DMC SigmaLITE SLA425T-01 Advanced User's Manual

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ADVANCED USER MANUAL

SigmaLITE Traction Controller

for Alternate Current induction motors (AC)

surfacemounted Permanent Magnet Synchronous motors (PMS)

Interiormounted Permanent Magnet synchronous motors (IPM)

Auf dem Hochstück 11

45701 Herten Germany

Tel:

Fax:

Email: info@dmcde.de

Web: www.dmcde.de

+49 (0) 2366 10070

+49 (0) 2366 100750

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Page 1 Auf dem Hochstück 11 45701 Herten Germany Tel: +49 (0) 2366 10070 Fax: +49 (0) 2366 100750 Email: info@dmcde.de Web: www.dmcde.de ADVANCED USER MANUAL SigmaLITE Traction Controller for Alternate Current induction motors (AC) surfacemounted Permanent Magnet Synchronous motors (PMS) Interiormounted Permanent Magnet synchronous motors (IPM) ...
Page 2: Modification History
Modification History: Revision Issue Date Author Changes 1.0 06/10/2023 SMFM First development Update schematics. Add information on minimum and maximum duty cycle 1.1 14/05/2024 SM for digital outputs when controller Via CAN in “duty cycle” mode. Add BMS node number for EMCY reaction. Add smooth start on slope description (EMbrake menu). Add note about GND connection on 23pole. 1.2 25/06/2024 SM New IPM and PMS error codes. Add parameters for enable/disable short circuit detection on digital outputs. ...
Page 3: Table Of Contents
3.4.3 Mechanical dimensions .......................... 27 3.4.4 Weight .............................. 27 3.4.5 Water and dust protection ........................ 27 3.4.6 Cooling .............................. 27 USE OF CAN OPEN CALIBRATOR AND DMC CONFIGURATOR ................29 .......................... 29 PEN ALIBRATOR 4.1.1 How to change the Calibrator’s baudrate: .................... 29 4.1.2 How to change the Calibrator’s CAN protocol: .................. 29 ...
Page 4 DRIVE FUNCTIONS OF DMC CONTROLLER ......................31 ............................... 31 UNCTIONAL INPUTS ............................ 33 ASIC DRIVE FUNCTIONS 5.2.1 Forward & Reverse ............................ 33 5.2.2 Footswitch .............................. 33 5.2.3 Seatswitch/Tillerswitch .......................... 33 5.2.4 Accelerator .............................. 33 ...
Page 5 Menu 1.14 “Advanced drive modes” ........................ 86 Menu 1.15 “Generator menu” .......................... 88 Menu 1.16 “Vehicle menu” ............................ 91 “C ” ...................... 92 ENU ONTROLLER ETUP FOR TRACTION SOFTWARE “A ” .............................. 96 ENU UTOTUNING Setting up auto tuning .............................. 96 Mandatory parameters ............................ 96 “M ” .............................. 98 ENU OTOR ETUP “L ” .............................. 99 ENU IMITS ...
Page 6 .......................... 166 UPERVISOR U ERROR CODES “F ” .............................. 167 ENU AULT LOG SOFTWARE UPDATES ........................... 1 68 DMC DISPLAYS ............................. 1 69 11.1 .............................. 169 ITE ISPLAY 11.2 ............................. 170 DVANCED ISPLAY ...
Page 7: About This Manual
IPM motor technology manual V1.5 DMC Configurator user manual V1.1.5 DMC BMS support V1.7 DMC Object Dictionary Variables description V1.7 1.2 Navigate into DMC manuals DMC manuals are structured with a hierarchical approach. The milestone for setting up a controller and the general overview is given in the “Application manuals”, whose embed a comprehensive description of the DMC SigmaLITE features, hardware configuration, parameters menu structure and monitoring possibilities. The “Motor technology” manuals should be used aside of the “Application manuals” to go further in details about configurable motor parameters and the autotuning procedure. If the Dual Motor function is required, the user should refer to the “Dual Motor manual” for a deeper level of detail about the vehicle configuration capabilities. DMC also provides a set of manuals for basic Dual Motor parameters to be configured in the two controllers used for running this function. ...
Page 8: How Settings Are Numbered In This Document
4) Perform the autotuning. 5) Enter “Menu 8.1 “Input/output assignment”” again and assign to analogue and digital inputs the desired functional inputs. Do the same for digital outputs and functional outputs. 6) In case the DMC SigmaLITE Controller should operate in a CAN network, enter the “Menu 7 “CAN Bus Setup”” menu and setup all the CAN communication parameters. In case more complex CAN mapping is necessary, it is suggested to use the DMC Configurator PC tool to do so. 7) Connect the DMC SigmaLITE Controller on the CAN bus with other devices. 8) Enter the “Menu 2 “Controller Setup” for traction software” and setup the basic controller configuration. ...
Page 9: Warning And Information Notices
The scope of the mentioned boxes are shown below, together with an example of their appearance. WARNING! A warning informs about possible dangerous installation methods and/or parameter’s configurations which can lead to controller’s damage and personal injuries. DMC declines any responsibility about any hazardous or potential hazardous situations which may arise due to the not respect of these warnings. NOTICE! A notice informs about a specific condition in which a certain example applies and/or adds ...
Page 10: Product Overview
Return to Table Of Contents 2 Product overview After the success of the SuperSigma2 Controller range, DMC has developed a new controller range, specially designed for small motors and cost effective applications with battery voltages in the range of 24V up to 48V, at nominal powers up to 6kW and peak powers up to 12kW. The power board design includes latest mosfet technology, combining superior heat sinking of components and connections with unmatched vibration protection. The mechanical design is improved to IP67 and we incorporated the industry standard 23 way AMPseal connector. The design is extremely compact to fulfil the market requirements in term of controller size. The control logic PCB utilises state of the art 32bit microcontroller technology that enables us to offer features required for today’s vehicle control. A completely new motor control module is introduced, using flux vector motor control for both AC induction and PMAC and IPM motor. New Features on SigmaLITE are for example fully automated tuning of AC induction motors and PMS IPM without the need for manual fine tuning or using a PC. The advanced auto tuning algorithms allow motor tuning even if the motor is installed on the vehicle. Just entering the motor name plate data into the controller tuning menu is enough to obtain optimal tuning results. Even when the motor name plate data is unknown it is possible to get the system running ...
Page 11: Features
✓ ✓ High frequency 16kHz (Silent Operation) Diagnostics with LED indication ✓ ✓ Dual micro watchdog monitoring Remote diagnostic LED ✓ microprocessor operation Adjustments made via a calibrator or DMC ✓ Arc less contactor switching and built in coil configurator programmer ✓ suppression Full CAN Open compliant ✓ ✓ Protected, active high inputs switched to B+ CAN J1939 compatible ✓ ✓ Thermally compensated current limit ...
Page 12: Sigmalite Controller Variants
Return to Table Of Contents 2.2 SigmaLITE Controller variants Part number description Available models Model Nr. Power ratings AC TRACTION SLA425T01 2448 250Arms PMS TRACTION SLP425T01 2448 250Arms IPM TRACTION SLI425T01 2448 250Arms Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 13: Original Equipment Manufacturer Responsibility
With each product, DMC offers a package of firstline support to its direct customers and Original Equipment Manufacturers, providing additional information possibly not covered by this manual and suggestions on hardware installation and software parameterization. This is intended to guarantee proper behaviour of the DMC controller with reference to its scope. The tuning of the DMC Controllers for the specific application, as well as installation troubleshooting due to system integration are anyway outside of the scope of DMC technical support. End customers and third parties should always refer to the reference OEMs or distributors, not to DMC directly. ...
Page 14: Controller Wiring And Integration
The provided information are general in their nature, each specific case must be addressed and analysed in a system integration design phase. WARNING! Voltage is exposed at each connection point of the DMC Controller. The B+ and B terminals, as well as the motor connection terminals, should be properly isolated from any accidental contact which could result in personal injury. WARNING! Electrostatic discharges (EDS) can be a severe risk for electronic components and result in damages. While handling the DMC controller, one must be aware that the connection pins on the 23pole connector must not be touched. The SigmaLITE Controller meets high standard for ESD protection, but those can not replace careful and professional handling of the device. 3.1 Controller’s components description The picture below should be taken as reference for the naming of the available terminals and connectors present on any DMC SigmaLITE Controllers. Entry Name Entry ...
Page 15: Signal Wiring
Return to Table Of Contents 3.2 Signal wiring This section aims at providing useful and complete information on the signal wire routing and specifications for a correct wiring of the DMC SigmaLITE controller. Each connection pin will be described in detail, providing information about functions available to it and its current output capability. Example wiring schematics will be provided in this section, to demonstrate a possible general purpose installation of the DMC SigmaLITE controller. Those schematics can not cover the whole wiring possibility range and it is therefore up to the system integrator to modify these generic wiring to adapt them to their requirements and needs. 3.2.1 Signal wires specifications Signal wiring connections should be made using 0.56mm² (AWG#20) or equivalent stranded wire. The correct pressure release crimping tools must be used for long term connection reliability. 3.2.2 Sizing of logic supply fuse The logic supply fuse, always indicated in the example schematic provided by DMC, provides safety in case of abnormal power consumption trough the key line. In case of multiple controller connection, it is up to the system integrator to use a single fuse for the whole number of controllers of to fuse each key line independently. NOTICE! The voltage and current for the available digital outputs is directly derived trough the key line of the SigmaLITE controller. Take this into account when sizing the logic supply fuse, identifying how many outputs will be used and the respective power consumption DMC suggest to use a slow acting fuse in the range of 8 to 10A, depending on the applied load. The standard consumption of a SigmaLITE controller, with no active output and not energizing the motor is lower than 5W. 3.2.3 Signal wiring connector The SigmaLITE controller is equipped with a 23way AMPSEAL connector (connector A) used to carry the input/output ...
Page 16: Internal Circuits
Return to Table Of Contents Connector A Vehicle Interface 23 Way (AMP SEAL Series) Internal Circuits Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 17 This output is the positive supply to the vehicle’s contactors and coils. The voltage level of this supply corresponds to the key line’s voltage (“Pin A15 Key B+ ”). The maximum supply current from this pin is 10A. This safety supply that can be cut by both micro controllers to enhance safety level of driver output. Pin A9 Analogue supply 0V This pin is the ground connection motor sensor, motor thermal sensor and analogue inputs for potentiometers and pedals. Do not connect this pin to B. Do not connect Pin A9 of different controllers together. NOTICE! Special care should be taken when connecting the screen of the motor speed sensor cable. Be sure only to connect the screen on the controller side at pin A9 WARNING! If and when the sensor cable screen is connected to both the controller and the motor side, battery current will flow over the screen, disturbing the signal from the sensor to the controller, resulting in causing control degradation and hazardous conditions Pin A10 Analogue supply – 5V / 30mA A supply for 110kΩ Potentiometers is available to this pin with max 30mA capability for sourcing current. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 11 ...
Page 18 Pin A15 Key B+ input This input has to be connected to the switched side of the key switch. The other side of the key switch has to be connected to the battery positive supply, or to an independent supply. A 10 A fuse has to be connected between the battery positive supply and the key switch. The position of the fuse should be as close as possible to the tapoff point for the key switch supply. Pin A16 Sensor supply 5V or 10V / 70mA Supply output for motor position/speed sensor (analogue sine/cosine or hall sensor or encoder). It delivers 5V or 10V according to the motor sensor supply selected in “Menu 3 “Autotuning”. The maximum supply current is 70mA. Adjustable thresholds for Wire Off detection, overload and short circuit detection are available in “ Menu 8.10 “Wireoff and Shortcircuit detection”” Pin A17 Motor sensor input Encoder 3 Hall 3 / Digital input 11 WARNING! Connecting this input to B+ voltage in AC motor technology applications may result is controller’s damage and functionality issues. The configuration of this pin is possible through the Menu 8 “Input/Output configuration”. By default, it has to be connected to the Hall sensor’s channel #3, if the Hall sensor technology is selected in “Menu 4 “Autotuning”. WARNING! Avoid routing the sensor cabling along with high power motor or battery cables. High power cables frequency may interfere with the low power feedback signal from the motor sensor, causing control degradation and hazardous situations. Alternatively, it can be assigned to a digital input function (i.e. Forward input, Reverse input, STO, SS1 and so on). In case of IPM and PMS motor technology, it is active high and have to be connected to B+ voltage. In case of AC motor technology, it is active low and has to be connected to B (GND). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 19 WARNING! Avoid routing the sensor cabling along with high power motor or battery cables. High power cables frequency may interfere with the low power feedback signal from the motor sensor, causing control degradation and hazardous situations. Pin A20 Thermistor input This pin has to be connected to the anode of KTY84130 thermistor or to one side of and RTD 1000 ohm 0°C or 25°C thermal sensor. The motor thermal sensor type can be selected by parameter “M5.21 Motor temperature sensor type “MtempTyp””. Custom thermal sensors can be connected and configured in the overmentioned menu. Pin A21 Digital Input 3 (safe) Pin A22 Digital Input 2 (safe) Pin A23 Digital Input 1 (safe) These pins are meant to be assigned to a digital input function (i.e. Forward input, Reverse input, STO, SS1 and so on). They are active high and have to be connected to B+ voltage. These pins are “safe inputs” since both microprocessors are reading the input value, thus they can be used for safety related functions. The configuration of these pins is possible through the Menu 8 “Input/Output configuration”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 13 ...
Page 20: Wiring Of Digital Inputs
Return to Table Of Contents 3.2.4 Wiring of digital inputs The DMC SigmaLITE controller can only accept active high inputs. Using a mechanical switch An active high digital input can be activated using a simple mechanical switch. The switch is wired between the B+ or Vbatt terminal and one of the digital inputs. To signal that the switch is activated, a lamp can be connected between the digital input and the B or GND terminal. Using an electronic switch supplied with more than 12V An active high digital input can be activated using an electronic switch. When the electronic switch is powered with a supply voltage greater than 12V, for example Vbatt, the digital output can be directly wired to one of the digital inputs. Using an electronic switch supplied with less than 12V An active high digital input can be activated using an electronic switch. When the electronic switch is powered with a supply voltage less than 12V, the digital output must drive a relay, which in turn switches the B+ or Vbatt voltage to one of the digital inputs. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 21: Wiring Of Analogue Inputs
In this way, the wireoff can be detected trough “Pin A10 Analogue supply – 5V / 30mA”. Please setup “M8.105 5V supply wireoff threshold “5V WrOff”” correctly to guarantee an adequate threshold for wireoff. Details on wireoff tuning can be found in “APPENDIX D – Wireoff detection tuning”. Wiring between +10V supply and GND This option consists in connecting one terminal of the potentiometer to “Pin A11 Analogue supply – 10V / 100mA” and the other to “Pin A9 Analogue supply 0V”. In this way, the wireoff can be detected trough “Pin A11 Analogue supply – 10V / 100mA”. Please setup “M8.103 10V supply wireoff threshold “10VWrOff”” correctly to guarantee an adequate threshold for wireoff. Details on wireoff tuning can be found in “APPENDIX D – Wireoff detection tuning”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 15 ...
Page 22 Return to Table Of Contents Wiring of multiple potentiometers More than one potentiometer can be wired between “Pin A10 Analogue supply – 5V / 30mA” or “Pin A11 Analogue supply – 10V / 100mA” and “Pin A9 Analogue supply 0V”. Details on wireoff tuning can be found in “APPENDIX D – Wireoff detection tuning”. Wiring of a wigwag type accelerator In case a wigwag has to be wired, it is suggested to add two 1Kohm resistances: Please notice that the slider voltage has to be >0.2V and <4.8V. The resistances are placed to this mean. If the voltage exceeds this range, wireoff is detected and F28 S004 happens. For more information about the wigwag type potentiometer refer to “M1.62 Accelerator type ”AccelTyp””. Wiring of Dual Pot “Half” Accelerator Accelerator pedals can be equipped with dual potentiometer for enhancing the wire off detection and safety. In this technology, the pedal has two potentiometer outputs: one channel is providing the full accelerator range, while the second is providing “half” signal compare to the other. The output signals have to be connected as in the wiring below. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 23 Return to Table Of Contents For tuning this kind of pedals please refer to “Tuning of a “dual channel” accelerator”. Wiring of Dual Pot “Crossed” Accelerator Accelerator pedals can be of the “crossed” technology for enhancing the wire off detection and safety. This kind of accelerators are equipped with two potentiometers swapped in connection between plus and minus. In this way, while pressing pedal, the main signal will increase and the second signal will decrease. The output signals have to be connected as in the wiring below. For tuning this kind of pedals please refer to “Tuning of a “dual channel” accelerator”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 17 ...
Page 24: Wiring Of The Can Bus
Return to Table Of Contents 3.2.6 Wiring of the CAN bus All DMC SigmaLITE Controller are equipped with a selfisolated CAN bus connection on “Pin A1 CAN H” and “Pin A2 CAN L”. CAN bus wires should be terminated at both ends with a 120Ω resistor. If a CAN bus network is installed in a machine, special care should be taken which two CAN nodes should have the build in termination resistor connected. Make sure that only 2 termination resistors are active. CAN bus should always be wired in a line, with no star connections. A twisted pair is strongly recommended. Shielded cables are suggested for best noise rejection. Wiring when no DC/DC converter is installed: In case the vehicle is not equipped with a DC/DC converter providing an auxiliary 12V or 24V, it is possible to wire the DMC Calibrator to the SigmaLITE, drawing the power needed to supply it from “Pin A11 Analogue supply – 10V / 100mA “and “Pin A9 Analogue supply 0V”. A DMC Lite Display cannot be connected to those same pins, as it would not be isolated from the power battery, possibly damaging the device. Wiring when a DC/DC converter is installed: In case the vehicle is equipped with a DC/DC converter providing an auxiliary 12V or 24V, it is possible to wire the DMC Calibrator to the SigmaLITE, drawing the power needed to supply it the DC/DC converter. In case a DMC Lite or Advanced Display is also installed on the vehicle, it is suggested to power it through the DC/DC converter as well. In case a VCU is installed in the system, DO NOT CONNECT a (possibly present) CAN GND wire to “Pin A9 Analogue supply 0V”. This Pin is not isolated from the B connector and would therefore spoils the CAN network isolation. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 25: Signal Wiring Example Traction Application (Factory Setup)
Return to Table Of Contents 3.2.7 Signal wiring example traction application (factory setup) NOTICE! This wiring corresponds to factory setup of a Sigma Lite traction controller DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 19 ...
Page 26: Signal Wiring Example For Traction "Walkie Vehicle Type
Return to Table Of Contents 3.2.8 Signal wiring example for traction “Walkie vehicle type” NOTICE! The reported wiring example implies a proper function assignment to input pins. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 27: Signal Wiring Example For Traction Control Via Can With Safe Stoss1
Return to Table Of Contents 3.2.9 Signal wiring example for traction control Via Can with Safe STOSS1 NOTICE! The reported wiring example implies a proper function assignment to input pins. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 21 ...
Page 28: Power Wiring
Return to Table Of Contents 3.3 Power Wiring The DMC SigmaLITE Controller has 5 highpower connection terminals. Two of them are used to connect the Controller to the battery pack providing the energy and three to connect the motor phases. They are identified on the Controller housing with B+, B, M1, M2 and M3. Power connections should be made with flexible heat resisting cables of suitable crosssectional area for the current to be carried. A general rule is to consider 4A/mm2 for continuous operation. These should be terminated in crimped lugs attached to controller and the contactors, properly isolated from water and moist. Note that bolts and washers are supplied for the connections on the controller. Be careful not to use to long bolts, as they can damage the PCB. A battery disconnect switch should be used (EC Directive). 3.3.1 Safety recommendations Electric vehicles can be dangerous. All testing, faultfinding and adjustment should be carried out by competent ...
