DMC SuperSigma2 - 2.4 Power Wiring

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2.4 Power Wiring

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.

Main Page

Table of Contents3
About this Manual9
References9
How Settings Are Numbered in this Document9
How to Correctly and Time-Efficiently Setup a Controller9
Control Connections10
Pin 110
Forward I/P -- Pump Potentiometer Switch 110
Reverse I/P -- Pump Switch 210
Footswitch / Belly Button -- Pump Switch 310
Pin 511
Seat / Tiller -- Pump Switch 411
Speed Limit 1 / Inch Forward -- Pump Switch 511
Pin 6 Speed Limit 2 / Inch Reverse -- Pump Switch 6 (Power Steer Input)11
Pin 7 Speed Limit 3 / Handbrake -- Pump Inhibit12
Pin 8 Analogue Supply 5V12
Pin 9 Analogue AD1 I/P Accelerator -- Potentiometer12
Pin 10 Analogue Supply 0V12
Pin 11 Analogue AD2 -- Footbrake Pot13
Pin 12 Analogue AD3 -- Steer Pot13
Pin 13 Key I/P13
Pin 14 Contactor Supply O/P13
Pin 15 Contactor 1 O/P (Line)13
Pin 16 Contactor 2 O/P (Magnet Brake - Fan Control)14
Pin 17 Contactor 3 O/P (Powersteer - Fan Control)14
Pin 18 Digital O/P -- Remote LED or Brake Lights or Drive OK14
Pin 19 Supply 12V -- 70Ma Max14
Pin 20 CAN +12V -- 70Ma Max14
Pin 21 CAN H114
Pin 22 CAN L114
Pin 23 CAN 0V14
Pin 24 CAN 120R Link14
Pin 25 CAN H215
Pin 26 CAN L215
Pin 27 Sensor Supply +5V / +12V15
Pin 28 Hall 1 I/P15
Pin 29 Hall 2 I/P15
Pin 30 Hall 3 I/P15
Pin 31 Sensor Supply 0V15
Pin 32 Motor Sensor Sine15
Pin 33 Motor Sensor Cosine15
Pin 34 Thermistor AD4 I/P15
Light Wiring of Pms Controller16
Connectors' Pin Assignment for Traction16
Light Wiring Example for Traction17
Connectors' Pin Assignment for Pump18
Light Wiring Example for Pump19
Selecting Active Low or High Digital Inputs20
Active Low Digital Inputs20
Active High Digital Inputs21
Use of Ohmic Potentiometers and Electronic Potentiometers21
Power Wiring22
Menu 1 "Adjustment23
Menu 1 "Traction Adjustments23
M1-1T Acceleration Delay "Accel24
M1-2T Deceleration Delay "Decel25
M1-67T Dual Motor Speed 3 "Dmspd340
M1-68T Speed Ratio (Display Kph) "Spdratio42
M1-69T Vehicle Max. Speed "Vmaxspd42
M1-70T Safe Stop Torque (Torque Mode Only) "Sfsttorque42
M1-71T Safe Stop Ramp Time "Sfstrmptm42
M1-72T Belly Switch Speed "Bellyspd42
M1-73T Belly Switch Time "Bellytim42
Menu 1 "Pump Adjustments43
M1-1P Acceleration Delay "Accel43
M1-2P Deceleration Delay "Decel43
M1-3P Creep Speed "Creep43
M1-4P Creep Speed Ramp "Creeprmp43
M1-5P Maximum Pot Speed 1 "Potmax143
M1-6P Speed 2 Demand "Pspeed243
M1-7P Speed 3 Demand "Pspeed343
M1-8P Speed 4 Demand "Pspeed444
M1-9P Speed 5 Demand "Pspeed544
M1-10P Speed 6 Demand (Power Steer) "Pspeed644
M1-11P Minimum Motor Speed in Cutback Conditions "Minspeed44
M1-12P Acceleration Delay for Speed 6 Demand (Pwrstr) "Paccel644
