PG Drives Technology SK79649-01 User manual

SIGMADRIVE PM TRACTION
TECHNICAL MANUAL
SK79649-01

©
©©
©
PG Drives Technology 2008
PG Drives Technology 2008PG Drives Technology 2008
PG Drives Technology 2008
All rights reserved.
This manual is furnished under copyright and may only be used in accordance ith the terms laid out by PG Drives Technology.
The information in this manual is furnished for informational use only, is subject to change ithout 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 other ise - ithout the prior ritten permission of PG Drives
Technology. +44 (0) 1425 27144.

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TABLE OF CONTENTS
About this manual..................................................... 6
Icons ...................................................................... 6
C apter 1 – Installation ...............................................................7
1
Introduction................................................... 9
2
Guidelines For Working On Electric Vehicles . 9
2.1
Precautions For Working On Electric Vehicles ..........9
2.1.1
Uncontrolled Operation .........................................9
2.1.2
High Current Arcs...................................................9
2.1.3
Lead Acid Batteries................................................9
2.2
Precautions For Use ...............................................9
Frame Dimensions....................................... 10
3.1
Small Frame........................................................11
3.2
Medium Frame ................................................... 12
3.3
Large Frame .......................................................13
4
Mounting..................................................... 14
4.1
Cable Routing .....................................................14
5
Wiring Guidance......................................... 15
5.1
Battery and Motor Connections ...........................16
5.1.1
Tightening Torque for Battery and Motor
Connections .......................................................16
5.2
Battery and Motor Wire Size and Type Selection .... 17
5.3
Battery and Motor Connection Crimps
and Tooling ......................................................... 17
5.4
Control Connections............................................ 17
5.5
Control Connection Wiring ................................... 17
5.6
Control Connections Crimps and Tooling ............. 18
6
Connections ............................................... 18
6.1
Battery Connection..............................................18
6.1.1
Po er Fuse.......................................................... 18
6.1.2
Line Contactor & Pre-charge Resistor ...................18
6.1.3
Discharge Resistor ............................................... 18
6.1.4
Emergency Disconnect S itch.............................18
6.2
Motor Connections..............................................19
6.3
Control Connections............................................ 19
6.4
Connector ‘A’ – Vehicle Interface (16- ay) ...........19
Pin 1 – For ard S itch ...................................................19
Pin 2 – Reverse S itch ................................................... 19
Pin 3 – Foots itch / Belly Button ......................................19
Pin 4 – Seat / Tiller .......................................................... 19
Pin 5 – Speed Limit 1 / Inch For ard...............................19
Pin 6 – Speed Limit 2 / Inch Reverse............................... 20
Pin 7 – Speed Limit 3 / Handbrake ................................. 20
Pin 8 – Accelerator / Footbrake...................................... 20
Pin 9 – Accelerator / Footbrake...................................... 20
Pin 10 – Keys itch ......................................................... 21
Pin 11 – Contactor Coil Supply ...................................... 21
Pin 12 – Line Contactor ................................................. 21
Pin 13 – Electric Brake Contactor ................................... 21
Pin 14 – Po er Steer Contactor...................................... 21
Pin 15 – +12V Supply .................................................... 21
Pin 16 – +5V Potentiometer Supply................................ 21
6.5
Connector ‘B’ – Communications (8- ay) ............ 21
Pin 1 – Not Used............................................................ 21
Pin 2 – Not Used............................................................ 21
Pin 3 – Flash Programming Mode (+12V)....................... 21
Pin 4 – Flash Programmer I/O......................................... 22
Pin 5 – CAN L ................................................................ 22
Pin 6 – CAN H................................................................ 22
Pin 7 – +12V Supply ...................................................... 22