Page 29: Power Wiring Examples
Calculate the maximum current absorption/regeneration of the controller; Select a fuse which can hold the said current indefinitely; Select a fuse which blows within2s, when double of the overmentioned current is flowing through it. 3.3.5 Power wiring examples Wiring example with selfdriven line contactor (recommended) WARNING! When an emergency battery disconnect switch is fitted, the key switch must be fed through an auxiliary switch to prevent over voltage damage due to disconnect during regenerative braking WARNING! No load other than the DMC Controller should be connected under the line contactor (between line contactor output and B+ terminal). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 23 ...
Page 30 Return to Table Of Contents Wiring example with external line contactor management NOTICE! The above scheme has to be followed strictly. Any variation must be agreed with DMC engineering. Wiring examples with external line contactor management and independent logic supply The following examples represents the suggested wiring for a situation in which the Key line for DMC SigmaLITE Controller is separated from the main power source. Please notice that the DC/DC converter supplying the SigmaLITE key line must be at least capable of outputting 5W for supplying the control logic. In case the application needs the DMC Sigma Lite Controller to drive one or more Digital Outputs, the user should consider upsizing the overmentioned DC/DC converter taking into account 2A for each driven output. Mind that the outputs will be driven at Key line voltage. NOTICE! The above scheme has to be followed strictly. Any variation must be agreed with DMC engineering. ...
Page 31 Return to Table Of Contents The following example represents the case in which the power battery embeds a dedicated output at 12 or 24V and therefore an auxiliary battery is not needed. Notice that in this case this output must be capable of outputting enough power for satisfying the consumption of DMC SigmaLITE Controller and all the connected auxiliary devices. The consideration at the begin of this section remain valid. NOTICE! The above scheme has to be followed strictly. Any variation must be agreed with DMC engineering. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 25 ...
Page 32: Mechanical Installation
Return to Table Of Contents 3.4 Mechanical installation 3.4.1 Mounting the controller The DMC SigmaLITE Controller location should be carefully chosen taking into account its mechanical dimensions and the outline of its mounting holes. Avoid mounting the controller too close to heat sources as those can decrease the overall performance of the controller itself. Choose a mounting location which can prevent corrosion and leakage from happening, thus keeping the controller as safe as possible clean and dry. Make sure that all power terminals of the controller are properly protected from excessive water and moist. Do not mount the controller on rough or curved surfaced, which can cause the distortion of the heatsink. Make sure the bolts keeping the controller in place are evenly tightened to the mounting surface. For proper cooling it is recommended to install the controller on a metal plate, with sufficient air ventilation against it and applying a layer of thermal paste to guarantee maximum heat transfer. 3.4.2 Lug assembly Five M6 aluminium power terminals are present. The lug should be assembled as follow: 1. Place the lug on top of the power terminal. If more than one lug has to be placed on the same terminal, make sure that the one carrying lowest current is on top and that the surface are well in contact. 2. Place a safety washer on top of the lugs. 3. Insert a M6 bolt to fix the assembly together and tighten with 8 (± 0.5) Nm strength. The picture below represents an assembly example of the components: Entry Name 1 Power terminal 2 Lug terminal M6, 35mm 3 Washer (DIN 6796) ...
Page 33: Mechanical Dimensions
Return to Table Of Contents 3.4.3 Mechanical dimensions The DMC SigmaLITE Controller family’s mechanical dimensions are reported in the figure below: 3.4.4 Weight The weight of the DMC SigmaLITE Controller family is 885 grams. 3.4.5 Water and dust protection The SigmaLITE controller meets a mechanical IP67 protection level against dust and water. it is anyway suggested to carefully choose the installation location to protect them harsh environment conditions, if possible. 3.4.6 Cooling The Controllers should be bolted down to a flat (0.2mm max. deviation) paint free surface, eventually lightly coated with a thermal transfer compound, by means of the 4 fixing M6 holes provided. Care should be taken not to trap any wires, etc., under the controller. The mounting surface must be a substantial metal section of the vehicle for the full controller ratings to be achieved. If there is no sufficient cooling surface available, then we advise to use a ripped aluminium heat sink supported by a fan, or mount the heat sink in such a way that the driving wind cools the system. For guaranteeing nominal 1h continuous current operating condition the heatsink must be kept at maximum 75°C, thus the cooling system should be able to dissipate the losses reported in the table below: DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 27 ...
Page 34 Return to Table Of Contents Unit 1h continuous current rating [A] Losses to be dissipated [W] XXX425Y1 130A 160W Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 35: Use Of Can Open Calibrator And Dmc Configurator
CAN node setup When powering the DMC CAN Open Calibrator, it will “scan” the CAN bus for all available DMC SigmaLITE controllers, to enable calibration of all DMC controllers on the same bus. All controllers are by factory default set to Node 1. Therefore before using the DMC CAN Open Calibrator, all DMC SigmaLITE Controllers MUST be given a unique Node number. To do this, the DMC Calibrator must be plugged into a DMC SigmaLITE Controller one after the other to give it an unique node number. ...
Page 36: Dmc Configurator
Return to Table Of Contents Adjustments and DMC Calibrator’s map The DMC Calibrator is easy to use. The “up” and “down” buttons are used for scrolling lists up and down. Selections can be made with the “SEL” button. The “plus” and “minus” buttons are used to increase or decrease the parameter’s values. NOTICE! • Press and hold the select button for 2 seconds to return to the first screen. • The calibrator remembers the cursor position in the submenus until keyoff. Where to plug the DMC Calibrator Connector A Vehicle Interface 23 Way The DMC Calibrator must be inserted in the CAN network wired from “ (AMP SEAL Series) ”. Please refer to “3.2.6 Wiring of the CAN bus” for wiring examples. 4.2 DMC Configurator DMC has developed a new and modern PC application that can be used to configure DMC Controllers and monitor data via the CAN bus. This application takes the name of DMC Configurator and is available to download from the DMC website. For more information about the DMC Configurator usage, please refer to [7]. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 37: Drive Functions Of Dmc Controller
Return to Table Of Contents 5 Drive functions of DMC Controller This section’s aim is to describe how the majority of the available functions are activated in the DMC SigmaLITE Controller. It will also provide important insights on the relationship between physical inputs and “fictious” inputs which can be sent Via CAN. 5.1 Functional inputs The DMC Controller embeds a number of so called “functional inputs”, which are used to activate certain functions. The DMC Controller can retrieve its functional inputs either from physical digital/analogue sources, either Via CAN. In order for the DMC Controller to retrieve a functional input from one of its physical inputs, the user must correctly setup “Menu 8.1 “Input/output assignment””. For example, setting “M8.11 DI1 configuration “Ip 1 Cfg”” to 0, would correspond to assign the “forward” functional input to “Pin A23 Digital Input 1 (safe)”. Therefore, when “Pin A23 Digital Input 1 (safe)” will be active, the DMC Controller will act as it is instructed to drive in the forward direction. In order for the DMC Controller to retrieve a functional input from the CAN bus, the user must map the said input to a CAN message, which must in turn be activated for reception. For example, mapping (i.e. including) object 0x3957 “HMI Forward command” into RxPDO1, would assign the “forward” functional input to the variable received Via CAN. The DMC Object dictionary ([9]) includes all the functional input objects. For details on how to map a CAN message and how to activate it, please refer to the CAN manual ([1]). In case a functional input is either assigned to a physical input and mapped in a CAN message, the information coming ...
Page 38 See “5.3.10 Analogue speed Analogue N N speed limit limitations” See “5.3.11 Analogue torque Torque limit Analogue N N limitation” Generator speed Analogue See “5.3.6 Generator” N Y setpoint Generator Analogue See “5.3.6 Generator” N Y Regenerative BCL Dual accelerator Analogue See “5.3.12 Dual accelerator” N N Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 39: Basic Drive Functions
Return to Table Of Contents 5.2 Basic drive functions With its standard configuration, the DMC Controller only requires 4 functional inputs to drive: Forward (or Reverse) Footswitch Interlock Accelerator These 4 functional inputs (3x Digital, 1x Analogue), can be either wired or sent Via CAN. There is also the possibility for the controller to retrieve functional inputs from both sources simultaneously, but this case will not be deepened in this manual and will be described in [1]. Any other functional input is optional, thus not necessary to drive a motor. 5.2.1 Forward & Reverse This functional inputs are used to select the rotating direction for the motor. It is mandatory to have at least one of these two functional inputs assigned to either a physical input or mapped into a CAN message for the motor to drive. Those functions are Normally Open, so to activate a direction the physical digital input must be closed or a value of 1 must be sent to the corresponding variable on the CAN bus. 5.2.2 Footswitch This functional input is only to be used when “M22 Vehicle type selection ”Ride/Wlk”” is set to 0 (rideon vehicle type) or 3 (evehicle type). In these cases, this functional input is considered a redundancy safety for an accelerator pedal: in fact, this switch is assumed to be closed in any moment when the accelerator pedal is pressed and open in any moment in which the accelerator pedal is released. Please consider this when sending this input Via CAN, as it must be managed according to the above description. This function is Normally Open, so to activate the footswitch signal the physical digital input must be closed or a value of 1 must be sent to the corresponding variable on the CAN bus. It is mandatory to have this functional input either assigned to a physical input or mapped into a CAN message in order to drive. The only exception to the above is having the “Dual accelerator” functional input assigned to a physical input. In this case, the footswitch functional input will be automatically managed inside the DMC SigmaLITE Controller and the status of the physical input to which this functional input is assigned, as well as the corresponding CAN input signal, will be disregarded. In case a “Walkie” vehicle type is selected trough “M22 Vehicle type selection ”Ride/Wlk”” (i.e. options 1 and 2), then the footswitch functional input does not need be assigned, as it is selfmanaged based on the accelerator, forward and ...
Page 40: Configurable Auxiliary Functions
Return to Table Of Contents 5.3 Configurable auxiliary functions Several functions are available in the DMC SigmaLITE Controller, which are activated automatically when a “functional input” is assigned to a physical input or mapped in a CAN bus message. 5.3.1 Bellyswitch When a “Walkie” vehicle type is selected (“M22 Vehicle type selection ”Ride/Wlk”” set to option 1 or 2), then this functional input is used to trigger an emergency drive forward function. This function is related to vehicle safety and allows a fast speed reversal to avoid that the vehicle injures the driver. For more information about the “Emergency Drive Forward” (EDF) function, please refer to “5.3.1 Bellyswitch”. For this functional input, several options are available: The standard functional input, with no safety applied. It is a Normally Open input, so to trigger the EDF function the physical digital input must be closed. The “normally closed” functional input, which can only be assigned to physical digital input 2, 3, 4 or 6. Those are “safe” input channels capable of providing PLd safety level. It is, as the name specifies, a Normally Closed input, so the enable the drive function the physical digital input must be open. This ...
Page 41: Inching
“handbrake” function is automatically activated. This function allows to make the controller act as if a physical handbrake was connected, thus emulating its behaviour electrically. If the said functional input is not assigned to any physical or fictious input, then the function is considered inactive. When the input is activated the speed and drive torque of the vehicle are limited to a level defined by the parameters “M5.18 Handbrake speed limit “HandBrk”” and “M5.19 Handbrake torque limit “MxDrTrq3””, respectively. This input is considered normally open, thus it will be activated when the physical switch is closed or when a digital value of 1 is received Via CAN. The handbrake functional input plays an important role in the Hill Hold function behaviour (refer to parameter “M1.5 1Hill hold enable ”Off/HH/S” M1.51Hill hold enable ”Off/HH/S””). 5.3.6 Generator When the functional input “Generator enable” is assigned to a physical input or mapped into a CAN message, then the “Generator” function is automatically activated. For details on how the generator function work, please refer to “Menu 1.15 “Generator menu””, where the function is described in details. Please notice that mapping the “generator activation” functional input, requires the mapping of “Generator speed setpoint” functional input as well. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 35 ...
Page 42: Digital Footbraking
In case the “Speed limit on maximum speed” input is assigned, then the analogue source will be used to set an adjustable speed limit scaled over maximum forward frequency. This means that the speed limit is absolute and referred to “M5.12 Maximum speed forward “SpdMaxF””. If a speed limit lower than that is active, it will take precedence. Example: SpdMaxF = 6000 RPM; AI2 = 50%; Speed limit = SpdMaxF*AI2% = 6000 RPM*50% = 3000 RPM. If “Spd1” becomes active with 1500 RPM speed limit, the motor would run at 1500 RPM and the analogue speed limit is not considered until its percentace will become lower than 1500 RPM/6000 RPM * 100% = 25%. • In case the “Speed limit on maximum speed” input is assigned, then the analogue source will be used to set an adjustable speed limit scaled over active speed limit. This means that the speed limit is relative and referred to the active speed limit. It will be a percentage going from 0 rpm to the active speed limit. Example: SpdMaxF = 6000 RPM; AI2 = 50%; Speed limit = SpdMaxF*AI2% = 6000 RPM*50% = 3000 RPM. If “Spd1” becomes active (and it is the lowest speed limit) with 1500 RPM, the speed limit will be calculated as Spd1*AI2% = 1500 RPM*50% = 750 RPM. 5.3.11 Analogue torque limitation When the functional input “Torque limitation” is assigned to a physical input, then the “Analogue torque limiting” function is automatically activated. This function allows to apply a variable torque limit trough an analogue source The torque limit is applied only for drive torque. It is therefore not considered when foot braking or neutral braking. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 43: Dual Accelerator
It is HIGLY RECOMMENDED to avoid configuring an analogue torque limit on Walkietype vehicles with speed control mode. This could lead to serious safety problems and cause operator’s injuries. DMC declines any responsibility for incorrect setup of this parameter. 5.3.12 Dual accelerator When the functional input “Dual accelerator” is assigned to a physical input, then the “Dual channel accelerator” function is automatically enabled. This function allows to connect to the DMC SigmaLITE Controller an accelerator pedal ...
Page 44: Functional Input Activation Through Can Mapping
× × Footbrake × × × × Steer × x × × Given the above table, please check the following example: Example: by mapping (i.e. including) in an RxPDO object 0x387A, objects 0x387C, 0x387D, 0x387E, 0x387F, 0x3880, 0x3881 and 0x3885 are all considered mapped, and the corresponding functional inputs are considered assigned. This means that, in case any of those functional input is also assigned to a physical input, the latter will have no effect (as CAN signals have priority over physical signals). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 45: Safety Function Specification
Normally Closed input, so the enable the drive function the physical digital input must be open. This functional input is to be used in conjunction with the corresponding “normally open” functional input to provide redundancy safety. The “normally open” functional input, which can only be assigned to physical digital input 2, 3, 4 or 6. Those are “safe” input channels capable of providing PLd safety level. It is, as the name specifies, a Normally Open input, so the enable the drive function the physical digital input must be closed. This functional input is to be used in conjunction with the corresponding “normally closed” functional input to provide redundancy safety. 5.5.3 Safe Stop 1 (SS1) CAN safety function The Safe Stop 1/Safe Brake Control function consists in a controlled deceleration of the motor, with a “function timer” monitoring the actual reaching of 0 speed. When 0 speed is achieved or when the timer is expired a removal of power from the motor and from the controller is actuated (in the second case, the operation is comparable to a STO operation). All the controller’s digital outputs are also deenergized, resulting in line contactor opening and electromechanical appliance. After power removal, the motor will be torqueless. In case an electromechanical brake is installed, the brake closes when the controller is deenergized and helps in decelerating the motor (timer expired) and keeping the motor still. For this functional input, several options are available: The “toggling” functional input, which can only be assigned to physical digital input 2, 3, 4 or 6. Those are “safe” input channels capable of providing PLd safety level. It is a Normally Closed input, so to trigger the SS1 function the physical digital input must be open. The safety is provided by the fact that the first time after a controller powerup or reset, the input must be “toggled” once, thus the controller must recognise a “rising edge” of the signal to actually consider it “active”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 39 ...
Page 46 Those are “safe” input channels capable of providing PLd safety level. It is, as the name specifies, a Normally Closed input, so the enable the drive function the physical digital input must be open. This functional input is to be used in conjunction with the corresponding “normally open” functional input to provide redundancy safety. The “normally open” functional input, which can only be assigned to physical digital input 2, 3, 4 or 6. Those are “safe” input channels capable of providing PLd safety level. It is, as the name specifies, a Normally Open input, so the enable the drive function the physical digital input must be closed. This functional input is to be used in conjunction with the corresponding “normally closed” functional input to provide redundancy safety. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 47: Functional Outputs
Return to Table Of Contents 5.6 Functional outputs The DMC SigmaLITE Controller has 5 configurable physical digital outputs. Each digital output can be assigned to a different functional output calculated inside the DMC SigmaLITE Controller, as output of a specific function, or autonomously driven through a CAN command. One functional output can be assigned to multiple physical outputs. Hereafter the available functions will be described. ...
Page 48: Remote Led
Drive OK indicator This function is run inside the DMC SigmaLITE Controller to signal when an error code is active. Assigning this functional output to a physical output may be useful to indicate that the SigmaLITE controller has some active error. The functional output is activated when an error code is present. 5.6.7 Brake light activator This function is run inside the DMC SigmaLITE Controller to signal when a foot braking operation is requested. Assigning this functional output to a physical output may be useful to drive a rear brake light indicator. The output is activated when the foot braking operation is requested. 5.6.8 No function assigned When the selection “no function assigned” is performed for a digital output, then the DMC SigmaLITE Controller is expecting that the command to drive the corresponding output is being sent Via CAN from a VCU. This allows the user to use the DMC SigmaLITE Controller’s outputs to drive customized functions. There is also the option to make the outputs to be ran as “PWMcontrolled”. In this case, the user must send Via CAN both the activation/deactivation command and the PWM duty cycle (in %) at which the output should be ran. Notice that, in this latter case, the output voltage will be a consequence of the specified PWM, ranging from 0V to the voltage present at “Pin A15 Key B+ input”. The minimum applicable duty cycle is 6%, while the maximum applicable is 94% Below the minimum threshold, it will default to 0%, while above the maximum threshold it will default to 100%. Page ...
Page 49: Configurable Parameters
