PG Drives Technology SK79647-02 User manual

SIGMADRIVE AC PUMP
TECHNICAL MANUAL
SK79647-02

©PG Drives Technology 2012
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].

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TABLE OF CONTENTS
About this manual ..................................................... 6
Icons ................................................................. 6
Chapter 1 –Installation ...............................................................7
1Introduction................................................... 9
2Guidelines for Working On Electric Pump
Applications .................................................. 9
2.1 Precautions For Working On Electric Pumps............. 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
3Frame Dimensions....................................... 10
3.1 Small Frame .......................................................... 10
3.2 Medium Frame...................................................... 11
3.3 Large Frame ..........................................................12
4Mounting..................................................... 13
4.1 Cable Routing .......................................................13
5Wiring Guidance......................................... 14
5.1 Battery and Motor Connections............................. 15
5.1.1 Tightening Torque for Battery and Motor
Connections ..........................................................15
5.2 Battery and Motor Wire Size and Type Selection ....16
5.3 Battery and Motor Connection Crimps
and Tooling............................................................16
5.4 Control Connections.............................................. 16
5.5 Control Connection Wiring..................................... 16
5.6 Control Connections Crimps and Tooling.............. 17
6Connections ............................................... 17
6.1 Battery Connection................................................ 17
6.1.1 Power Fuse............................................................. 17
6.1.2 Line Contactor & Pre-charge Resistor ....................17
6.1.3 Discharge Resistor..................................................17
6.1.4 Emergency Disconnect Switch ..............................17
6.2 Motor Connections ................................................18
6.3 Control Connections.............................................. 18
6.4 Connector ‘A’ – Pump Interface (16-way)..............18
Pin 1 –Pump Potentiometer Switch 1 ..............................18
Pin 2 –Pump Switch 2...................................................... 18
Pin 3 –Pump Switch 3...................................................... 18
Pin 4 –Pump Switch 4...................................................... 18
Pin 5 –Pump Switch 5...................................................... 19
Pin 6 –Power Steer Trigger ............................................... 19
Pin 7 –Pump Inhibit.......................................................... 19
Pin 8 –Potentiometer....................................................... 19
Pin 9 –Potentiometer....................................................... 19
Pin 10 –Keyswitch............................................................ 20
Pin 11 –Contactor Coil Supply ........................................ 20
Pin 12 –Line Contactor.................................................... 20
Pin 13 –Power Steer Contactor ....................................... 20
Pin 14 –Remote LED........................................................ 20
Pin 15 –+12V Supply....................................................... 20
Pin 16 –+5V Potentiometer Supply ................................. 20
6.5 Connector ‘B’ – Communications (8-way) ............. 20
Pin 1 –Not Used............................................................... 20
Pin 2 –Not Used............................................................... 20
Pin 3 –Flash Programming Mode (+12V) ........................ 20
Pin 4 –Flash Programmer I/O........................................... 21
Pin 5 –CAN L ................................................................... 21
Pin 6 –CAN H................................................................... 21
Pin 7 –+12V Supply......................................................... 21
Pin 8 –0V ......................................................................... 21
6.6 Connector ‘C’ – Motor Feedback (6-way) ............. 21
Pin 1 –Encoder Speed (A) ............................................... 21
Pin 2 –Encoder Direction (B) ............................................ 21
Pin 3 –Not Used............................................................... 21
Pin 4 –Motor Thermistor ................................................... 21
Pin 5 –+12V Supply......................................................... 21
Pin 6 –0V ......................................................................... 22
7Electromagnetic Compatibility (E.M.C.) .......22
7.1 Emissions................................................................ 22
7.1.1 Power Cables ........................................................ 22
7.1.2 Signal Cables ........................................................ 22
7.1.3 Controller ............................................................... 22
Chapter 2 –Adjustments ......................................................23
1Adjustments .................................................25
1.1 Acceleration –(Accel) ........................................... 26
1.2 Deceleration –(Decel) .......................................... 26
1.3 Creep Speed –(Creep)......................................... 26
1.4 Speed 1 (Pot. Maximum) –(Potmax1) ................... 26
1.5 Speed 2 –(Pspeed2) ............................................. 26
1.6 Speed 3 –(Pspeed3) ............................................. 26
1.7 Speed 4 –(Pspeed4) ............................................. 26

