Simga2N Traction Advanced Manual– V1.3 Page 33 (166) ©2021 DMC GmbH Herten Germany
3.2 Power Wiring
The DMC Simga2NController has 5 high-power 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 cross-sectional area for the current to
be carried. These should be terminated in crimped lugs attached to controller and the contactors. 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).
3.2.1 Lug assembly
Five M8 aluminum 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 M8 bolt to fix the assembly together and tighten with 9.5 (± 0.5) Nm strength.
3.2.2 Safety recommendations
Electric vehicles can be dangerous. All testing, fault-finding and adjustment should be carried out by competent
personnel. The drive wheels should be off the floor and free to rotate during the following procedures.
Before working on the controls disconnect the battery and connect the B+ and B- controller terminals via a 10 ohm 25
watt resistor to discharge the internal capacitors.
Never connect the controller to a battery with its vent caps removed as an arc may occur due to the controller’s internal
capacitance when it is first connected.
The controller wiring must be completely isolated from the chassis, NEVER CONNECT B- OR B+ TO THE CHASSIS OF THE
VEHICLE.
On road vehicles with a 12 Volt on-board electrical system, the 12 Volt system MUST be galvanic separated from the
drive power system. This can be done via a DC-DC converter that charges the 12 Volt system from the drive battery
system.
Always use a line contactor, controlled by the DMC controller, to enable the controller to switch off in unsafe situations.
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 regen.
3.2.3 Power up delay and Internal Capacitors Precharge
At power up the internal capacitor bank needs to be charged. The controller has a build in pre-charge resistor, and is
monitoring the capacitor bank voltage. As soon as the voltage is at the required level, the line contactor will pull in.
Especially at 24V systems using a Large size controller, the time delay to charge the capacitor bank can be longer.
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