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SIGMADRIVE PM TRACTION TECHNICAL MANUAL

1. Conn A pin 1 1 0 Open 1 Closed Conn A 2 0 Open 1 Closed Conn A pin 3 0 Open 1 Closed Conn A pin 4 0 Open Closed Conn A pin 5 0 Open 1 Closed Conn A pin 0 Open 1 Closed Conn A pin 7 0 Open Closed 5 Footbrake P Conn A pin 8 9 Open 1 Closed Conn A 8 9 0 to 10096 lr RR Conn 8 9 511 Footbrake 7 9 0 to 100 5 12 Footbrake V 8 9 Conn 4 0 1 100 Conn 4 a Conn A pin 12 0 OV 1 5 16 Conn A pin 13 0 OV Vbatt Com 14 0 1 0 OV 1 E Speed Encoder Conn C pin 1 0 1 0 OV 1 5V Red Remote ED Conn 2 010 OV 1 Reserved For Future Use Red LED 0 1 0 Off 1 On 0 1 0 Off 1 On 0 1 0 Off 1 On 15 24 2 0 1 0 12 Internal Rail Low 12V 42 5 79649 PG DRIVES TECHNOLOGY PM TRACTION CONTROLLER SET UP CHAPTER 4 CONTROLLER SET UP 5 79649 01 43 PM TRACTION CONTROLLER SET UP 44 PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY Controller Set up PM TRACTION CONTROLLER SET UP The Sigmadrive Programmer Controller Set up menu 3 Controller Set up contains the parameters shown in the table below Each parame
2. 20 Pin 9 Accelerator 20 Pitt TO KeVsWII Clas 21 Pin 11 Contactor Coil Supply 21 Pim 12 Eine COMOACTON uccisi xcci nien 1 Pin 13 Electric Broke Contactor Pin 14 Power Steer ContaocTor 4 2 Pin 16 5V Potentiometer Supply 6 5 Connector B Communications 8 way Eolo HET 21 PNZ 21 Pin 3 Flash Programming Mode 12 21 Pin 4 Flash Programmer Pia CAN 12V SUDDlV siiis vg teta 6 6 Connector C Motor Feedback 6 way Pin 1 Speed 11 2 Remote LED Pin 3 NOT USSO s ta ans Pin 4 Thermistor or Steering Potentiometer Pini 5 12V SUDOV oii sed ed Ped o e 7 Electromagnetic Compatibility 23 23 TT Power Cables iue 23 7 1 2 Signal atta se iria a 23 ole eH HE E 23 Chapter AdjuStMe nt 25 1 Adjusiments 27
3. 14 COB 14 5 Wiring 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 ONG 61119 suci tnt moet tees 5 4 Control 55 Control Connection 5 6 Control Connections Crimps and Tooling 18 Connections 0 400 121 18 61 Batey Connection cesserit cnr 18 AME adm 18 6 1 2 Line Contactor Pre charge Resistor 18 6 1 3 Discharge ResistOr cernentes 18 6 1 4 Emergency Disconnect SWIC 44 18 6 2 Motor 19 6 3 Control 19 64 Connector A Vehicle Interface 16 way 19 PIN 1 Forward SWIICh ccce tno Pin 2 Reverse Switch Pin 3 Footswitch Belly Button enhn ct as Pin 5 Speed Limit 1 Inch Forward 5 79649 01 Pin 6 Speed Limit 2 Inch 20 Pin 7 Speed Limit 3 Handbrake 20 Pin 8 Accelerator
4. Sigmagauge 5 79649 01 15 TRACTION INSTALLATION PG Drives TECHNOLOGY Steering Potentiometer Wiring 5 4 16 15 14 13 12 11 10 9 6 2 876542321 Steering Pot 4 Ov 2 16 5V Potentiometer Supply _ BK Motor Thermistor Wiring 6 5 4 16 15 14 13 12 1110 9 2 1 8 7 6 5 4 3 2 1 Motor Thermistor 4 pU LOI xit Thermistor 1 6 5 Potentiometer Supply 2K2 0 25W 5l 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 M threaded holes while the medium and large frame sizes have M8 threaded holes Brass Screw t a Spring Washer Fiat Washer 14mm Damage to the controller may occur if this depth is exceeded After securely fitting the high current cable
5. PG DRIVES TECHNOLOGY PM TRACTION SIGMAGAUGE Once the cut out is ready ensure that all debris is removed and the surface is clean Place the Sigmagauge in the hole e Raise the Securing Bracket from beneath the dash surface and locate onto the mounting bolts Once located fasten using the M5 nuts supplied To maintain a good weather seal it is suggested that a waterproof adhesive is used to seal and secure the Sigmagauge to the dash 4 Configuring the Sigmagauge To access the Gauge Set up menu press and hold the SEL button for 3 seconds Features such as the Service Interval Timer Hours Counter and Text Field can be adjusted and optionally protected with a pin code Use the up and down arrow buttons to choose an option SEL to select an option and the amp buttons to amend the current value The table below shows the structure of the Gauge Set up menu It describes the action and range of each available parameter 2 Hours counter 3 Information field 4 Pincodes 5 About 6 Return 5 79649 01 1 Service timer 1 Svc interval Set the time interval for the O 32767 Hrs Warning starts next service 40 hours before service required 2 Count hours Set to count work drive or Work Key Hrs key hours 3 Reset timer To confirm press SEL sub menu ref 4 4 Svc time Indication only counter value Key 2 Work Select with up a
6. Acceleration Accel This sets the time taken to accelerate from zero speed to maximum speed The maximum speed demand is set by 1 4 Maximum Forward Speed and 1 5 Maximum Reverse Speed Increasing the value results in a slower vehicle acceleration while decreasing the value results in a faster vehicle acceleration The adjustable range is 0 15 to 10 05 O 1s steps Le Deceleration Decel This sets the time taken to decelerate from maximum speed to zero speed Increasing the value results in a slower vehicle deceleration while decreasing the value results in a faster vehicle deceleration The adjustable range is 0 1s to 10 0s in O 1s steps 13 Creep Speed Creep This effectively sets the initial speed that the vehicle will adopt on entering drive Increasing the value will help minimise any delay from selecting drive to creeping the vehicle The adjustable range is 0 to 25 in 1 steps 14 Maximum Forward Speed SpdMaxF This sets the maximum forward speed of the vehicle The adjustable range is 0 to 100 in 1 steps 15 Maximum Reverse Speed This sets the maximum reverse speed of the vehicle The adjustable range is 0 to 100 in 1 steps 16 Speed Limit Inching Speed Spl Inch The function of this parameter is dependent on the setting of 3 5 Connector A Pin 5 and in the Controller Set up menu That parameter sets whether pins 5 and 6 are used as speed limiting inputs or as inc
7. 414 Motor Set up This menu includes parameters specifically related to the type of motor being used Refer to the Motor Set up chapter for full details 415 Test This menu allows you to select controller I O status for display such as the state of digital and analogue inputs or contactor LED outputs Refer to the Diagnostics chapter for full details 5 79649 01 PM TRACTION HAND HELD PROGRAMMER PG DRIVES TECHNOLOGY 416 About This menu option displays information about the system The information is factory programmed into the controller by PGDT and is displayed as follows Customer Name Cust Standard 2 Application App Standard 3 Motor Type Motor PM 4 Controller Type Type PPM835TMO1 5 Hardware Voltage and Current HW 80V 350A 6 Software Version SW 3 01 00 150107 5 Diagnostics If the controller has detected an error this will be displayed as a number preceded by F the right hand side of the Controller Type screen as shown below 0 Standard Calibrator 0 gt 4 Traction F22 About In this instance the error code is 22 For details of this error refer to the Diagnostics chapter 6 Software Upgrades The Programmer can be used to load revised software into the controller Likewise the Programmers own software can revised If either of these operations is required to be undertaken PGDT will supply more detailed and specific ins
8. Storage Temperature 409C to 709 Humidity 95 maximum non condensing 5 79649 01 7 PM TRACTION TECHNICAL SPECIFICATIONS PG DRIVES TECHNOLOGY 3 Mechanical Dimensions Refer to frame drawings in Installation chapter Enclosure Aluminium heatsink with ABS plastic cover Recommended fixing torques Large and Medium frame 11Nm Small frame 9Nm Maximum screw thread penetration depth frame sizes 14mm Weight Small 1 2Kg Medium 4 1Kg Large 6 1Kg Q Always use a torque screwdriver when fixing the power terminals Exceeding the maximum specified torque can cause serious damage to the controller and warranty may be void Screws that too long will damage the controller 72 5 79649
9. In the zone between 1 34 Dual Motor Reverse and the full turning angle 100 the speed of the inner motor will be linearly scaled between zero and the value set by 1 35 Dual Motor Speed In the zone between 1 33 Dual Motor Cutback and the full turning angle i e 100 the speed of the outer motor will be linearly scaled between the driving speed and the value set by 1 35 Dual Motor Speed The parameters 1 33 Dual Motor Cutback 1 34 Dual Motor Reverse and 1 35 Dual Motor Speed have an adjustable range of 0 to 100 in 1 steps Example A vehicle is fitted with a 5kQ steering potentiometer that reaches 1kQ at full left lock and 4kQ at full right lock The mechanical angle between the two points is 270 i e 135 each side of centre The steering potentiometer supply voltage is 5V If the vehicle has a steering angle of less than 15 from centre then both drive wheels should be driven at the same speed If the steering angle is greater than 15 from centre the speed of the inner wheel should start to reduce This reduction should continue until an angle of 100 at which point the inner wheel should be at zero speed If the steering angle is increased further then the inner wheel should start to drive in reverse until the full steering lock is reached when the speed of the inner wheel should be 25 in the reverse direction of the outer wheel 1 Determine which controller will be the left hand unit and w
10. Til 71 1 2 CumentSpecifiCations ime cere eerta 71 2 Environmental 71 3 Mechanical 72 5 79649 01 SIGMADRIVE TECHNICAL MANUAL PM TRACTION SIGMADRIVE TECHNICAL MANUAL PM TRACTION PG Drives TECHNOLOGY About this manual This manual is divided into 8 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 Hand held Programmer This chapter provides an overview of the Sigmadrive Hand held Programmer Chapter 7 Sigmagauge This chapter provides an overview 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 draw the reader s attention The icons used are Note A general point for best practice Caution A point of safety which if
11. amp minutes selectable in the Gauge Set up menu The hours counter value is stored in the display The controllers have their own separate counter 16 Information Field A 2x9 character field to show customized text e g vehicle OEM and type The membrane buttons can be used in the Gauge Set up menu to edit the text displayed 5 79649 01 65 PM TRACTION SIGMAGAUGE PG Drives TECHNOLOGY 2 Connection The Sigmagauge is connected the Sigmadtive via the controllers 8 way Connector The PGDT part number for the Sigmagauge mating connector is 051069 Sigmadrive Connector B 87 6 5 6 CANH 7 12 Supply e 8 OV Sigmagauge 3 Mounting Mounting the Sigmagauge module requires a rectangle to be cut into the vehicle dashboard allowing the module to rest on the surface of the dash 68 98 Dimensions shown in mm Before cutting the hole ensure that enough room is available within the dash for the area of the module and the Securing Bracket Access to the back of the dash will be required to secure the Sigmagauge 110 r 1 Securing o 1 5 Nuts m a z Securing Bracket 1 e 5 Bolts a a e 0 90 Cable 1 93 8 105 7 Dimensions shown 66 5 79649