Pin 8 – 0V...................................................................... 22
6.6
Connector ‘C’ – Motor Feedback (6- ay)............. 22
Pin 1 – Speed Encoder.................................................. 22
Pin 2 – Remote LED ....................................................... 22
Pin 3 – Not Used............................................................ 22
Pin 4 – Thermistor or Steering Potentiometer ................... 22
Pin 5 – +12V Supply ...................................................... 22
Pin 6 – 0V...................................................................... 23
7
Electromagnetic Compatibility (E.M.C.) .......2
7.1
Emissions............................................................. 23
7.1.1
Po er Cables...................................................... 23
7.1.2
Signal Cables ...................................................... 23
7.1.3
Controller ............................................................ 23
C apter 2 – Adjustments ......................................................25
1
Adjustments .................................................27
1.1
Acceleration – (Accel) ......................................... 28
1.2
Deceleration – (Decel)......................................... 28
1.3
Creep Speed – (Creep) ....................................... 28
1.4
Maximum For ard Speed – (SpdMaxF) ................ 28
1.5
Maximum Reverse Speed – (SpdMaxR) ................ 28
1.6
Speed Limit 1 / Inching Speed – (Sp1/Inch)........... 28
1.7
Speed Limit 2 / Inching Time – (Sp2/Time)............. 28
1.8
Speed Limit 3 – (Sp3) ........................................... 29

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1.9
Direction Regen. Braking – (DBrake)...................... 29
1.10
Neutral Regen. Braking – (NBrake) ........................29
1.11
Footbrake Regen. Braking – (FBrake).....................29
1.12
Direction Braking Ramp – (DBrkRamp) ..................29
1.13
Direction Braking End Delay – (DBrkEnd) ................29
1.14
Neutral Braking Ramp – (NBrkRamp) .....................30
1.15
Neutral Braking End Delay – (NBrkEnd) ..................30
1.16
Regen Speed – (RegSpd) ....................................30
1.17
Maximum Current – (MaxCurr)..............................30
1.18
Battery Voltage – (BattV).......................................30
1.19
Po er Steering Delay – (PStrDly) ............................ 30
1.20
Electric Brake Delay – (EBrkDly).............................. 30
1.21
Accelerator 0% Voltage – (AccMin) .....................30
1.22
Accelerator 100% Voltage – (AccMax).................31
1.23
Footbrake 0% Voltage – (AuxMin)......................... 31
1.24
Footbrake 100% Voltage – (AuxMax)....................31
1.25
Motor Pot. Min. – (MotMin)....................................31
1.26
Motor Pot. Max. – (MotMax).................................. 31
1.27
Max. Vehicle Speed – (VmaxSpd) ........................31
1.28
BDI Reset Level – (BDIreset)................................... 31
1.29
BDI Empty Level – (BDIempty) ...............................32
1.30
BDI Warning Level – (BDI arn)...............................32
1.31
BDI Cut-out Level – (BDIcut) ..................................32
1.32
BDI Speed Limit – (BDIspeed)................................32
1.33
Dual Motor Cutback – (DMcut).............................32
1.34
Dual Motor Reverse – (DMrev) .............................. 32
1.35
Dual Motor Speed – (DMspeed) ...........................32
1.36
Standby Delay – (StdByDly)................................... 33
C apter 3 – Diagnostics.........................................................35
1
Error Detection ............................................ 7
2
Error Codes ................................................. 8
Status .......................................................... 40
4
Further Status Information............................ 41
5
Test.............................................................. 42
C apter 4 – Controller Set-Up ........................................43
1
Controller Set-up ......................................... 45
1.1
Accelerator Characteristic – (Lin/Curv)..................46
1.2
Not Used ............................................................. 46
1.3
Proportional Braking – (Bpro/Off) ........................... 46
1.4
Anti Roll-back (Restraint) – (Arol/Off) ......................47
1.5
Connector A Pin 5 and 6 – (Spd/Inch)...................47
1.6
Connector A Pin 7 – (Spd3/Hbk)............................47
1.7
Po er Steering Trigger – (PsF/FR/S)......................... 47
1.8
Truck Type Select (Ride/Wlk).................................. 47
1.9
Not Used ............................................................. 47
1.10
Display Error Indication – (Of/M/M&W) ................... 48
1.11
Display Status Field – (Of/D/V/K) ............................ 48
