PG Drives Technology SK79649-01 Technical Manual
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PG Drives Technology SK79649-01 Technical Manual

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SIGMADRIVE PM TRACTION
TECHNICAL MANUAL
SK79649-01

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Summary of Contents for PG Drives Technology SK79649-01

  • Page 1 SIGMADRIVE PM TRACTION TECHNICAL MANUAL SK79649-01...
  • Page 2 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.

  • Page 3: Table Of Contents

    Speed Limit 1 / Inching Speed – (Sp1/Inch)... 28 Pin 4 – Seat / Tiller ............19 Speed Limit 2 / Inching Time – (Sp2/Time) ..... 28 Pin 5 – Speed Limit 1 / Inch Forward....... 19 Speed Limit 3 – (Sp3) ........... 29 SK79649-01...
  • Page 4 Not Used ............. 46 Software Upgrades ........62 Proportional Braking – (Bpro/Off) ......46 Anti Roll-back (Restraint) – (Arol/Off) ...... 47 Connector A Pin 5 and 6 – (Spd/Inch)....47 Chapter 7 – Sigmagauge............63 Connector A Pin 7 – (Spd3/Hbk)......47 Introduction ..........65 SK79649-01...
  • Page 5 1.1.5 Hours Counter ............. 65 1.1.6 Information Field..........65 Connection..........66 Mounting............. 66 Configuring the Sigmagauge ..... 67 Chapter 8 – Technical Specifications......69 Electrical ............. 71 Voltage Specifications ......... 71 Current Specifications.......... 71 Environmental ..........71 Mechanical ..........72 SK79649-01...

  • Page 6: About This Manual

    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. SK79649-01...

  • Page 7: Chapter 1 - Installation

    PG D PM T – I RIVES ECHNOLOGY RACTION NSTALLATION CHAPTER 1 – INSTALLATION SK79649-01...
  • Page 8 PM T – I PG D RACTION NSTALLATION RIVES ECHNOLOGY SK79649-01...

  • Page 9: Introduction

    Beyond restrictions indicated in your vehicle user manual, for example inclines, curb heights etc. In places or on surfaces where a loss of wheel grip could be hazardous, for example on wet grassy slopes. • If you know that the controller or other crucial components require repair. • SK79649-01...

  • Page 10: Frame Dimensions

    The Sigmadrive is constructed in three frame sizes – small, medium and large. This can be identified from the last character of the product code. For example, PMT425S S S S is a S S S S mall frame size. SK79649-01...

  • Page 11: Small Frame

    PG D PM T – I RIVES ECHNOLOGY RACTION NSTALLATION Small Frame SK79649-01...

  • Page 12: Medium Frame

    PM T – I PG D RACTION NSTALLATION RIVES ECHNOLOGY Medium Frame SK79649-01...

  • Page 13: Large Frame

    PG D PM T – I RIVES ECHNOLOGY RACTION NSTALLATION Large Frame SK79649-01...

  • Page 14: Mounting

    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. SK79649-01...

  • Page 15: Wiring Guidance

    PG D PM T – I RIVES ECHNOLOGY RACTION NSTALLATION Wiring Guidance SK79649-01...

  • Page 16: Battery And Motor Connections

    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. SK79649-01...

  • Page 17: Battery And Motor Wire Size And Type Selection

    A, B and C on the cover of the controller and provide the following functions. 16-way Vehicle Interface Connector 8-way Communications Connector 6-way Motor Feedback Connector Control Connection Wiring Use 0.5mm /18AWG wire gauge for all control connections. It is also recommended that Tri-rated wire with a 105ºC insulation rating is used. SK79649-01...

  • Page 18: Control Connections Crimps And Tooling

    It is the responsibility of the vehicle manufacturer to ensure appropriate fuses, line contactors and emergency disconnect switches are used and that these devices are appropriately located. PGDT accepts no liability for losses of any kind if inappropriate devices or arrangements are used. SK79649-01...

  • Page 19: Motor Connections

    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. SK79649-01...

  • Page 20: Pin 6 - Speed Limit 2 / Inch Reverse

    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 100% drive demand from the Accelerator. SK79649-01...

  • Page 21: Pin 10 - Keyswitch

    Accelerator or Footbrake potentiometer connected to pin 9 and the remote LED connected to pin 2 of Connector C (if fitted). 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. SK79649-01...

  • Page 22: Pin 4 - Flash Programmer I/O

    1.26 Motor Pot. Max. sets the voltage that relates to the maximum (full right hand lock) steering angle. Pin 5 – +12V Supply A 12V supply with a maximum current of 20mA. This output can be used for the motor encoder supply. SK79649-01...

  • Page 23: Pin 6 - 0V

    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. SK79649-01...
  • Page 24 PM T – I PG D RACTION NSTALLATION RIVES ECHNOLOGY SK79649-01...