12. 0 1V steps The Accelerator input can be configured via the parameter 3 14 Analogue Inputs Set up in the Controller Set up menu 123 Footbrake O Voltage AuxMin This sets the voltage on the Footbrake input that will correspond to zero braking force The adjustable range is OV to 5V 0 1V steps The Footbrake input can be configured the parameter 3 14 Analogue Inputs Set up in the Controller Set up menu 124 Footbrake IOO Voltage AuxMax This sets the voltage on the Footbrake input that will correspond to the braking force as set by the parameter 1 11 Footbrake Regen Braking The adjustable range is OV to 5 in 0 1V steps The Footbrake input can be configured the parameter 3 14 Analogue Inputs Set up in the Controller Set up menu 125 Motor Pot Min MotMin The operation of this parameter is dependent on the setting of 3 15 Single Dual Motor Select in the Controller Set up menu If that parameter is set to O motor temperature then this setting has no effect If it is set to 1 or 2 dual motor left or dual motor right then this parameter sets the voltage on the Steering Pot input pin 4 of Connector C which will correspond to the minimum steering angle By convention the minimum steering angle relates to the full left hand lock of the vehicle The adjustable range is OV to 5V in 0 1V steps 126 Motor Pot MotMax The operation of this parameter is dependent on the setting of 3 15 Singl
13. 100 0 100 0 100 Inching Speed Inch 0 25 Speed Limit 2 902 0 100 Inching Time Time 0 15 10 05 Speed Limit 3 903 0 100 Direction Regen Braking DBrake 50A Unit max Neutral Regen Braking NBrake Unit max Footbrake Regen Braking FBrake 50A Unit max Direction Braking Ramp DBrkRamp 0 15 10 05 Direction Braking End Delay DBrkEnd 0 15 10 05 Neutral Braking Ramp NBrkRamp 0 15 10 05 Neutral Braking End Delay NBrkEnd 0 15 10 05 Regen Speed Regspd 0 100 Maximum Current MaxCurr 10A Unit max Battery Voltage BattV 24V Unit Power Steering Delay PStrDly Os 50s Electric Brake Delay EBrkDly Os 50s Accelerator 0 Voltage AccMin OV 5V Accelerator 100 Voltage AccMax OV 5V Footbrake 0 Voltage AuxMin OV 5V Footbrake 100 Voltage AuxMax OV 5V Motor Pot Min MotMin OV 5V Motor Pot Max MotMax OV 5V Max Vehicle Speed BDI Reset Level BDI Empty Level Vmaxspd BDlreset BDlempty kph 100 kph 18V 125 Bat 12V 125 Bat V 5 79649 01 BDI Warning Level 0 99 BDI Cut out Level BDIcut 096 99 BDI Speed Limit BDlspeed 096 10096 Dual Motor Cutback DMcut 0 100 Dual Motor Reverse DMrev 0 100 Dual Motor Speed DMspeed 0 100 Standby Delay StaByDly min off 10 min PM TRACTION ADJUSTMENTS PG DRIVES TECHNOLOGY
14. Accelerator 100 Voltage 31 1 23 Footbrake 0 Voltage 31 1 24 Footbrake 100 Voltage 31 1 25 Motor Pot Min 3 1 26 Motor Pot Mox 31 1 27 Mox Vehicle Speed VMAXSPA 3 1 28 BDI Reset Level BDIresef 3 1 29 BDI Empty Level 32 1 30 BDI Warning Level 32 1 31 BDI Cut out Level 32 1 32 Speed Limit BDIspeed 32 1 33 Dual Motor Cutback 32 1 34 Dual Motor Reverse DMrev 32 1 35 Dual Motor Speed 0 32 36 Standby Delay 33 Chapter 013880051 35 Error 61 37 2 5 38 3 40 4 Further Status Information 41 5 M 42 Chapter 4 Controller 43 1 Controller Set up 45 11 Accelerator Characteristic Lin Curv 46 1 2 SeQlsc s a fee taste ee iter i 46 1 3 Proportional Braking Boro Of
15. affected by Electro Magnetic Interference EMI Such interference may be generated by radio stations TV stations other radio transmitters and cellular phones If the vehicle exhibits erratic behavior due to EMI turn the controller off immediately and consult your service agent PGDT accepts no liability for losses of any kind arising from failure to comply with this condition It is the responsibility of the vehicle manufacturer to ensure that the vehicle complies with appropriate National and International EMC legislation PGDT accepts no liability for losses of any kind arising from failure to comply with this condition The vehicle user must comply with all vehicle safety warnings PGDT accepts no liability for losses of any kind arising from failure to comply with this condition 3 Frame Dimensions The Sigmadrive is constructed in three frame sizes small medium and large This can be identified from the last character of the product code For example 4258 is a Small frame size IO 5 79649 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION 41 5 79649 01 II Small Frame 155 100 FIXING HOLE 177 163 FIXING HOLE 41 PG Drives TECHNOLOGY PM TRACTION INSTALLATION Medium Frame 32 200 150 FIXING H
16. can be dangerous Work on electric vehicles should only be undertaken by skilled or supervised persons in a segregated location that eliminates the risk of injury to other persons Before performing any kind of work on electric vehicles ensure that the following basic safety advice is followed ell Uncontrolled Operation Fault conditions or programming changes may cause the motor to run out of control Disconnect the motor or raise the drive wheels above the ground If lifting the vehicle use the correct jacking procedure as recommended by the vehicle manufacturer to lift the vehicle s drive wheels clear of the ground Once lifted fit axle stands to safely support the vehicle and remove the jack Ensure that all such lifting equipment is in serviceable condition and suitable for the vehicle in question eie High Current Arcs Batteries contain very high levels of energy and can be extremely dangerous if mishandled or abused Always disconnect the batteries before working on the vehicle s electrical system and the motor controller wiring Remove all jewellery from wrist and fingers and use properly insulated tools to prevent shorts Wear safety glasses at all times 213 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 manufacturers safety recommendations Wear safety glasses at all times 2
17. four clearance holes provided Ideally a flat clean metal surface will provide maximum heat dissipation and ensure full rated power output Failure to use all four mounting points may result in a loss in performance Any airflow around the controller will further enhance the thermal performance If desired the controller s thermal performance may be further improved by applying a silicone free thermal compound between the baseplate and the machine chassis The Small Frame controller has M 1 4 clearance holes The Medium and Large Frame controllers have 5 16 clearance holes exceed 41 06 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 F is very close to normal body temperature prolonged contact with surfaces above 6 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 e Under strenuous driving conditions it is possible for metal sections of the controller s case to 41 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
18. ignored could result in damage to the control system or the vehicle e 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 6 5 79649 0 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION CHAPTER INSTALLATION 5 79649 01 7 TRACTION INSTALLATION PG DRIVES TECHNOLOGY 8 5 79649 0 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION Introduction The Sigmaarive 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 1116 Sigmadrive has been designed to easily withstand the harsh operating environments that electric vehicles typically endure State of the art construction techniques ensure the controller can withstand shock vibration and extremes of temperature To ensure the Sigmadrive installation is as robust as possible follow the guidelines in this manual 2 Guidelines For Working On Electric Vehicles el Precautions For Working On Electric Vehicles Working on any electrical system
19. level of current used for braking when the brake pedal is fully operated the voltage from the footbrake potentiometer is equal to the setting of the parameter 1 24 Footbrake 100 Voltage The adjustable range is 50A to the maximum controller current in 10A steps The Footbrake Regen Current is proportional to the brake pedal from OA to this value Direction Braking Ramp DBrkRamp This sets the time taken to ramp down from maximum speed in the current direction to zero upon a change of direction After passing through zero speed the normal acceleration time as described in 1 1 Acceleration applies Increasing the value gives a smoother but longer transition to zero speed The regenerative current during braking is limited by 1 9 Direction Regen Braking When this level is reached the direction braking ramp time is prolonged until the regenerative current falls below the maximum current level At this point the ramp time takes over again The adjustable range is 0 15 to 10s 0 15 steps Direction Braking End Delay DBrk nd This setting allows a time to hold the vehicle at zero soeed when 1 12 Direction Braking Ramp time has passed The value set by this parameter is ignored during Belly Button and Inching operation The adjustable range is 0 15 to 10 05 0 15 steps 5 79649 01 PM TRACTION ADJUSTMENTS PG Drives TECHNOLOGY 14 Neutral Braking Ramp NBrkRamp This sets the time taken to r
20. of motor temperature sensor that the controller will interface to via pin 4 of Connector There are 2 programmable options but at present all PM Traction units should have this parameter set to 0 The input should be connected to a Philips KTY81 220 thermistor PTC 2K 25 C used with an external 2K2 pull up resistor to 5V 14 Analogue Inputs Set up Accel 8 9 This sets the function of input pins 8 and 9 on Connector A There are three programmable options 0 1 and 2 If set to 0 then pin 8 will be the Accelerator input and pin 9 will be the Footbrake input If set to 1 then pin 8 will be the Footbrake input and pin 9 will be the Accelerator input Single Dual Motor Select Si DL DR This sets the function of the input associated with pin 4 on Connector C and whether a controller is the left or right hand unit in a dual motor system There are three relevant programmable options 0 1 2 If set to 0 Motor Temperature then the input can be used to reduce the controllers current output as the motor temperature rises The relationship between controller output and motor temperature is set by the parameter 4 1 Motor Temperature Cutback If set to 1 Dual Motor Left then the input can be used to connect to the vehicle s Steering potentiometer which will feed back the angle of the steered wheels The controller will be assigned as the left hand unit 48 5 79649 PG DRIVES TECHNOLOGY PM TRACTION CON
