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. [phone].

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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.

PG D RIVES T ECHNOLOGY PM T RACTION – I NSTALLATION
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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.