1.12
Not Used ............................................................. 48
1.13
Motor Temperature Sensor Type – (MtempTyp) ..... 48
1.14
Analogue Inputs Set-up – (Accel 8/9) ................... 48
1.15
Single / Dual Motor Select – (Si/DL/DR).................. 48
1.16
Not Used ............................................................. 49
1.17
CAN Node Number – (CAN node)........................ 49
C apter 5 – Motor Set-up .....................................................51
1
Motor Set-up ................................................5
1.1
Motor Temperature Cutback – (TempStrt) ............. 54
1.2
Motor to Vehicle Speed Ratio – (SpdRatio) ........... 54
1.3
Number of Teeth – (SpdTeeth).............................. 54
1.4 – 1.29
Not Used ...................................................... 54
:: Timed Current Limit Explained :: .................................. 54
1.30
Current Threshold – (CurrTH).................................. 55
1.31
Lo er Maximum Current – (ImaxLo ) ................... 55
1.32
Threshold Timer – (IthTime).................................... 55
1.33 – 1.38 Offset and Gain Settings.............................. 55
C apter 6 – Hand-Held Programmer .........................57
1
Introduction .................................................59
1.1
Interface S itch................................................... 59
2
Connection .................................................60
2.1
CAN Node Set-up................................................ 60
Using the Programmer .................................60
4
Programmer Map ........................................61
4.1
Programming, Diagnostic and Test Options.......... 61
4.1.1
Adjustments ........................................................ 61
4.1.2
Status .................................................................. 61
4.1.3
Controller Set-up.................................................. 61
4.1.4
Motor Set-up ....................................................... 61
4.1.5
Test ..................................................................... 61
4.1.6
About.................................................................. 62
5
Diagnostics ..................................................62
6
Software Upgrades ......................................62
C apter 7 – Sigmagauge.......................................................63
1
Introduction .................................................65

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1.1
General Information ............................................65
1.1.1
Membrane Buttons..............................................65
1.1.2
Battery Discharge Indicator ..................................65
1.1.3
Fault Indication Field............................................65
1.1.4
General Indication Field ......................................65
1.1.5
Hours Counter .....................................................65
1.1.6
Information Field..................................................65
2
Connection................................................. 66
Mounting..................................................... 66
4
Configuring the Sigmagauge ..................... 67
C apter 8 – Tec nical Specifications........................69
1
Electrical ..................................................... 71
1.1
Voltage Specifications .........................................71
1.2
Current Specifications..........................................71
2
Environmental ............................................. 71
Mechanical ................................................ 72

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About t is manual
This manual is divided into 8 chapters.
Chapter 1 – Installation
This chapter deals ith the mounting, connection and iring of the Sigmadrive.
Chapter 2 – Adjustments
This chapter deals ith the Sigmadrive’s ‘Adjustments’ parameters.
Chapter 3 – Diagnostics
This chapter provides an overvie of the diagnostic capabilities of the Sigmadrive range.
Chapter 4 – Controller Set-up
This chapter deals ith the Sigmadrive’s ‘Controller Set-up’ parameters.
Chapter 5 – Motor Set-up
This chapter deals ith the Sigmadrive’s ‘Motor Set-up’ parameters.
Chapter 6 – Hand-held Programmer
This chapter provides an overvie of the Sigmadrive Hand-held Programmer.
Chapter 7 – Sigmagauge
This chapter provides an overvie of the Sigmagauge.
Chapter 8 – Technical Specifications
This chapter provides a summary of the Sigmadrive’s Technical Specifications.
Icons
Throughout this manual, icons are used to dra the reader’s attention.
The icons used are:
Note – A general point for best practice.
Caution – A point of safety w ic if ignored could result in damage to t e control system or t e
ve icle.
Warning – A point of safety w ic if ignored could cause injury to t e individual.