21. operating frequency It is the objective of a good installation to contain or absorb the resultant emissions All wiring is capable of acting as receiving or transmitting antenna Wiring should be arranged to take maximum advantage of the structural metal work inherent in most vehicles Vehicle metalwork should be electrically linked with conductive braids 7 1 Power Cables All cables should be routed within the vehicle framework and kept as low in the structure as is practical a cable run within a main chassis member is better screened from the environment than one routed through or adjacent 10 an overhead guard Power cables should be kept short to minimize emitting and receiving surfaces Shielding by the structure may not always be sufficient cables run through metal shrouds may be required to contain emissions Parallel runs of cables in common circuits can serve to cancel emissions 9 the battery positive and negative cables following similar paths Tie all cables into a fixed layout and do not deviate from the approved layout in production vehicles A re routed battery cable could negate any approvals obtained 712 Signal Cables All wiring harnesses should be kept short Wiring should be routed close to the vehicle metalwork All signal wires should be kept clear of power cables or made from screened cable This is particularly important if the control wiring caries analogue information e g Accelerator wiring Tie all wiring sec
22. relates to zero drive demand from the Accelerator while the latter parameter sets the voltage that relates to 100 drive demand from the Accelerator When set to 1 the active range of the footbrake input is defined by the programmable parameters 1 23 Footbrake 096 Voltage and 1 24 Footbrake 100 Voltage The former parameter sets the voltage that relates to zero braking demand from the Footbrake while the latter parameter sets the voltage that relates to 10096 braking demand from the Footbrake If Footbrake switch is used on the brake pedal instead of an analogue device the switch should connect this input to the voltage corresponding to the value of parameter 1 24 Footbrake 100 Voltage in order to effect full braking Pin 9 Accelerator Footbrake This is an analogue input that will accept 3 wire 5 potentiometer or a to 5V voltage signal The function of this input is set by the programmable parameter 3 14 Analogue Inputs Set up If set to O 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 the active range of the footbrake input is defined by the programmable parameters 1 23 Footbrake 096 Voltage and 1 24 Footbrake 100 Voltage The former parameter sets the voltage that relates to zero braking demand from the Footbrake while the latter parameter sets the voltage that relates to 10096 braking dem
23. the flow of moisture into the connectors Route wiring to keep lengths as short as possible especially the high current motor and battery cabling 14 5 79649 0 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION 5 Wiring Guidance A 16 15 14 13 12 11 10 9 eeeeeee 8 7 6 5 4 3 2 1 M3 1 Forward Switch 6 2 Reverse Switch 3 Foot Switch Belly Switch niemal Circuits amp e 4 Seat Tiller Switch D 5 Speed 1 Inch Fwd 6 Speed 2 Inch Rev 7 Speed 3 Handbrake Switch 5K 8 Accelerator Footbrake 5K 9 Accelerator Footbrake 1 10 Keyswitch M3 B B 11 Contactor Coil Supply 8 12 Line Contactor OV analogue 5 5 13 Electric Brake Contactor a FUSE 14 Power Steer Contactor T 15 12V Supply MOOR FUSE 16 Potentiometer Supply mm mu C B EG 8 7 6 5 e ee T 4 3 2 1 1 Speed Encoder 2 Remote LED e 4 Motor Thermistor Steering Pot See following diagram 5 12V Supply PG DRIVES TECHNOLOGY 6
24. top right hand side of the Programmer there is a 3 way switch that is used to select the operating mode of the Programmer For normal Sigmadrive programming and diagnostics this switch must be set to position 2 Positions 1 and 3 are for Sigmadrive and Programmer software upgrades Refer to the section Software Upgrades later in this manual for more details 5 79649 01 59 PM TRACTION HAND HELD PROGRAMMER PG DRIVES TECHNOLOGY Connection The Programmer is generally connected to a Sigmadrive via the controllers 8 way Connector The exact method of connection of the Programmer will depend how many Sigmadrive controllers are fitted to the vehicle being programmed If there is just one Sigmadrive then connect the Programmer directly to Connector B on that controller there is more than Sigmaarive fitted but these are not connected to each other via their CANbus then program each controller separately If there is more than one Sigmadrive fitted and they are linked their CANbus connections on Connector B then it will be necessary to use an adaptor to provide a spare connection point for the programmer In this instance it will also be necessary to initially give each controller a unique CAN node number see section CAN Node Set up below The Programmer can be connected and disconnected at any time regardless of whether the controller is on or off el CAN Node Set up If the vehicle you are programmi
25. 1 1 Acceleration 28 1 2 Deceleration 28 13 Creep Speed Creep 28 1 4 Maximum Forward Speed SOdMaxXF 28 1 5 Maximum Reverse Speed 28 1 6 Speed Limit 1 Inching Speed 5 1 28 1 7 Speed Limit 2 Inching Time Sp2 Time 28 1 8 Speed Limit SPI 29 TECHNICAL MANUAL PM TRACTION 19 Direction Regen Braking DBrake 29 1 10 Neutral Regen Braking NBrake 29 1 11 Footbrake Regen Braking 29 1 12 Direction Braking Ramp DBrkRamp 29 1 13 Direction Braking End Delay DBrkEnd 29 1 14 Neutral Braking Ramp 30 1 15 Neutral Braking End Delay 30 1 16 Regen Speed RegSpg 30 1 17 Maximum Current ere 30 1 18 Battery Voltage 30 1 19 Power Steering Delay PStrDly 30 1 20 Electric Brake Delay 30 1 21 Accelerator 0 Voltage ACCMIN 30 1 22
26. 2 Precautions For Use Do not drive the vehicle Beyond restrictions indicated in your vehicle user manual for example inclines curb heights etc n places or on surfaces where loss of wheel grip could be hazardous for example on wet grassy slopes f you know that the controller or other crucial components require repair 5 79649 01 9 TRACTION INSTALLATION PG DRIVES TECHNOLOGY Although the controller is designed to be extremely reliable and each unit is rigorously tested during manufacture the possibility of system malfunction always exists however small the probability Under some conditions of system malfunction the controller must for safety reasons stop the vehicle instantaneously If there is any possibility of the user falling out of the vehicle as a result of a sudden braking action it is imperative that a restraining device such as a seat belt is supplied with the vehicle and that it is in use at all times when the vehicle is in motion PGDT accept no liability for losses of any kind arising from the unexpected stopping of the vehicle or arising from the improper use of the vehicle or controller Do not operate the controller if the vehicle behaves erratically or shows abnormal signs of heating sparks or smoke Turn the controller off at once and consult your service agent PGDT accepts no liability for losses of any kind arising from failure to comply with this condition Electronic equipment can be
27. CONTROLLER SET UP PG DRIVES TECHNOLOGY Display Error Indication Of M M amp W This sets the type of errors that are displayed on the Sigmagauge if fitted There are three programmable options 0 1 and 2 If set to 0 None only Hard errors will be displayed on the Sigmagauge If set to 1 Main both Hard and Main errors that prevent driving will be displayed on the Sigmagauge If set to 2 Main and Warning all errors Hard Main and Warning which do not prevent driving will be displayed on the Sigmagauge Ll Display Status Field Of D V K This sets the type of information that will appear in the General Indication Field of the Sigmagauge if fitted There are five programmable options 0 1 2 3 and 4 If set to O None then the General Indication Field will be blank If set to 1 Accelerator then the Accelerator deflection as a percentage will be displayed from 0 to 100 If set to 2 Motor then the motor speed in units of V will be displayed from 0 to 10096 If set to Speed then the vehicle speed in units of kph will be displayed from 0 to the value set in 1 27 Vehicle Speed If 1 27 is set to zero then no speed will be displayed in the General Indication Field If set to 4 Steering then the vehicle s steering angle will be displayed using crosshoirs Not Used Not used Motor Temperature Sensor MtempTup This sets the type
28. Inch then this is used to inch the vehicle in the reverse direction Inching will occur when the switch is closed The exact functionality of inching is set by the programmable parameters 1 6 Inching Speed and 1 7 Inching Time Pin 7 Speed Limit Handbrake This input is primarily intended to be used with a handbrake switch however its function can be set by the programmable parameter 3 6 Connector A Pin 7 If set to Spd3 then this input be used to limit the speed of the vehicle to a value set by the programmable parameter 1 8 Speed Limit 3 The speed limit will occur when the switch is open If set to Hbk then this input should be connected to the vehicle s handbrake switch When the switch is closed i e the handbrake is on the vehicle s speed will be as set by the programmable parameter 1 8 Speed Limit 3 Pin 8 Accelerator Footbrake This is an analogue input that will accept 2 wire 5 potentiometer or a to 5V voltage signal The function of this input is set by the programmable parameter 3 14 Analogue Inputs Set up If set to O 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 O the active range of the accelerator input is defined by the programmable parameters 1 21 Accelerator 096 Voltage and 1 22 Accelerator 10096 Voltage The former parameter sets the voltage that
