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PG Drives Technology S45A User Manual

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S-DRIVE CONTROLLER FAMILY
TECHNICAL MANUAL
SK76745/10

Table of Contents

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PG Drives Technology S45A Specifications

General IconGeneral
BrandPG Drives Technology
ModelS45A
CategoryController
LanguageEnglish

Summary

About this manual

Manual Icons Explained

Explains icons for Note, Caution, and Warning.

Chapter 1: Operation

Introduction to S-Drive Operation

Introduces the S-Drive controller and its manual.

General Handling and Operation

Covers general handling, operating conditions, and reliability.

S-Drive Controls Overview

Details the various controls on the S-Drive controller like On/Off, indicators, and throttle.

Using Your Controller

Driving Technique and General Use

Offers tips for effective controller operation and driving technique.

Precautions for Use

Lists hazards, system malfunction risks, and EMI precautions.

Safety Checks

Daily and Weekly Checks

Outlines essential daily and weekly maintenance checks for the scooter.

Servicing Recommendations

Recommends periodic inspections by a qualified service agent.

Understanding Status Indication

Explains how the status indicator reflects the controller's operational status.

Battery Gauge Operation

Reading Battery Gauges

Refers to sections for reading single bulb/LED and TruCharge gauges.

Pushing and Programming the Scooter

Outlines controller programming methods and safe scooter pushing.

Warranty and Servicing Information

S-Drive Controller Warranty Terms

Lists conditions that may void the controller's warranty.

Authorized Servicing Procedures

Emphasizes that servicing must be done by authorized personnel.

Chapter 2: Installation

Documentation and S-Drive Operation

Guides to study Chapter 1 for operation details.

S-Drive Controller Dimensions

Provides dimensional data for S45A, S70A, and S90A controllers.

S-Drive Connections

General Connection Guidelines

Covers general advice on wiring, connectors, and ensuring reliable connections.

Wiring Diagram: S45A, S70A & S90A

Provides specific wiring diagrams for S45A, S70A, and S90A models.

Wiring Diagram: S120A & 140A

Offers wiring diagrams for S120A and S140A controllers.

Crimping Procedures

Wire Gauge and Types

Battery Connection Requirements

Motor Connection Guidelines

Solenoid Brake Connection

Tiller Interface Connections

Throttle Potentiometer Configuration

Explains how to configure throttle potentiometers for various throttle types.

Speed Limiting Potentiometer Setup

Details connecting and configuring a speed limiting potentiometer.

Status Indicator Connections

Status Indicator Diagnostic Settings

Explains programming the diagnostic flash sequence for status indicators.

24V Supply Pin

Discusses the use of pin 7 for tiller supply and charging current.

Inhibit Inputs

Inhibit 2 Input Configuration

Details the Inhibit 2 input at pin 6 and its programmable parameters.

Drive Motor Considerations

Gradient Performance Optimization

Discusses minimizing rollback and roll-forward for comfort on inclines.

Freewheeling Functionality

Explains methods for providing a scooter freewheel function.

Charger and Programming Connections

Inhibit 1 Input

Details the Inhibit 1 input located on the 4-way charger connector.

S-Drive Mounting Instructions

Mounting S45A, S70A & S90A

Illustrates mounting procedures for specific S-Drive models.

Mounting S120A & S140A

Shows mounting illustrations for S120A and S140A models.

Production Tests

Mounting and Cable Checks

Verifies secure mounting and integrity of cables and connectors.

Preset Settings Verification

Ensures correct program settings are applied for the scooter.

Operational and Test Drive Procedures

Guides through operational tests and test drives before dispatch.

Electromagnetic Compatibility (EMC)

Minimizing Radio Frequency Emissions

Provides recommendations for reducing radio frequency emissions.

Electro-Static Discharge (ESD) Precautions

Details precautions to prevent ESD damage to the controller.

Chapter 3: Programming

Introduction to S-Drive Programming

Overview of programmable parameters and methods using SP1a or PC.

SP1a Programmer Details

Explains the use of the SP1a handheld programmer for parameter adjustments.

PC Programmer Usage

Describes using PC software and interface cables for programming.

Parameter Groupings

Lists parameter categories for easy reference.

Speed Parameter Adjustments

Forward Acceleration and Deceleration

Allows adjustment of forward acceleration and deceleration rates.

Reverse Acceleration and Deceleration

Allows adjustment of reverse acceleration and deceleration rates.

Operation Parameter Settings

Throttle Invert Functionality

Selects polarity for throttle or reverse switch operation.

Sleep Timer Configuration

Sets the inactivity period before entering sleep mode.

Throttle Parameter Adjustments

Throttle Type Selection

Allows selection of Single-ended, Wig-wag, or Unipolar throttle types.

Throttle Deadband Configuration

Sets throttle movement before brake disengagement.

Throttle Operation at Power-up

Defines controller behavior when powered on with throttle deflected.

Battery Parameter Settings

Low Battery Flash Level

Sets the threshold for low battery warning flashes.

