pin 7 – (Spd3/Hbk)............................. 49
1.14 Footbrake Ramp – (FBrkRamp) .............................. 30
1.7 Power Steering Trigger – (PsF/FR/S).......................... 49
1.15 Neutral Braking End Delay – (NBrkEnd) ................... 31
1.8 Truck Type Select (Ride/Wlk) ................................... 50
1.16 Sweep Speed – (SweepSpd).................................. 31
1.9 Tiller Function (TillFunc) ........................................... 50
1.17 Maximum Current – (MaxCurr)...............................31
1.10 Display Error Indication – (Of/M/M&W).................... 50
1.18 Battery Voltage – (BattV) ........................................ 31
1.11 Display Status Field – (Of/D/V/K).............................. 50
1.19 Power Steering Delay – (PStrDly) ............................. 31
1.12 Not Used ................................................................ 51
1.20 Electric Brake Delay – (EBrkDly)...............................31
1.13 Motor Temperature Sensor Type – (MtempTyp)...... 51
1.21 Accelerator 0% Voltage – (AccMin) ......................31
1.14 Analogue Inputs Set-up – (Accel 8/9) .................... 51
1.22 Accelerator 100% Voltage – (AccMax) .................31
1.15 Single / Dual Motor Select – (Si/DL/DR) .................. 51
1.23 Footbrake 0% Voltage – (AuxMin).......................... 32
1.16 Remote LED / Brake Light – (RL/BL) ......................... 51
1.24 Footbrake 100% Voltage – (AuxMax).....................32
1.17 CAN Node Number – (CAN node)......................... 52
1.25 Steer Pot. Min. – (StrMin) .........................................32
1.18 Shared Line Contactor – (ShareLC)........................ 52
1.26 Steer Pot. Mid. – (StrMid).........................................32
1.19 Last Sharing Node – (LstNode) ............................... 52
1.27 Steer Pot. Max. – (StrMax) ....................................... 32
1.28 Forward Threshold – (FwdTH) .................................. 32
Chapter 5 – Motor Set-up.................................................. 53
1.29 Reverse Threshold – (RevTH) ................................... 33
1.30 Max. Vehicle Speed – (VmaxSpd) ......................... 33 1Motor Set-up ................................................55
1.31 BDI Reset Level – (BDIreset) .................................... 33
1.1 Motor Temperature Cutback – (TempStrt).............. 56
1.32 BDI Empty Level – (BDIempty) ................................ 33
1.2 Motor to Vehicle Speed Ratio – (SpdRatio)............56
1.33 BDI Warning Level – (BDIwarn) ................................ 33
1.3 Number of Teeth – (SpdTeeth) ............................... 56
1.34 BDI Cut-out Level – (BDIcut).................................... 33
1.4 Number of Motor Poles – (SpdPoles)...................... 56
1.35 BDI Speed Limit – (BDIspeed) .................................33
:: Motor Driving Set-up Explained :: .................................. 57
1.36 Dual Motor Cutback – (DMcut) .............................. 34
1.5 Motor Speed Minimum – (SPDmin) ........................ 57
1.37 Dual Motor Angle 1 – (DMang1) ............................34
1.6 Motor Speed Boost – (SPDboost)............................ 57
1.38 Dual Motor Angle 2 – (DMang2) ............................34
1.7 Motor Speed Base (Rated) – (SPDbase) ................. 58
1.39 Dual Motor Angle 3 – (Dmang3)............................ 34
1.8 Motor Speed Maximum – (SPDmax) ...................... 58
1.40 Dual Motor Speed 1 – (DMspd1) ...........................34
1.9 Minimum Voltage – (Vmin) .................................... 58
1.41 Dual Motor Speed 2 – (DMspd2) ...........................34
1.10 Drive Voltage Minimum – (D Vmin) ........................ 58
1.42 Dual Motor Speed 3 – (DMspd3) ...........................34
1.11 Drive Voltage Boost – (D Vboost)............................ 58
1.43 Standby Delay – (StdByDly) ....................................35
1.12 Drive Voltage Base (Rated) – (D Vbase)................. 58
1.13 Drive Voltage Maximum – (D Vmax) ...................... 58
Chapter 3 – Diagnostics ...................................................... 37 1.14 Drive Slip Minimum – (D Smin)................................ 58
1Error Detection ............................................ 39 1.15 Drive Slip Boost – (D Sboost) ................................... 59
1.16 Drive Slip Base – (D Sbase) ..................................... 59
2Error Codes ................................................. 40
1.17 Drive Slip Maximum – (D Smax) ............................. 59
3Status .......................................................... 42 :: Motor Braking Set-up Explained :: ................................. 59
4Further Status Information............................ 43 1.18 Direction Braking Voltage Minimum – (BDVmin)..... 60
1.19 Direction Braking Voltage Boost – (BDVboost) ........ 60
5Test.............................................................. 44
1.20 Braking Voltage Base – (B Vbase) .......................... 60
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1.21 Braking Voltage Maximum – (B Vmax) ................... 60 2.1 CAN Node Set-up .................................................. 78
1.22 Direction Braking Slip Minimum – (BDSmin) ............60 3Using the Programmer .................................78