29. OLE 9 12144 5 79649 0 le PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION 33 Large Frame 200 150 FIXING HOLE 9 Y N ee 0 8 S 2 B Jj 5 Hug i 5 79649 01 TRACTION INSTALLATION PG DRIVES TECHNOLOGY 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 amp contaminants If vertical orientation mounting is not possible then a cover should be used 10 shield the controller Cables must be routed to prevent liquids flowing into the connections The mounting position should also allow access to all connections and allow the connection and removal of a programming device Secure the controller to the vehicle the
30. Programmer 0 For use with the Flash Programmer Pin 5 L CAN Low communications line to the Programming Device Display or other Controller s Pin 6 CAN H CAN High communications line to the Programming Device Display or other Controller s Pin 7 l2V Supply A 12V supply The maximum supply current is 20mA from this pin Pin 8 OV A OV supply for the Programming Device or Display Connector Motor Feedback 6 way Pin Speed Encoder Connect to the speed signal of the motor encoder Pin 2 Remote LED This output can be connected via pin 16 of Connector A to an external fault indication LED If an error is detected during operation the external fault indicator will flash synchronously with the Sigmaarive s integral red diagnostic LED Pin 3 Not Used Not used Pin 4 Thermistor or Steering Potentiometer The function of this input is set by the programmable parameter 3 15 Single Dual Motor Select in the Controller Set up menu If set to Motor Temperature then this input can be connected to an external thermistor typically on the motor which can be used 1o reduce controller current output with respect to temperature The type of thermistor is set by the parameter 3 13 Motor Temperature Sensor Type Once the correct sensor type has been set the parameter 4 1 Motor Temperature Cutback can then be used to set the temperature at which current foldback will begin If set to either 1 Dual Mot
31. TROLLER SET UP If set to 2 Dual Motor Right then the input be used to connect to the vehicle s Steering potentiometer which will feed back the angle of the steered wheels The controller will be assigned as the right hand unit When a Dual Motor selection is made the speed when steering will change as described by the parameter 1 35 Dual Motor Speed in the Adjustments chapter 6 Not Used Not used 17 CAN Node Number CAN node The sets the CAN node number for the controller There are sixteen programmable options 0 to 15 If set to 0 Master then this controller is responsible for the following e General Indication Field as described in 3 11 Display Status Field e information for the Sigmagauge e BDI information to all other controllers slaves attached to the CANbus Device fault icon and pulsing information to the Sigmagauge If set from 1 to 15 the controller will be a slave In multiple controller systems it is essential that all CAN nodes have a unique number A slave uses the BDI from the master so disregards it s own BDI and associated settings 1 28 1 29 amp 1 30 However the BDI cut out levels 1 31 and BDI speed 1 32 still apply In this way the BDI is equal to all devices on the CANbus while each controller can set up it s own cut out and speed levels All slaves also send out their device fault code icon and pulsing information to the Sigmagauge In a non CANbus system the controllers sh
32. a result of a neutral drive demand Fbrk Footbraking i e the controller is braking as a result of the Footbrake being operated Abrk Anti Roll back active Fxx Error Code where xx denotes the specific error The status information 2 10 Motor on also relays some controller limit indication data Again this is in the form of a two letter abbreviation that replaces the on the Programmer s screen These abbreviations are listed below SM Maximum Speed i e maximum speed is available no limits or interlocks active 91 Speed Limit 1 is active 92 Speed Limit 2 is active 53 Speed Limit 3 is active 94 Not used 95 Not used 90 Not used Sl Inching Speed is being applied SB BDI Speed Limit is being applied SD Dual Motor Speed Limit is being applied CL Current Limit i e the controller is in drive current limit mode BL Brake Current Limit i e the controller is in braking Current limit mode CT Controller Temperature i e the controller has reduced its output due to a high heatsink temperature MT Motor Temperature i e the controller has reduced its output due to a high motor temperature 5 79649 01 4 PM TRACTION DIAGNOSTICS Test PG DRIVES TECHNOLOGY The Programmer s Test menu allows live readout of the controllers inputs and outputs This is extremely useful when carrying out diagnostic work The table below gives details of the inouts and outputs that may be viewed
33. aint Arol Off This sets whether there is a restraint function when the vehicle is at rest There are two programmable options 0 and 1 If set to O Restraint then the controller will limit the coasting speed of the vehicle Following neutral braking and omitting any programmed neutral brake end delay the vehicle will enter and remain in Anti Roll back mode Whilst in this mode the vehicle will be restrained i e rolling speed will be limited If set to 1 Coast or Off then there is no restraint function and the vehicle is free to coast after any programmed neutral brake end delay Connector A Pin 5 6 Spd Inch This sets the function of the pins 5 6 Connector There are two programmable options 0 and 1 If set to 0 Speed Limit then the inputs can be used to limit the speed of the vehicle via the parameters 1 6 Speed Limit 1 1 7 Speed Limit 2 If set to 1 Inching then the inputs can be used to inch the vehicle In this case the function of parameters 1 6 and 1 7 will become 1 6 Inching Speed and 1 7 Inching Time Both pins are normally closed inputs Connector A Pin 7 Spd3 Hbk This sets the function of input pin 7 on Connector A There are two programmable options 0 and 1 If set to 0 Speed Limit 3 then the input can be used to limit the speed of the vehicle to a level set by the parameter 1 8 Speed Limit 3 The limit will apply when a switch
34. amp down from maximum speed zero when the vehicle enters neutral drive signal in either direction Increasing the value gives a smoother but longer transition to zero speed The regenerative current during braking is limited by 1 10 Neutral Regen Braking When this level is reached the neutral braking ramp time is prolonged until the regenerative current falls below the maximum current level At this point the ramp time takes over again The adjustable range is 0 15 to 10s 0 15 steps LIS Neutral Braking End Delay NBrk nd This setting is normally associated with a Walkie type vehicle fitted with an electromechanical brake connected to pin 13 on Connector A This setting allows a time to hold the vehicle at zero speed when the 1 14 Neutral Braking Ramp time has passed It is usually used in conjunction with the parameter 1 20 Electric Brake Delay to operate the electromechanical brake The value set by this parameter is ignored during Belly Button and Inching operation The adjustable range is 0 1s to 10 0s in O 1s steps 6 Regen Speed RegSpd This sets the minimum speed a vehicle has to reach in order for the braking end delay functionality to operate The adjustable range is 0 to 100 in steps of 1 17 Maximum Current MaxCurr This sets the maximum current limit during driving The adjustable range is 10A to the maximum rating of the controller in 10A steps Battery Voltage T
35. and from the Footbrake If Footbrake switch is used on the brake pedal instead of an analogue device the switch should connect this input to the voltage corresponding to the value of parameter 1 24 Footbrake 100 Voltage in order to effect full braking 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 while the latter parameter sets the voltage that relates to 10096 drive demand from the Accelerator 5 79649 0 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION Pin IO 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 Il Contactor Coil Supply This output is the positive supply to the vehicle s contactors The voltage level of this supply corresponds to the vehicle s battery voltage The maximum supply current from this pin is 3A Pin Line Contactor This pin should be connected to the negative side of the Line Contactor coil The Sigmadrive will control the Line Co
36. c PG DRIVES TECHNOLOGY SIGMADRIVE PM TRACTION TECHNICAL MANUAL SK79649 Ol PG Drives Technology 2008 All rights reserved This manual is furnished under copyright and may only be used in accordance with the terms laid out by PG Drives Technology The information in this manual is fumished 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 44 0 1425 27144 PG DRIVES TECHNOLOGY SIGMADRIVE TECHNICAL MANUAL PM TRACTION TABLE OF CONTENTS About this man dl 6 6 Chapter Installation ss 7 9 2 Guidelines For Working On Electric Vehicles 9 21 Precautions For Working On Electric Vehicles 9 2 1 1 Uncontrolled Operation 2 1 2 High Current 05 2 1 3 Lead Acid Batteries tre rete 2 2 JPrecautioris FOF USC ew naasa 9 3 Frame Dimensions 10 3 1 SMAA G 11 3 2 Medium Frame eee 12 3 3 Large Frame 4
37. connected to pin 7 of Connector A is open If set to 1 Handbrake then the input can be used to limit the speed of the vehicle to a level set by the parameter 1 8 Speed Limit 3 The limit will apply when a switch normally the Handbrake switch connected to pin 7 of Connector A is closed 7 Power Steering Trigger PsF FR S This sets the trigger source for the power steer contactor When the vehicle has stopped driving a timer sets a delay for the power steering to remain active The length of the delay is set by the parameter 1 19 Power Steering Delay There are three programmable options 0 1 and 2 If set to 0 Footswitch then the power steer contactor is driven at the instant the Footswitch Connector A pin 3 is closed If set to 1 Forward Reverse then the power steer contactor is driven at the instant either the Forward Switch Connector A pin 1 or the Reverse Switch Connector A pin 2 are closed If set to 2 Seat then the power steer contactor is driven at the instant the Seat Switch Connector A pin 4 is closed 18 Truck Type Select Ride WIk This sets the function of the input pins 3 and 4 on Connector A There are two programmable options 0 and 1 If set to O Ride on then pin 3 will be a Footswitch input and pin 4 will be Seat Switch input If set to 1 Walkie then pin 3 will be a Belly Button input and pin 4 will be a Tiller Switch input 19 Not Used Not used 5 79649 01 47 PM TRACTION