Menu 4 “Motor Setup” to proper manual ([4] for AC, [5] for PMS and [6] for IPM) Menu 5.1 “Speed limits” Menu 5.2 “Motor thermal limits” Menu 5.3 “Voltage limits” Menu 5.4 “Battery current limits” Menu 5 “Limits Setup” Menu 5.5 “Performance table” Menu 5.6 “Timed current limit” Menu 5.8 “Stall protection” Menu 5.9 “Speed guard function” Menu 5.10 “Encoder noise detection” Menu 6 “Battery setup” Menu 7.1 “CAN general” Menu 7.2 “PDO premap” Menu 7 “CAN Bus Setup” Menu 7.3 “Shared line contactor” Menu 7.4 “Display” Menu 7.5 “Safe Stop 1” Menu 8.1 “Input/output assignment” Menu 8.2 “Analogue input 1 configuration” Menu 8.3 “Analogue input 2 configuration” Menu 8.4 “Analogue input 3 configuration” Menu 8.5 “Digital output 1 configuration” Menu 8 “Input/Output configuration” Menu 8.6 “Digital output 2 configuration” Menu 8.7 “Digital output 3 configuration” Menu 8.8 “Digital output 4 configuration” Menu 8.9 “Digital output 5 configuration” Menu 8.10 “Wireoff and Shortcircuit detection” Menu 9.1 “Dual motor with steerpot” Menu 9 “Dual motor” Menu 9.2 “Dual motor without steerpot” DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 43 ...
Page 50: Menu 1 "Adjustment" For Traction Software
Menu 1 “Adjustment” for traction software This menu includes all the adjustments for a more comfortable driving experience. The following submenus are available: • Menu 1.1 “Drive response” • Menu 1.2 “End Of Braking” • Menu 1.3 “Creep” • Menu 1.4 “Speed regulator” • Menu 1.5 “Hill hold” • Menu 1.6 “Accelerator” • Menu 1.7 “Steer” • Menu 1.8 “Cooling” • Menu 1.9 “EM brake” • Menu 1.10 “Powersteer” • Menu 1.11 “Inching” • Menu 1.12 “Walkie” • Menu 1.13 “Speed fine tuning” • Menu 1.14 “Advanced drive modes” • Menu 1.15 “Generator menu” • Menu 1.16 “Vehicle menu” Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 51 (according to “M29 Variable/Constant ramp time “CnRmpTm””). Speed or Torque control mode depends on “M21 Control Mode “Spd/Torq”” selection. The maximum torque demand is set by “Maximum motor current” (adjustable in “Menu 3 “Autotuning””), and it is assumed correspond to 100% of the deliverable Torque. The maximum speed demand is set by ”Maximum motor frequency” (adjustable in “Menu 3 “Autotuning””), and it is assumed correspond to 100% of the speed. In torque mode increasing the value results in a slower torque response, while decreasing the value results in a faster torque response. In speed mode increasing the value results in a slower vehicle acceleration, while decreasing the value results in a faster vehicle acceleration. If controller is in torque mode the acceleration delay correspond to the time, when accelerator fully pressed, for torque to rise from 0 % to 100%. If controller is in speed mode the acceleration delay correspond to the time, when accelerator fully pressed, for speed to rise from 0 % to 100% or from 0% to the active speed limit, depending upon parameter “M29 Variable/Constant ramp time “CnRmpTm””. NOTICE! Important for speed control: When speed control selected (“M21 Control Mode “Spd/Torq””=0) using a low value of ramp time will bring bumpy response to accelerator deflection. M1.12 Accelerator release ramp time “Rel Ramp” This sets the time taken to reduce torque from maximum torque to zero torque in Torque Control mode, or to decelerate from maximum speed (or from active speed limit) to zero speed in Speed Control (according to “M2 9 Variable/Constant ramp time “CnRmpTm””). Speed or Torque control mode depends on “M21 Control Mode “Spd/Torq”” selection. In torque mode increasing the value results in a slower torque reduction rate, while decreasing the value results in a faster torque reduction rate. In speed mode Increasing the value results in a slower vehicle deceleration, while decreasing the value results in a faster vehicle deceleration. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 45 ...
Page 52 M1.15 Proportional direction brake ”PropDB” This sets how the strength of the direction regenerative braking is controlled. The behavior in direction braking also depends on the parameter “M21 Control Mode “Spd/Torq””: Torque Control • If set to 0 (Fixed), the braking strength is as set by the parameter “M1.16 Direction brake torque “DBrake””, regardless of Accelerator potentiometer position. • If set to 1 (Proportional), the braking strength depends on the Accelerator potentiometer position. At the minimum Accelerator potentiometer position, the braking strength will be as set by the parameter “M1.13 Neutral brake torque “NBrake””, while at the maximum Accelerator potentiometer position the braking strength will be as set by the parameter “M1.16 Direction brake torque “DBrake””. Between minimum and maximum, the braking strength is a value between the neutral and direction braking settings, proportional to the Accelerator potentiometer position. Speed Control Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 53 III. If the motor speed is above “MdDbrSp” and neutral is selected, the motor slows down according to neutral brake settings (“M1.14 Neutral brake ramp time “NBrkRamp””, “M1.13 Neutral brake torque “NBrake””). When the speed drops below “MxDbrSp” it is possible to select the reverse direction only if the accelerator position is 0% (pedal fully released). If the motor speed is above “MdDbrSp” and the accelerator is released (forward direction still selected), the motor slows down according to “M1.14 Neutral brake ramp time “NBrkRamp””. When the speed drops below “MxDbrSp” it is possible to select the reverse direction regardless of the accelerator position. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 47 ...
Page 54 If any RV switch is activated while driving forward and the speed is above the “Max. Direction change speed”, F12 S011 occurs. The same happens for complimentary situation (FW switch activated while reverse driving with speed above threshold). In general, every time an input switch is selected but is blocked by the “Inhibit the change of direction” algorithm F12 S011 occur. WARNING! If “Inhibit the change of direction” function is activated by a selection of MxDbrkSp lower than 100%, the “Accelerator” must be tuned properly. In fact the drive direction change is allowed when speed is below the threshold and if accelerator is fully released (its value is 0%). To avoid strange behavior check if with accelerator fully released the signal is 0% by reading the line 9 and 10 of ”Test menu” by means of calibrator. If not, the Adjustment 51 “AccMin” has to be increased. For example if with accelerator fully released the volt value at line 10 of test menu “Accel Pot [V]” is 0,3V set 51 “AccMin” to 0,5V for a proper behavior of the function Inhibit the change of direction”. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 55 This sets the time taken to ramp down from full driving torque to zero torque when a brake operation is required (direction, footbrake, neutral). Increasing the value gives a smoother but longer transition from drive to braking. Too long values (i.e. 2s) give a smooth transition but a bad drive feeling. The suggested value for this setting is between 0.3s and 1s. M1.112 Brake torque reduction time “BrTrqRtm” This parameter is active only in torque mode. This sets the time taken to ramp down from full braking torque to zero torque when brake operation (direction, footbrake, neutral) is ended and a drive condition is detected. Increasing the value gives a smoother but longer transition from braking to driving. Too long values (i.e. 2s) give a smooth transition but a bad drive feeling. The suggested value for this setting is between 0.3s and 1s. M1.113 Halt brake torque “HltBrake” This parameter is active only in torque mode. This sets the strength of the braking when a “Halt” operation is commanded by the Can Open DS402 profile. For details please refer to [1]. The setting is a percentage of maximum motor torque. The maximum motor torque is defined by “Maximum motor current” (adjustable in “Menu 3 “Autotuning””), assumed to be 100% of torque. M1.114 Halt brake ramp time “HltRamp” In Torque Control mode this sets the time taken to ramp from zero braking torque demand to full braking torque (100% of torque) when a “Halt” operation is commanded by the Can Open DS402 profile. For details, please refer to [1]. Increasing the value gives a smoother but longer transition from drive to braking. Example: if “Hltbrake” is set to 10% and “HltRamp” is set to 10s the time to apply “Hltbrake” torque is 1.0s. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 49 ...
Page 56 [1]. The setting is a percentage of maximum motor torque. The maximum motor torque is defined by “Maximum motor current” (adjustable in “Menu 3 “Autotuning””), assumed to be 100% of torque. M1.116 Quick Stop brake ramp time “QSRamp” In Torque Control mode this sets the time taken to ramp from zerio braking torque demand to full braking torque (100% of torque when a “Quick Stop” operation is commanded by the DS402 profile. For details please refer to [1]. Increasing the value gives a smoother but longer transition from drive to braking. Example: if “QSbrake” is set to 10% and “QSRamp” is set to 10s the time to apply “QSbrake” torque is 1.0s. In Speed Control mode this sets the time taken to ramp down the speed from 100% to zero (0%) or from the active speed limit to 0% (depending on “M29 Variable/Constant ramp time “CnRmpTm””), when a “Quick Stop” operation is commanded by the DS402 profile. For details please refer to [1]. Increasing the value gives a smoother but longer transition to zero speed. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 57 This setting defines the zero speed threshold to detect when the vehicle has reached stationary condition. M1.23 Neutral brakeend delay “NBrkEnd” This setting is normally associated with a Walkie type vehicle fitted with an electromechanical brake, driven by one of the DMC SigmaLITE controller outputs as configured in “Menu 8.1 “Input/output assignment””. This setting allows a time to hold the vehicle at zero speed when the zero speed is detected (speed lower than “M1.22 Zero speed threshold ”ZSpdTh””). The vehicle will be held to speed zero if “M21 Control Mode “Spd/Torq”” is set to 0 (Speed Mode) or 2 (Torque mode with speed mode for the end of braking) or 3 (Torque mode with speed mode for the end of braking or for footbrake operation). In case “M21 Control Mode ...
Page 58 Return to Table Of Contents derived based on the brake pot value between this parameter and “6M1.25 Ramp time from the EoB speed threshold to zero with Footbrake “SpdRTmFB””. M1.25 Ramp time from the EoB speed threshold to zero with Footbrake “SpdRTmFB” This parameter is only active when “M21 Control Mode “Spd/Torq”” is set to 3. It defines the ramp time to go from “M1.21 Speed threshold to enter EndofBraking (EoB) mode ”SpdThEoB””. to zero speed when the footbrake is 100% pressed. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 59 “M1.24 Ramp time from the EoB speed threshold to zero ”SpdRmpTm”” value. In this way a curved ramp is performed; 3. when ramp time is equal to M116 Speed threshold Ramp time to zero speed ”SpdRmpTm”” it realize a linear ramping; 4. when speed is below “M1.22 Zero speed threshold ”ZSpdTh””, the vehicle is held still until “M1.23 Neutral brakeend delay “NBrkEnd”” time is elapsed. The vehicle is kept still by means of speed control algorithm; 5. the controller stops giving power to the motor and the vehicle is let coast or roll on slope (if any) unless mechanical brake or electromechanical brake is applied. During the end of braking operation, If pedal brake is removed and a direction selected with accelerator pedal demand (add foot switch in case of ride vehicle) the vehicle will start to move in the selected direction. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 53 ...
Page 60 The following list describes the “end of braking” steps: 1. the speed decreases according to “M1.13 Neutral brake torque “NBrake”” (if neutral braking is happening) or to “M1.19 Foot brake torque “FBrake”” and the “Brake pot %” value (if foot brake is operated); 2. when speed is below setting “M1.21 Speed threshold to enter EndofBraking (EoB) mode ”SpdThEoB””, the controller reduces brake torque in a smooth way (proportionally to speed) to assure a smooth stop operation; 3. when speed is below “M1.22 Zero speed threshold ”ZSpdTh””, the vehicle is let coast with the controller giving power to the motor until “M1.23 Neutral brakeend delay “NBrkEnd”” time is elapsed; 4. the controller stops giving power to the motor and the vehicle is let coast or roll on slope (if any) unless mechanical brake or electromechanical brake is applied. During the end of braking operation, If pedal brake is removed and a direction selected with accelerator pedal demand (add foot switch in case of ride vehicle) the vehicle will start to move in the selected direction. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 61 1. the speed decreases according to “M1.13 Neutral brake torque “NBrake”” (if neutral braking is happening) or to “M1.19 Foot brake torque “FBrake”” and the “Brake pot %” value (if foot brake is operated); 2. when speed is below setting “M1.21 Speed threshold to enter EndofBraking (EoB) mode ”SpdThEoB””, the controller reduces brake torque in a smooth way (proportionally to speed) to assure a smooth stop operation; 3. when speed is below “M1.22 Zero speed threshold ”ZSpdTh””, the controller starts to control speed, slowing linearly down to zero according to “M1.24Ramp time from the EoB speed threshold to zero ”SpdRmpTm””; 4. when the vehicle stops, it is held still until “M1.23 Neutral brakeend delay “NBrkEnd”” time is elapsed. The vehicle is kept still by means of speed control algorithm; 5. the controller stops giving power to the motor and the vehicle is let coast or roll on slope (if any) unless mechanical brake or electromechanical brake is applied. During the end of braking operation, If pedal brake is removed and a direction selected with accelerator pedal demand (add foot switch in case of ride vehicle) the vehicle will start to move in the selected direction. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 55 ...
Page 62 “M1.24Ramp time from the EoB speed threshold to zero ”SpdRmpTm””; 4. when the vehicle stops, it is held still until “M1.23 Neutral brakeend delay “NBrkEnd”” time is elapsed and the footbrake has not been released. The vehicle is kept still by means of speed control algorithm; 5. the controller stops giving power to the motor and the vehicle is let coast or roll on slope (if any) unless mechanical brake or electromechanical brake is applied. During the end of braking operation, If pedal brake is removed and a direction selected with accelerator pedal demand (add foot switch in case of ride vehicle) the vehicle will start to move in the selected direction. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 63 WARNING! • VERY IMPORTANT: If the braking has been commanded by setting the direction switches to neutral or by removing the seat switch input, the steps 3) and 5) of the above list use a different time. In other words the hill hold time is ignored and the “M1.23 Neutral brakeend delay “NBrkEnd”” time is used. After that time the vehicle will roll on the slope at the restraint hill hold speed. • VERY IMPORTANT: Take care of consideration at step 5). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 57 ...
Page 64 Level ground is detected when actual torque drops below “M1.54 Restraint hill hold torque threshold ”HHTrqTH””. 6. The controller keeps giving power to the motor until handbrake input (digital input 7) becomes active and “M1.52 Hill hold time ”HHTime”” is elapsed. Otherwise the controller never stops giving power to the motor until it is switched off! If digital input 7 is select as speed input 3 it never stops giving power to the motor even if this is activated. WARNING! • VERY IMPORTANT: If the braking has been commanded by setting the direction switches to neutral or by removing the seat switch input, the steps 4) and 6) of the above list use a different time. In other words the hill hold time is ignored and the “M1.23 Neutral brake end delay “NBrkEnd”” time is used. After that time the vehicle will roll on the slope at the restraint hill hold speed. • VERY IMPORTANT: Take care of consideration at step 6). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 65 “M1.24Ramp time from the EoB speed threshold to zero ”SpdRmpTm””. 4. when the vehicle stops, it enters in Hill Hold mode and is held still until “M1.52 Hill hold time ”HHTime”” time is elapsed. The vehicle is kept still by means of speed control algorithm; 5. when “M1.52 Hill hold time ”HHTime”” is elapsed, two situations are possible: if the vehicle is on a slope it will roll (back or forward according to the slope) at “M1.53 Restraint hill hold speed ”HHspeed”” until level ground is detected, then it stops moving. If the vehicle is already at level ground the vehicle is held still. Level ground is detected when actual torque drops below “M1.54 Restraint hill hold torque threshold ”HHTrqTH””. The controller keeps giving power to the motor until handbrake input (digital input 7) becomes active and “M1.52 Hill hold time ”HHTime”” is elapsed. Otherwise the controller never stops giving power to the motor until it is switched off! If digital input 7 is select as speed input 3 it never stops giving power to the motor even if this is activated. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 59 ...
Page 66 Return to Table Of Contents WARNING! • VERY IMPORTANT: If the braking has been commanded by setting the direction switches to neutral or by removing the seat switch input, the steps 5) and 7) of the above list use a different time. In other words the hill hold time is ignored and the “M1.23 Neutral brake end delay “NBrkEnd”” time is used. After that time the vehicle will roll on the slope at the restraint hill hold speed. • VERY IMPORTANT: Take care of consideration at step 7). NOTICE! IMPORTANT for Situation 5, 6 and 7: If “M34T Hill hold ”Off/HH/S””= 2 (Hill Hold & Stop giving power to the motor) the controller will stop giving power to the motor when at the end of restraint hill hold the level ground is reached. The situation is described in the following picture. Stop giving power to the motor and applying zero current on level ground if ““M34T Hill hold ”Off/HH/S””= 2 (Hill Hold & Stop giving power to the motor) Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 67 Increasing the value will help minimize any delay from selecting drive to creeping the vehicle. The value corresponds to the minimum demand. In case inching is demanded (i.e. the physical digital input assigned to the “inching forward” or “inching reverse” functional input is active), the Creep speed is disregarded and the vehicle will run at inching speed (“M1.111 Inching speed “InchSpd””) even if it is lower than the creep speed, using the inching ramp time (“M1.113 Inching ramp time “IncRmpTm””). M1.33 Creep ramp time “CreepRmp” This parameter set the ramp time for applying creep speed/torque. It is valid for both speed and torque control. In Torque Control mode this sets the time taken to ramp from zero torque demand to 100% drive torque when creep torque has to be applied. In Speed Control mode this sets the time taken to ramp up the speed from 0% to 100% or from 0% to the creep speed (depending on “M29 Variable/Constant ramp time “CnRmpTm””), when creep speed has to be applied. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 61 ...
Page 68 0x9 M1.41 Proportional gain speed controller “KpSpd” In torque mode it determines how aggressively the speed controller limits the speed of the motor to the active speed limit value. Larger values provide tighter control. If Kp is set too high, oscillations could arise when the controller starts to limit speed. If Kp is set too low, the top speed might result higher than speed limit (overshoot). NOTICE! This adjustment has no effect in torque mode if “M1.48 Speed limit tolerance “SpLimTol”” is set greater than 0%. The speed limitation won’t be fully accurate and the speed limit value will be “held” with a tolerance defined by “M1.48 Speed limit tolerance “SpLimTol””. In speed mode it determines how quickly the speed controller attempts to match the demanded speed. Larger values provide quicker control. If Kp is set too high, oscillations may arise as the motor approaches demanded speed. If Kp is set too low, the top speed might result higher than speed limit (overshoot) and the speed control might be very slow. M1.42 Integral gain speed controller “KiSpd” In torque mode it determines how quickly the speed steady state error is zeroed. In other words how quickly speed is stabilized to the active speed limit value. Larger values provide faster speed limiting. If Ki is set too high, oscillations could arise when the controller starts to limit speed. If Ki is set too low, it may take a long time before speed is stabilized to the speed limit value. NOTICE! This adjustment has no effect in torque mode if “M1.48 Speed limit tolerance “SpLimTol”” is set greater than 0%. The speed limitation won’t be fully accurate and the speed limit value will be “held” with a tolerance defined by “M1.48 Speed limit tolerance “SpLimTol””. In speed mode it determines how quickly the speed steady state error is zeroed. In other words how quickly speed is stabilized to the speed demand value. Larger values provide faster speed stabilization. If Ki is set too high, oscillations could arise when the controller starts to limit speed. If Ki is set too low, it may take a long time before speed is stabilized to the speed limit value. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 69 M1.44 Double PI speed threshold “SpdPITh” This parameter sets the speed threshold for speed control to move from low speed PI gains to high speed PI gains. It is referred to “Maximum motor frequency” set in “Menu 3 “Autotuning””. M1.45 Proportional gain speed controller below threshold “KpSpdLow” This parameter has the same meaning as “Proportional gain speed controller”. This is applied if “Enable double PI gains for speed controller” is set to 1 and actual speed is above “Double PI speed threshold”. M1.46 Integral gain speed controller below threshold “KiSpdLow” This parameter has the same meaning as “Integral gain speed controller”. This is applied if “Enable double PI gains for speed controller” is set to 1 and actual speed is above “Double PI speed threshold”. M1.47 Transition time between the double PI regulators for speed controller “TransTim” This parameter sets the time needed for moving from lowspeed gains to highspeed gains and vice versa. A too small value can produce a bumpy transition. Parameters for “smooth speed limiting” function A second speed limiting function is available.. The new speed limiting feature is active in both speed and torque mode with different effects, with the goal to keep the drive feeling of the vehicle more comfortable and avoid bumps caused by rough ground conditions. M1.48 Speed limit tolerance “SpLimTol” This parameter is active in both speed and torque mode for traction control. It is not active for pump control. "��"×"��" It sets the error tolerance in % around a speed limitation. It is defined as: , thus setting this parameter to 0% would deactivate the function. Example: if “SpLimTol” is set to 10% and the active speed limit is 100 Hz, the speed will be allowed to vary in range of 90110 Hz. To have a smooth speed limitation without overshoot it is suggested to set this parameter between 5% and 15%. Too large values will allow a very smooth action but the speed variation around the limit may be very large. Too small values will give a tighter speed limitation but it may result more aggressive and bumpy. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 63 ...