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1.8 Speed 5 –(Pspeed5) .............................................27
1.9 Speed 6 (Power Steer) –(Psteer6)........................... 27
1.10 Not Used ................................................................ 27
1.11 Not Used ................................................................ 27
1.12 Not Used ................................................................ 27
1.13 Not Used ................................................................ 27
1.14 Not Used ................................................................ 27
1.15 Not Used ................................................................ 27
1.16 Acceleration / Deceleration Speed 6
–(Paccel 6) ...........................................................27
1.17 Maximum Current –(MaxCurr) ...............................28
1.18 Battery Voltage –(BattV).........................................28
1.19 Power Steer Delay (Speed 6) –(PStrDly)..................28
1.20 Not Used ................................................................ 28
1.21 Accelerator 0% Voltage –(AccMin) ...................... 28
1.22 Accelerator 100% Voltage –(AccMax) .................28
1.23 Not Used ................................................................ 28
1.24 Not Used ................................................................ 28
1.25 Not Used ................................................................28
1.26 Not Used ................................................................ 28
1.27 Not Used ................................................................ 28
1.28 Not Used ................................................................ 29
1.29 Not Used ................................................................ 29
1.30 Not Used ................................................................ 29
1.31 BDI Reset Level –(BDIreset) ....................................29
1.32 BDI Empty Level –(BDIempty) ................................29
1.33 BDI Warning Level –(BDIwarn) ................................29
1.34 BDI Cut-out Level –(BDIcut).................................... 29
1.35 Not Used ................................................................ 29
1.36 Not Used ................................................................ 29
1.37 Not Used ................................................................ 29
1.38 Not Used ................................................................ 29
1.39 Not Used ................................................................ 30
1.40 Not Used ................................................................ 30
1.41 Not Used ................................................................ 30
1.42 Not Used ................................................................ 30
1.43 Not Used ................................................................ 30
Chapter 3 –Diagnostics...........................................................31
1Error Detection ............................................ 33
2Error Codes ................................................. 34
3Status .......................................................... 36
4Further Status Information ............................ 37
5Test.............................................................. 38
Chapter 4 –Controller Set-Up.........................................39
1Controller Set-up..........................................41
1.1 Accelerator Characteristic –(Lin/Curv)................... 42
1.2 Not Used ................................................................ 42
1.3 Power Steer Input –(Sp6Lo/Hi)................................ 42
1.4 Pump Inhibit Input –(HibLo/Hi)................................ 42
1.5 Pump Power-up –(Nchk/Chk) ................................ 42
1.6 Pot. & Switch –(NoSw/Sw) ...................................... 43
1.7 Not Used ................................................................ 43
1.8 Not Used ................................................................ 43
1.9 Not Used ................................................................ 43
1.10 Display Error Indication –(Of/M/M&W).................... 43
1.11 Display Status Field –(Of/D/V/K).............................. 43
1.12 Not Used ................................................................ 44
1.13 Motor Temperature Sensor Type –(MtempTyp)...... 44
1.14 Analogue Inputs Set-up –(Accel 8/9) .................... 44
1.15 Not Used ................................................................ 44
1.16 Not Used ................................................................ 44
1.17 CAN Node Number –(CAN node)......................... 44
1.18 Shared Line Contactor –(ShareLC)........................ 45
1.19 Last Sharing Node –(LstNode) ............................... 45
Chapter 5 –Motor Set-up ...................................................47
1Motor Set-up ................................................49
1.1 Motor Temperature Cutback –(TempStrt).............. 50
1.2 Not Used ................................................................ 50
1.3 Number of Teeth –(SpdTeeth) ............................... 50
1.4 Number of Motor Poles –(SpdPoles)...................... 50
:: Motor Driving Set-up Explained :: .................................. 50
1.5 Motor Speed Minimum –(SPDmin) ........................ 51
1.6 Motor Speed Boost –(SPDboost)............................ 51
1.7 Motor Speed Base (Rated) –(SPDbase) ................. 51
1.8 Motor Speed Maximum –(SPDmax) ...................... 51
1.9 Minimum Voltage –(Vmin) .................................... 52
1.10 Drive Voltage Minimum –(D Vmin) ........................ 52
1.11 Drive Voltage Boost –(D Vboost)............................ 52
1.12 Drive Voltage Base (Rated) –(D Vbase)................. 52
1.13 Drive Voltage Maximum –(D Vmax) ...................... 52
1.14 Drive Slip Minimum –(D Smin)................................ 52
1.15 Drive Slip Boost –(D Sboost) ................................... 52
1.16 Drive Slip Base –(D Sbase)..................................... 52
1.17 Drive Slip Maximum –(D Smax).............................. 52
:: Motor Braking Set-up Explained :: ................................. 53
1.18 Braking Voltage Minimum –(B Vmin) ..................... 53
1.19 Braking Voltage Boost –(B Vboost)......................... 53
1.20 Braking Voltage Base –(B Vbase) .......................... 53