38. d Timer 55 1 33 1 38 Offset and Gain 5 8 55 Chapter Hand Held Programrner 57 INTOCUCHION a t 59 11 60606 Switch ettet trees 59 2 Connection 60 21 CAN 60 Using the Programmer 60 4 Programmer 61 4 1 Programming Diagnostic and Test Options 61 A TS 2 facii a rr Paid 61 61 4 1 3 Controller 5 61 4 1 4 MOTOR Set UD ed ed e taa ena 6 MESE EIE 6 62 rnt etes 62 Software Upgrades 62 Chapter 7 63 Introduction 65 5 79649 PG DRIVES TECHNOLOGY General Information seme 65 1 1 Membrane Buttons esee 65 1 2 Battery Discharge INGICATON 65 1 3 Fault Indication 1 4 General Indication Field cane 1 6 Information Field 2 CONNECTION 66 MOUNINO 66 4 Configuring the Sigmagauge 67 Chapter 8 Technical Specifications 69 71
39. d error code Measured in Key Hours Units displayed as or C Actual input from Accelerator Actual input from Auxiliary input Expressed as of FET on time Actual motor on allows the duty cycle of the PWM to be deduced Drive Current Brake Current 224 PG DT Use Only See section Further Status Information The use of a current clamp or similar measuring device is recommended at lower levels 5 79649 PG DRIVES TECHNOLOGY PM TRACTION DIAGNOSTICS 4 Further Status Information The status information 2 9 Motor Demand also relays some operational status data about the controller This is in the form of a two letter abbreviation that replaces on the Programmer s screen These abbreviations are listed below Neut Neutral no drive demand and controller is not pulsing Fdrv Forward Drive i e controller is applying forward drive to the motor Forward Drive Left controller in dual motor configuration Farm Forward Drive Right controller in dual motor configuration Reverse Drive controller is applying reverse drive to the motor Reverse Drive Left controller dual motor configuration Reverse Drive Right controller dual motor configuration Dbrk Direction Braking i e the controller is braking os the result of q direction change Neutral Braking the controller is braking as
40. e If set to WIk then the vehicle s Belly Button switch should be connected to this pin When the Belly Button switch is closed The vehicle will drive in the opposite direction for 1 5s Pin 4 Seat Tiller The function of this input is to provide a general safety interlock This could be a Seat switch on a ride on vehicle a Tiller switch on a walkie vehicle or a general deadman s trigger on other vehicle types The switch must be closed to allow drive Pin 5 Speed Limit Inch Forward The function of this input is set by the programmable parameter 3 5 Connector A Pin 5 and 6 If set to Spd then this input can be used to limit the speed of the vehicle to a value set by the programmable parameter 1 6 Speed Limit 1 The speed limit will occur when the switch is open If set to Inch then this input is used to inch the vehicle in the forward direction Inching will occur when the switch is closed The exact functionality of inching is set by the programmable parameters 1 6 Inching Speed and 1 7 Inching Time 5 79649 01 TRACTION INSTALLATION PG Drives TECHNOLOGY 20 Pin 6 Speed Limit 2 Inch Reverse The function of this is set by the programmable parameter 3 5 Connector A Pin 5 and 6 If set to Spd then this input can be used to limit the speed of the vehicle to a value set by the programmable parameter 1 7 Speed Limit 2 The speed limit will occur when the switch is open If set 10
41. e Dual Motor Select in the Controller Set up menu If that parameter is set to O motor temperature then this setting has no effect If it is set to 1 or 2 dual motor left or dual motor right then this parameter sets the voltage on the Steering Pot Input pin 4 of Connector C which will correspond to the maximum steering angle By convention the maximum steering angle relates to the full right hand lock of the vehicle The adjustable range is OV to 5V in steps 27 Max Vehicle Speed VmaxSpd This sets the maximum value that is indicated on the Sigmagauge LCD when the vehicle is driving maximum speed To calibrate this value to the output from the encoder set the parameter 4 2 Motor to Vehicle Speed Ratio in the Motor Set up menu The adjustable range is Okph to 100kph in 1kph steps Setting the parameter Okph means that there will be no indication of speed shown on the Sigmagauge LCD 28 BDI Reset Level BDIreset This sets the voltage at which the BDI will reset to show a 100 charged battery on the Sigmagauge This setting only has an effect at power up The adjustable range is 18V to 125 of the nominal operating voltage of the controller in 0 1V steps 5 79649 01 PM TRACTION ADJUSTMENTS PG DRIVES TECHNOLOGY 129 BDI Empty Level BDlempty This sets the 0 charge level for the BDI Whenever the battery voltage is equal to or less than 1 18 Battery Voltage the BDI on the Sigmagauge wi
42. eriod of time after which the Line Contactor will be de energised if there is no drive activity and the seat or tiller switch is open When the seat or tiller switch is closed the controller powers up performs all necessary hardware and software checks and closes the line contactor The adjustable range is 0 min to 10 min 0 5 min steps 5 79649 01 PM TRACTION ADJUSTMENTS 34 PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY PM TRACTION DIAGNOSTICS CHAPTER DIAGNOSTICS 5 79649 01 35 PM TRACTION DIAGNOSTICS 36 PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY PM TRACTION DIAGNOSTICS Error Detection If the controller detects an error it can be displayed in up to five different ways Firstly the red LED on the controller itself will flash The number of flashes in the sequence will reflect the error code In addition an external LED or fault indication device can be connected to the Sigmadrive which will flash synchronously with the red LED The error code can also be read by the Programmer It will be displayed as a number preceded by on the right hand side the Controller Type screen as shown below 0 Standard Calibrator 0 gt 4 Traction F22 About The Programmer s Status menu also allows both the current and previous error codes be viewed See section Status for more details Lastly the Sigmagauge display can signal an error
43. f 46 1 4 Anti Roll back Restraint Arol Off 47 1 5 Connector A Pin 5 and 6 Spa Inch 47 16 Connector Pin 7 5 47 4 PG Drives TECHNOLOGY 1 7 Power Steering Trigger 47 1 8 Truck Type Select 47 818 47 1 10 Display Error Indication Of M M amp W 48 1 11 Display Status Field Of D V K 48 48 1 13 Motor Temperature Sensor Type Mtemplyp 48 1 14 Analogue Inputs Set up Accel 8 9 48 1 15 Single Dual Motor Select Si DL DR 48 oM oH 49 1 17 CAN Node Number CAN 49 Chapter 5 Motor Set up 51 1 Motor Set Up 53 11 Motor Temperature Cutback 5 54 1 2 Motor to Vehicle Speed Ratio 54 1 3 Number of Teeth 54 1 4 1 29 NOP 54 Timed Current Limit Explained 54 1 30 Current Threshold 55 1 31 Lower Maximum Current ImaxLow 55 1 32 Threshol
44. he output will be 0 25 and 100 There are 9 programmable options the effect of each is shown below 0 Accelerator Linear Footbrake Linear 1 Accelerator Curved 1 Footbrake Linear 2 Accelerator Curved 2 Footbrake Linear 3 Accelerator Linear Footbrake Curved 1 4 Accelerator Curved 1 Footbrake Curved 1 5 Accelerator Curved 2 Footbrake Curved 1 6 Accelerator Linear Footbrake Curved 2 7 Accelerator Curved 1 Footbrake Curved 2 8 Accelerator Curved 2 Footbrake Curved 2 Le Not Used Not used 13 Proportional Braking Bpro Off This sets how the strength of the direction regenerative braking is controlled There are two programmable options 0 and 1 If set to Proportional the regenerative braking current corresponds to the Accelerator potentiometer position At the minimum Accelerator potentiometer position the braking current will be a minimum of 50A while at the maximum Accelerator potentiometer position the braking current will be as set by the parameter 1 9 Direction Regen Braking Between minimum and maximum deflection the braking Current will be proportional to the Accelerator potentiometer position If set to 1 Fixed or the regenerative direction braking current is as set by the parameter 1 9 Direction Regen Braking regardless of Accelerator potentiometer position 46 5 79649 PG DRIVES TECHNOLOGY PM TRACTION CONTROLLER SET UP 14 Anti Roll back Restr
45. hich will be the right hand unit then set 3 15 Single Dual Motor Select accordingly 2 Set the parameters 1 25 Motor Pot Min and 1 26 Motor Pot Max At the full left hand position the steering potentiometer voltage 5 x 5V 1V At the full right hand position the steering potentiometer voltage 4 5kQ x 5V These voltages can also be checked and set using the Programmer s Test menu see Diagnostics chapter 3 Set the parameter 1 33 Dual Motor Cutback The steering angle from centre to either lock is 135 and it is not required to start reducing the inner motor speed until 15 The percentage of full lock at which speed reduction will commence 15 135 x 100 11 A combination of practical testing observation and use of the Programmer s Status and Test menus is recommended for each application 4 Set the parameter 1 34 Dual Motor Reverse The inner wheel should be at zero speed when the steering angle is 100 This expressed as a percentage of full lock 100 135 x 100 74 A combination of practical testing observation and use of the Programmer s Status and Test menus is recommended for each application 5 Set the parameter 1 35 Dual Motor Speed Simply set this value to the maximum permitted speed of the inner wheel in this case 25 when it is driving in the opposite direction to that selected 136 Standby Delay StdByDly This sets a p
46. hing control inputs If set to then Speed Limit 1 sets the maximum speed of the vehicle when a switch connected to pin 5 on Connector A is open The speed limit is not applied when the switch is closed or a lower speed limit is in operation The adjustable range is between 0 and 100 in 1 steps If set to 1 then Inching Speed sets the speed of the vehicle both directions that will be active when a switch connected to pin 5 or pin 6 of Connector A is closed The vehicle will not inch when the switch is open The adjustable range is 0 to 25 in 1 steps 17 Speed Limit 2 Inching Time Spe Time The function of this parameter is dependent on the setting of 3 5 Connector A Pin 5 and 6 in the Controller Set up menu That parameter sets whether pins 5 and 6 are used as speed limiting inputs or as inching control inputs If set to then Speed Limit 2 sets the maximum speed of the vehicle when a switch connected to pin 6 on Connector A is open The speed limit is not applied when the switch is closed or a lower speed limit is in operation The adjustable range is between 0 and 100 in 196 steps If set to 1 then Inching Time sets the period in both directions the vehicle will be moving for when a switch connected to pin 5 or pin 6 of Connector A is closed The vehicle will not inch when the switch is open e8 5 79649 PG Drives TECHNOLOGY PM TRACTION ADJUSTMENTS The adjustable range is 0 15 to 10s 0 15