PG Drives Technology accepts no liability for any losses of any kind if these points are not follo ed.

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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 ithstand the harsh operating environments that electric vehicles typically endure.
State-of-the-art construction techniques ensure the controller can ithstand shock, vibration and extremes of temperature. To
ensure the Sigmadrive installation is as robust as possible, follo the guidelines in this manual.
2 Guidelines For Working On Electric Ve icles
2.1 Precautions For Working On Electric Ve icles
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 ork on electric
vehicles, ensure that the follo ing basic safety advice is follo ed.
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
heels above the ground. If lifting the vehicle, use the correct jacking procedure as recommended by the vehicle manufacturer
to lift the vehicle’s drive heels 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 Hig Current Arcs
Batteries contain very high levels of energy and can be extremely dangerous if mishandled or abused. Al ays disconnect the
batteries before orking on the vehicle’s electrical system and the motor controller iring. Remove all je ellery from rist 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, hich can build up in and around the battery area. Ensure
charging is performed in a ventilated area. Follo 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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Alt oug t e controller is designed to be extremely reliable and eac unit is rigorously tested
during manufacture, t e possibility of system malfunction always exists ( owever small t e
probability). Under some conditions of system malfunction t e controller must (for safety
reasons), stop t e ve icle instantaneously. If t ere is any possibility of t e user falling out of t e
ve icle as a result of a sudden braking action, it is imperative t at a restraining device suc as a
seat belt is supplied wit t e ve icle and t at it is in use at all times w en t e ve icle is in
motion. PGDT accept no liability for losses of any kind arising from t e unexpected stopping of
t e ve icle, or arising from t e improper use of t e ve icle or controller.
Do not operate t e controller if t e ve icle be aves erratically, or s ows abnormal signs of
eating, sparks or smoke. Turn t e controller off at once and consult your service agent. PGDT
accepts no liability for losses of any kind arising from failure to comply wit t is condition.
Electronic equipment can be affected by Electro Magnetic Interference (EMI). Suc interference
may be generated by radio stations, TV stations, ot er radio transmitters and cellular p ones. If
t e ve icle ex ibits erratic be avior due to EMI, turn t e controller off immediately and consult
your service agent. PGDT accepts no liability for losses of any kind arising from failure to comply
wit t is condition.
It is t e responsibility of t e ve icle manufacturer to ensure t at t e ve icle complies wit
appropriate National and International EMC legislation. PGDT accepts no liability for losses of
any kind arising from failure to comply wit t is condition.
T e ve icle user must comply wit all ve icle safety warnings. PGDT accepts no liability for
losses of any kind arising from failure to comply wit t is condition.
3 Frame Dimensions
The Sigmadrive is constructed in three frame sizes – small, medium and large. This can be identified from the last character of
the product code. For example, PMT425S
SS
S is a S
SS
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 ater & 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 flo ing into the connections. The mounting position should also allo access to all connections and allo 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 ill provide
maximum heat dissipation and ensure full rated po er output. Failure to use all four mounting points may result in a loss in
performance. Any airflo around the controller ill further enhance the thermal performance. If desired, the controller’s thermal
performance may be further improved by applying a silicone-free thermal compound bet een 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 t e controller’s case to
exceed 41°C (106 °F). Under suc conditions, t e mac ine manufacturer s ould ensure t at eit er
t e user cannot touc t ese surfaces, or t at t e user is warned not to touc t ese surfaces.
W ile 41°C (106 °F) is very close to normal body temperature, prolonged contact wit surfaces
above 41°C (106 °F) can result in burns to t e skin. PGDT accepts no liability for losses of any
kind arising from failure to comply wit t is condition.
4.1 Cable Routing
The cables to the controller must be routed and secured in such a ay 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 flo of moisture into the connectors. Route iring 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 ith threaded holes are provided for the high current connections. These are identified as B+, B-, M1, M2
and M3. The controller is provided ith suitable scre s, spring ashers and flat ashers for fastening the battery and motor
cables. PGDT recommends the arrangement of scre , spring asher and flat asher as sho n belo for the correct termination
of the high po er connectors.