1.23 Direction Braking Slip Boost – (BDSboost)................60
4Programmer Map ........................................79
1.24 Braking Slip Base (Rated) – (B Sbase) ..................... 60
4.1 Programming, Diagnostic and Test Options .......... 79
1.25 Braking Slip Maximum – (B Smax)........................... 60
4.1.1 Adjustments ........................................................... 79
1.26 Neutral Braking Voltage Minimum – (BNVmin)........ 61
4.1.2 Status ..................................................................... 79
1.27 Neutral Braking Voltage Boost – (BNVboost) ...........61
4.1.3 Controller Set-up .................................................... 79
1.28 Neutral Braking Slip Minimum – (BNSmin) ...............61
4.1.4 Motor Set-up .......................................................... 79
1.29 Neutral Braking Slip Boost – (BNSboost) .................. 61
4.1.5 Test ........................................................................ 79
1.30 Braking Motor Speed Base (Rated) – (BSPDbase)... 61
4.1.6 About..................................................................... 80
1.31 Proportional Gain for Voltage Change – (PgainV) .61
1.32 Proportional Gain for Outer Speed Loop –
(PgainSpd) .............................................................61 5Diagnostics ..................................................80
6Software Upgrades ......................................80
1.33 Proportional Gain for Inner Torque Loop
– (PgainTrq) ............................................................61
1.34 Ramp Delay for Inner Torque Loop – (Ramp Trq)...62 Chapter 8 – Calibration..........................................................81
1.35 Proportional Gain for Outer Speed Loop
in Neutral Braking – (PgainSpN) .............................. 62 1Calibration...................................................83
1.1 Load Defaults – (LoadDefs).................................... 83
:: Timed Current Limit Explained :: ................................... 62
1.2 – 1.7 Offset and Gain Settings ................................... 83
1.36 Current Threshold – (CurrTh) ................................... 62
1.37 Lower Maximum Current – (ImaxLow) .................... 62
Chapter 9 – Sigmagauge.....................................................85
1.38 Threshold Timer – (IthTime) ..................................... 63
1.39 Hill Hold Time (HHTime)........................................... 63 1Introduction .................................................87
1.40 Hill Hold Speed – (HHSpeed) .................................. 63
1.1 General Information .............................................. 87
1.41 Hill Hold Voltage Minimum – (HHVmin)................... 63
1.1.1 Membrane Buttons................................................ 87
1.42 Brake End Speed – (BrkEndSpd) .............................64
1.1.2 Battery Discharge Indicator ................................... 87
1.1.3 Fault Indication Field ............................................. 87
Chapter 6 – Motor Set-Up Example..........................65 1.1.4 General Indication Field ........................................ 87
1Example Set-up Procedure ......................... 67 1.1.5 Hours Counter........................................................ 87
1.1.6 Information Field.................................................... 87
1.1 Drive speed set-up ................................................ 67
1.2 Drive voltage set-up .............................................. 68 2Connection .................................................88
1.3 Drive slip set-up......................................................68 3Mounting .....................................................88
1.4 Motor set-up – Braking ...........................................69
4Configuring the Sigmagauge......................89
1.5 Defining the Braking Motor Speed Base Point ........ 69
1.6 Brake Slip Set-up ....................................................70
Chapter 10 – Technical Specifications........................91
1.7 Brake Voltage Set-up ............................................. 70
1.8 Braking Percentage Levels..................................... 71 1 Electrical......................................................93
1.9 Fine-tuning Drive ....................................................71 1.1 Voltage Specifications........................................... 93
1.10 Additional Torque................................................... 71 1.2 Current Specifications............................................ 93
1.11 The Results After Fine-tuning................................... 71
2Environmental..............................................93
1.12 Fine-Tuning Braking ................................................72
3Mechanical .................................................94
Chapter 7 – Hand-Held Programmer.........................75
1Introduction................................................. 77
1.1 Interface Switch .....................................................77
2Connection................................................. 78
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SIGMADRIVE TECHNICAL MANUAL – AC TRACTION PG DRIVES TECHNOLOGY
About this manual
This manual is divided into 10 chapters.