47. his should be set to the nominal battery voltage of the system Whenever the battery voltage is equal 10 or less than this value the BDI on the Sigmagauge will start to decrease The adjustable range is 24V to the maximum rating of the controller in 2V steps Power Steering Delay PStrDly This sets the period that the Power Steer Contactor input pin 14 on Connector A will remain active after the trigger source has been removed The trigger source is as set by the parameter 3 7 Power Steering Trigger in the Controller Set up menu The adjustable range is Os to 50s 0 15 steps Electric Brake Delay EBrkDlu This setting is normally associated with a Walkie type vehicle fitted with an electromechanical brake connected to pin 13 on Connector A The value sets the delay before the electric brake is applied after the vehicle has ramped down to zero speed The adjustable range is Os to 50s in 0 1s steps Lel Accelerator 0 Voltage AccMin This sets the voltage on the Accelerator input that will correspond to zero speed The adjustable range is OV to 5V steps The Accelerator input can be configured via the parameter 3 14 Analogue Inputs Set up in the Controller Set up menu 30 5 79649 DRIVES TECHNOLOGY PM TRACTION ADJUSTMENTS Accelerator IOO Voltage AccMax This sets the voltage on the Accelerator input that will correspond to maximum speed The adjustable range is OV to 5V in
48. is selected there are then programming diagnostic and test options available 0 Standard Calibrator AC Traction 1 Adjustments 1 Adjustments 0 AC Traction OK 1 Adjustments 1 gt 1 1 6 1 gt 1 1 7 2 Status 2 Decel 2 3 gt 2 Decel 2 3 Controller Setup Creep 0 00 Hz 3 Creep 0 00 Hz 4 Motor Setup 4 SpdMaxF 255 00 Hz 4 SpdMaxF 255 00 Hz 5 Test 5 SpdMaxR 115 00 Hz 5 SpdMaxR 115 00 Hz About 6 About 6 InchSpd 255 00 6 InchSpd 255 00 Hz Press SEL Press SEL Press Value changes to adjust value in real time Some parameters e g 3 8 Truck Type Select require that the power to the controller be cycled the keyswitch before the new value will be accepted These parameters are marked on the Programmer s screen with the word Key 41 Programming Diagnostic and Test Options 411 Adjustments This menu includes parameters related to the application s performance such as acceleration speeds and calibration Refer to the Adjustments chapter for full details 4129 Status This menu allows you to select system and controller information for display such as vehicle speed battery voltage and controller temperature Refer to the Diagnostics chapter for full details 413 Controller Set up This menu includes parameters related to the controllers operation such as configuration throttle response and CAN 6 set up Refer to the Controller Set up chapter for full details
49. ith 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 53 Battery and Motor Connection Crimps and Tooling Good quality crimping is essential in ensuring the long term reliability of the vehicle s electrical system Poor quality crimps may initially appear satisfactory but can deteriorate over time ultimately causing the vehicle to break down For the battery and motor connections the use of AMP AMPower 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 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
50. ity for losses of any kind if inappropriate devices or arrangements are used I8 5 79649 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION 62 Motor Connections The motor should be connected between the M1 terminal and the M3 terminal of the controller The M2 terminal remains unconnected If when a forward command is applied the vehicle drives in reverse swap the motor wires Control Connections The control connections are via three connectors with pin outs as follows 161514 1312 11 10 9 8 7 6 5 6 8 4 876543 2 1 4 3 2 1 3 2 1 Connector Vehicle Interface Connector B Communications to display module and or programmer Connector C Motor Feedback Details of the functions of each of the pins for these connectors are shown in the following section 64 Connector Vehicle Interface Pin Forward Switch This switch must be closed in conjunction with the Accelerator to give a forward drive signal Pin 2 Reverse Switch This switch must be closed in conjunction with the Accelerator to give a reverse drive signal Pin 3 Footswitch Belly Button The function of this input is set by the programmable parameter 3 8 Truck Type Select If set to Ride then the vehicle s Footswitch should be connected to this pin and must be closed to allow driv
51. liability for losses of any kind if the recommendations made in this section are not followed 54 Control Connections The low current control connections on the Sigmadrive are via Molex SMD Micro Fit 3 0 Series connectors These connectors are labeled as A B and C on the cover of the controller and provide the following functions A 16 way Vehicle Interface Connector B 8 way Communications Connector 6 way Motor Feedback Connector 55 Control Connection Wiring Use 0 5mm 18AWG wire gauge for all control connections It is also recommended that Tri rated wire with a 105 C insulation rating is used 5 79649 01 7 TRACTION INSTALLATION PG DRIVES TECHNOLOGY 56 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 D51066 43025 1600 43030 0007 D51068 43025 0800 43030 0007 69008 0982 11 03 0043 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 vehicle PGDT accepts no liability for losses of any kind if non recommended parts are used 0 6 Connections Battery Connection Connect the positive supply to the B terminal and the nega
52. ll start to decrease The adjustable range is 12V to 125 of the nominal operating voltage of the controller in 0 1V steps 130 BDI Warning Level BDlwarn This sets the level of battery charge at which the BDI warning icon on the Sigmagauge will start to flash The value is set as a percentage of battery charge 100 battery charge corresponds to the voltage set by the parameter 1 28 BDI Reset Level and 0 battery charge corresponds to the voltage set by the parameter 1 29 BDI Empty Level The adjustable range is 0 to 99 in 1 steps BDI Cut out Level BDIcut This sets the level of battery charge at which the speed of the vehicle will be limited to a value set by the parameter 1 32 BDI Speed Limit The cut out value is set as a percentage of battery charge 100 battery charge corresponds to the voltage set by the parameter 1 28 BDI Reset Level and 0 battery charge corresponds to a level set by the parameter 1 29 BDI Empty Level The adjustable range is 0 to 99 in 1 steps 132 Speed Limit BDIspeed This sets the maximum speed of the vehicle if the BDI level is below the value set by the parameter 1 31 BDI Cut Out Level The adjustable range is 0 to 100 in 1 steps 133 Dual Motor Cutback DMcut 134 Dual Motor Reverse DMrev 135 Dual Motor Speed DMspeed For these functions to be active the parameter 3 15 Single Dual Motor Select in the Controller Set up menu must be set 10 1 or 2 The
53. mp down arrows key hours and confirm with SEL 1 Adjust field Use up and down arrows for show customized text position amp to change 1 Service timer value and SEL to return to timer access menu 2 Information field information field access 3 Reset all pincodes Reset all pin codes Contact PGDT SW version and date Indication only version and date Select with up amp down arrows menu and confirm with SEL 67 PM TRACTION SIGMAGAUGE 68 PG Drives TECHNOLOGY 5 79649 DRIVES TECHNOLOGY PM TRACTION TECHNICAL SPECIFICATIONS CHAPTER 8 TECHNICAL SPECIFICATIONS 5 79649 01 69 PM TRACTION TECHNICAL SPECIFICATIONS 70 PG DRIVES TECHNOLOGY 5 79649 DRIVES TECHNOLOGY PM TRACTION TECHNICAL SPECIFICATIONS Electrical Ll Voltage Specifications 48 Units 24 48 14 5 61 0 80 Units 72 80V 43 0 98 0V Le Current Specifications 4255 250A 205 80A PMT445M 450A 60s 180A PMT465L 650A 60s 260A PMT835M 350A 60s 120A Switching Frequency 14 5 KHz Electrical Isolation Enclosure to any live part 1KV Controller internal insulation specified at gt 10MQ 500V DC 2 Environmental Ingress Protection IP The enclosure is protected to IP54 varnished PCB Vibration 6G 40 200Hz for 1 hour in x y and z planes Operating Temperature 309C to 40 C ambient around controller
54. ng has multiple Sigmadrive controllers connected CANbus then the Programmer will automatically scan the bus for all available CANbus nodes Each CANbus node is identified by a number and the factory default for each controller is O Therefore before undertaking any programming each controller should be given a unique node number To do this disconnect the CANbus from each Sigmadrive then connect the Programmer directly to each controller in turn and set the unique number This is done via the programmable parameter 3 17 CAN Node Number in the Controller Set up menu 3 Using the Programmer The Programmer has five buttons The function of each is explained below This button is used to scroll up the on screen menu This button is used to scroll down the on screen menu This button is used to select a highlighted menu item and to return to the main menu This button is used to decrement the value of a highlighted parameter This button is used to increment the value of a highlighted parameter 6 5 79649 PG DRIVES TECHNOLOGY PM TRACTION HAND HELD PROGRAMMER 4 Programmer Map The Programmer has a menu structure that allows smooth and swift parameter adjustments as well as system diagnostics and testing Upon initialization the Programmer will display the Calibrator screen as shown below which prompts you to select the controller type AC Traction is shown in this example Once the controller type