The small frame size has M6 threaded holes, hile the medium and large frame sizes have M8 threaded holes.
If alternate screws or bolts are used, it is essential t at t e t read insertion dept is less t an
14mm. Damage to t e controller may occur if t is dept is exceeded.
After securely fitting t e ig current cables, do not put undue upward pressure on t em by
twisting or pulling – t is may result in damage to t e terminal pillars. If t e cable position needs
to be readjusted, loosen t e screw and was er arrangement first.
5.1.1 Tig tening Torque for Battery and Motor Connections
The medium and large frame sizes use M8 scre s and these should be tightened to 11Nm.
The small frame size uses M6 scre s and these should be tightened to 9Nm.

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5.2 Battery and Motor Wire Size and Type Selection
The iring arrangement used on a particular vehicle can greatly affect the current carrying capacities of individual ires.
Ambient temperature, grouping and ire length can all significantly de-rate cable performance and other factors such as
vehicle duty cycles and airflo should also be taken into consideration hen selecting vehicle iring.
PGDT recommends the use of BS6231 (UL 1015, 1028, 1283 or 1284 dependent on ire gauge), Tri-rated ire due to its superior
flexibility and 90/105°C temperature rating. The table belo sho s the minimum recommended ire sizes for the Motor and
Battery connections on the Sigmadrive controllers.
Frame Size
Frame SizeFrame Size
Frame Size
Motor
MotorMotor
Motor
Battery
BatteryBattery
Battery
Small 16 mm
2
16 mm
2
Medium 35 mm
2
35 mm
2
Large 70 mm
2
70 mm
2
It is t e responsibility of t e ve icle manufacturer to ensure t at t e ve icle’s wiring arrangement
is suitable for t e intended application, and complies wit all necessary standards t at are
dictated by t e 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 do n. For the battery and
motor connections, the use of AMP
®
AMPo er III or Solistrand copper tube leg terminals is recommended. It is absolutely vital
that the selected crimp terminal is designed to be used ith the ire 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 ire, and that the
procedure for doing so is follo ed correctly. Contact the crimp terminal manufacturer to ensure that the tooling employed is
suitable for use ith the chosen combination of ire 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 t at only fully trained and skilled operators perform t e crimping procedure and t at t e
instructions provided by t e crimp terminal manufacturer are followed. PGDT accepts no liability
for losses of any kind if t e recommendations made in t is section are not followed.
5.4 Control Connections
The lo 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 follo ing functions.
A 16-way Vehicle Interface Connector
B 8-way Communications Connector
C 6-way Motor Feedback Connector
5.5 Control Connection Wiring
Use 0.5mm
2
/18AWG ire gauge for all control connections. It is also recommended that Tri-rated ire ith a 105ºC insulation
rating is used.

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5.6 Control Connections Crimps and Tooling
The follo ing table sho s 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 sho n.
Connector
ConnectorConnector
Connector
PGDT Connector
PGDT Connector PGDT Connector
PGDT Connector
Kit Part No.
Kit Part No.Kit Part No.
Kit Part No.
Molex Housing
Molex Housing Molex Housing
Molex Housing
Part No.
Part No.Part No.
Part No.
Molex Crimp
Molex CrimpMolex Crimp
Molex Crimp
Part No.
Part No.Part No.
Part No.
Molex Crimp
Molex CrimpMolex Crimp
Molex Crimp
Tool Part No.
Tool Part No.Tool Part No.
Tool Part No.
Molex Extraction
Molex Extraction Molex Extraction
Molex Extraction
Tool Part No.
Tool Part No.Tool Part No.
Tool Part No.