Page 70 When “Speed tolerance” is activated in torque mode the PI speed controller adjustment “M1.41 Proportional gain speed controller “KpSpd””, “M1.42 Integral gain speed controller “KiSpd””, “M1.45 Proportional gain speed controller below threshold “KpSpdLow”” and “M1.46 Integral gain speed controller below threshold “KiSpdLow”” are not used for limiting the speed. The speed limitation won’t be fully accurate and the speed limit value will be “held” with a tolerance defined by “M1.48 Speed limit tolerance “SpLimTol””. In speed mode this function allows to avoid continuous adjustment of current while driving on flat ground with vehicle unloaded at speed limit, thus reducing the heating up of motor and controller. In speed mode the M1.4 8 Speed limit tolerance “SpLimTol” is acting on the Drive torque limit as indicate in the following figure. M1.49 Speed limit action ramp time “SpLimTim” This parameter is active only if torque mode is selected (“M21 Control Mode “Spd/Torq”” = 1, 2 or 3) and “Speed limit tolerance” is set greater than zero. It sets the time taken for speed limitation to become active when the speed reaches the limitation. To have a good drive feeling it is suggested to set this parameter between 0.2s and 0.05s. Too large values make the speed limitation unstable and provoking overshoots. Too small values make speed limitation fast but more aggressive. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 71 Walkie vehicle type) (refer to “M22 Vehicle type selection ”Ride/Wlk”” for more information about vehicle configuration) the vehicle will enter and remain in Hill Hold mode for a period set by parameter “M1.52 Hill hold time ”HHTime””. During this period, the vehicle will remain stationary. After this time has elapsed, the vehicle will enter in “Restraint Hill Hold mode” and move at speed set by the parameter “M1.53 Restraint hill hold speed ”HHspeed””. On Ride On vehicle (“M22 Vehicle type selection ”Ride/Wlk”” set to 0), if neutral braking is operated by means of selecting neutral with direction switch while the accelerator pedal is still pressed (i.e. foot switch still active), the Hill Hold mode is skipped and the Restraint hill hold is applied directly. If the vehicle reaches level ground and the vehicle is no longer moving, the controller will reduce the current applied to the motor to save battery power. Level ground is detected when the torque necessary to hold vehicle in restraint Hill hold is lower than “M1.54 Restraint hill hold torque threshold ”HHTrqTH””. If the motor then begins to move again, without any accelerator demand being applied, the controller will reenter in Restraint Hill Hold mode automatically until the handbrake is applied. When the handbrake is applied the controller stops giving power to the motor to save battery power. If hand brake is released, the vehicle will coast unless accelerator is pressed and one direction input is active. In case the handbrake function is not active (“Handbrake” functional input not assigned to a physical input or not mapped in a CAN message), the controller will keep giving power to the motor and will exit from Hill Hold mode only if accelerator is pressed and one direction input is active. • If Set to 2 (Hill Hold & Stop giving power to the motor on level ground), it has the same features when set 1 (Hill Hold & Restraint) except the following: If the vehicle reaches level ground and the vehicle is no longer moving, the controller stop giving power to the motor and reduce current applied to the motor to zero. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 65 ...
Page 72 “M1.132 Drive torque during braking release time “DrvTRmDw”” and “M1.133 Drive torque during braking rise time “DrvTRmUp”” have a big influence on stopping on a hill and entering in hill hold. In case “M1.131 Drive torque allowed during braking ”DTrq@Brk”” is set to 0, before to change dramatically “KpPos”, “KdPos” and “PosDband” for achieving a proper stop on a hill and hill hold, please first check the values of “M1.132 Drive torque during braking release time “DrvTRmDw”” and “M1.13 3 Drive torque during braking rise time “DrvTRmUp””. Small values (0.1s0.3.s) will improve the stop and hold on a slope but can give not a nice feeling on flat ground when accelerator pedal is fully released. So an intermediate value between proper stop and hold on a slop and pedal release have to be found for these settings. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 73 0.0V – 10.0V 0.1V 2.0V 0x2009 0x6 Travel Control minimum accelerator value 7 0.0V – 2.0V 0.1V 0.0V 0x2009 0x8 “MinAccTC” M1.61 Accelerator characteristic “Lin/Curv” This parameter defines the accelerator pedal characteristic: Linear or Curved. • If set to 0, the controller will apply a linear accelerator input. • If set to 1, the controller will apply a curved accelerator input. 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%. Curved: For input values of 0%, 50% and 100%, the output will be 0%, 25% and 100%. M1.62 Accelerator type ”AccelTyp” This set the acceleration type. • If set to 0 (normal), a normal accelerator that can operate with direction switches is selected. • If set to 1 (wigwag), a Wig Wag accelerator is selected and no direction switch is required. The voltage admitted range is from 0.2V to 4.5V. For a proper operation, the wigwag potentiometer connected to the analogue input to which the “accelerator” functional input is assigned has to operate within this range. The wigwag behavior is represented in the following image: DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 67 ...
Page 74 If set greater than 1 (damped), the accelerator is “damped” in the range between 0% and 75% according to the number. This can help to avoid aggressive and oscillating response at low pedal demand with light vehicles and high torque motors. If it is necessary to use it, for torque mode the suggested values are between 2 and 4, while for speed mode it is suggested to use values from 4 to 9. The behaviour of this parameter is explained by the following figure for Torque Mode: “ M314 AccDamp” effect in torque mode Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 75 Return to Table Of Contents In other words if accelerator is pressed below 75% the torque responsiveness will be softer than if pressed more than 75%. The responsiveness increases as much as the accelerator pedal is pressed and approaching the 75% of the range. This damping affects both “M1.11 Accelerator ramp time “Acc Ramp”” and “M1.12 Accelerator release ramp time “Rel Ramp”” in torque mode. The behaviour of this parameter is explained by the following figure for Speed mode : “M314 AccDamp” effect in speed mode In other words if accelerator is partially pressed the speed responsiveness will be softer than if fully pressed. The responsiveness increases as much the accelerator pedal is pressed and approaching the 100% of the range. This damping affects only the “M11 Acceleration delay “Accel”” in speed mode. M1.64 Accelerator/Neutral braking threshold “AccNBThr” This adjustment is active in torque mode and if “M22 Vehicle type selection ”Ride/Wlk”” is set to 3 (Electric Vehicle). It is useful to perform a neutral brake operation in torque mode with a braking effect proportional to the first part of accelerator range. This adjustment is tuning the range of accelerator pedal that is used for braking and the threshold where the accelerator starts to demand driving torque. The following graph helps to understand the parameter behaviour. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 69 ...
Page 76 “Menu 8.1 “Input/output assignment””) from which reverse drive commences. Together with “M1.65 Wig/Wag forward threshold ”FwdTH””, this parameter forms a ‘dead band’ in which the wigwag assumes a neutral position. The travel control will be active with a fixed 0.2V threshold above this value M1.67 Travel Control minimum accelerator value “MinAccTC” This parameter defines the minimum accelerator value for the purpose of travel control. In case the motor is being energized with drive torque and the accelerator read value is below this threshold, a fault will happen and the controller will be brought to a safe state, with Line Contactor open and Electromechanical brake closed. This parameter is active only in case “M1.62 Accelerator type ”AccelTyp”” is setup to 0. In case “Wigwag” option for the accelerator is selected, please refer to “M1.65 Wig/Wag forward threshold ”FwdTH”” and “M1.66 Wig/Wag reverse threshold ”RevTH”” for the definition of the travel control threshold. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 77 Return to Table Of Contents Menu 1.7 “Steer” Cal. Step Sub Parameter name “Calibrator text” Range Default Index Ref. size index 1 Steer pot middle point voltage level ”StrMid” 0.0V – 10V 0.1V 2.5V 0x200A 0x6 M1.71 Steer pot middle point voltage level ”StrMid” This parameter sets the voltage on the analogue input to which the “Steerpot” functional input is assigned (assigned in “Menu 8.1 “Input/output assignment””) which will correspond to 0° steering angle. For tuning this parameter refer to “APPENDIX C – Analogue Input tuning”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 71 ...
Page 78 0x1 2 Controller temperature threshold “CtrTmpTh” 10°C – 100°C 1°C 45°C 0x2C03 0x2 M1.81 Motor temperature threshold “MotTmpTh” M1.82 Controller temperature threshold “CtrTmpTh” These two settings represent the motor and controller temperature thresholds to activate the Digital Output configured as “Motor fan”, “Controller Fan” or “Combo fan”. Assign the proper function to the output in “Menu 8.1 “Input/output assignment”” to activate the said functions. Please notice that the deactivation threshold is 10 °C lower than the set parameter. Example: “Motor fan” function is assigned to output 3. “M1.81 Motor temperature threshold “MotTmpTh”” is set to 80°C. DO3 will be activated when the motor threshold raises above 80°C. Once active, DO3 will only be deactivated when the motor temperature drops below 70°C (80°C10°C). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 79 The EMbrake function is working totally independent with respect to the “Hill Hold” function and the “Neutral brake end delay”. This means that, in case the Hill Hold function is enabled ( “M1.51 Hill hold enable ”Off/HH/S”” set different than 0) or “M1.23 Neutral brakeend delay “NBrkEnd”” set greater than 0, then the motor will still be energized while the EMbrake may be already applied. This means that the overmentioned functions, due to some residual speed PI controller charge, might cause the “fight” of speed control against the EMbrake. M1.91 Electric brake delay “EBrkDly” This setting is normally associated with a vehicle fitted with an electromechanical brake connected to the SigmaLITE controller’s digital output to which the “Electromechanical brake management” function is assigned (Menu 8.1 “Input/output assignment”). Its behaviour depends on “M1.94 Electric brake configuration “EBrk Cfg””. • If “M1.94 Electric brake configuration “EBrk Cfg”” is set to 0 or 4, this parameter sets the delay between the entering of “end of braking mode” (speed lower than “M1.21 Speed threshold to enter EndofBraking (EoB) mode ”SpdThEoB””) and the electric brake being applied. If the vehicle is detected at standstill (speed lower than “6M1.22 Zero speed threshold ”ZSpdTh””) before “M1.91 Electric brake delay “EBrkDly”” is elapsed, the EM brake is applied and therefore this has no effect. Resuming: the EM brake is applied if “M1.91 Electric brake delay “EBrkDly”” is elapsed from the instant of entering in end of braking OR if zero speed is detected. The Following picture shows a situation when the “M1.91 Electric brake delay “EBrkDly”” is set longer than the time the vehicle takes to slow down below the “M1.22 Zero speed threshold ”ZSpdTh””. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 73 ...
Page 80 Return to Table Of Contents The Following picture shows a situation when the “M154 Electric brake delay “EBrkDly”” is set shorter than the time the vehicle takes to slow down below the “M118 Zero Speed Threshold to enter hill hold or neutral brake end ”ZSpdTh””. • If “M1.94 Electric brake configuration “EBrk Cfg”” is set to 5 or 6, this parameter has no effect: the electric brake will in fact be applied only when zero speed is detected (speed lower than “6M1.22 Zero speed threshold ”ZSpdTh””). • If “M1.94 Electric brake configuration “EBrk Cfg”” is set to 7 or 8, this parameter sets the delay between the detection of zero speed (speed lower than “6M1.22 Zero speed threshold ”ZSpdTh””) and the electric brake being applied. An example is reported in the following picture. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 81 This can be useful for having the EMbrake acting like a pure “park brake”, thus allowing for low speed manoeuvring, but can lead to dangerous driving conditions. M1.92 Electric brake release delay “EBRelDly” This setting is useful on vehicle equipped with an electromechanical brake. It sets a delay in opening the EM brake from the time at which controller starts giving power to the motor. This helps to prevent roll back of a vehicle when starting to drive on a gradient. This delay gives time to the motor to build up torque before the EM brake is released. Please notice that increasing this value too much will cause jumpstart on flat land. M1.93 Electric brake ramp lock delay “ELkRdly” This setting is useful on vehicle equipped with an electromechanical brake and is active only in speed mode. It sets a time delay for avoiding to build up torque before the brake is released. This can lead to a smoother and bump less acceleration, since there is a minimum fixed time of 0.1s from when controller starts giving power to the motor to when electromechanical brake is actually released (see parameter “M1.92 Electric brake release delay “EBRelDly””). To avoid the roll back on slope “M1.93 Electric brake ramp lock delay “ELkRdly”” has to be set lower than “M1.92 Electric brake release delay “EBRelDly””. If smooth starting on flat ground is wanted “M1.93 Electric brake lock delay “ELkRdly”” has to be set higher than “M1.92 Electric brake release delay “EBRelDly””. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 75 ...
Page 82 In case some safetyrelated failure is tiggered (i.e. Safe Torque Off, SafeStop1, Prevent to travel or Travel Control, Emergency Drive Forward) or an input inconsistency is detected, then the outputs will be disabled by the hardware and the EMbrake will close regardless of this option. M1.95 Smooth start on hill enable “EBtrqDly” This parameter enables the “smooth start on hill” function. When this is set to #1, the DMC controller, at the end of brake, will apply position holding for a time defined by “M1.23 Neutral brakeend delay “NBrkEnd””, before closing the EM brake. During this time, the DMC controller will measure the torque required to hold the vehicle in place. At the next drive demand, the DMC controller will therefore build up the memorized torque before opening the brake, to avoid rollback on the gradient caused by slow torque buildup. Please notice that in case this parameter is set to #1, “M1.92 Electric brake release delay “EBRelDly”” must be left at 0.1s (default value), as the opening delay is managed automatically. Please notice that in case this parameter is set to #1, the delay defined by “M1.93 Electric brake ramp lock delay ...
Page 83 Speed is below “M1.22 Zero speed threshold ”ZSpdTh”” for a time longer than “M1.91 Electric brake delay “EBrkDly””. This option is not compatible with speed mode control (“M21 Control Mode “Spd/Torq”” set to 0). WARNING! When this option selected, if a failure occurs in the Controller the EM brake WILL NOT be applied until there a sufficient low speed. This option is NOT suggested on vehicles not equipped with a mechanical brake. In case some safetyrelated failure is tiggered (i.e. Safe Torque Off, SafeStop1, Prevent to travel or Travel Control, Emergency Drive Forward) or an input inconsistency is detected, then the outputs will be disabled by the hardware and the EMbrake will close regardless of this option. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 77 ...
Page 84 If set to 3 (Footswitch & Motor Speed), then the power steer contactor is driven either by the Footswitch as described above or when the motor speed is greater than zero. So if vehicle is moving power steer trigger output is active. • If set to 4 (FS1, Fwd/Rev, Footbrake), then the power steer contactor is driven either by the Footswitch or forward and reverse input or Foot Brake operation. M1.102 Power steer delay “PStrDly” This sets the period that the digital output to which the “Power steer management” function is assigned (Menu 8.1 “Input/output assignment”) will remain active after the trigger source has been removed. The trigger source is set by the parameter “M1.101 Power steer trigger ”PsF/FR/S”” in the Controller Setup menu. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 85 This setting is used to set the speed at which the motor will rotate when one the pins to which “Inching” functional inputs are assigned (Menu 8.1 “Input/output assignment”) is activated. It is therefore valid for both “inching forward” and “inching reverse” operation. M1.112 Inching time “InchTime” This setting is used to set the maximum time for which the motor will rotate when one the pins to which “Inching” functional inputs are assigned (Menu 8.1 “Input/output assignment”) is activated. Even trough one of the mentioned input remains active for longer, then the motor will not run unless the input is deactivated and activated again. M1.113 Inching ramp time “IncRmpTm” It sets the acceleration ramp time when inching function is activated. This sets the time taken to ramp up the speed from 0% to 100% or from 0% to the inching speed (depending on “M29 Variable/Constant ramp time “CnRmpTm””). The maximum speed demand is set by ”Maximum motor frequency” (adjustable in “Menu 3 “Autotuning””), and it is assumed correspond to 100% of speed. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 79 ...
Page 86 In a vehicle of this kind, if the input to which the “Bellyswitch” functional input is assigned (Menu 8.1 “Input/output assignment”) is activated while driving reverse or when the vehicle is in neutral (according to “M22 Vehicle type selection ”Ride/Wlk””), the motor is immediately stopped (with fastest ramp time if in speed mode or with maximum breaking torque if in torque mode) and an emergency drive forward is performed until the input remains active. These parameters define, respectively, the speed at which the vehicle will drive forward if the belly switch gets activated and the time for which the vehicle will drive forward. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 87 Please notice that in case the vehicle is recognised to be braking, but any limitation is active and/or the produced braking torque is not enough to stop the motor, then the safety requirements are considered fulfilled and the motor will not be de energized, the electromechanical brake will not be engaged and the line contactor will not be opened. Bellyswitch operation/Emergency Drive Forward (EDF) examples The following examples are reported to clarify the behaviour of the controller in case the input to which the “Bellyswitch” function is assigned is activated. Please notice that in case the “NO/NC” redundant inputs are used to activate the function, the function will be activated only in case both input will be consistent (i.e. the NO input is closed and the NC input is open). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 81 ...
Page 88 M1.132 Drive torque during braking release time “DrvTRmDw” This setting is only active in speed mode and when parameter “M1.131 Drive torque allowed during braking ”DTrq@Brk”” is set to 0. It is used to avoid that drive torque is cut too quickly and an uncomfortable drive feeling is experienced when accelerator is fully released. It therefore sets a time in which driving torque is cut, instead of cutting it completely and immediately, when the accelerator is fully released. Increasing the value will also help to reduce the roll back when fully releasing the pedal while climbing on a slope. Too long value will cause a bad drive feeling. The suggested value for this setting is between 0.7s and 1.0 s. M1.133 Drive torque during braking rise time “DrvTRmUp” This setting is only active in speed mode and when when parameter “M1.131 Drive torque allowed during braking ”DTrq@Brk”” is set to 0. This correspond to the time taken to build up the torque when hill hold becomes active at the very end of braking. Increasing the value will smooth the activation of holding torque, but if set too long it will cause more roll back. The suggested value is between 0.5s and 2s. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 89 The behaviour of this parameter is explained by the following figure. “M315 LsAcDamp” effect (speed mode only) This damping affects only the “M11 Acceleration delay “Accel”” in speed mode. This setting can be used in conjunction with “M1.63 Accelerator Damping Factor ”AccDamp”” to obtain the behaviour described in the following figure, where a damping effect on speed responsiveness depending on accelerator demand and actual speed is obtained. “M314 AccDamp” and “M315 LsAcDamp” combined effect (speed mode only) DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 83 ...