55. ntactor as required The maximum rating for this connection is 3A and it is fully protected for use with inductive loads Pin Electric Brake Contactor This pin should be connected to the negative side of the Braking Contactor coil The Sigmadrive will control the Braking Contactor as required The maximum rating for this connection is 3A and it is fully protected for use with inductive loads Pin 14 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 Please contact PGDT for further information if a Power Steer Contactor is required for this size external contactor driver is required when using pin 14 on small frame Sigmadrive controllers 65 of Sigmadrive Pin l2V Supply 12 supply The maximum supply current is 20mA from this pin Pin 5V Potentiometer Supply A supply for the 5kO Accelerator or Footbrake potentiometer connected to pin 9 and the remote LED connected to pin 2 of Connector C if fitted Connector Communications 8 way Pin Not Used Not used Pin 2 Not Used Not used Pin Flash Programming Mode l2V For use with the Flash Programmer 5 79649 01 el TRACTION INSTALLATION PG Drives TECHNOLOGY 6 6 Pin 4 Flash
56. or Left or 2 Dual Motor Right then this input can be connected to a 3 wire 5kO potentiometer that measures the steering angle of the vehicle The potentiometer should be connected to a 5V supply a convenient connection point can be found on pin 16 of Connector A The active range of the input when used by a steering potentiometer is defined by the parameters 1 25 Motor Pot Min and 1 26 Motor Pot Max 1 25 Motor Pot Min sets the voltage that relates to the minimum full left hand lock steering angle while 1 26 Motor Pot Mox sets the voltage that relates to the maximum full right hand lock steering angle Pin 5 l2V Supply 12V supply with a maximum current of 20mA This output can be used for the motor encoder supply 5 79649 0 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION Pin 6 OV A OV connection point for the Speed Encoder and Steering Potentiometer Avoid routing the 6 way motor feedback cables close to the motor power cables they must not be tie wrapped together If screened cable is used contact PGDT for details on how to connect this at the motor and controller ends This is critical to help avoid any noise or incorrect speed measurement issues 7 Electromagnetic Compatibility M C You should consider EMC and perform relevant tests as early as possible in the design phase 7 Emissions Any high speed switch is capable of generating harmonics at frequencies that are many multiples of its basic
57. ould have this parameter set to O This is particularly important if the BDI is used As detailed above the BDI will not work when set up as a slave controller To set the CAN node number in a controller it must be disconnected from the CANbus 5 79649 01 49 PM TRACTION CONTROLLER SET UP 50 PG DRIVES TECHNOLOGY 5 79649 DRIVES TECHNOLOGY PM TRACTION MOTOR SET UP CHAPTER 5 MOTOR SET UP 5 79649 01 5I PM TRACTION MOTOR SET UP 5e PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY Motor Set up Motor Temperature Cutback Motor to Vehicle Speed Ratio Number of Teeth Not Used Current Threshold Lower Maximum Current Threshold Timer Offset M1 Applicable in Reverse Drive Offset M2 Not Applicable Offset M3 Applicable in Forward Drive Gain MI Applicable in Reverse Drive Gain M2 Not Applicable PM TRACTION MOTOR SET UP Tempstrt SedRatio SpdTeeth ImaxLow IthTime OsetlR Oset3F Gain1R E n a 5 79649 01 Gain M3 Applicable in Forward Drive Gain3F 53 PM TRACTION MOTOR SET UP PG DRIVES TECHNOLOGY Motor Temperature Cutback TempStrt This sets the point at which the controller will begin to reduce its drive output in order to protect the motor The temperature is measured by the motors thermal sensor which provides feedback via
58. pin 4 of Connector C The output will reduce linearly to zero at a point set by the value of this parameter plus 10 C The adjustable range is 1 C to 151 C in 1 C steps If set to 151 C then the function will be disabled and no reduction in current will occur Le Motor to Vehicle Speed Ratio SpdRatio This sets the relationship between the rotational speed of the motor and the actual driving speed of the vehicle i e the overall vehicle gear ratio This information in conjunction with parameter 1 27 Max Vehicle Speed is used to set the speed display on The Sigmagauge The value of this parameter should be the result of dividing the motors speed in units of rom by the vehicle s speed in units of kph Example if a vehicle speed of 15kph corresponds to a motor speed of 3000rpm then the value of this parameter should be 3000 15 200 The adjustable range is 1 0 to 999 9 in 0 1 step increments I3 Number of Teeth SpdTeeth This sets the number of pulses i e teeth on the encoder that correspond to one motor revolution The adjustable range is 1 to 255 in 1 step increments After the value has been changed the keyswitch must be cycled for the new value to be accepted 14 129 Not Used Not used z Timed Current Limit Explained The following graph shows the parameters that are involved in setting up the Timed Current Limit This feature can be used to protect the vehicle s motor s from overheating If the current
59. rises above a set threshold for a specified period of time the controller can reduce the maximum curent available to the motor s After the reduction has occurred the maximum current output will remain at the lower level for a period of 3 times the threshold time If necessary once this period has expired the current can then be returned to its original level Current Current Threshold Lower Maximum Current Time n 1 Threshold Threshold Time Time 54 5 79649 DRIVES TECHNOLOGY PM TRACTION MOTOR SET UP Current Threshold CurrTH This sets the level of current which if exceeded will activate 4 32 Threshold Timer The adjustable range is 50A to the maximum rating of the controller in 10A steps Lower Maximum Current ImaxLow This sets the value of the reduced current available to the motor s once the 4 32 Threshold Timer period has elapsed The adjustable range is 50A to the maximum rating of the controller in 10A steps 132 Threshold Timer IthTime This sets the period of time which if exceeded will initiate reduction in the controllers maximum current output A programmed value of zero disables the Timed Current Limit feature The adjustable range is Os to 60s in 1s steps Example 4 30 Current Threshold is set to 600A 4 31 Lower Maximum Current is set to 450A 4 32 Threshold Timer is set to 10s If the mo
60. s 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 If alternate screws or bolts are used it is essential that the thread insertion depth is less than 1 to be readjusted loosen the screw and washer arrangement first 511 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 M screws and these should be tightened to 9Nm le 5 79649 0 PG DRIVES TECHNOLOGY PM TRACTION INSTALLATION 52 Battery and Motor Wire Size and Type Selection The wiring arrangement used on a particular vehicle can greatly affect the current carrying capacities of individual wires Ambient temperature grouping and wire length can all significantly de rate cable performance and other factors such as vehicle duty cycles and airflow should also be taken into consideration when selecting vehicle wiring PGDT recommends the use of BS6231 UL 1015 1028 1283 or 1284 dependent on wire gauge Tri rated wire due to its superior flexibility and 90 105 C temperature rating The table below shows the minimum recommended wire sizes for the Motor and Battery connections on the Sigmadrive controllers Medium It is the responsibility of the vehicle manufacturer to ensure that the vehicle s wiring arrangement is suitable for the intended application and complies w
61. s is extremely useful when fine tuning the system carrying out diagnostic work The table below gives details of the parameters that may be viewed Some of the menu items have additional functions that can be accessed via the and buttons The options that display recorded minimum and maximum values relate to the lifetime of the controller The functions 2 9 Motor Demand and 2 10 Motor 96on also display further status information This information is displayed in place of the usual units shown on the screen See Further Status Information for more details 2 1 Drive Hours Counter Drive 0 1Hrs B Key Hours Counter 2 2 Error Log Fault B Time of Error Battery Discharge Indicator 1 Vehicle Speed Vehicle 1kph 2 5 Battery Voltage Battery 0 5V B Maximum Voltage 2 6 Controller Temperature Control 1 C E Minimum Temperature B Maximum Temperature 2 7 Steering Angle Steer 1 Motor Temperature M 1 C Minimum Temperature B Maximum Temperature M3 0 1V 2 20 M3 Voltage 2 21 PGDT Use Only 2 22 PGDT Use Only 2 23 2 8 Accelerator Accel 1 B Auxiliary Inout Motor Demand Demand 1 on Motor on Molor 1 on Motor Voltage Motor 0 5V Motor Current Motor 10A Used n a Motor Speed RPM Speed RPM Used n a Used n a Capacitor Bridge Voltage Cap 0 5V M1 Voltage MI 0 1V Used n a 220 221 222 DT Use Only Last recorde
62. steps 7 ease of adjustment this parameter should be set to before programming 3 5 Connector A Pin 5 and 6 to Inching 18 Speed Limit Sp3 The function of this parameter is dependent on the setting of 3 6 Connector A Pin 7 in the Controller Set up menu If set to then Speed Limit 3 sets the maximum speed of the vehicle when a switch connected to Pin 7 on Connector A is open The speed limit is not applied when the switch is closed or a lower speed limit is in operation If set to 1 then Speed Limit 3 sets the maximum speed of the vehicle when a switch connected to Pin 7 on Connector A is closed The speed limit is not applied when the switch is open or a lower speed limit is in operation Please note that even if this parameter is set to 0 the controller will continue to pulse whilst the Foot Switch is closed This is designed to avoid rollback on gradients The adjustable range is 0 to 100 in 1 steps 19 Direction Regen Braking DBrake This sets the maximum level of current used for braking upon a direction change The adjustable range is 50A to the maximum controller current in 10A steps 110 Neutral Regen Braking NBrake This sets the maximum level of current used for braking when the vehicle is in neutral i e no drive signal in either direction The adjustable range is 50A to the maximum controller current in 10A steps LII Footbrake Regen Braking FBrake This sets the maximum