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1.21 Braking Voltage Maximum –(B Vmax) ...................53
1.22 Braking Slip Minimum –(B Smin)............................. 54
1.23 Braking Slip Boost –(B Sboost) ................................54
1.24 Braking Slip Base (Rated) –(B Sbase) .....................54
1.25 Braking Slip Maximum –(B Smax)........................... 54
1.26 Not Used ................................................................ 54
1.27 Not Used ................................................................ 54
1.28 Not Used ................................................................ 54
1.29 Not Used ................................................................ 54
1.30 Not Used ................................................................ 54
1.31 Proportional Gain for Voltage Change –(PgainV) . 54
1.32 Proportional Gain for Outer Speed Loop
–(PgainSpd)........................................................... 55
1.33 Proportional Gain for Inner Torque Loop
–(PgainTrq) ............................................................55
1.34 Ramp Delay for Inner Torque Loop –(Ramp Trq)...55
1.35 Not Used ................................................................ 55
:: Timed Current Limit Explained ::.................................... 55
1.36 Current Threshold –(CurrTh)....................................55
1.37 Lower Maximum Current –(ImaxLow) ....................56
1.38 Threshold Timer –(IthTime) .....................................56
1.39 Not Used ................................................................ 56
1.40 Not Used ................................................................ 56
1.41 Not Used ................................................................ 56
1.42 Not Used ................................................................ 56
Chapter 6 –Motor Set-Up Example .......................... 57
1Example Set-up Procedure ......................... 59
1.1 Drive Speed Set-up................................................ 59
1.2 Drive Voltage Set-up ..............................................60
1.3 Drive Slip Set-up .....................................................60
1.4 Motor Set-up –Braking ...........................................61
1.5 Fine-tuning Drive ....................................................62
1.6 Additional Torque...................................................62
1.7 The Results After Fine-tuning...................................63
1.8 Final Checks ..........................................................64
Chapter 7 –Hand-Held Programmer .........................65
1Introduction................................................. 67
1.1 Interface Switch .....................................................67
2Connection................................................. 68
2.1 CAN Node Set-up ..................................................68
3Using the Programmer................................. 68
4Programmer Map........................................ 69
4.1 Programming, Diagnostic and Test Options .......... 69
4.1.1 Adjustments ........................................................... 69
4.1.2 Status ..................................................................... 69
4.1.3 Controller Set-up.................................................... 69
4.1.4 Motor Set-up .......................................................... 69
4.1.5 Test ........................................................................ 69
4.1.6 About..................................................................... 70
5Diagnostics ..................................................70
6Software Upgrades ......................................70
Chapter 8 –Calibration ............................................................ 71
1Calibration...................................................73
1.1 Load Defaults –(LoadDefs).................................... 73
1.2 –1.7 Offset and Gain Settings................................... 73
Chapter 9 –Sigmagauge ......................................................75
1Introduction .................................................77
1.1 General Information .............................................. 77
1.1.1 Membrane Buttons ................................................ 77
1.1.2 Battery Discharge Indicator ................................... 77
1.1.3 Fault Indication Field ............................................. 77
1.1.4 General Indication Field ........................................ 77
1.1.5 Hours Counter........................................................ 77
1.1.6 Information Field.................................................... 77
2Connection .................................................78
3Mounting .....................................................78
4Configuring the Sigmagauge ......................79
Chapter 10 –Technical Specifications.........................81
1 Electrical......................................................83
1.1 Voltage Specifications........................................... 83
1.2 Current Specifications............................................ 83
2Environmental ..............................................83
3Mechanical .................................................84