  • Page 25: Chapter 2 - Adjustments

    PG D PM T – A RIVES ECHNOLOGY RACTION DJUSTMENTS CHAPTER 2 – ADJUSTMENTS SK79649-01...
  • Page 26 PM T – A PG D RACTION DJUSTMENTS RIVES ECHNOLOGY SK79649-01...

  • Page 27: Adjustments

    BDI Speed Limit BDIspeed 0% – 100% 1.33 Dual Motor Cutback DMcut 0% – 100% 1.34 Dual Motor Reverse DMrev 0% – 100% 1.35 Dual Motor Speed DMspeed 0% – 100% 1.36 Standby Delay StdByDly 0 min (off) – 10 min SK79649-01...

  • Page 28: Acceleration - (Accel)

    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. SK79649-01...

  • Page 29: Speed Limit 3 - (Sp3)

    This setting allows a time to hold the vehicle at zero speed 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 0.1s to 10.0s in 0.1s steps. SK79649-01...

  • Page 30: Neutral Braking Ramp - (Nbrkramp)

    This sets the voltage on the Accelerator input that will correspond to zero speed. The adjustable range is 0V to 5V in 0.1V steps. The Accelerator input can be configured via the parameter, 3.14 Analogue Inputs Set-up, in the Controller Set-up menu. SK79649-01...

  • Page 31: Accelerator 100% Voltage - (Accmax)

    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. SK79649-01...

  • Page 32: Bdi Empty Level - (Bdiempty)

    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. SK79649-01...

  • Page 33: Standby Delay - (Stdbydly)

    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 in 0.5 min steps. SK79649-01...
  • Page 34 PM T – A PG D RACTION DJUSTMENTS RIVES ECHNOLOGY SK79649-01...

  • Page 35: Chapter 3 - Diagnostics

    PG D PM T – D RIVES ECHNOLOGY RACTION IAGNOSTICS CHAPTER 3 – DIAGNOSTICS SK79649-01...
  • Page 36 PM T – D PG D RACTION IAGNOSTICS RIVES ECHNOLOGY SK79649-01...

  • Page 37: Error Detection

    The Programmer’s Status menu also allows both the current and previous error codes to be viewed. See section, Status, for more details. Lastly, the Sigmagauge display can signal an error, using specific icons. Refer to the Sigmagauge chapter for further details. SK79649-01...

  • Page 38: Error Codes

    Battery voltage too low. Charge battery or check its condition and connections. Not used. Not used. High-side MOSFET error in neutral or while pulsing. Check motor insulation and line contactor. If error persists, contact Service Agent. SK79649-01...
  • Page 39 Service Agent. Contactor error. Check coil(s) & contacts. Controller error. Contact Service Agent. Low-side MOSFET error before line contactor has closed. Check motor insulation and line contactor. If error persists, contact Service Agent. Not used. Not used. Not used. SK79649-01...

  • Page 40: Status

    M3 Voltage 0.1V 2.21 PGDT Use Only 2.22 PGDT Use Only 2.23 PGDT Use Only 2.24 PGDT Use Only *See section, Further Status Information. **The use of a current clamp or similar measuring device is recommended at lower levels. SK79649-01...

  • Page 41: Further Status Information

    Brake Current Limit, i.e. the controller is in braking current limit mode. Controller Temperature, i.e. the controller has reduced its output due to a high heatsink temperature. Motor Temperature, i.e. the controller has reduced its output due to a high motor temperature. SK79649-01...

  • Page 42: Test

    5.21 Red LED 0/1 0 = Off, 1 = On 5.22 Green LED 0/1 0 = Off, 1 = On 5.23 Contactor Feedback 0/1 0 = Off, 1 = On 5.24 0/1 0=12V Internal Rail Low, 1= 12V OK SK79649-01...

  • Page 43: Chapter 4 - Controller Set-Up

    PG D PM T – C RIVES ECHNOLOGY RACTION ONTROLLER CHAPTER 4 – CONTROLLER SET-UP SK79649-01...
  • Page 44 PM T – C PG D RACTION ONTROLLER RIVES ECHNOLOGY SK79649-01...

  • Page 45: Controller Set-Up

    Display Status Field Of/D/V/K 3.12 Not Used InitDisp 3.13 Motor Temperature Sensor Type MTempTyp 3.14 Analogue Inputs Set-up Accel 8/9 3.15 Single / Dual Motor Select Si/DL/DR 3.16 Not Used - n/a - 3.17 CAN Node Number CAN node SK79649-01...

  • Page 46: Accelerator Characteristic - (Lin/Curv)

    Accelerator potentiometer position. If set to 1 (Fixed or ‘Off’), the regenerative direction braking current is as set by the parameter, 1.9 Direction Regen. Braking, regardless of Accelerator potentiometer position. SK79649-01...