63. ter has a unique reference number 3 x as shown in the left hand column The right hand column shows the parameter name as it appears on the Programmer screen Accelerator Characteristic Not Used Proportional Braking Anti Roll back Restraint Connector A Pin 5 and 6 Connector A Pin 7 Power Steering Trigger Truck Type Select Not Used Display Error Indication Display Status Field Not Used Motor Temperature Sensor Analogue Inputs Set up Single Dual Motor Select Lin Curv Spd Torq Bpro Off Arol Off Spd Inch PsF FR S Ride WIk Key Drv Of M M amp W Of D V K InitDiso Accel 8 9 Si DL DR 5 79649 01 Not Used CAN Node Number 45 PM TRACTION CONTROLLER SET UP PG Drives TECHNOLOGY Accelerator Characteristic Lin Curv 100 T 2 2 5 a 096 Accelerator Deflection 100 This sets the type of response for both the Accelerator and Footbrake inputs pins 8 amp 9 on Connector A There are three options for Permanent Magnet Traction control Linear Curved and Curved2 The definition of each type is detailed below Linear For input values of 0 50 and 100 the output will be 0 50 and 100 For input values 0 50 100 the output will 0 40 100 Curved2 For input values of 0 50 and 100 t
64. tive supply to the B terminal 6 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 612 Line Contactor amp Pre charge Resistor A suitable line contactor must be connected to the battery positive supply This should be fitted with a 5W 10kQ pre charge resistor connected in parallel across the contacts The coil of the line contactor can be controlled by the Sigmaadtive via pin 12 of Connector A 613 Discharge Resistor Units manufactured before October 2008 require an external discharge resistor The resistor should be fitted between the Sigmadrive s B and B terminals The correct value for each controller model is shown below 24V only Sigmadrive 10kO 1 4W 24V 48V Sigmadrive 22kO 1 4W 72N 80V Sigmadrive 47kO 1 4W 614 Disconnect Switch For certain vehicle types safety legislation requires that an emergency battery disconnect switch or switches should be fitted in The battery positive supply in order to allow complete isolation of the vehicle s electrical system from the battery The location of this switch or switches should be as stipulated in the appropriate legislative documentation It is the responsibility of the vehicle manufacturer to ensure appropriate fuses line contactors and emergency disconnect switches are used and that these devices are appropriately located PGDT accepts no liabil
65. tor current is above 600A for 10 seconds then the controller will reduce the maximum current available to 450A for a period of 30 seconds 3 x 10 secs There are maximum permissible values which must not be exceeded for each of these parameters These values are shown in the table below PMT835M 350A 350A 60s 350A PMT465L 650A 650A 60s 650A PMT445M 450A 450A 60s 450A PMT4255 250A 250A 20s 250A The values in the table above should never be exceeded 33 138 Offset and Gain Settings e These parameters are factory settings and should not be altered under any circumstances 5 79649 01 55 PM TRACTION MOTOR SET UP 56 PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY PM TRACTION HAND HELD PROGRAMMER CHAPTER 6 HAND HELD PROGRAMMER 5 79649 01 57 PM TRACTION HAND HELD PROGRAMMER 58 PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY PM TRACTION HAND HELD PROGRAMMER Introduction The Sigmadrive Hand held Programmer is a powerful tool that can be used to configure all Sigmadrive controllers as well as the Sigmagauge display In addition to multiple programming menus there are status and test functions with powerful real time system information making set up or diagnosis particularly intuitive The Programmer also has an interface for updating the controller s flash memory as well as updating the Programmer s own software Ll Interface Switch On the
66. tructions 62 5 79649 PG DRIVES TECHNOLOGY PM TRACTION SIGMAGAUGE CHAPTER 7 SIGMAGAUGE 5 79649 01 63 PM TRACTION SIGMAGAUGE 64 PG Drives TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY PM TRACTION SIGMAGAUGE Introduction The Sigmagauge LCD is a highly versatile backlit dot matrix display which presents vehicle status and diagnostic information to the operator using clear easy to read icons Ll General Information Membrane Buttons These are used for navigating and setting parameters in the Gauge Set up menu Battery Discharge Indicator Indicates the battery discharge state as set by CAN Node Master Fault Indication Field Indicates the status of all Sigmadrive controllers in the system A number is displayed within a traction pump steering wheel or CAN I O icon to indicate which controller is experiencing a problem When a fault is detected the symbol below the CAN node indicator is replaced with a fault icon see Diagnostics chapter The value of 3 10 Display Error Indication determines which failure types are displayed or ignored 14 General Indication Field The information shown in this area of the Sigmagauge is determined by the value set 3 11 Display Status Field Options are none accelerator demand motor speed vehicle speed and steering angle 15 Hours Counter Indicates either work drive or key hours
67. ttempted without releasing the belly switch after time out period has passed 5 B Battery voltage too low Charge battery or check its condition and connections 5 18 Ael High side MOSFET error in neutral or while pulsing Check motor insulation and line contactor If error persists contact Service Agent 38 5 79649 PG DRIVES TECHNOLOGY PM TRACTION DIAGNOSTICS Low side MOSFET error while pulsing Check motor insulation If error persists contact Service Agent Motor over current Check programming of motor parameters Hard Error Recycle Key switch 21 2 gm Contactor coil error Check contactor coil s and connections 22 Battery voltage too high Reduce braking levels or speed 23 Low side MOSFET error in neutral Check motor insulation line contactor If error persists contact Service Agent 24 Controller error or line contactor coil error Check line contactor coil If error persists contact Service Agent 2 Contactor error Check coil s amp contacts 26 Controller error Contact Service Agent 27 4 Low side MOSFET error before line contactor has closed Check motor insulation and line contactor If error persists contact Service Agent 28 Not used 29 Not used 7 5 79649 01 3 PM TRACTION DIAGNOSTICS 3 Status PG DRIVES TECHNOLOGY The Programmers Status menu shows live readout of parameter values Thi
68. urely and ensure it always follows the same layout 713 Controller Thermal and EMC emissive requirements tend to work in opposition Additional insulation between the controller assembly and the vehicle framework reduces capacitive coupling and hence emissions but tends to reduce the thermal performance A working balance needs to be established by experiment The complete installation should be documented in detail and faithfully reproduced on all production vehicles When making changes consider their effect on compliance ahead of other factors such as cost reduction 5 79649 01 TRACTION INSTALLATION PG DRIVES TECHNOLOGY 24 5 79649 0 DRIVES TECHNOLOGY PM TRACTION ADJUSTMENTS CHAPTER ADJUSTMENTS 5 79649 01 25 PM TRACTION ADJUSTMENTS 26 PG DRIVES TECHNOLOGY 5 79649 PG DRIVES TECHNOLOGY Adjustments PM TRACTION ADJUSTMENTS The Sigmadrive Programmer Adjustments menu 1 Adjustments contains the parameters shown in the table below Each parameter has a unique reference number 1 x as shown in the left hand column The parameter name as it appears on the Programmer screen and parameter range are also shown Acceleration Deceleration Creep Speed Maximum Forward Speed Maximum Reverse Soeed Speed Limit 1 Accel Decel Creep SpdMaxF SpdMaxR 5 1 0 15 10 05 0 15 10 05 0 25 0
69. using specific icons Refer to the Sigmagauge chapter for further details 5 79649 01 37 PM TRACTION DIAGNOSTICS PG Drives TECHNOLOGY Error Codes Once the error type has been noted refer to the following table to identify the cause If the error persists after taking the suggested action contact your Service Agent Controller is functioning Handbrake switch closed Release Handbrake Not used Not used Battery voltage becoming too high Reduce braking levels or vehicle speed Thermal foldback Allow motor to cool operate vehicle within specification Out of Range programming Check all parameters are within permitted limits LI Default settings restored after re flash Cycle power o Motor brushes worn out Replace brushes Controller over temperature Allow controller to cool and check drive train LI u Internal memory error Contact Service Agent LI cR ons Direction selection error both Fwd and Rev selected Check direction switch operation and connections 1 Seat or Tiller switch not closed Check switch operation and connections Sequence error the Footswitch or Direction switch is operated at power up Check switch operation and connections 2 13 Accelerator deflected at power up Check Accelerator operation and connections 14 TR ss Ride on forbidden input selected Fwd Rev FS Seat Handbrake when inching the vehicle Walkie drive is a
70. value for 1 33 Dual Motor Cutback is expressed as a percentage where 100 a voltage corresponding to the parameter 1 26 Motor Pot Max normally full right hand lock 100 a voltage corresponding to the parameter 1 25 Motor Pot Min normally full left hand lock 0 a voltage midway between the above two 1 33 Dual Motor Cutback sets the point at which the inner motor starts to reduce speed in response to the position of the steering potentiometer For example if a value of 10 is chosen the speed reduction will commence if the steering potentiometer is outside of a central deadband of 10 1 34 Dual Motor Reverse sets the point at which the inner motor starts to reverse in response to the position of the steering potentiometer For example if a value of 70 is chosen the inner motor will begin to reverse at steering angles of or 70 1 35 Dual Motor Speed sets the maximum reverse speed of the inner motor and outer wheel when the vehicle has reached the maximum turning angle The speed of the motor while turning is scaled as follows In the central deadband the inner motor speed is equal to the outer motor speed and corresponds to the driving speed of the vehicle In the zone between 1 33 Dual Motor Cutback and 1 34 Dual Motor Reverse the speed of the inner motor will be linearly scaled between the driving speed of the vehicle and zero 32 5 79649 DRIVES TECHNOLOGY PM TRACTION ADJUSTMENTS

SIGMADRIVE PM TRACTION TECHNICAL MANUAL

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