A – 16- ay D51066 43025-1600 43030-0007
B – 8- ay D51068 43025-0800 43030-0007
C – 6- ay D51067 43025-0600 43030-0007
69008-0982
11-03-0043
PGDT recommends t at only genuine Molex parts s ould be used. Inferior quality crimps or
incorrect tooling can seriously reduce t e reliability and longevity of t e controller or ve icle.
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-c arge Resistor
A suitable line contactor must be connected to the battery positive supply. This should be fitted ith a 5W 10kΩ pre-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 Disc arge Resistor
Units manufactured before October 2008 require an external discharge resistor. The resistor should be fitted bet een the
Sigmadrive’s B+ and B- terminals. The correct value for each controller model is sho n belo .
24V only Sigmadrive – 10kΩ 1/4W
24V – 48V Sigmadrive – 22kΩ 1/4W
72V – 80V Sigmadrive – 47kΩ 1/4W
6.1.4 Emergency Disconnect Switc
For certain vehicle types, safety legislation requires that an emergency battery disconnect s itch or s itches should be fitted in
the battery positive supply, in order to allo complete isolation of the vehicle’s electrical system from the battery. The location of
this s itch or s itches should be as stipulated in the appropriate legislative documentation.
It is t e responsibility of t e ve icle manufacturer to ensure appropriate fuses, line contactors
and emergency disconnect switc es are used and t at t ese 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 motor should be connected bet een the M1 terminal and the M3 terminal of the controller. The M2 terminal remains
unconnected. If, hen a for ard command is applied, the vehicle drives in reverse, s ap the motor ires.
6.3 Control Connections
The control connections are via three connectors ith pin-outs as follo s.
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 sho n in the follo ing section.
6.4 Connector ‘A’ – Ve icle Interface (16-way)
Pin 1 – Forward Switc
This s itch must be closed in conjunction ith the Accelerator to give a for ard drive signal.
Pin 2 – Reverse Switc
This s itch must be closed in conjunction ith the Accelerator to give a reverse drive signal.
Pin 3 – Footswitc / 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 Foots itch should be connected to this pin, and must be closed to allo drive.
If set to Wlk, then the vehicle’s Belly Button s itch should be connected to this pin. When the Belly Button s itch is closed,
the vehicle ill 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 s itch on a ride-on vehicle, a Tiller
s itch on a “ alkie” vehicle or a general deadman’s trigger on other vehicle types. The s itch must be closed to allo
drive.
Pin 5 – Speed Limit 1 / Inc 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 ill occur hen the s itch is open.
If set to Inch, then this input is used to “inch” the vehicle in the for ard direction. Inching ill occur hen the s itch is
closed. The exact functionality of inching is set by the programmable parameters, 1.6 Inching Speed and 1.7 Inching
Time.

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Pin 6 – Speed Limit 2 / Inc 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 ill occur hen the s itch is open.
If set to Inch, then this input is used to “inch” the vehicle in the reverse direction. Inching ill occur hen the s itch 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 ith a handbrake s itch, ho ever, 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 ill occur hen the s itch is open.
If set to Hbk, then this input should be connected to the vehicle’s handbrake s itch. When the s itch is closed, i.e. the
handbrake is on, the vehicle’s speed ill be as set by the programmable parameter, 1.8 Speed Limit 3.
Pin 8 – Accelerator / Footbrake
This is an analogue input that ill accept a 2- ire 5kΩ potentiometer 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.
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, hile 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, hile the latter parameter sets the voltage that relates to 100% braking demand from the Footbrake.
If a Footbrake s itch is used on the brake pedal instead of an analogue device, the s itch 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 ill accept a 3- ire 5kΩ potentiometer 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.
When set to 0, 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, hile the latter parameter sets the voltage that relates to 100% braking demand from the Footbrake.
If a Footbrake s itch is used on the brake pedal instead of an analogue device, the s itch should connect this input to
the voltage corresponding to the value of parameter, 1.24 Footbrake 100% Voltage, in order to effect full braking.
When set to 1, 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, hile the latter parameter sets the voltage that relates to 100% drive demand from the Accelerator.
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