Chapter 1 – Installation
This chapter deals with the mounting, connection and wiring of the Sigmadrive.
Chapter 2 – Adjustments
This chapter deals with the Sigmadrive’s ‘Adjustments’ parameters.
Chapter 3 – Diagnostics
This chapter provides an overview of the diagnostic capabilities of the Sigmadrive range.
Chapter 4 – Controller Set-up
This chapter deals with the Sigmadrive’s ‘Controller Set-up’ parameters.
Chapter 5 – Motor Set-up
This chapter deals with the Sigmadrive’s ‘Motor Set-up’ parameters.
Chapter 6 – Motor Set-up Example
This chapter provides a typical motor set-up guide for the Sigmadrive.
Chapter 7 – Hand-held Programmer
This chapter provides an overview of the Sigmadrive Hand-held Programmer.
Chapter 8 – Calibration
This chapter deals with the Sigmadrive’s ‘Calibration’ parameters.
Chapter 9 – Sigmagauge
This chapter provides an overview of the Sigmagauge.
Chapter 10 – Technical Specifications
This chapter provides a summary of the Sigmadrive’s Technical Specifications.
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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CHAPTER 1 – INSTALLATION
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1 Introduction
The Sigmadrive is an advanced digital controller for all popular motor types and is designed for electric vehicle applications such
as Industrial Trucks, Personnel Carriers, Golf Cars, Aerial Work Platforms and Materials Handling Equipment.
Advanced drive algorithms are employed to ensure smooth, accurate, predictable and efficient control of vehicle speed and
torque. Motor reversing and regenerative braking in both directions is achieved via solid-state electronics.
The Sigmadrive has been designed to easily withstand the harsh operating environments that electric vehicles typically endure.
State-of-the-art construction techniques ensure the controller can withstand shock, vibration and extremes of temperature. To
ensure the Sigmadrive installation is as robust as possible, follow the guidelines in this manual.
2 Guidelines For Working On Electric Vehicles
2.1 Precautions For Working On Electric Vehicles
Working on any electrical system can be dangerous. Work on electric vehicles should only be undertaken by skilled or supervised
persons, in a segregated location that eliminates the risk of injury to other persons. Before performing any kind of work on electric
vehicles, ensure that the following basic safety advice is followed.
2.1.1 Uncontrolled Operation
Fault conditions or programming changes may cause the motor to run out of control. Disconnect the motor or raise the drive
wheels above the ground. If lifting the vehicle, use the correct jacking procedure as recommended by the vehicle manufacturer
to lift the vehicle’s drive wheels clear of the ground. Once lifted, fit axle stands to safely support the vehicle and remove the jack.
Ensure that all such lifting equipment is in serviceable condition and suitable for the vehicle in question.
2.1.2 High Current Arcs
Batteries contain very high levels of energy and can be extremely dangerous if mishandled or abused. Always disconnect the
batteries before working on the vehicle’s electrical system and the motor controller wiring. Remove all jewellery from wrist and
fingers and use properly insulated tools to prevent shorts. Wear safety glasses at all times.
2.1.3 Lead Acid Batteries
Charging or discharging lead acid batteries generates hydrogen gas, which can build up in and around the battery area. Ensure
charging is performed in a ventilated area. Follow the battery manufacturer’s safety recommendations. Wear safety glasses at all
times.
2.2 Precautions For Use
Do not drive the vehicle:
• Beyond restrictions indicated in your vehicle 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.
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Although the controller 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 vehicle instantaneously. If there is any possibility of the user falling out of the
vehicle as a result of a sudden braking action, it is imperative that a restraining device such as a
seat belt is supplied with the vehicle and that it is in use at all times when the vehicle is in
motion. PGDT accept no liability for losses of any kind arising from the unexpected stopping of
the vehicle, or arising from the improper use of the vehicle or controller.
Do not operate the controller if the vehicle behaves erratically, or shows abnormal signs of
heating, sparks or smoke. Turn the controller 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.
Electronic equipment can be affected by Electro Magnetic Interference (EMI). Such interference
may be generated by radio stations, TV stations, other radio transmitters and cellular phones. If
the vehicle 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 vehicle manufacturer to ensure that the vehicle 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 vehicle user must comply with all vehicle safety warnings. PGDT accepts no liability for
losses of any kind arising from failure to comply with this condition.