Page 90 Return to Table Of Contents M1.135 Low speed deceleration damping factor “LSDcDamp” This setting is used to damp the accelerator demand at speeds below 50% and is only active in speed mode. In this case the damping effect is related to the actual speed value. If speed is low the speed responsiveness is softer than at high speed while deceleration thus when release the accelerator • If set to 1.0 (no damping), means no effect on accelerator when released. • If set greater than 1.0 (low speed damped), the accelerator is “damped” at speeds below 50% according to the number. This can help to be more precise and assure a smooth and accurate driving at low speeds while releasing the pedal. This setting is active for any partial release of the accelerator pedal. For full release of accelerator pedal the neutral brake behaviour take over. The behavior of this parameter is explained by the following figure. ”M1.135 LsDcDamp” effect (speed mode only) This damping is only active in speed mode. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 91 If the actual speed when Neutral brake is entered is 50%, the ramp time will be (5s+(5s*2s 5s)*50%)*50% For an optimal tuning it is suggested to proceed as follows: 1. Tune “M1.14 Neutral brake ramp time “NBrkRamp””, by driving at full speed and releasing the accelerator pedal completely. Adjust until the stop time and brake feeling is fine. 2. Tune “M1.136 Low speed neutral brake ramp time factor “LsNBDamp””, by driving at low speed (10% to 20%) and releasing the accelerator pedal completely. Adjust slightly (suggested values are between 1.2 and 3) until brake feeling and stop time is fine. 3. Also try the feeling at medium speeds (40%, 50% and 60%). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 85 ...
Page 92 100 % 0x2003 0x5 18 Foot brake ramp time adv mode 2 “FBrkRmp2” 0.1s 20.0s 0.1 s 4.0 s 0x2003 0x6 M1.141 Accelerator ramp time adv mode 1 “Accel1” M1.142 Accelerator release ramp time adv mode 1 “Decel1” M1.143 Maximum drive torque adv mode 1 “MxDrTrq1” M1.144 Neutral brake torque adv mode 1 “NBrkTrq1” M1.145 Neutral brake ramp time adv mode 1 “NBrkRmp1” M1.146 Direction brake torque adv mode 1 “DBrkTrq1” M1.147 Direction brake ramp time adv mode 1 “DBrkRmp1” M1.148 Foot brake torque adv mode 1 “FBrkTrq1” M1.149 Foot brake ramp time adv mode 1 “FBrkRmp1” These settings are used to define the drive style when “Advanced mode #1” is active. They replace the drive parameters in “Menu 1.1 “Drive response””, defining the corresponding ramp times and torque levels for the different situations (driving and neutral/foot/direction braking). To activate “Advanced mode #1”, assign the “Advanced mode #1” functional input to a physical input (“Menu 8.1 “Input/output assignment””) or map the corresponding command in a CAN message. Recall that “advanced mode” inputs are considered “normally closed”, thus the input must be inactive (or the CAN command must be equal to 0) in order to activate the “Advanced mode #1” function. Please notice that, when “Advanced mode #1” is active, also “Cutback speed 1 “Speed1”” will be active, and the battery current limits defined by “Drive battery current limit adv mode 1 “IBatMax1”” and “Regenerative battery current limit adv mode 1 “IBatReg1”” will be effective. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 93 Return to Table Of Contents M1.1410 Accelerator ramp time adv mode 2 “Accel2” M1.1411 Accelerator release ramp time adv mode 2 “Decel2” M1.1412 Maximum drive torque adv mode 2 “MxDrTrq2” M1.1413 Neutral brake torque adv mode 2 “NBrkTrq2” M1.1414 Neutral brake ramp time adv mode 2 “NBrkRmp2” M1.1415 Direction brake torque adv mode 2 “DBrkTrq2” M1.1416 Direction brake ramp time adv mode 2 “DBrkRmp2” M1.1417 Foot brake torque adv mode 2 “FBrkTrq2” M1.1418 Foot brake ramp time adv mode 2 “FBrkRmp2” These settings are used to define the drive style when “Advanced mode #2” is active. They replace the drive parameters in “Menu 1.1 “Drive response””, defining the corresponding ramp times and torque levels for the different situations (driving and neutral/foot/direction braking). To activate “Advanced mode #2”, assign the “Advanced mode #1” functional input to a physical input (“Menu 8.1 “Input/output assignment””) or map the corresponding command in a CAN message. Recall that “advanced mode” inputs are considered “normally closed”, thus the input must be inactive (or the CAN command must be equal to 0) in order to activate the “Advanced mode #2” function. Please notice that, when “Advanced mode #1” is active, also Cutback speed 2 “Speed2”” will be active, and the Battery current limits defined by “Drive battery current limit adv mode 2 “IBatMax2”” and “Regenerative battery current limit adv mode 2 “IBatReg2”” will be effective DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 87 ...
Page 94 • If this parameter is set to 1 (linear brake torque limiting, not saturated generator speed setpoint), the generator speed setpoint is not saturated to the overmentioned value, thus maximum breaking torque will never be applied in case AI2 percentage + “M1.152 Generator speed threshold ”GenSpdTh”” is > 100%. This guarantees that smooth braking torque limiting is active also at high speeds (close to 100%). • If this parameter is set to 2 (constant brake torque limiting), then the AI2 will directly apply a constant brake torque limit. The user is then free to implement a variable torque limitation to its wishes. The image bellows aims at clarifying the meaning of this parameter: Option 0 limits the blue curve from moving forward. Option 1 allows to reach also the green curves. Thus, at the example speed of 90% depicted in red, with option 0 torque can only be limited at its 95%. With option 1, torque can also be limited to lower values (depending on AI2 generator setpoint). Option 2 sets a constant brake torque, as the yellow line. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 95 Brake torque (regeneration power) will be automatically allowed gradually when speed rises above the generating speed set point set by means of the “generator speed setpoint” input. Full braking torque is available if speed is above the speed set point plus an adjustable threshold in % set by means of “M1.152 Generator speed threshold ”GenSpdTh””. Please notice that, when the controller is set in torque mode (“M21 Control Mode “Spd/Torq”” set >= 1), the maximum braking torque is limited by parameter “M1.19 Foot brake torque “FBrake””. In speed mode, this limitation is not active and 100% braking torque is always allowed. If any brake torque limitation becomes active in the controller, the regenerative power will be automatically cut to the said level. Brake torque limit is managed by the generator function as following graph: When in “generator mode” analog Input 3 will not be used anymore as a steer potentiometer. Instead, it will be used to set the maximum generator power, by cutting the regenerative current limit. In case the user is sending a regenerative BCL to the controller, the value of the Analogue input 3 will be used to rescale the said value. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 89 ...
Page 96 Please use the “Menu 10 “Test” for traction software” to tune the said values. If “generator speed setpoint” is missing, then the generator speed setpoint will generally be 0% (actually limited to “M1.21 Speed threshold to enter EndofBraking (EoB) mode ”SpdThEoB””), meaning that the motor will generate starting from very low speed. If “generator BCL” is missing, the regenerative BCL will generally be set to 0%, and the motor will not generate any current. Check “APPENDIX C – Analogue Input tuning” for analogue input tuning details. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 97 Menu 1.16 “Vehicle menu” Cal. Step Parameter name “Calibrator text” Range Default Index Subindex Ref. size 1 Motor2Vehicle speed ratio ”SpdRatio” 1.0 – 999.9 0.1 120.0 0x200F 0x1 2 Vehicle maximum speed ”VmaxSpd” 0.0Kph – 999.9Kph 0.1 Kph 20.0 Kph 0x200F 0x2 M1.161 Motor2Vehicle speed ratio ”SpdRatio” This set the ratio between the motor speed in RPM. and the vehicle speed in km per hour (KPH) or miles per hour (MPH). For example if the actual motor speed is 3000 RPM and ”SpdRatio” is set to 100, the Vehicle Speed value that can be seen in the status menu or in the DMC display is 30.0 Kph (or 30.0 Mph). M1.162 Vehicle maximum speed ”VmaxSpd” This set the full scale indication on the Sigmagauge LCD or Display bargraph speed indicator. Setting the parameter to 0kph means that there will be no indication of speed shown on the Sigmagauge LCD. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 91 ...
Page 98: Menu 2 "Controller Setup" For Traction Software
Return to Table Of Contents Menu 2 “Controller Setup” for traction software This menu embraces all the settings that are used to activate the DMC SigmaLITE Controller functions. It of extreme importance to set up this menu according to the desired functions required and then recycle the key to make changes active. Cal. Step Parameter name “Calibrator text” Range Default Index Subindex Ref. size 1 Control Mode “Spd/Torq” 0 – 3 1 1 0x2400 0x0 2 Vehicle type selection ”Ride/Wlk” 0 – 3 1 0 0x2401 0x0 3 Dual motor configuration ”DMconfig” 0 11 1 0 0x2403 0x0 4 Standby delay timer ”StdByDly” 0min – 10min ...
Page 99 If set to 9, controller will be configured as 4WD Motor Left system (global) master, with steering potentiometer. • If set to 10, controller will be configured as 4WD Motor Left local master, with steering potentiometer. • If set to 11, controller will be configured as 4WD Motor Right (slave), with steering potentiometer. For more details about the Dual Motor feature, parameters and setup please refer to [3]. This parameter requires a key cycle offon to be effective. M24 Standby delay timer ”StdByDly” This sets a period of time after which the Line Contactor will be deenergized 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. • If set to 0, then the feature is deactivated and no timer is used. • If set from 0.5 to 10 [minutes] the standby timer is considered and active. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 93 ...
Page 100 If set to 0 (variable ramp times), all the set ramp times will be referred to the “Maximum motor frequency” in “Menu 3 “Autotuning””. • If set to 1 (constant ramp times), the ramp times will be referred to the active speed limit. Example: the “Maximum motor frequency” in “Menu 3 “Autotuning”” is set to 200Hz, “M29 Variable/Constant ramp time “CnRmpTm”” is set to 0, “M1.11 Accelerator ramp time “Acc Ramp”” is set to 2 seconds and “M5.1 2 Maximum speed forward “SpdMaxF”” is set to 100Hz. If the accelerator is fully pressed (100% demand), it will take 1 second for the motor to reach the desired speed. Instead, if “M29 Variable/Constant ramp time “CnRmpTm”” is set to 1, it would take 2 seconds to reach the desired speed. This means that the acceleration/deceleration slope changes with the active speed limit. In fact, continuing from the previous example, if the Speed limit #1 (“M5.14 Cutback speed 1 “Speed1””) becomes active and is set to 50Hz, it would take 0.5 seconds to reach the said speed with “M29 Variable/Constant ramp time “CnRmpTm”” set to 0 (variable ramp time, constant slope) and 2 seconds with “M29 Variable/Constant ramp time “CnRmpTm”” set to 1 (constant ramp time, variable slope). The above applies for both acceleration and deceleration ramps. Please notice that not all the speed limits are under the user’s control: some may in fact come from controller internal limitation (i.e. temperature cutback, low voltage cutback, etc.). If constant ramp time is selected, the set ramp times will be referred also to those limits, if they become active. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 101 Return to Table Of Contents M210 Calibration data option “CalValue” Not used. M211 Load default ”LoadDefs” If this parameter is set to 1 (load defaults) all the setting in all menus will be restored to the default factory values. This parameter requires a key cycle offon to be effective. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 95 ...
Page 102: Menu 3 "Autotuning
Return to Table Of Contents Menu 3 “Autotuning” The DMC SigmaLITE Controller embeds the possibility to perform an automatic tuning of the motor’s sensor and parameters. Several feedback sensors can used and autotuned: Sin/Cos Encoder, Incremental encoder and Hall sensors. This feature allows the user to have plugandplay configuration that ease the usage of the controller. A small set of data have to be entered for the procedure to be completed. After initiating the auto tuning, the motor will spin: it is therefore important for the motor to have the possibility to spin freely. This reflects on traction software in the way that the vehicle must be lifted such that the wheels can rotate freely.
Page 103 Return to Table Of Contents After autotuning it is possible to change this parameter if necessary, but a recycle of the key and a “Recalculation” procedure is required. WARNING! Maximum care must be taken when selecting the maximum motor frequency. Especially on permanent magnets synchronous motors, consider that at very high speeds the motor rotation may produce a high backEMF. In case of faults at high rotational speeds, when line contactor is opened, the produced voltage reflects on the controller’s internal capacitors, which, due to natural low power absorption capability, will rapidity increase in voltage and may blow. DMC has developed the so called “overvoltage shortcircuit protection” and can actively shortcircuit the motor phases in case a fault happens at a speed which is considered to be critical. This feature has to enabled manually. Please see [4] for AC, [5] for PMS and [6] for IPM for details. DMC declines any responsibility for incorrect setup of this parameters. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 97 ...
Page 104: Menu 4 "Motor Setup
Return to Table Of Contents Menu 4 “Motor Setup” This menu embraces all the parameter related to the motor configuration. It is automatically set up by the Autotuning, but some parameters can be tuned manually to achieve an even better motor behaviour. For more information about these parameters and the possible option for the final user configuration, please refer to the motor technology manual of interest ([4] for AC, [5] for PMS and [6] for IPM). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 105: Menu 5 "Limits Setup
Return to Table Of Contents Menu 5 “Limits Setup” The following setup menu includes all the limits adjustable in the SigmaLITE Controller for assuring a proper behaviour within voltage, current and temperature operative range. The following submenus are available: • Menu 5.1 “Speed limits” • Menu 5.2 “Motor thermal limits” • Menu 5.3 “Voltage limits” • Menu 5.4 “Battery current limits” • Menu 5.5 “Performance table” • Menu 5.6 “Timed current limit” • Menu 5.8 “Stall protection” • Menu 5.9 “Speed guard function” • Menu 5.10 “Encoder noise detection” DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 99 ...
Page 106 This parameter sets a static speed limit which can be activated by assigning the function “Speed limit #2” (“Menu 8.1 “Input/output assignment””) to a physical digital input or sending the enabling command Via CAN. The said input is considered “normally closed”, thus the input must be inactive (or the CAN command must be equal to 0) in order to activate the speed limit. This speed limit is also automatically enabled when the “Advanced drive mode #2” function is activated. This can be done by assigning the function “Advanced mode #2” (“Menu 8.1 “Input/output assignment””) to a physical digital input or sending the enabling command Via CAN. The said input is considered “normally closed”, thus the input must be inactive (or the CAN command must be equal to 0) in order to activate the speed limit. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 107 M5.18 Handbrake speed limit “HandBrk” This parameter sets a static speed limit to be adopted when the “Handbrake” function is activated. To enable this function, assign the “Handbrake” functional input to a controller’s physical input (“Menu 8.1 “Input/output assignment””) or map the corresponding activation command in a CAN message. Then, the function is activated when the physical switch is closed or when the CAN command is 1. 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 0RPM the controller will continue to energize the motor if the function is active and there is some gear selected. This is designed to avoid rollback on gradients. M5.19 Handbrake torque limit “MxDrTrq3” This parameter sets a torque limit to be adopted when the “Handbrake” function is activated. To enable this function, assign the “Handbrake” functional input to a controller’s physical input (“Menu 8.1 “Input/output assignment””) or map the corresponding activation command in a CAN message. Then, the function is activated when the physical switch is closed or when the CAN command is 1. The torque limit is not applied when the switch is open or a lower torque limit is in operation. M5.110 Speed limit ramp time “SpLimRmp” This parameter is active only in torque mode. This sets the time taken to decelerate from maximum speed to zero speed when a speed limit (1, 2 or 3) is activated. The speed limit ramp time is applied only if the actual motor speed is higher than speed limit one. Speed limit ramping is not applied when speed limit is removed. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 101 ...
Page 108 If set to 1, than the accelerator will be always scaled over “M5.12 Maximum speed forward “SpdMaxF””. If a lower speed limit becomes active, it will work as a cut (i.e. the accelerator has no effect from a certain point on). M5.112 Speed limit function of steer pot “SpLimstr” If set to 1 (Single Motor with steer pot as speed limit), the vehicle is considered a singlemotor vehicle equipped with a steer pot that gives a speed limitation when entering a curve. For details refer to adjustments. “M9.11 Dual motor cut out ”DMcut””, “M9.14 and “M9.17 Dual motor speed 3 ”DMspd3””. M5.113 Steerpot speed limit ramp selection “StrLimRm” This setting is only used in speed mode. This sets the ramp adopted when the controller is configured as single motor with steerpot (“M5.112 Speed limit function of steer pot “SpLimstr”” set to 1) and the vehicle enters a turn: • If set to 0 (use deceleration ramp time), then “M1.12 Accelerator release ramp time “Rel Ramp”” will be used to decelerate the motor to the speed limit; • If set to 1 (use speed limit ramp time), then “M5.110 Speed limit ramp time “SpLimRmp”” will be used to decelerate the motor. Please notice that this parameter only acts on the speed limit set by the steerpot, all other limits will still use standard deceleration ramp time Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 109 If set to 3 a configurable 5 point Resistance/Temperature curve temperature sensor can be connected. Refer to “Pin A20 Thermistor input” for details of connection. M5.22 Motor temperature cutback start level “TempStrt” M5.23 Motor temperature cutback span “TempSpan” M5.24 Motor temperature high error level “TempErr” High temperature cutback This parameter sets the temperature at which the controller starts to cut back the motor current or the motor speed, according to “M28 Use speed limits instead of torque limits “TmpLVSpL””. The maximum current/speed value is cut as soon as the motor temperature is above “M5.22 Motor temperature cutback start level “TempStrt”” and is cut back proportionally to the temperature between the starting point and an adjustable span above it, selectable by means of “M5.23 Motor temperature cutback span “TempSpan””. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 103 ...
Page 110 M5.25 Motor temperature offset “T offset” This parameter is used to set an offset for the motor temperature measured by the sensor connected. It is useful to compensate sensor accuracy tolerance. It can be both positive and negative. M5.26 Sensor resistance at temperature 1 “Res at T1” M5.27 Motor temperature 1 “MTemp1” M5.28 Sensor resistance at temperature 2 “Res at T2” M5.29 Motor temperature 2 “MTemp2” M5.210 Sensor resistance at temperature 3 “Res at T3” M5.211 Motor temperature 3 “MTemp3” M5.212 Sensor resistance at temperature 4 “Res at T4” M5.213 Motor temperature 4 “MTemp4” M5.214 Sensor resistance at temperature 5 “Res at T5” M5.215 Motor temperature 5 “MTemp5” Those parameters are visible only if “M5.21 Motor temperature sensor type “MtempTyp”” is set to 3. They define the Resistance/Temperature curve in 5 points for a temperature sensor connected that is not covered by the controller built in sensor types 012. The curve might cover both “classical” and NTC (Negative Thermal Coefficient) thermal sensors. The sensor type will be automatically detected and managed by the entered curve. Please notice that it is only possible to enter only either ALL increasing resistance values (for classical thermal sensors) or ALL decreasing resistance values (for NTC thermal sensors). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 111 0x2605 0x3 M5.31 Low voltage cutback start level “LVCBstrt” M5.32 Low voltage cutback end level “LVCBend” M5.33 Low voltage error level “LVerror” Low voltages occur when the battery is discharged. Or when a large power (current) surge from the battery occurs, for example, the vehicle is about to drive. Low voltage cut back When the voltage is getting low, the controller will limit the power withdrawn from the battery. It will do this by cutting back the maximum drive power with a percentage as shown in the graph below. Only drive power is cut back. Brake power is not cut back. When there is no cut back, the maximum drive power is 100 %. When the cut back is 100 %, the maximum drive power is at 0 %. The maximum drive power is the drive power that is available to the user. As long as the user doesn’t use this drive power, it will not be noticed. But when the user demands more drive power, the drive power is limited to the maximum drive power available. When this occurs, the Status menu of the controller shows the ‘LV’ limit indication. Also the error F02 is displayed during low voltage cut back. The maximum drive power limit will run from 100 % (no cut back) to 0 % (full cut back). This is displayed also in the Status Menu at “DriveTqLim”. The low voltage start and end cut back levels are adjustable in the SigmaLITE controllers. Low voltage limit The low voltage limit is the absolute limit of the controller and the motor. When the voltage is below this level, the controller will immediate stop driving (and braking) the motor (stops with giving power to the motor) and will report an error F17. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 105 ...