M1-13P Power Steer Delay "Pstrdly44
M1-14P Accelerator Pot Minimum "Accmin44
M1-15P Accelerator Pot Maximum "Accmax44
M1-16P Speed Threshold to Enter in End of Braking Mode "Spdthebm44
M1-17P Ramp Time from Spdthspc to Zero "Spdrmptm44
Menu 2 "Status45
Status Tables46
M2-3 BDI States Table46
M2-6 Drive and Brake Status Table46
Speed Limits Table46
Torque Limits Table46
M2-9 Motor Limits Table46
Menu 3 "Controller Setup47
Menu 3 "Controller Setup for Traction47
M3-1T Accel. Characteristic "Lin/Curv49
M3-2T Control Mode "Spd/Torq49
M3-3T Proportional Direction Brake "Off /Bpro50
M3-4T Hill Hold "Off/Hh/S50
M3-5T I/O Pin 5 and 6 "Sp/In/Ad51
M3-6T I/O Pin 7 "Spd3/Hbk52
M3-7T Power Steer Trigger "Psf/Fr/S52
M3-8T Vehicle Type Select "Ride/Wlk52
M3-9T Tiller Function "Tillfunc53
M3-10T Belly Switch Disabled at Zero Speed and in Neutral "Bellfunc53
M3-11T Display Status Field "Of/D/V/K53
M3-12T Accelerator Type "Acceltyp53
M3-13T Accelerator Damping Factor "Acceldam54
M3-14T Single or Dual Motor "Si/Dl/Dr54
M3-15T Digital O/P 4 Config "Do4Typ54
M3-16T Active Low or High Digital Inputs "Actvl/H54
M3-17T Accelerator Supply Wire off Detection "Splywrof55
M3-18T Standby Timer "Stdbydly55
M3-19T Driver Output 2 Configuration "Drv2Cfg55
M3-20T Driver Output 3 Configuration "Drv3Cfg55
M3-21T Motor Temperature Threshold (for Output Driver) "Mottmpth55
M3-22T Controller Temperature Threshold (for Output Driver) "Ctrtmpth55
M3-23T Line Contactor Pull-In Level "Lcplinlv56
M3-24T Line Contactor Pull-In Time out "Lcplinto56
M3-25T Drive Torque During Braking "Dtrq@Brk56
M3-26T Line Contactor Coil Pull-In Voltage "Lcplinvl56
M3-27T Line Contactor Coil Holding Voltage "Lcholdvl56
M3-28T Digital Output 2 Pull-In Voltage "Do2Plinv56
M3-29T Digital Output 2 Hold Voltage "Do2Holdv56
M3-30T Digital Output 3 Pull-In Voltage "Do3Plinv56
M3-31T Digital Output 3 Hold Voltage "Do3Holdv56
M3-32T N/A56
M3-33T Calibration Data Option "Calvalue57
M3-34T Loading Default "Loaddefs57
Menu 3 "Controller Setup for Pump58
M3-1P Accel. Characteristic "Lin/Curv59
M3-2P Speed 6 Input Normally Closed or Normally Open "Sp6No/Nc59
M3-3P Inhibit Input Normally Closed or Normally Open "Hibno/Nc59
M3-4P Enable Power up Checks "Nchk/Chk59
M3-5P Enable Pot with Switch "Nosw/Sw59
M3-6P Display Status Field - "Of/D/V/K60
M3-7P Digital O/P 4 Config "D04Typ60
M3-8P Active Low or High Digital Inputs* "Actv L/H60
M3-9P Supply Wire off Detection "Splywrof60
M3-10P Line Contactor Pull-In Level "Lcplinlv60
M3-11P Line Contactor Pull-In Time out "Lcplinto60
M3-12P Line Contactor Coil Pull-In Voltage "Lcplinvl60
M3-13P Line Contactor Coil Holding Voltage "Lcholdvl61
M3-14P Digital Output 2 Pull-In Voltage "Do2Plinv61
M3-15P Digital Output 2 Hold Voltage "Do2Holdv61