3 Frame Dimensions
The Sigmadrive is constructed in three frame sizes – small, medium or large. This can be identified from the last character of the
product code. For example, ACT425Sis a Small frame size.
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3.1 Small Frame
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3.2 Medium Frame
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3.3 Large Frame
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4 Mounting
Careful consideration should be given to the location chosen to mount the controller. Although the Sigmadrive benefits from
excellent environmental protection, it is good engineering practice for the selected position to be clean and dry, to minimize
shock, vibration, temperature changes and exposure to water & contaminants.
If vertical orientation mounting is not possible, then a cover should be used to shield the controller. Cables must be routed to
prevent liquids flowing into the connections. The mounting position should also allow access to all connections and allow the
connection and removal of a programming device.
Secure the controller to the vehicle via the four clearance holes provided. Ideally, a flat clean metal surface will provide
maximum heat dissipation and ensure full rated power output. Failure to use all four mounting points may result in a loss in
performance. Any airflow around the controller will further enhance the thermal performance. If desired, the controller’s thermal
performance may be further improved by applying a silicone-free thermal compound between the baseplate and the machine
chassis.
The Small Frame controller has M6 (1/4") clearance holes.
The Medium and Large Frame controllers have M8 (5/16") clearance holes.
Under strenuous driving conditions, it is possible for metal sections of the controller’s case to
exceed 41°C (106 °F). Under such conditions, the machine manufacturer should ensure that either
the user cannot touch these surfaces, or that the user is warned not to touch these surfaces.
While 41°C (106 °F) is very close to normal body temperature, prolonged contact with surfaces
above 41°C (106 °F) can result in burns to the skin. PGDT accepts no liability for losses of any
kind arising from failure to comply with this condition.
4.1 Cable Routing
The cables to the controller must be routed and secured in such a way as to prevent damage, for example by chafing or
crushing, or exposure to solvents or other chemicals that may degrade the insulation. It is suggested that the cables are
mounted so that they loop up to the controller, therefore minimizing the flow of moisture into the connectors. Route wiring to
keep lengths as short as possible, especially the high current motor and battery cabling.
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5 Wiring Guidance
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5.1 Battery and Motor Connections
Five copper terminals with threaded holes are provided for the high current connections. These are identified as B+, B-, M1, M2
and M3. The controller is provided with suitable screws, spring washers and flat washers for fastening the battery and motor
cables. PGDT recommends the arrangement of screw, spring washer and flat washer as shown below for the correct termination
of the high power connectors.
The small frame size has M6 threaded holes, while the medium and large frame sizes have M8 threaded holes.
If alternate screws or bolts are used, it is essential that the thread insertion depth is less than
14mm. Damage to the controller may occur if this depth is exceeded.
After securely fitting the high current cables, do not put undue upward pressure on them by
twisting or pulling – this may result in damage to the terminal pillars. If the cable position needs
to be readjusted, loosen the screw and washer arrangement first.
5.1.1 Tightening Torque for Battery and Motor Connections
The medium and large frame sizes use M8 screws and these should be tightened to 11Nm.
The small frame size uses M6 screws and these should be tightened to 9Nm.
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5.2 Battery and Motor Wire Size and Type Selection
The wiring arrangement used on a particular vehicle can greatly affect the current carrying capacities of individual wires.
Ambient temperature, grouping and wire length can all significantly de-rate cable performance and other factors such as
vehicle duty cycles and airflow should also be taken into consideration when selecting vehicle wiring.
PGDT recommends the use of BS6231 (UL 1015, 1028, 1283 or 1284 dependent on wire gauge), Tri-rated wire due to its superior
flexibility and 90/105°C temperature rating. The table below shows the minimum recommended wire sizes for the various
connections on the Sigmadrive controllers.
Frame Size Motor Battery
Small 16 mm216 mm2
Medium 35 mm235 mm2
Large 70 mm270 mm2
It is the responsibility of the vehicle manufacturer to ensure that the vehicle’s wiring arrangement
is suitable for the intended application, and complies with all necessary standards that are
dictated by the relevant approvals of regulatory organizations. PGDT accepts no liability for
losses of any kind arising from an inappropriate wiring arrangement.