Page 112 M5.34 High voltage cutback start level “HVCBstrt” M5.35 High voltage cutback end level “HVCBend” M5.36 High voltage error level “HVerror” High voltage occurs when the battery is fully charged. Or when a large power (current) surge to the battery occurs, for example, the vehicle is braking hard. High voltage cut back When the voltage is getting high, the controller will limit the power delivered to the battery. It will do this by cutting back the maximum brake power with a percentage as shown in the graph below. Only brake power is cut. Drive power is not cut. When there is no cut back, the maximum brake power is 100 %. When the cut back is 100 %, the maximum brake power is at 0 %. The brake maximum power is the power that is available to the user. As long as the user doesn’t use this brake power, it will not be noticed. But when the user demands more brake power, the brake power is limited to the maximum brake power available. When this occurs, the Status menu of the controller shows the ‘HV’ limit. Also the error F04 is displayed during high voltage cut back. The maximum brake power limit will run from 100 % (no cut back) to 0 % (full cut back). This is displayed also in the Status Menu at “BrakeTqLim”. High voltage limit The high voltage limit is the absolute limit of the controller and the motor. When the voltage is above this level, the controller will immediate stop driving and braking the motor (stops with giving power to the motor) and will report an error F22. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 113 Example • Controller temperature limit 50 % • Low voltage cut back limit 70 % • High voltage cut back limit 30 % • → ‘CT’ Applicable drive limit → 50 % • → ‘HV’ Applicable brake limit → 30 % Of course, both a high voltage and a low voltage cut back should not occur simultaneously, but is done here to illustrate the applicable limits. A note on drive and brake A traction controller is able to drive and brake a motor. Driving can be demanded by the user, for example, forward drive or reverse drive. Braking can also be demanded by the user, for example, neutral brake and foot brake. However, when the user changes the direction from, say forward to reverse, the vehicle must first come to a stop before the actual direction can be changed. The controller will then use ‘direction braking’. But there is more. When the controller is using speed control, or is in a speed limit, the user is thinking he is driving the motor, but it is possible that the controller is braking the motor in order to control the speed. This is also a form of braking and here the high voltage cut back applies as well. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 107 ...
Page 114 1 0x2606 0x9 braking “BCLRegDB “ M5.41 Drive battery current limit “IBattMax” M5.42 Regenerative battery current limit “IBattReg” These two settings define the static Battery Current Limits (BCL) for motor drive or regen current in the battery. They are active both for pump and traction software. If set to maximum value (default value) the corresponding BCL is disabled. The behaviour of these values depend on setting “M7.24 Battery current limit via CAN enable “BclCanMs””. WARNING! It is HIGLY RECOMMENDED to avoid using the Drive Battery current Limit on Walkietype vehicles with speed control mode. This could lead to serious safety problems and cause operator’s injuries. DMC declines any responsibility for incorrect setup of this parameters. M5.43 Drive battery current limit adv mode 1 “IBatMax1” M5.44 Regenerative battery current limit adv mode 1 “IBatReg1” These two settings define the static Battery Current Limits (BCL) for motor drive or regen current in the battery. They are active for traction software only. If set to maximum value (default value) the corresponding BCL is disabled. They define the Battery Current Limits adopted when the “Advanced mode #1” is enabled. WARNING! It is HIGLY RECOMMENDED to avoid using the Drive Battery current Limit on Walkietype vehicles with speed control mode. This could lead to serious safety problems and cause operator’s injuries. DMC declines any responsibility for incorrect setup of this parameters. M5.45 Drive battery current limit adv mode 2 “IBatMax2” M5.46 Regenerative battery current limit adv mode 2 “IBatReg2”...
Page 115 Return to Table Of Contents WARNING! It is HIGLY RECOMMENDED to avoid using the Drive Battery current Limit on Walkietype vehicles with speed control mode. This could lead to serious safety problems and cause operator’s injuries. DMC declines any responsibility for incorrect setup of this parameters. M5.47 Battery current limit cut rate “ICutRate” This setting is to tune how fast the battery current limit is acting. It sets the rate of action when the battery current is far from the battery current limit value. Most of the times default values are fine. It has to be increased if the battery current limit is too slow in action. It has to be decreased if battery current limit when is start to be active is too harsh. This adjustment is active on both drive and regen battery current limits. M5.48 Battery current limit cut rate fine adjustment “ICutRtFN” This setting is to tune how fast the battery current limit is acting when the battery current value is close to the battery current limit one. Thus is setting the fine action on battery current limitation. Most of the times default values are fine. It has to be adjusted if some battery current oscillation in the range of 515 A are noticed or if the drive feeling shows some oscillation when battery current limitation is active. In this case try first to increase and if not solve the oscillation try to reduce it. This adjustment is active on both drive and regen battery current limits. M5.49 Regenerative BCL enabled during direction braking “BCLRegDB “ • If this parameter is set to 0, Regenerative battery current is not limited during Direction Braking ...
Page 116 (if lower) ADV drive style 1 active BCL Via CAN enabled BCL Via CAN timed out  ADV mode enabled ADV drive style 1 active BCL Via CAN enabled   BCL Via CAN not timed out ADV mode enabled (If lower) (if lower) ADV drive style 1 active BCL Via CAN enabled BCL Via CAN timed out  ADV mode enabled ADV drive style 1 active Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 117 M5.51 Performance table speed 1 “PTSpd1” M5.52 Performance table speed 2 “PTSpd2” M5.53 Performance table speed 3 “PTSpd3” M5.54 Performance table cutback 1 “PTCutBk1” M5.55 Performance table cutback 2 “PTCutBk2” M5.56 Performance table cutback 3 “PTCutBk3” The Performance Table feature (setting from 5.51 to 5.56) is a Torque limiting feature: the maximum torque is limited with increasing speed. The Performance Table sets a specified percentage of the maximum Torque for a specified speed as shown in the graph below. The Performance Table will only limit the drive torque/current, not the brake torque/current. The brake torque/current is limited as the drive current for speed below the 5% of the maximum motor speed that is expressed in the setting “FmotMax” in the Autotune menu. The controller will have a set of parameters with which the Performance Table can be set up. The table consists of three speed settings and three current settings: • Performance Table Speed 1 (5.51) • Performance Table Speed 2 (5.52) • Performance Table Speed 3 (5.53) • Percentage of the maximum Torque at speed 1 (5.54) • Percentage of the maximum Torque at speed 2 (5.55) • Percentage of the maximum Torque at speed 3 (5.56) Note that the performance table speed are percentage of ”Maximum motor frequency” (adjustable in “Menu 3 “Autotuning””) . For example if Maximum motor frequency is 200 Hz and the desired three Performance table speeds are: Speed1 50Hz, Speed2 130 Hz and Speed3 185Hz set PTSpeed 1 to 25% (50x100%/200) Speed2 to 65% (130x100%/200) and Speed 3 to 92% (185*100%/200) DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 111 ...
Page 118 • Performance Table 80 % • Applicable limit → 50 % • Applicable module → Controller temperature (indicated by ‘CT’). Interaction with Motor Module performance table The motor module current reduction map in field weakening is reducing current as a function of the speed too. See settings in motor set up menu field weakening. It means that the lower value for torque limiting between the Performance table and motor module torque reduction map is applied. Disabling Performance Table Performance Table Drive Torque Reduction is totally excluded when the three percentage of reduction settings are set to 100%. To disable the torque cutback due to Performance Table; set the maximum torque at speed 1,2 ,3 to 100 % (setting 5.54 to 5.56) Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 119 M5.64 Timed current limit cooldown time “CoolDwTm” WARNING! It is HIGLY RECOMMENDED to avoid using this function on Walkietype vehicles with speed control mode. This could lead to serious safety problems and cause operator’s injuries. DMC declines any responsibility for incorrect setup of this parameters. The graph below 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 rises above a set threshold (“M5.62 Timed current limit maximum current threshold “CurrTh””) for a specified period of time (“M5.61 Timed current limit timer “IthTime””), the controller will reduce the maximum current available to the motor to a lower current (“M5.63 Timed current limit low current threshold “ImaxLow””). After the reduction has occurred, the maximum current output will be limited at the lower level ...
Page 120 Speed control guard timer “SpdGrdTm” 0.1s – 12.0s 0.1s 0.1s 0x260C 0x2 M5.91 Speed control guard tracking error threshold “SpdGrdTH” M5.92 Speed control guard timer “SpdGrdTm” Those parameters define the “Speed guard function” behaviour. The “Speed guard” function is enabled when parameter “M5.91 Speed control guard tracking error threshold “SpdGrdTH”” is set greater than 0. This function provided an high safety level for vehicles controlled in speed mode (“M21 Control Mode “Spd/Torq”” set to 0), since it tracks the error between the demanded speed and the actual speed of the motor. If this error is above the set threshold for a time grated than “M5.92 Speed control guard timer “SpdGrdTm””, the motor stops and the EMbrake closes immediately. Therefore if, for example, the vehicle is trying to climb a slope but is has not enough torque to succeed, the speed error will be very large and the function will recognise the “stall” condition, closing the EMbrake and avoiding the vehicle to roll back. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 121 0x1 2 Noise detection error threshold “Noise Err” 1 200 1 100 0x260B 0x2 3 Noise speed difference threshold “Noise Diff” 0 400 0.1 25 0x260B 0x3 M5.101 Encoder noise detection “EncodND” This setting is used only in AC motor technology. This set enable a check for excessive noise on motor encoder signals. • if set to 0 (disabled) no Encoder noise detection is active. • If set to 1 (enabled) the noise detection is active and the noise threshold are adjustable by parameters “M724 Noise detection Threshold Error “Noise Err”” and “M725 Noise Speed Diff Threshold “Noise Diff””. This settings is not used with PMS/IPM motor technology since noise detection is enabled by factory setup. M5.102 Noise detection error threshold “Noise Err” M5.103 Noise speed difference threshold “Noise Diff” These two settings are active if “M5.101 Encoder noise detection “EncodND”” is set to 1. When the measured speed present a variation in Hz greater than “M725 Noise Speed Diff Threshold “Noise Diff”” for a number of times greater than “M724 Noise detection Threshold Error “Noise Err”” in a time of 100 ms a failure is signaled (F28 S001). This happen for excessive noise on encode signal (sensor damaged or bad wiring). ! IMPORTANT The change of these settings is active if key cycle power off/on is performed DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 115 ...
Page 122: Menu 6 "Battery Setup
• If set to 8 (Vanguard DoublePack BMS), the SigmaLITE Controller will expect to communicate with a DoublePack Vanguard BMS system. • If set to 9 (Eleo BMS), the SigmaLITE Controller will expect to communicate with a Eleo BMS system. • If set to 10 (Maxwell&Spark BMS), the SigmaLITE Controller will expect to communicate with a Maxwell&Spark BMS system • If set to 11 (Custom BMS), then the Sigma2N Rx messages must be configured by the user in order to communicate with a customized BMS. Details for this implementation will be given in [9]. M62 BMS master controller “BMS Mast” This parameter is used to define if the DMC SigmaLITE Controller will act as a “BMS master”. This implies that the following tasks will be performed: 1) Manage the NMT message to BMS (in case it is required by the adopted BMS); 2) Manage the SYNC message to the BMS (in case it is required by the adopted BMS); 3) Manage the RxPDOs messages to the BMS (in case it is required by the adopted BMS); 4) Manage the BMS information to be sent to the DMC Display. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 123 Return to Table Of Contents Notice that, even if a DMC Controller has this parameter set to “0”, it will receive all the BMS information and react to BMS warnings, errors and timeouts. Anyway, it will not manage the BMS itself (sending NMT, SYNC, etc..) and this might cause a misfunction. In a CAN network with a BMS and only one DMC SigmaLITE Controller, it is mandatory that the DMC SigmaLITE Controller has this parameter set to “1”. In a CAN network with a BMS and more than one DMC SigmaLITE Controller, it is mandatory that only one Controller has this parameter set to “1”. All other Controllers must have this parameter to “0”. M63 BMS current repartition “ShareCur” This parameter defines the percentage of Drive/Regenerative battery current actually absorbed by the DMC SigmaLITE Controller among the total available Drive/Regenerative current value limited by the BMS. For examples and details please refer to [8]. M64 Allow driving during BMS recharge “Drv@Chg” This parameter can be used to allow the SigmaLITE controller to drive even while the BMS is commanding a battery charge. Mind that this situation may be dangerous, as the vehicle can be driven away with the battery charger still plugged in. It is only suggested to enable it on stationary vehicles/actuators. M65 BMS node number “BMS Node” This parameter sets the BMS node number, it only works when set to > 0 and when the “General BMS” function is active (“M61 BMS configuration “BMS cfg”” set to #11”). ...
Page 124 This sets the maximum speed of the vehicle if the BDI level is below the value set by the parameter “M611 BDI cutout level “BDIcut””. M613 Maximum BMS temperature “MaxBattT” This parameter defines the maximum battery temperature allowed. It used for scaling the battery temperature bargraph on the DMC Display. It only has to be configured in the DMC SigmaLITE Controller with parameter “M62 BMS master controller “BMS Mast”” set to 1. Notice that only custom displays have the capability to display the BMS temperature. Refer to DMC for customization request M614 Minimum BMS temperature “MinBattT” This parameter defines the maximum battery temperature allowed. It used for scaling the battery temperature bargraph on the DMC Display. It only has to be configured in the DMC SigmaLITE Controller with parameter “M62 BMS master controller “BMS Mast”” set to 1. Notice that only custom displays have the capability to display the BMS temperature. Refer to DMC for ...
Page 125: Menu 7 "Can Bus Setup
Return to Table Of Contents Menu 7 “CAN Bus Setup” The SigmaLITE Controller comes with a fully standard CAN Open protocol for sending and receiving information to and from other CAN nodes. It is highly advisable to refer to the proper Application Note [1]. For the sake of simplicity, only the basic CAN parameters will be described in this section. Detailed information about CAN Open protocol will be provided on request. As default the CAN system is deactivated. The following submenus are available: • Menu 7.1 “CAN general” • Menu 7.2 “PDO premap” • Menu 7.3 “Shared line contactor” • Menu 7.4 “Display” • Menu 7.5 “Safe Stop 1” DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 119 ...
Page 126 6 CAN Open master SYNC produced enable 0 1 1 0 0x2A0F 0x0 7 SYNC generation time 10ms – 1000ms 10ms 100ms 0x2A10 0x0 M7.11 CAN node number “CAN node” This sets the CAN node number for the controller. It must be uniquely assigned to each node of the network This is the ID on which SDO communication will be based. In case “M7.21 PDO free type “FreeMapT”” is set to 0 or 1, this is the nodeID that will be used for constructing the identifier of each message that the DMC SigmaLITE Controller will be able to send/receive. In case “M7.21 PDO free type “FreeMapT”” is set to 2 or 3, the user has the possibility to assign any node number to the message identifiers, but SDO communication. DualMotor function and SharedLineContactor function will still be based upon this parameter. M7.12 CAN bit rate “CANbitRt” It changes the Can communication rate of the controller: • If set to 0, the bitrate is 100 kbit/s • If set to 1, the bitrate is 125 kbit/s • If set to 2, the bitrate is 250 kbit/s • If set to 3, the bitrate is 500 kbit/s The change is active only after a key power offon cycle. WARNING! ! VERY IMPORTANT if the bit rate of the controller is changed also the calibrator bit rate has to be changed to communicated again with the controller. If the calibrator bit rate and ...
Page 127 ▪ 0x480 | Line Contactor Slave #1 Node Number ▪ 0x480 | Line Contactor Slave #n Node Number Please notice that if using 11bit IDs for the said function, the user might create conflicts with the standard CAN Open IDs. Huge attention must be adopted when mapping the Controller’s PDOs. M7.15 CAN communication powerup delay “PwrUpDly” This parameter sets a delay in starting any activity on the CAN bus. Until the delay is elapsed, the DMC Controller will not try to send and/or receive any message on the bus. This delay is useful in case the CAN network is isolated and powered by a DCDC converter. Under this condition, in case the DCDC and Controller are powered up together with the same Key switch, it might happen that the DCDC takes time to charge and actually provide output power, while the Controller is already "ready to run" and tries to start CAN bus activities. This would result in application errors, since the CAN bus could not be accessed (not powered). M7.16 CAN Open master SYNC produced enable “SYNCprod” This parameter instructs the Sigma2N or SigmaLITE controller to be a SYNC producer (role usually covered by a CAN Open Master). As default, the SYNC COBID follows the standard CAN Open specification (i.e. ID 0x080). This SYNC ...
Page 128 9 Event timer RxPDO1 “RxPDO1TO” 10ms – 1000ms 5ms 150ms 0x1400 0x5 10 Event timer RxPDO2 “RxPDO2TO” 10ms – 1000ms 5ms 500ms 0x1401 0x5 M7.21 PDO free type “FreeMapT” M7.22 RxPDO premap configuration “RxPDOmap” M7.23 TxPDO configuration “PDO cfg” M7.24 Battery current limit via CAN enable “BclCanMs” M7.25 Event timer TxPDO1 “TxPDO1Rt” M7.26 Event timer TxPDO2 “TxPDO2Rt” M7.27 Event timer TxPDO3 “TxPDO3Rt” M7.28 Event timer TxPDO4 “TxPDO4Rt” M7.29 Event timer RxPDO1 “RxPDO1TO” M7.210 Event timer RxPDO2 “RxPDO2TO” For details about those parameters, please refer to the specific CAN Open manual [1]. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 129 Subindex Ref. size 1 Shared line contactor option “SharedLC” 0 4 1 0 0x2A00 0x1 Shared line contactor reference node “Ref 2 1 127 1 1 0x2A00 0x2 Node” 3 Shared line contactor refresh rate “SHLCRate” 15ms – 50ms 1ms 15ms 0x2A00 0x3 M7.31 Shared line contactor option “SharedLC” M7.32 Shared line contactor reference node “Ref Node” M7.33 Shared line contactor refresh rate “SHLCRate” For details about those parameters, please refer to the specific CAN Open manual [1]. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 123 ...
Page 130 0x2A01 0x2 3 Display refresh rate “RefRate” 100ms – 1000ms 10ms 200ms 0x2A01 0x3 M7.41 Display node number “DispNode” If the DMC Controller is intended to communicate with a DMC Display, this parameter is used to set the node number of the DMC Display. It should be set coherently with the setting made inside the Display. If the DMC Controller is intended to communicate with an iGauge, this parameter assumes different meanings depending on “M7.42 Display status field ”DispInfo””: If the Controller is setup as an iGauge Master (“M7.42 Display status field ”DispInfo”” set to 8), this parameter should indicate the node number of the last iGauge slave connected. In case no iGauge slave is connected, this parameter should match “M7.11 CAN node number “CAN node””. If the Controller is setup as an iGauge Slave (“M7.42 Display status field ”DispInfo”” set to 9), this ...
Page 131 Return to Table Of Contents M7.43 Display refresh rate “RefRate” This parameter sets the refresh rate of the messages used to communicate with the DMC Display or with the iGauge master/slaves. It is not suggested to change this value unless there is too much traffic on the CAN bus. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 125 ...
Page 132 Subindex Ref. size 1 SafeStop1 ramp time “SfStRmpTm” 30ms – 120ms 10ms 50ms 0x2A02 0x3 2 Safe Stop 1 cut timer “SS1 Time” 0.1s – 10.0s 0.1s 5.0s 0x2A02 0x4 3 SafeStop1 ramp time “SfStRmpTm” 30ms – 120ms 10ms 50ms 0x2A02 0x3 M7.51 SafeStop1 ramp time “SfStRmpTm” M7.52 Safe Stop 1 cut timer “SS1 Time” M7.53 SafeStop1 ramp time “SfStRmpTm” These settings are active if Control Via CAN HMI is enabled (“M7.23 TxPDO configuration “PDO cfg”” set lower than 4 and premapping mode OR any variable mapped in RxPDOs in freemapping mode). For details about those parameters, please refer to the specific CAN Open manual [1]. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 133: Menu 8 "Input/Output Configuration
The menu embeds the assignment of functional inputs and the configuration for the available physical inputs and outputs. The following submenus are available: • Menu 8.1 “Input/output assignment” • Menu 8.2 “Analogue input 1 configuration” • Menu 8.3 “Analogue input 2 configuration” • Menu 8.4 “Analogue input 3 configuration” • Menu 8.5 “Digital output 1 configuration” • Menu 8.6 “Digital output 2 configuration” • Menu 8.7 “Digital output 3 configuration” • Menu 8.8 “Digital output 4 configuration” • Menu 8.9 “Digital output 5 configuration” • Menu 8.10 “Wireoff and Shortcircuit detection” DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 127 ...