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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 primarily 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 pump speed.
The Sigmadrive has been designed to easily withstand the harsh operating environments that electric pump applications 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 Pump Applications
2.1 Precautions For Working On Electric Pumps
Working on any electrical system can be dangerous. Work on electric pump applications 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 pumps, 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. Always exercise caution when working on
the pump and seek advice from the manufacturer or PGDT if any doubt.
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 pump’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 pump:
If you know that the controller or other crucial components require repair.
Do not operate the controller if the pump 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 pump 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.

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It is the responsibility of the pump’s application manufacturer to ensure that it 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 pump user must comply with all pump 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 and large. This can be identified from the last character of
the product code. For example, ACP425Sis a Small frame size.
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 application 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 thermal transfer 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 operating 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 application 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
machine duty cycles and airflow should also be taken into consideration when selecting the pump 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 Motor and
Battery connections on the Sigmadrive controllers.
Frame Size
Motor
Battery
Small
16 mm2
16 mm2
Medium
35 mm2
35 mm2
Large
70 mm2
70 mm2
It is the responsibility of the application’s manufacturer to ensure that the pump 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 pump’s electrical system. Poor quality crimps may
initially appear satisfactory, but can deteriorate over time, ultimately causing the application 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 Pump Interface Connector
B 8 way Communications Connector
C 6 way Motor Feedback Connector
5.5 Control Connection Wiring
Use 0.5mm2/20AWG 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
63819-0000
11-03-0043
B –8-way
D51068
43025-0800
43030-0007
C –6-way
D51067
43025-0600
43030-0007
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 pump. 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 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 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 –48V Sigmadrive –22kΩ 1/4W
72V –80V Sigmadrive –47kΩ 1/4W
6.1.4 Emergency Disconnect Switch
For certain application 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 application’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 application’s 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 pump
operates incorrectly, 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: Pump 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’ – Pump Interface (16-way)
A priority system is in place for pins 1 to 5. If more than one switch is closed, the pump speed will
be set by the switch with the lowest numerical value.
Pin 1 –Pump Potentiometer Switch 1
A pump potentiometer is typically used to lift the forks on a forklift truck.
If the pump potentiometer is fitted with a switch, the switch should be connected to this input.
The programmable parameter, 3.6 Pot. & Switch, should also be set to 1.
If these conditions are met, the pump motor will not drive until the switch is closed and the potentiometer is operated.
Pin 2 –Pump Switch 2
Pump Switch 2 is typically used for tilting the forks on a forklift truck.
When closed, this switch will activate the pump speed set by the programmable parameter, 1.5 Speed 2.
Pin 3 –Pump Switch 3
Pump Switch 3 is typically used for side shifting the forks on a forklift truck.
When closed, this input will activate the pump speed set by the programmable parameter, 1.6 Speed 3.
Pin 4 –Pump Switch 4
Pump Switch 4 is typically used to operate an auxiliary pump function.
When closed, this input will activate the pump speed set by the programmable parameter, 1.7 Speed 4.