M3-16P Digital Output 3 Pull-In Voltage "Do3Plinv61
M3-17P Digital Output 3 Hold Voltage "Do3Holdv61
M3-18P Driver Output 2 Configuration "Drv2Cfg61
M3-19P Driver Output 3 Configuration "Drv3Cfg62
M3-20P Motor Temperature Threshold (for Output Driver) "Mottmpth62
M3-21P Controller Temperature Threshold (for Output Driver) "Ctrtmpth62
M3-22P N/A62
M3-23P Calibration Data Option "Calvalue62
M3-24P Load Defaults "Loaddefs62
Pms Motor Auto Tuning63
Setting up Auto Tuning63
Menu 4 "Pms Motor Auto Tuning64
M4-1 Number of Motor Poles "Nmotpole64
Sensor Technology "Senstype64
M4-3 Sensor Supply Voltage "Sensuppv65
M4-4 Number of Sensor Poles "Nsnspole65
M4-5 Reverse Sensor Reading "Spdrev65
M4-6 Reverse Motor Direction "Motorrev65
M4-7 Battery Voltage "Battv at65
M4-8 RMS Motor Current for Tuning "Ifor at65
M4-9 Maximum RMS Motor Current "Imotmax65
M4-10 Back-EMF Constant (Kev) "K Emf65
M4-11 Motor Phase to Phase Inductance "L Ph-Ph65
M4-12 Maximum Demagnetizing (Field Weakening) Current "I Demag65
M4-13 Maximum Motor Frequency "Fmotmax66
M4-14 Start Auto-Tuning "Autotune66
M4-15 Recalculation after Changing One of the Adjustments of this Menu Marked with One Star "Recalcul66
M4-16 Sin/Cos Sensor Delay Angle at 100 Hz "Sensdel66
M4-17 Auto Tuning Type "Atunetype66
Initiating Auto Tuning67
Auto Tuning Errors68
Recalculation69
Fine Motor Tuning69
How to Have more Torque69
How to Have more Power69
How to Have more Speed69
Motor Is Vibrating or Driving Unstable69
Menu 5 "Pms Motor Setup70
M5-1 Proportional Gain Speed Controller "Kp Spd70
M5-2 Integral Gain Speed Controller "Ki Spd70
M5-3 Enable Double PI Settings for Speed Controller "Spdpix271
M5-4 Double PI Speed Threshold "Spdpith71
M5-5 Proportional Gain Speed Controller below Threshold "Kpspdlow71
M5-6 Integral Gain Speed Controller below Threshold "Kispdlow71
M5-7 Transition Time between the Two PI Settings for the Speed Controller "Transtim71
M5-8 Speed Limit Tolerance "Splimtol71
M5-9 Speed Limit Action Ramp Time "Splimtim72
M5-10 Extra Field Weakening Level Referred to the Ideal Flux at Maximum Speed "Fwextra72
M5-11 Speed Threshold for Beginning Field Weakening "F_FW TH72
M5-12 Torque Reduction Map in Field Weakening Range Point 1 "Treduc172
M5-13 Torque Reduction Map in Field Weakening Range Point 2 "Treduc272
M5-14 Torque Reduction Map in Field Weakening Range Point 3 "Treduc372
M5-15 Torque Reduction Map in Field Weakening Range Point 4 "Treduc472
M5-16 Torque Reduction Map in Field Weakening Range Point 5 "Treduc572
M5-17 Capacitor Voltage Ramp Time Capvtime72
M5-18 Voltage Limiter Filter Frequency Fvlimflt72
Menu 6 "Pms Motor Advanced73
M6-1 Decouple Iq and ID Controllers "Decouple73
M6-2 Enable Software PWM Algorithm Delay Compensation "Pwmdelay73