Page 134 SSI NO 16 SSI NO 17 SS1 NC 17 SS1 NC 18 SS1 toggle 19 Inching forward 18 SS1 toggle 20 Inching reverse 19 Inching forward 20 Inching reverse 21 Digital footbrake 21 Digital footbrake 22 Generator activation 22 Generator activation 23 No function (digital) 23 No function (digital) 24 Accelerator 25 Footbrake 26 Steerpot Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 135 28 active speed limit 3 Speed limit #3 29 Analogue torque limit 4 Advanced mode #1 30 Generator speed setpoint 5 Advanced mode #2 31 Generator BCL 6 Handbrake 32 Dual accelerator Inching forward 33 No function (analogue) 8 Inching reverse 9 Digital footbrake 10 Generator activation 11 Encoder 3 12 No function DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 129 ...
Page 136 No function – available Via CAN No function – available Via CAN, PWM No function – available Via CAN, 10 10 control PWM control DO5 Description config 0 Line contactor 1 EM brake 2 Powersteer 3 Motor fan 4 Controller fan 5 Combo fan 6 Remote LED 7 Drive OK 8 Brake light 9 No function – available Via CAN No function – available Via CAN, PWM 10 control 11 Proportional output control Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 137 In “Torque mode”, the brake torque applied will depend on Footbrake value; In “Speed Mode”, the footbrake deceleration ramp will depend on Footbrake value. • If the input is configured as “Steer Pot”, this sets the voltage on the analogue input X that will correspond to the minimum steering angle. By convention, the minimum steering angle relates to the full left hand lock of the vehicle. • If the input is configured as “Analogue torque limit”, this sets the voltage on the analogue input X that will correspond to 0% drive torque limit. • If the input is configured as “Analogue speed limit”, this sets the voltage on the analogue input X that will correspond to 0 rpm speed limit. • If the input is configured as “Dual accelerator”, this sets the voltage on the analogue input X that will correspond to 0% of 2 channel accelerator input. For tuning this parameter refer to “APPENDIX C – Analogue Input tuning”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 131 ...
Page 138 • If the input is configured as “Analogue torque limit”, this sets the voltage on the analogue input X that will correspond to 100% drive torque limit. • If the input is configured as “Analogue speed limit”, this sets the voltage on the analogue input X that will correspond to a speed limit equal to ”Maximum motor frequency” (adjustable in “Menu 3 “Autotuning””) or to the maximum speed limit active. • If the input is configured as “Dual accelerator”, this sets the voltage on the analogue input X that will correspond to 100% of 2 channel accelerator input. For tuning this parameter refer to “APPENDIX C – Analogue Input tuning”. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 139 Step Parameter name “Calibrator text” Range Default Index Subindex Ref. size 1 Digital output 5 pullin voltage ”Do5PlInV” 7V – 48V 1V 12V 0x2C05 0x1 2 Digital output 5 holding voltage ”Do5HoldV” 7V – 48V 1V 12V 0x2C05 0x2 M8.51 Digital output 1 pullin voltage ”Do1PlInV” M8.61 Digital output 2 pullin voltage ”Do2PlInV” M8.71 Digital output 3 pullin voltage ”Do3PlInV” M8.81 Digital output 4 pullin voltage ”Do4PlInV” M8.91 Digital output 5 pullin voltage ”Do5PlInV” It sets the Digital Output X pull in voltage applied for 1s. If this parameter is set to its maximum value (i.e. the nominal battery voltage for each SigmaLITE Controller size), the actual battery voltage will be applied, even if it is higher than the nominal battery voltage. Example: Nominal battery voltage = 48V, Parameter set to 48V, Actual battery voltage = 52V. The applied voltage is 52V. Nominal battery voltage = 48V, Parameter set to 47V, Actual battery voltage = 52V. The applied voltage is 47V. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 133 ...
Page 140 M8.72 Digital output 3 holding voltage ”Do3HoldV” M8.82 Digital output 4 holding voltage ”Do4HoldV” M8.92 Digital output 5 holding voltage ”Do5HoldV” It sets the Digital Output X holding voltage applied after 1s is elapsed from the initial closing command. If this parameter is set to its maximum value (i.e. the nominal battery voltage for each SigmaLITE Controller size), the actual battery voltage will be applied, even if it is higher than the nominal battery voltage. Example: Nominal battery voltage = 48V, Parameter set to 48V, Actual battery voltage = 52V. The applied voltage is 52V. Nominal battery voltage = 48V, Parameter set to 47V, Actual battery voltage = 52V. The applied voltage is 47V. M8.53 Digital output 1 wireoff enable “WireOff1” M8.63 Digital output 2 wireoff enable “WireOff2” M8.73 Digital output 3 wireoff enable “WireOff3” M8.83 Digital output 4 wireoff enable “WireOff4” This parameter is used to enable the wireoff detection on Digital Output X: 0: Wireoff disabled on Digital Output X. 1: Wireoff enabled on Digital Output X. M8.54 Digital output 1 shortcircuit enable “ShortCt1” M8.64 Digital output 2 shortcircuit enable “ShortCt2” M8.74 Digital output 3 shortcircuit enable “ShortCt3” M8.84 Digital output 4 shortcircuit enable “ShortCt4” This parameter is used to enable the shortcircuit and overcurrent detection on Digital Output X: 0: Shortcircuit disabled on Digital Output X. 1: Shortcircuit enabled on Digital Output X. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 141 0mA – 100mA 1mA 0mA 0x2F83 0x3 4 10V supply shortcircuit threshold “10VShortC” 0mA – 100mA 1mA 100mA 0x2F83 0x4 5 5V supply wireoff threshold “5V WrOff” 0mA – 100mA 1mA 0mA 0x2F83 0x5 6 5V supply shortcircuit threshold “5V ShortC” 0mA – 100mA 1mA 100mA 0x2F83 0x6 M8.101 Motor sensor wireoff threshold “MotWrOff” M8.102 Motor sensor shortcircuit threshold “MotShortC” M8.103 10V supply wireoff threshold “10VWrOff” M8.104 10V supply shortcircuit threshold “10VShortC” M8.105 5V supply wireoff threshold “5V WrOff” M8.106 5V supply shortcircuit threshold “5V ShortC” DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 135 ...
Page 142: Menu 9 "Dual Motor
Steer pot dead zone “StrDdZn” M9.117 Speed share based on demand or actual speed “SpdShare” M9.118 Steerpot speed limit as a cut “StrAsCut” For a complete description of dualmotor related parameters please refer to [3]. The only parameters that will be analysed in this manual are “M9.11 Dual motor cut out ”DMcut””, “M9.14 Dual motor angle 3 ”DMang3”” and “M9.17 Dual motor speed 3 ”DMspd3”. If parameter ”M5.112 Speed limit function of steer pot “SpLimstr”” is set to 1, the vehicle is considered a singlemotor vehicle equipped with a steer pot that gives a speed limitation when entering a curve. The following figure explains the above settings. • “M9.11 Dual motor cut out ”DMcut”” defines a deadband around zero steering in which speed is not limited; • “M9.14 Dual motor angle 3 ”DMang3”” defines the angle at which the speed limitation will act at its maximum value; Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 143 Return to Table Of Contents • “M9.17 Dual motor speed 3 ”DMspd3”” defines, as a percentage over the maximum speed set by ”Maximum motor frequency” (adjustable in “Menu 3 “Autotuning””), the maximum the speed limit applied. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 137 ...
Page 144: Menu 9.2 "Dual Motor Without Steerpot
Dual motor slave’s limitations affect master 7 0 1 1 0 0x2E0A 0x0 “DMlimMas” M9.21 Dual motor fail speed limit “DMMFlSpd” M9.22 Dual motor speed trimmer “SpdTrimm” M9.23 Dual motor antislip help gain “HelpGain” M9.24 Dual motor antislip help dead zone “HlpZone” M9.25 Dual motor speed ratio “DMMSpdRt” For a complete description of dualmotor related parameters please refer to [3]. M9.26 Dual motor failure option “DMFailOpt” This sets the behaviour of the Master and Slave controllers when dual motor configuration is active and one of the two controllers has detected a fault. For more details about the Dual Motor feature, parameters and setup please refer to [3]. This parameter requires a key cycle offon to be effective. M9.27 Dual motor slave’s limitations affect master “DMlimMas” This parameter is active only if “M23 Dual motor configuration ”DMconfig”” is set to 4. As better described in [3], a torque/speed limitation in a controller working with dual motor functionality also affects the other controller. If this setting is set to 0 (Limit in slave does not limit master), the master is not influenced at all by limitations happening in the slave controller. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 145: Safety Related Functions
Return to Table Of Contents 7 Safety related functions The SigmaLITE motor controller has some safety related functions that can be enable to enhance the application safety. The following list resumes the main function related to safety. Controller overheating protection DMC Sigma2N controllers have a builtin overheating protection. This function is meant to cut the available drive torque to the motor in case the controller is overheating, to avoid hardware damage. The following diagram shows how motor drive torque is cut as a function of controller temperature: It is worth noticing that brake torque is never cut to guarantee the motor/vehicle is always able to stop. The only exception of this is when the controller is driving in torque mode. In this case, brake torque is limited linearly starting from controller’s 90°C. Speed Guard Function In applications where speed control is adopted together with EM brake and no mechanical brake is installed, the system is relying on speed control accuracy for stopping and holding the vehicle until the EM brake is locking it in position. A function monitoring and tracking how close the motor is in following the speed request can help to prevent issues. ...
Page 146 The “prevent to travel” is achieved through a functional input, which takes the general name of “interlock” or the specific name of “Seatswitch” (for rideon vehicles) or “Tiller switch” (for walkietype vehicles), that is available for all type of vehicle options. The assignment of this functional input is mandatory for driving and, in case it is missing, motor control will be inhibited. In case it is missing during driving, the motor will be stopped and brought to a safe state with EMbrake closed. The ”travel control” function is achieved by monitoring the direction inputs and the accelerator signal. Driving will be inhibited in case those inputs are missing. “Prevent to travel” function in SigmaLITE controller meets safety level PLd CAT 2. “Travel control” function in SigmaLITE controller meets safety level PLd CAT 2. Potentiometers supply wire off and short-circuit detection Is it possible to enable the detection for the wire off or shortcircuit of potentiometer supplies. Both 5V and 10V outputs are protected against wire off and shortcircuits. The corresponding parameters can be found under “Menu 8.10 “Wireoff and Shortcircuit detection””. Possible wiring solutions to cover multiple potentiometer wire off and/or short circuit can be found under “Wiring of analogue inputs”. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 147: Monitoring
Actual Flux Filtered capacitor 28 voltage 29 Vehicle Speed Vehicle 1 Kph 30 Motor RPM speed RPMspeed 1 rpm Mapping error F7 Input assignment F7 Duplicate mapping F7 31 MapErr S64 specifier S107 specifier S65 specifier To reset the max and min temperatures logged data, press the + and – button at the same time when the controller is in neutral. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 141 ...
Page 148 18 Speed limit from high controller °C RH 18 Restraint hill hold MT 19 Speed limit from high motor °C Advanced mode speed 1 or 2 and torque AA 19 from AI2/3 limits DS 20 Speed limit from other motor AN 20 Torque limit from AI2/3 SF 21 Dual motor fail speed limit TV 21 Torque limit Via CAN DB 22 Unknown speed limit DD 22 Drive torque limit from other motor DB 23 Brake torque limit from other motor GL 24 Generator torque limit Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 149 Circle limitation PH 10 Unable to do positioning M06 DS301 status table BDI States Description STOP Node state stopped PREOP Node state pre operational OP Node state operational M07 DS402 status table BDI States Description STARTUP Startup SOD Switch on disabled RTSO Ready to switch on SO Switched on OE Operation enabled QS Quick stop FR Fault reset F Fault DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 143 ...
Page 150: Menu 10 "Test" For Traction Software
0 1 (op) 38 WD1 output WD1 out Output 0 1 39 SuP reset command SuP rest Output 0 1 SuP OE1 fbk 40 SuP digital input 1 SuP_DI1 Input 0 1 (ip) 41 SuP digital input 2 SuP_DI2 Input 0 1 Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 151 DI3 status is shown (1, as it is high/closed). In case the button will be pressed, the text will show “Speed1” and the function status will be visualized (0 in this case, as the function is “normally open”, therefore inactive). N/A in case no function is assigned to the corresponding digital/analogue input. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 145 ...
Page 152: Menu 10.2 "Test Software
Input % 0.0 % 100.0 % *See below °See Below 30 Generator speed input GenSpd Input % 0.0 % 100.0 % *See below °See Below 31 Dual accelerator input DualAcc Input % 0.0 % 100.0 % *See below °See Below *When pressing the button, the functional input coming Via CAN is visualized. In case the unit is “N/A”, it means that the corresponding variable is not mapped. In case the input name is substituted with “N/A” it means that the corresponding functional input is not available in CAN mapping at all. °When pressing the button, the functional input name is replaced with the physical input to which it is assigned and the corresponding physical input status is visualized. In case the unit is “N/A”, it means that the corresponding functional input is not assigned to any physical input. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 153: Menu 12 "About
Size 1 48V 10 Hardware BOM HWbom V3.02 11 BSP Version BSP Vxx.yy.zz 12 IPM/PMS/AC FOC version IPMFOC Vxx.yy.zz 13 Product serial number SN P AABBCCCC 14 Logic serial number SN L AABBCCCC 15 Logic version and variant HWver V3.02STD 16 Product tested and calibrated HWcal Y Y HW LEM 17 Safety uP version SUP Vxx.yy.zz 18 Bootloader version BOOT Vxx.yy.zz DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 147 ...
Page 154: Diagnostics
002 slave. Check that all the controllers supposed to be Shared line contactor slaves are configured as that, with the shared line contactor master’s node number set as reference node. 003 N/A Wigwag selected as accelerator type, but walkie vehicle is not enabled. Adjustment out of The wigwag accelerator type can only be used in conjunction with walkie range type vehicles. Either enable the walkie vehicle type or disable the wigwag option for accelerator input type. Inching function and walkie vehicle type are both enabled. Make sure only 005 one of the two is enabled. 006 N/A 007 N/A Inching function and Control Via CAN HMI are both enabled. Make sure 008 only one of the two is enabled. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 155 Dual motor mode 1 is enabled, but “steerpot” functional input is neither 026 assigned to any analogue physical input nor mapped into a RxPDO. 027 N/A 028 N/A 029 N/A 030 N/A Parameter “M38 RideOn, Walkie, EVehicle” not consistent between two 031 controllers. Make sure both Dual Motor Controllers have the same setting (only for Dual Motor modes 1/2, 5/6 and 7/8). Parameter “M35 DI5/6 configuration” not consistent between two 032 controllers. Make sure both Dual Motor Controllers have the same setting (only for Dual Motor modes 1/2, 5/6 and 7/8). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 149 ...
Page 156 Check active control mode (“M21 Control Mode 050 “Spd/Torq””), active premapped configuration (“M7.22 RxPDO premap configuration “RxPDOmap””) or custom free mapping performed (check for objects 0x3833, 0x3835, 0x6071, 0x60FF). Control Via CAN active and AI2/AI3 configured different than “Brake 051 Pot”/”Steer Pot” Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 157 0x1A00 to 0x1A07, subindex 0) actually corresponds to the number of 064 objects mapped (Index 0x1600 to 0x1607 and 0x1A00 to 0x1A07, subindex 1 to 8). Check that mapped object length does not exceed 64bit for each PDO. The error comes with a specifier, stored in object 0x3893. By monitoring this object, the user can get details about the message, containing the error, its byte position and causing object’s index. Check [9] for object 0x3893 decoding details. The mentioned command specifier can also be found in the Calibrator’s status menu. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 151 ...
Page 158 OR driver configuration selected to “No software function” and no command Via CAN mapped. Dual motor external line contactor activation not consistent between 077 controller pair. 078 DMC Controller is setup with the same node nr as DMC Display Generator mode setting conflict. Either disable generator mode or disable analogue speed and torque limit, set the controller as single motor or Dual Front Master (“M23 Dual motor configuration ”DMconfig”” to 0 or 3), disable the speed guard function (“M5.91 Speed control guard tracking ...
Page 159 Make sure either both or none of the two functional inputs are assigned to physical inputs. Walkie type vehicle selected trough “M22 Vehicle type selection ”Ride/Wlk”” and Control Via CAN activated, but none between 99 “Bellyswitch” or “Bellyswitch NO” or “Bellyswitch NC” functional input is assigned to a physical input. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 153 ...
Page 160 RxPDO), but the active selection for “M23 Dual motor configuration ”DMconfig”” does not allow it to be active. “Safe Stop 1” function activation is not consistent in Dual Motor couple. 110 Make sure either all controllers have this function active or none of them have it. “Safe Torque Off” function activation is not consistent in Dual Motor 111 couple. Make sure either all controllers have this function active or none of them have it. “Bellyswitch” function activation is not consistent in Dual Motor couple. 112 Make sure either all controllers have this function active or none of them have it. 998 Logic PCB doesn’t match firmware 999 Power PCB doesn't match firmware Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 161 Description fault Description Code code Parameter found out of range and set to default. This information can be stored in two different objects: Object index 0x3842 subindex 0x0 (Fault subcode extended), embeds this information in the format XXYYZZ, where XX is the menu number, YY is the >999 submenu number and ZZ is the item number. This is what the DMC calibrator shows. Object index 0x3841 subindex 0x0 (Fault subcode), embeds this information in the format XYYZZ (if X <=6) or XYZZ (if X > 6), where X is the menu number, YY or Y is the submenu number and ZZ is the item number. Default adjustments ...
Page 162 7 M3 positive overcurrent during initialization 8 M3 negative overcurrent during initialization 9 M1 positive overcurrent during running 10 M3 positive overcurrent during running 11 M3 negative overcurrent during running 1 N/A 2 N/A 3 N/A 4 N/A Contactor coil driver 5 N/A fault 6 N/A (e.g. short circuit) 7 N/A 8 N/A 9 N/A 10 N/A Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 163 Low sided mosfets short 2 M2 mosfets circuit in neutral 3 M3 mosfets 1 N/A 2 N/A 3 N/A 4 N/A 5 N/A 6 N/A 7 Main loop is stuck. Refer to DMC. Software watchdog caused a reset. Refer to DMC. 8 9 N/A 10 N/A 11 N/A 12 N/A 13 N/A 14 Safety uP hardware initialization failure. Refer to DMC 15 Safety uP communication initialization data failure. Refer to DMC 16 Safety uP communication initialization timeout. Refer to DMC 17 ...
Page 164 Main uP reading OE2 high before normal running 66 Safety uP fails to enter normal running state 67 An error occurs during normal running, refer to Safety uP error codes Safety uP reading M2 voltage and B+Safe pin timeout before releasing 68 short circuit 69 Safety uP communication configuration failure, refer to DMC Could not discharge the capacitor bank before closing the line contactor. 1 Line contactor might be stuck close or battery voltage might be directly applied to B+ terminal. Capacitor bank did not charge sufficiently to safely close the line contactor. Precharge cannot be finalized. Check the precharge voltage level set by “M25 Precharge voltage threshold ”PreChgLv””. Make sure the controller 2 is wired according to diagrams in “3.3.5 Power wiring examples”. Make ...
Page 165 “Tuning of a “dual channel” accelerator” for dual potentiometer accelerator tuning. 11 N/A Wire off detected 12 B+ Safe feedback signal is missing. Refer to DMC. Driver output 1 wire off detected. Make sure the load is connected, 13 otherwise disable the check by means of parameter “M8.53 Digital output 1 wireoff enable “WireOff1””. Driver output 2 wire off detected. Make sure the load is connected, ...
Page 166 10V supply shortcircuit detected. Check connected device’s status and 20 eventually configuration of parameter “M8.104 10V supply shortcircuit threshold “10VShortC”” 5V supply shortcircuit detected. Check connected device’s status and 21 eventually configuration of parameter “M8.106 5V supply shortcircuit threshold “5V ShortC”” 22 Safety uP Digital input 1 inconsistency. Refer to DMC. 23 Safety uP Digital input 2 inconsistency. Refer to DMC. 24 Safety uP Digital input 2 inconsistency. Refer to DMC. 25 Safety uP Digital input 4 / Analogue input 1 inconsistency. Refer to DMC. 26 Safety uP Digital input 5 / Analogue input 2 inconsistency. Refer to DMC. ...
Page 167 Check for CAN bus disturbances. Make sure CAN bus is wired properly. 43 Make sure that some device is present on the CAN bus further than the DMC Controller in case the latter is configured to output any HEARTBEAT or EMCY messages. Rx messages overload. The DMC Controller received more than 20 44 messages in 10ms. Reduce refresh rate of one or more messages. CAN bus Tx error counter above critical threshold. The CAN peripheral could not transmit the messages on the bus. Check CAN bus wiring and ...
Page 168 Time out on configuration upload 2 Time out on getting stable inputs Time out on motor ready. Make sure precharge sequence has succeeded Generic time out by checking battery and capacitor voltage as read by the controller. 3 Possibly check any F7 configuration error. Disable shared line contactor configuration for proper investigation of the issue. <700 Internal system error Contact DMC System Fault 700 Safety uP FW is not compatible with current main uP FW 710 The current FW is not compatible with the HW. ...