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Pin 5 –Pump Switch 5
Pump Switch 5 is typically used to operate an auxiliary pump function.
When closed, this input will activate the pump speed set by the programmable parameter, 1.8 Speed 5.
Pin 6 –Power Steer Trigger
This input should be connected to the pump’s power steer trigger switch. Once activated, power steering will be available
to the operator.
The active polarity of the switch is set by the programmable parameter, 3.3 Power Steer Input.
If set to 0, the input will be active when the switch is closed.
If set to 1, the input will be active when the switch is open.
This input can be connected to a hydraulic pressure switch used for steering or to the traction controller’s power steer
contactor input. If neither are present, the seat, direction or foot switches can be used to provide the power steer trigger.
The minimum pump speed required to operate the Power Steer Trigger will always be available
when requested by activating pin 6.
Pin 7 –Pump Inhibit
This input can be used to inhibit pump operation.
The active polarity of the switch is set by the programmable parameter, 3.4 Pump Inhibit.
If set to 0, the input will be active when the switch is closed.
If set to 1, the input will be active when the switch is open.
Pin 8 –Potentiometer
This is an analogue input that will accept a 2-wire 5kΩ potentiometer or a 5V to 0V voltage signal.
This input can be connected to the pump’s potentiometer.
The active range of the 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 pump
potentiometer while the latter parameter sets the voltage that relates to 100% drive demand from the potentiometer.
For maximum safety, 0V to 5V voltage signals should always by connected to pin 9.
Pin 9 –Potentiometer
This is an analogue input that will accept a 3-wire 5kΩ potentiometer or a 0V to 5V voltage signal.
This input can be connected to the pump’s potentiometer.
The active range of the 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 pump
potentiometer while the latter parameter sets the voltage that relates to 100% drive demand from the potentiometer.
For maximum safety, 5V to 0V voltage signals should always by connected to pin 8.

AC PUMP –INSTALLATION PG DRIVES TECHNOLOGY
SK79647-02
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Pin 10 –Keyswitch
This input should be connected to the switched side of the keyswitch. The other side of the keyswitch should be
connected to the battery positive supply.
A fuse of sufficient value to supply all contactor coil currents should be connected between the battery positive supply
and the keyswitch. The position of the fuse should be as close as possible to the tap-off point for the keyswitch supply.
Pin 11 –Contactor Coil Supply
This output is the positive supply to the application’s contactors. The voltage level of this supply corresponds to the pump’s
battery voltage. The maximum supply current from this pin is 3A.
Pin 12 –Line Contactor
This pin should be connected to the negative side of the Line Contactor coil. The Sigmadrive will control the Line
Contactor as required. The maximum rating for this connection is 3A and it is fully protected for use with inductive loads.
Pin 13 –Power Steer Contactor
This pin should be connected to the negative side of the Power Steer Contactor coil. The Sigmadrive will control the Power
Steer Contactor as required. The maximum rating for this connection is 3A and it is fully protected for use with inductive
loads.
Pin 14 –Remote LED
This input can be connected, via pin 11, to an external fault indicator, such as an LED. Depending on the type of indicator
fitted, a suitable current limiting resistor may also be required.
If an error is detected during operation, the external fault indicator will flash synchronously with the red LED on the
Sigmadrive.
When using small frame controllers, an additional ‘driver module’ is required to provide this
functionality. Please contact PGDT for further advice.
Pin 15 –+12V Supply
A 12V supply. The maximum supply current is 20mA from this pin.
Pin 16 –+5V Potentiometer Supply
A supply for the 5kΩ pump potentiometer that is the input to pin 9.
6.5 Connector ‘B’ – Communications (8-way)
Pin 1 –Not Used
Not used.
Pin 2 –Not Used
Not used.
Pin 3 –Flash Programming Mode (+12V)
For use with the Flash Programmer.