5.3 Battery and Motor Connection Crimps and Tooling
Good quality crimping is essential in ensuring the long-term reliability of the vehicle’s electrical system. Poor quality crimps may
initially appear satisfactory, but can deteriorate over time, ultimately causing the vehicle to break down. For the battery and
motor connections, the use of AMP®AMPower IIIor Solistrandcopper tube leg terminals is recommended. It is absolutely vital
that the selected crimp terminal is designed to be used with the wire size and type being used.
It is also vital that for the selected crimp terminal the correct tooling is used for its installation onto the wire, and that the
procedure for doing so is followed correctly. Contact the crimp terminal manufacturer to ensure that the tooling employed is
suitable for use with the chosen combination of wire and crimp terminal.
If insulated crimps are used, ensure the insulation is firmly pushed into place. If uninsulated crimps are used, it is recommended
that heatshrink or similar sleeving is used to insulate the barrel of the crimp terminal.
Ensure that only fully trained and skilled operators perform the crimping procedure and that the
instructions provided by the crimp terminal manufacturer are followed. PGDT accepts no liability
for losses of any kind if the recommendations made in this section are not followed.
5.4 Control Connections
The low current control connections on the Sigmadrive are via Molex® SMD Micro Fit 3.0 Series connectors. These connectors are
labeled as A, B and C on the cover of the controller and provide the following functions.
A 16-way Vehicle Interface Connector
B 8-way Communications Connector
C 6-way Motor Feedback Connector
5.5 Control Connection Wiring
Use 0.5mm2/18AWG wire gauge for all control connections. It is also recommended that Tri-rated wire with a 105ºC insulation
rating is used.
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5.6 Control Connections Crimps and Tooling
The following table shows the Molex part numbers for the mating crimps, housings, crimp tool and extraction tool.
Alternatively, the mating connectors can be purchased directly from PGDT using the connector kit part numbers shown.
Connector PGDT Connector
Kit Part No.
Molex Housing
Part No.
Molex Crimp
Part No.
Molex Crimp
Tool Part No.
Molex Extraction
Tool Part No.
A – 16-way D51066 43025-1600 43030-0007
B – 8-way D51068 43025-0800 43030-0007
C – 6-way D51067 43025-0600 43030-0007
69008-0982
11-03-0043
PGDT recommends that only genuine Molex parts should be used. Inferior quality crimps or
incorrect tooling can seriously reduce the reliability and longevity of the controller or vehicle.
PGDT accepts no liability for losses of any kind if non-recommended parts are used.
6 Connections
6.1 Battery Connection
Connect the positive supply to the B+ terminal and the negative supply to the B- terminal.
6.1.1 Power Fuse
A suitable fuse must be fitted to the battery positive supply. This fuse should be fitted as closely as possible to the battery’s positive
terminal.
6.1.2 Line Contactor & Pre-charge Resistor
A suitable line contactor must be connected to the battery positive supply. This should be fitted with a 5W 10kΩpre-charge
resistor connected in parallel across the contacts. The coil of the line contactor can be controlled by the Sigmadrive, via pin 12
of Connector A.
6.1.3 Discharge Resistor
Units manufactured before October 2008 require an external discharge resistor. The resistor should be fitted between the
Sigmadrive’s B+ and B- terminals. The correct value for each controller model is shown below.
24V only Sigmadrive – 10kΩ1/4W
24V – 48V Sigmadrive – 22kΩ1/4W
72V – 80V Sigmadrive – 47kΩ1/4W
6.1.4 Emergency Disconnect Switch
For certain vehicle types, safety legislation requires that an emergency battery disconnect switch or switches should be fitted in
the battery positive supply, in order to allow complete isolation of the vehicle’s electrical system from the battery. The location of
this switch or switches should be as stipulated in the appropriate legislative documentation.
It is the responsibility of the vehicle manufacturer to ensure appropriate fuses, line contactors
and emergency disconnect switches are used and that these devices are appropriately located.
PGDT accepts no liability for losses of any kind if inappropriate devices or arrangements are
used.
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6.2 Motor Connections
The three motor connections are marked M1, M2 and M3. There is no convention as to how these relate to the phase windings
on individual motors, so the controller to motor connections are arbitrary. If, when a forward command is applied, the vehicle
drives in reverse, swap any two of the motor connections.
6.3 Control Connections
The control connections are via three connectors with pin-outs as follows.
Connector A: Vehicle Interface
Connector B: Communications to display module and/or programmer
Connector C: Motor Feedback
Details of the functions of each of the pins for these connectors are shown in the following section.
6.4 Connector ‘A’ – Vehicle Interface (16-way)
Pin 1 – Forward Switch
This switch must be closed in conjunction with the Accelerator to give a forward drive signal.