M6-3 Limit Torque Controller During Voltage Limiting "Voltsat73
M6-4 Speed Control Filter "Scfilter73
M6-5 Enable Voltage Limiter "Voltctrl73
M6-6 Speed Filter Cut-Off Frequency "Fspdfilt73
M6-7 Percentage of Correction for Inductance Value "Decoleak73
M6-8 Back EMF Correction Factor "Bemfcorr73
M6-9 Speed Estimator Rate "Obs.rate73
Menu 7 "Limits Setup74
M7-1 Motor Temp Sensor Type "Mtemptyp74
M7-2 Motor Temp. Cutback Start "Tempstrt75
M7-3 I²T Nominal Motor Current "Nomcurr75
M7-4 I²T Start Motor Temperature "I2Ttemp75
M7-5 I²T Time "I2Ttime75
M7-6 I²T Cutback1 "I2Tcutb175
M7-7 I²T Cutback2 "I2Tcutb275
M7-8 I²T Cutback3 "I2Tcutb375
M7-9 Performance Table Speed 1 "Ptspd178
M7-10 Performance Table Speed 2 "Ptspd278
M7-11 Performance Table Speed 3 "Ptspd378
M7-12 Performance Table Cutback 1 "Ptcutbk178
M7-13 Performance Table Cutback 2 "Ptcutbk278
M7-14 Performance Table Cutback 3 "Ptcutbk378
M7-15 Low Voltage Cut Back Start Threshold "Lvcbstrt80
M7-16 Low Voltage Cut Back End Threshold "Lvcbend80
M7-17 Low Voltage Error Threshold "Lverror80
M7-18 High Voltage Cut Back Start Threshold Hvcbstrt81
M7-19 High Voltage Cut Back End Threshold "Hvcbend81
M7-20 High Voltage Error Threshold "Hverror81
M7-21 Absolute Maximum Motor Speed "Absmaxsp82
M7-22 Torque Threshold for Stall Protection "Trqthlim82
M7-23 Stall Protection Time "Stalltim82
M7-24 N/A82
M7-25 N/A82
M7-26 Timed Current Limit Timer "Ithtime83
M7-27 Timed Current Limit Max. Current Threshold "Currth83
M7-28 Timed Current Limit Low Current Threshold "Imaxlow83
Menu 8 "Bdi" Battery Discharge Indicator84
M8-1 Battery Current Limit Via Can Type "Blccanmsg84
M8-2 Nominal Battery Voltage "Nombatv85
M8-3 BDI Reset Level "Bdireset85
M8-4 BDI Empty Level "Bdiempty85
M8-5 BDI Warning Level "Bdiwarn85
M8-6 BDI Cut out Level "Bdicut85
M8-7 BDI Speed Limit "Bdispeed85
M8-8 Drive Battery Current Limit (Max. Value) "Ibattmax85
M8-9 Regen Battery Current Limit "Ibattreg85
Menu 9 "Can Bus Setup86
M9-1 CAN Node Number "CAN Node87
M9-2 CAN Bit Rate "Canbitrt87
M9-3 Transmit/Receive CAN Messages "Canmsgs87
M9-4 Shared Line Contactor "Sharelc87
M9-5 Last Node Sharing Line Contactor "Lstnode88
M9-6 Can Control Type "Cancttyp88
M9-7 CAN Motor Status Transmit Rate "CAN_MS88
M9-8 CAN Controller Status Transmit Rate "CAN_CS88
M9-9 CAN Drive Status Transmit Rate "CAN_DS88
M9-10 CAN Controller Timeout Timer "CAN_TO88
M9-11 CAN Node ID Via Digital Input "CAN_DIG88
Diagnostics89
Error Codes89
Pms Motor Sub Error Codes94
Use of Calibrator and Pc Interface95
Available Application Notes and Manuals96
Mechanical Drawings97
Supersigma2 Controllers97
Contact Information97

DMC SuperSigma2 - 2.4 Power Wiring

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