Page 169: Ac Motor Sub Error Codes
Return to Table Of Contents 9.1.1 AC Motor sub error codes Sub Description Code 0 No errors in the motor module. The motor module could not be initialized. Internal init failure: load default and reparametrize. If persist refer 1 to DMC. 2 The motor could not be fluxed in time or motor not connected, Check motor wiring. A motor overcurrent is detected. Check motor wiring and motor cable isolation. Be sure controller is properly 3 tuned 4 Internal unrecoverable Failure: Refer to DMC. Wrong maximum current: selected maximum current is lower than expected nominal current for the controller size: Increase Maximum Current in the Autotune menu and recycle the key until error disappear and autotune 5 again. If a lower maximum current is required first finish autotuning with a consistent max current and then lower the maximum current and autotune again. 6 Internal error. Refer to DMC. 7 Internal error. Refer to DMC. 8 Internal error: load default and reparametrize by means of autotuning. If persist refer to DMC. 9 Internal error: load default and reparametrize by means of autotuning. If persist refer to DMC. 10 Internal error: load default and reparametrize by means of autotuning. If persist refer to DMC. 11 Internal error: load default and reparametrize by means of autotuning. If persist refer to DMC. 12 Internal error: load default and reparametrize by means of autotuning. If persist refer to DMC. ...
Page 170: Pms Motor Error Subcodes
Return to Table Of Contents 9.1.2 PMS motor error subcodes Sub Description Code 0 No errors in the motor module. 1 The motor module could not be initialized. Load Default Parameter and key cycle 2 An motor overcurrent is detected. Check if motor tuned properly, check motor wiring (lack of isolation).. 3 Internal error refer to DMC 4 Wrong current setup: current for Autotuning is set greater than maximum current. Check current setup in the autotuning menu. 5 Wrong number of motor poles. An odd number has been set as number of motor poles in the autotuning menu. 6 Internal error refer to DMC 7 Internal error refer to DMC 8 Sine signal is out of range: check sin cos sensor wiring, sensor supply and sensor 9 Cosine signal is out of range: check sin cos sensor wiring, sensor supply and sensor 10 No Hall sensor signals; check hall sensor wiring. 11 Number of motor poles and sin cos sensor number of teeth (poles) are not consistent. The ratio between ...
Page 171: Ipm Motor Error Subcodes
Return to Table Of Contents 9.1.3 IPM motor error subcodes Sub Description Code No errors in the motor module 1 The motor module could not be initialized. Report to DMC 2 An overcurrent is detected: Motor is overloaded or wrong position sensor settings 3 Internal error Report to DMC 4 Wrong current: rated motor current is greater than maximum: Check setting 8 and 7 in the autotune menu 5 Wrong poles number. 6 Internal error Report to DMC 7 Internal error Report to DMC 8 Sine signal is out of range: check connection and sensor 9 Cosine signal is out of range: check connection and sensor 10 No Hall sensor signal; check connection and sensor 11 Unable to perform recalculation: motor calculated maximum speed exceeds 500 Hz: ; check motor parameters (LD,LQ Ke, Fmax) in auto tune menu. 12 Unable to perform recalculation: two or more speed points are equal. The maximum current set is too high for the motor. Decrease the Maximum current in the Autotune menu and perform a recalculation. 13 In one point or several points of the tables the total current (Sqrt(Id^2+Iq^2)) exceeds the maximum current set in the autotuning menu. Current tables are not consistent with autotuning menu. How to eliminate this error: ...
Page 172: Supervisor Up Error Codes
Return to Table Of Contents 9.2 Supervisor uP error codes The supervisor uP is able communication its error code trough the Main uP. This error code can be investigate by means of the DMC CAN Open Calibrator in “Menu 0 “Status””, or by retrieving object 0x38A1 via CAN. The SuP error code is represented by means of a 32bit bitsignificant double word, with the following meaning: Bit Description 0 Input 1 inconsistency. SuP is reading a different input value than MuP. 1 Input 2 inconsistency. SuP is reading a different input value than MuP. 2 Input 3 inconsistency. SuP is reading a different input value than MuP. 3 Input 4 inconsistency. SuP is reading a different input value than MuP. 4 Input 5 inconsistency. SuP is reading a different input value than MuP. 5 Input 6 inconsistency. SuP is reading a different input value than MuP. 6 N/A 7 N/A 8 Input 1 toggle check error. SuP recognised the input toggling, while MuP did not acknowledge it. 9 Input 2 toggle check error. SuP recognised the input toggling, while MuP did not acknowledge it. 10 Input 3 toggle check error. SuP recognised the input toggling, while MuP did not acknowledge it. 11 Input 4 toggle check error. SuP recognised the input toggling, while MuP did not acknowledge it. 12 ...
Page 173: Menu 11 "Fault Log
Return to Table Of Contents Menu 11 “Fault log” The fault log remembers the last 10 faults and stores the key hours when the fault happened. Holding the () button shows the registered hours counter time when the fault occurred. Holding the (+) button shows the fault sub error code. NOTICE! To reset the fault log data, press the + and – button at the same time when the controller is in neutral. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 167 ...
Page 174: Software Updates
Return to Table Of Contents 10 Software updates DMC reserves the right to issue Software Updates without prior notice. Software Updates are intended to introduce new functionalities, update existing ones or fix bugs in the application or motor module. In case an update has to be performed on a DMC SigmaLITE Controller, this must be carried out trough the CAN network using the DMC Configurator. Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 175: Dmc Displays
Return to Table Of Contents 11 DMC Displays 11.1 DMC Lite Display Developed as a the new generation for the DMC Display, the DMC Lite Display maintains the flexibility of its predecessor, introducing a brand new graphical design. The DMC Lite Display still operates on the CAN bus and has the capability of showing the information of up to 6 DMC SigmaLITE Controllers at the same time. The DMC Lite Display features 5 different pages to display all the available information: 1) The Main page displays Drive and BDI information of the “Display Master Controller” and, if any, the active faults of every DMC Controller in the Network configured to send messages to the DMC Display. 2) The Second Page shows a detailed status of each DMC SigmaLITE Controller configured to send messages to the DMC Display. 3) The Third page shows the drive and key hour counters, plus a configurable vehicle number to uniquely identify the machine. 4) The Fourth page shows a fault logger, gathering the fault of every DMC SigmaLITE Controller. 5) The Fifth page displays information about Display SW and HW. In addition to this, a setup menu is present and can be accessed from every page by pressing the central button. For more information about the DMC Lite Display please refer to the dedicated Application Note ([2]). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 169 ...
Page 176: Dmc Advanced Display
Return to Table Of Contents 11.2 DMC Advanced Display Developed as a plugin vehicle dashboard, the DMC Advanced Display represents the stateofart of vehicle monitoring. It features a modern graphical design, combined with the capability of interacting with up to 8 nodes, further than with a BMS. All driving information are easily visible in the main page, while service information about each controller connected can be accessed in auxiliary pages. For more information about the DMC Advanced Display please refer to the dedicated Application Note ([2]). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 177: Appendix A Technical Specifications
PWM switching Frequency 8 kHz Motor PWM equivalent frequency 16 kHz Maximum encoder/hall sensor frequency 75 kHz Maximum sin/cos frequency 2 kHz Electrical Isolation Reverse Battery Polarity Yes, if Line Contactor installed I/O details AMPSEAL 23pole connector Power consumption 5W CAN chip current Key line inrush current Precharge current Environmental Mechanical Impact Protection (IP) rating IP67 (with AMPSEAL 23pole connector fitted) Vibration 16 kHz Storage ambient temperature 40 °C to +70 °C (40 °F to 158 °F) Operating ambient temperature 40 °C to +50 °C (40 °F to 122 °F) Internal operating temperature 40 °C to +95 °C (40 °F to 203 °F) Vibration Humidity 95% maximum, noncondensing EMC Designed to the requirements of EN12895:2015 DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 171 ...
Page 178 Return to Table Of Contents Mechanical Power connectors 5 vertical aluminium studs (B+, B, M1, M2, M3) Dimensions (W x L x H) 109 x 147 x 56 mm (4.29 x 5.79 x 2.2 inches) Weight 0.885 kg ( 1.95 lbs) Baseplate material Aluminium Mounting holes 4x ∅6.5 Enclosure material ABS plastic Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 179: Appendix B - Emc Guidelines
Controller Thermal and EMC (emissive) requirements tend to be in opposition. Additional insulation between the controller assembly and the vehicle frame work reduce capacitive coupling and hence emissions but tend to reduce thermal ratings. 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 any consideration of cost reduction or other “improvement”. DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 173 ...
Page 180: Appendix C - Analogue Input Tuning
#9, in case the “accelerator” functional input was assigned to AI2; #11, in case the “accelerator” functional input was assigned to AI3; 4. With the accelerator fully pressed, take note of the voltage value al line: #7, in case the “accelerator” functional input was assigned to AI1; #9, in case the “accelerator” functional input was assigned to AI2; #11, in case the “accelerator” functional input was assigned to AI3; 5. Depending on which analogue input the functional input “accelerator” has been assigned, set “M8.21 Analogue Input 1 minimum voltage level “AI1 min”” in case the “accelerator” functional input was assigned to AI1 “M8.31 Analogue Input 2 minimum voltage level “AI2 min”” in case the “accelerator” functional input was assigned to AI2 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “accelerator” functional input was assigned to AI3 as the voltage level found at point 3). 6. Depending on which analogue input the functional input “accelerator” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “accelerator” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “accelerator” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “accelerator” functional input was assigned to AI3 as the voltage level found at point 4). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 181 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “brake” functional input was assigned to AI3 as the voltage level found at point 3). 6. Depending on which analogue input the functional input “brake” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “brake” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “brake” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “brake” functional input was assigned to AI3 as the voltage level found at point 4). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 175 ...
Page 182 #11, in case the “steer pot” functional input was assigned to AI3; 5. Set the wheels straight, take note of the voltage value al line: #7, in case the “steer pot” functional input was assigned to AI1; #9, in case the “steer pot” functional input was assigned to AI2; #11, in case the “steer pot” functional input was assigned to AI3; 6. Depending on which analogue input the functional input “steer pot” has been assigned, set “M8.21 Analogue Input 1 minimum voltage level “AI1 min”” in case the “steer pot” functional input was assigned to AI1 “M8.31 Analogue Input 2 minimum voltage level “AI2 min”” in case the “steer pot” functional input was assigned to AI2 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “steer pot” functional input was assigned to AI3 as the voltage level found at point 3). 7. Depending on which analogue input the functional input “steer pot” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “steer pot” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “steer pot” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “steer pot” functional input was assigned to AI3 as the voltage level found at point 4). 8. Set parameter “M1.71 Steer pot middle point voltage level ”StrMid”” as the voltage level found at point 5). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 183 #9, in case the “analogue torque limit” functional input was assigned to AI2; #11, in case the “analogue torque limit” functional input was assigned to AI3; 4. With the potentiometer fully turned to the end that should correspond to 100%,, take note of the voltage value al line: #7, in case the “analogue torque limit” functional input was assigned to AI1; #9, in case the “analogue torque limit” functional input was assigned to AI2; #11, in case the “analogue torque limit” functional input was assigned to AI3; 5. Depending on which analogue input the functional input “analogue torque limit” has been assigned, set “M8.21 Analogue Input 1 minimum voltage level “AI1 min”” in case the “analogue torque limit” functional input was assigned to AI1 “M8.31 Analogue Input 2 minimum voltage level “AI2 min”” in case the “analogue torque limit” functional input was assigned to AI2 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “analogue torque limit” functional input was assigned to AI3 as the voltage level found at point 3). 6. Depending on which analogue input the functional input “analogue torque limit” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “analogue torque limit” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “analogue torque limit” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “analogue torque limit” functional input was assigned to AI3 as the voltage level found at point 4). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 177 ...
Page 184 #11, in case the “analogue speed limit” functional input was assigned to AI3; 4. With the potentiometer fully turned to the end that should correspond to 100%,, take note of the voltage value al line: #7, in case the “analogue speed limit” functional input was assigned to AI1; #9, in case the “analogue speed limit” functional input was assigned to AI2; #11, in case the “analogue speed limit” functional input was assigned to AI3; 5. Depending on which analogue input the functional input “analogue speed limit” has been assigned, set “M8.21 Analogue Input 1 minimum voltage level “AI1 min”” in case the “analogue speed limit” functional input was assigned to AI1 “M8.31 Analogue Input 2 minimum voltage level “AI2 min”” in case the “analogue speed limit” functional input was assigned to AI2 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “analogue speed limit” functional input was assigned to AI3 as the voltage level found at point 3). 6. Depending on which analogue input the functional input “analogue speed limit” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “analogue speed limit” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “analogue speed limit” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “analogue speed limit” functional input was assigned to AI3 as the voltage level found at point 4). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 185 Return to Table Of Contents Tuning of a “dual channel” accelerator pedal Accelerator pedals are generally produced in various types for providing the required safety. The majority embeds a single potentiometer to provide the analogue signal and a digital switch (namely “footswitch”) to provide safety redundancy for accelerator presence. Other accelerators on the other hand do not have this digital output, but embed a second potentiometer which provides a second analogue output. The DMC Controller has the capability of working with this kid of accelerator, which normally come in two different type: “halfsignal” type and “crossed signal” type. “Half signal” dual output accelerator The dual potentiometer accelerators of the “half signal” type have a voltage versus pedal range curve as indicated in the following picture. “Crossed signal” dual output accelerator The dual potentiometer accelerators of the “crossed signal” type have a voltage versus pedal range curve as indicated in the following picture . DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 179 ...
Page 186 6. Depending on which analogue input the functional input “dual accelerator” has been assigned, set “M8.21 Analogue Input 1 minimum voltage level “AI1 min”” in case the “dual accelerator” functional input was assigned to AI1 “M8.31 Analogue Input 2 minimum voltage level “AI2 min”” in case the “dual accelerator” functional input was assigned to AI2 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “dual accelerator” functional input was assigned to AI3 as the voltage level found at point 4). 7. Depending on which analogue input the functional input “dual accelerator” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “dual accelerator” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “dual accelerator” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “dual accelerator” functional input was assigned to AI3 as the voltage level found at point 5). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 187 “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “generator speed setpoint” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “generator speed setpoint” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “generator speed setpoint” functional input was assigned to AI3 as the voltage level found at point 5). DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) Page 181 ...
Page 188 “M8.31 Analogue Input 2 minimum voltage level “AI2 min”” in case the “generator regenerative BCL” functional input was assigned to AI2 “M8.41 Analogue Input 3 minimum voltage level “AI3 min”” in case the “generator regenerative BCL” functional input was assigned to AI3 as the voltage level found at point 4). 7. Depending on which analogue input the functional input “generator regenerative BCL” has been assigned, set “M8.22 Analogue Input 1 maximum voltage level “AI1 max”” in case the “generator regenerative BCL” functional input was assigned to AI1 “M8.32 Analogue Input 2 maximum voltage level “AI2 max”” in case the “generator regenerative BCL” functional input was assigned to AI2 “M8.42 Analogue Input 3 maximum voltage level “AI3 max”” in case the “generator regenerative BCL” functional input was assigned to AI3 as the voltage level found at point 5). Page DMC SigmaLite Traction Advanced manual V1.0 (SW V04.00.00) ...
Page 189: Appendix D - Wireoff Detection Tuning
Return to Table Of Contents APPENDIX D – Wireoff detection tuning The DMC SigmaLITE Controller has tuneable current threshold for guaranteeing wireoff detection on both its “Pin A10 Analogue supply – 5V / 30mA”, “Pin A11 Analogue supply – 10V / 100mA” and “Pin A16 Sensor supply 5V or 10V / 70mA” supply outputs. Is it given for granted that, in case any load is connected to the mentioned pins, it will absorb a certain amount of current. The parameters “M8.105 5V supply wireoff threshold “5V WrOff””, “M8.103 10V supply wireoff threshold “10VWrOff”” and “M8.101 Motor sensor wireoff threshold “MotWrOff”” define, respectively, the current threshold below which the load is considered disconnected, as too low current absorption is measured. Please notice that setting a value of 0mA to the mentioned parameters, corresponds in disabling the wireoff detection. Hereafter a procedure for tuning the wireoff detection parameter is reported: 1 Perform the final wiring of the machine. This point is very important, as more than 1 load can be connected at the same time under one supply. Changing the machine wiring might lead to spoiling the setup of the wireoff related parameter. 2 Enter “Menu 10.1 “Test Hardware””. 3 Scroll down to line: ...
Page 190: Appendix E - Safety Compliance To En 13849
Return to Table Of Contents APPENDIX E – Safety compliance to EN 13849 The DMC SigmaLITE controller is designed to meet the highest standards with respect to vehicle construction safety. The European Machinery Directive states that the guidelines defined by EN 13849 must be followed when designing safetyrelated parts of control systems, and the said systems must be proven to comply to the norm. EN 13849 introduces the concept of safety Performance Level (PL), which is achieved through an appropriate hardware design, the requirement of high enough Mean Time To Dangerous Failure (MTTFd) and adequate Diagnostic Coverage (DC). Based on these elements, vehicle manufacturers can calculate the Performance Level for each function which requires it. DMC guaranteed the compliancy with EN 13849 using advanced hardware design and modern monitoring techniques. A “safety” microcontroller (SµC) has been introduced, acting in parallel to the “main” microcontroller (MµC), providing redundancy on input reading, function activation and monitoring and output management. This hardware design can be represented by the block scheme reported below. Both SµC and MµC run diagnostic checks at every powerup and system reset to guarantee hardware, software and memory integrity. Once this has been proved, their normal operation is made completely independent from one another to guarantee maximum safety redundancy. In case these initial checks fail, power is never applied to the system and drive will be inhibited. At runtime a communication exists between the two µC, guaranteeing live input status crosscheck, drive information exchange and system status crossfeedback at a rate exceeding 40 times per second. This communication is ...
Page 191 Return to Table Of Contents Incorrect direction of motion The table reported below lists the implemented safety functions implemented in the DMC SigmaLITE controller, alongside with the useful parameters that OEM’s may need to check the overall safety compliancy of their product. Safety function PL Category MTTFd Safe Torque Off d 3 Safe Stop 1 d 2 Prevent To Travel D 2 Travel Control d 2 ...

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