Pin 2 – Reverse Switch
This switch must be closed in conjunction with the Accelerator to give a reverse drive signal.
Pin 3 – Footswitch / Belly Button
The function of this input is set by the programmable parameter, 3.8 Truck Type Select.
If set to Ride, then the vehicle’s Footswitch should be connected to this pin, and must be closed to allow drive.
If set to Wlk, then the vehicle’s Belly Button switch should be connected to this pin. When the Belly Button switch is closed,
the vehicle will drive in the opposite direction for 1.5s.
Pin 4 – Seat / Tiller
The function of this input is to provide a general safety interlock. This could be a Seat switch on a ride-on vehicle, a Tiller
switch on a “walkie” vehicle or a general deadman’s trigger on other vehicle types. The switch must be closed to allow
drive.
Pin 5 – Speed Limit 1 / Inch Forward
The function of this input is set by the programmable parameter, 3.5 Connector A Pin 5 and 6.
If set to Spd, then this input can be used to limit the speed of the vehicle to a value set by the programmable parameter,
1.6 Speed Limit 1. The speed limit will occur when the switch is open.
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AC TRACTION – INSTALLATION PG DRIVES TECHNOLOGY
If set to Inch, then this input is used to “inch” the vehicle in the forward direction. Inching will occur when the switch is
closed. The exact functionality of inching is set by the programmable parameters, 1.6 Inching Speed and 1.7 Inching
Time.
Pin 6 – Speed Limit 2 / Inch Reverse
The function of this input is set by the programmable parameter, 3.5 Connector A Pin 5 and 6.
If set to Spd, then this input can be used to limit the speed of the vehicle to a value set by the programmable parameter,
1.7 Speed Limit 2. The speed limit will occur when the switch is open.
If set to Inch, then this input is used to “inch” the vehicle in the reverse direction. Inching will occur when the switch is
closed. The exact functionality of inching is set by the programmable parameters, 1.6 Inching Speed and 1.7 Inching
Time.
Pin 7 – Speed Limit 3 / Handbrake
This input is primarily intended to be used with a handbrake switch, however, its function can be set by the programmable
parameter, 3.6 Connector A Pin 7.
If set to Spd3, then this input can be used to limit the speed of the vehicle to a value set by the programmable
parameter, 1.8 Speed Limit 3. The speed limit will occur when the switch is open.
If set to Hbk, then this input should be connected to the vehicle’s handbrake switch. When the switch is closed, i.e. the
handbrake is on, the vehicle’s speed will be as set by the programmable parameter, 1.8 Speed Limit 3.
Pin 8 – Accelerator / Footbrake
This is an analogue input that will accept a 2-wire 5kΩpotentiometer or a 0V to 5V voltage signal.
The function of this input is set by the programmable parameter, 3.14 Analogue Inputs Set-up.
If set to 0, then this input should be connected to the vehicle’s Accelerator device.
If set to 1, then this input should be connected to the vehicle’s Footbrake device.
If set to 2, then this input will not be used.
When set to 0, the active range of the accelerator input is defined by the programmable parameters, 1.21 Accelerator
0% Voltage and 1.22 Accelerator 100% Voltage. The former parameter sets the voltage that relates to zero drive demand
from the Accelerator, while the latter parameter sets the voltage that relates to 100% drive demand from the Accelerator.
When set to 1, the active range of the footbrake input is defined by the programmable parameters, 1.23 Footbrake 0%
Voltage and 1.24 Footbrake 100% Voltage. The former parameter sets the voltage that relates to zero braking demand
from the Footbrake, while the latter parameter sets the voltage that relates to 100% braking demand from the Footbrake.
If a Footbrake switch is used on the brake pedal instead of an analogue device, the switch should connect this input to
the voltage corresponding to the value of parameter, 1.24 Footbrake 100% Voltage, in order to effect full braking.
Pin 9 – Accelerator / Footbrake
This is an analogue input that will accept a 3-wire 5kΩpotentiometer or a 0V to 5V voltage signal.
The function of this input is set by the programmable parameter, 3.14 Analogue Inputs Set-up.
If set to 0, then this input should be connected to the vehicle’s Footbrake device.
If set to 1, then this input should be connected to the vehicle’s Accelerator device.
If set to 2, then this input should be connected to the vehicle’s Wig-Wag Throttle device.
If a Wig-Wag Throttle Type device is to be connected to this pin, additional 1kΩresistors should
be fitted between the potentiometer and its supplies, as shown below.
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