  • Page 47: Anti Roll-Back (Restraint) - (Arol/Off)

    If set to 0 (Ride-on), then pin 3 will be a Footswitch input and pin 4 will be a 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. Not Used Not used. SK79649-01...

  • Page 48: Display Error Indication - (Of/M/M&W)

    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. SK79649-01...

  • Page 49: Not Used

    In a non-CANbus system, the controller(s) should have this parameter set to 0. 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. SK79649-01...
  • Page 50 PM T – C PG D RACTION ONTROLLER RIVES ECHNOLOGY SK79649-01...

  • Page 51: Chapter 5 - Motor Set-Up

    PG D PM T – M RIVES ECHNOLOGY RACTION OTOR CHAPTER 5 – MOTOR SET-UP SK79649-01...
  • Page 52 PM T – M PG D RACTION OTOR RIVES ECHNOLOGY SK79649-01...

  • Page 53: Motor Set-Up

    Offset M2 (Not Applicable) - n/a - 4.35 Offset M3, (Applicable in Forward Drive) Oset3F + 4.36 Gain M1, (Applicable in Reverse Drive) Gain1R 4.37 Gain M2 (Not Applicable) - n/a - 4.38 Gain M3, (Applicable in Forward Drive) Gain3F SK79649-01...

  • Page 54: Motor Temperature Cutback - (Tempstrt)

    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. SK79649-01...

  • Page 55: Current Threshold - (Currth)

    650A PMT445M 450A 450A 450A PMT425S 250A 250A 250A The values in the table above should never be exceeded. 1.33 – 1.38 Offset and Gain Settings These parameters are factory settings and should not be altered under any circumstances. SK79649-01...
  • Page 56 PM T – M PG D RACTION OTOR RIVES ECHNOLOGY SK79649-01...

  • Page 57: Chapter 6 - Hand-Held Programmer

    PG D PM T – H RIVES ECHNOLOGY RACTION HELD ROGRAMMER CHAPTER 6 – HAND-HELD PROGRAMMER SK79649-01...
  • Page 58 PM T – H PG D RACTION HELD ROGRAMMER RIVES ECHNOLOGY SK79649-01...

  • Page 59: Introduction

    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. SK79649-01...

  • Page 60: Connection

    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. SK79649-01...

  • Page 61: Programmer Map

    This menu includes parameters specifically related to the type of motor being used. Refer to the Motor Set-up chapter for full details. 4.1.5 Test This menu allows you to select controller I/O status for display, such as the state of digital and analogue inputs, or contactor and LED outputs. Refer to the Diagnostics chapter for full details. SK79649-01...

  • Page 62: 4.1.6 About

    Software Upgrades The Programmer can be used to load revised software into the controller. Likewise, the Programmer’s own software can be revised. If either of these operations is required to be undertaken, PGDT will supply more detailed and specific instructions. SK79649-01...

  • Page 63: Chapter 7 - Sigmagauge

    PG D PM T – S RIVES ECHNOLOGY RACTION IGMAGAUGE CHAPTER 7 – SIGMAGAUGE SK79649-01...
  • Page 64 PM T – S PG D RACTION IGMAGAUGE RIVES ECHNOLOGY SK79649-01...

  • Page 65: Introduction

    The controllers have their own separate counter. 1.1.6 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. SK79649-01...

  • Page 66: Connection

    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. SK79649-01...

  • Page 67: Configuring The Sigmagauge

    3. Reset all pincodes Reset all pin codes Contact PGDT About SW version and date Indication of the software Indication only version and date Return Select to return to main Select with up & down arrows menu and confirm with ‘SEL’ SK79649-01...
  • Page 68 PM T – S PG D RACTION IGMAGAUGE RIVES ECHNOLOGY SK79649-01...

  • Page 69: Chapter 8 - Technical Specifications

    PG D PM T – T RIVES ECHNOLOGY RACTION ECHNICAL PECIFICATIONS CHAPTER 8 – TECHNICAL SPECIFICATIONS SK79649-01...
  • Page 70 PM T – T PG D RACTION ECHNICAL PECIFICATIONS RIVES ECHNOLOGY SK79649-01...

  • Page 71: Electrical

    The enclosure is protected to IP54 (varnished PCB). Vibration: 6G, 40-200Hz for 1 hour, in x, y and z planes. -30 o C to +40 o C ambient around controller. Operating Temperature: -40 o C to +70 o C. Storage Temperature: Humidity: 95% maximum, non-condensing. SK79649-01...

  • Page 72: Mechanical

    Small: 1.2Kg; Medium: 4.1Kg; Large: 6.1Kg. 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 are too long will damage the controller. SK79649-01...

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