Cable Resistance Calibration

Sets value for cable and connector resistance for gauge accuracy.

Low Battery Alarm Enable

Enables an audible alarm for low battery conditions.

Inhibit Parameter Configuration

Inhibit 1 Parameters

Details Inhibit 1 Mode, Speed, and Latch settings.

Inhibit 2 Parameters

Details Inhibit 2 Mode, Speed, and Latch settings.

Inhibit 3 Parameters

Details Inhibit 3 Mode, Speed, and Latch settings.

Auxiliary Output Mode Settings

Configures when the auxiliary output relay is active.

General Parameter Settings

Soft-Stop Feature Enable

Enables or disables the soft-stop feature for gradual deceleration.

Brake Time Adjustment

Sets the delay between zero motor speed and solenoid brake application.

Status Output Type Selection

Selects the connection type for status indicators.

Diagnostic Flash Sequence Settings

Configures diagnostic flash patterns for status indicators.

Brake Fault Detection Enable

Motor Parameter Adjustments

Current Limit Settings

Sets the minimum and maximum current limits for the S-Drive controller.

Boost Drive Current and Time

Provides temporary current boost for demanding drive requirements.

Motor Protection Parameters

Includes threshold, time, level, and cooling settings to protect the motor.

Motor Compensation Tuning

Memory Functions

Reading the System Log

Accesses the diagnostic log storing detected system problems.

Reading the Scooter Timer

Records and allows viewing of the scooter's total usage time.

Chapter 4: Tiller Module

Surface Mount Tiller Module

Details the surface mount variant of the Tiller Module, including its part number.

Inset Mount Tiller Module

Details the inset mount variant of the Tiller Module, including part numbers.

Tiller Module Mounting

Handling Tiller Module Components

Provides guidelines for handling Tiller Module components safely.

Surface Variant Fixing

Suggests hole placements for fitting the surface mount Tiller Module.

Tiller Module Wiring

Recommended Wire Gauge

Specifies the minimum recommended wire size for Tiller Module connections.

Surface Mount Variant Connectors

Details the Molex connector used for the surface mount Tiller Module.

Tiller Module Connections

Surface Variant Connection Diagram

Shows the connection diagram for the surface mount Tiller Module.

Controller Connection Mapping

Table mapping TruCharge module types to controller pins.

ESD Connection Options

Details optional ESD connections for both variants.

Electromagnetic Compatibility (EMC) for Tiller Module

Tiller Module ESD Precautions

Outlines precautions against ESD for the tiller module.

Tiller Module Production Tests

Tiller Module Mounting and Cable Checks

Verifies secure mounting and integrity of tiller module connections.

Tiller Module Operational Test

Guides through operational tests for the tiller module.

Chapter 5: Warning Summary

Introduction to Manual Warnings

Summarizes important warnings found throughout the manual.

General Scooter Warnings

Lists hazards, system malfunctions, EMI, and driving safety.

Safety Checks and Restraints

Low Battery Operation Warnings

Programming Safety and Warranty

Servicing and Unauthorized Modifications

Program Settings and Stability Risks

Charger Interlock Responsibility

Wiring and Connection Responsibility

Battery and Motor Connection Warnings

Crimping Quality and Warranty

Battery Connection Circuit Protection

24V Connection Safety

Drive Motor Matching and Compatibility

Freewheeling Safety Precautions

Charger Connection Safety

Controller Position and Hot Surfaces

Production Test Safety

Programming Safety and Controller Stability

Safety Fence Value Specification

Forward Acceleration and Tipping Risk

Forward Deceleration and Stopping Distance

Reverse Deceleration and Tipping Risk

Max Forward Speed and Stability

Throttle at Power-up Safety

Soft-Stop Function and Stopping Distance

Freewheeling Hazard Precautions

Motor Compensation Matching Responsibility

Chapter 6: Specifications

Electrical Specifications

Appendix A

ISO 7176-14:2008 Compliance Summary

Reviews S-Drive compliance with ISO 7176-14:2008 sections.

General Conformity Findings

Summarizes the document's assessment of S-Drive conformity.

Single-Fault Safety Design

S-Drive products are designed for single-fault safety.

Command Signal Failure Requirements

S-Drive meets open-circuit, short-circuit, and leakage requirements.

Substance/Liquid Ingress and EMC

Annex A: Wiring Guidance

Wiring Guidance Summary

S-Drive supports conformity if installed per instructions, with connector rating exception.

Annex: S-Drive Command Signal Leakage

Meeting Command Signal Leakage Requirements

Outlines steps to meet ISO 7176-14:2008 command signal leakage requirements.

Input Circuit Configuration and Potentiometers

Discusses input configurations and potentiometer fitting for leakage management.

Potentiometer Specifications

Specifies tolerances for Wig-wag/unipolar and single-ended throttles.

Printed Circuit Board Leakage Prevention

Connection Management for Leakage Prevention

Appendix B

Set Up Procedure

Motor Compensation Setup

Matches S-Drive to motor resistance for optimal performance.

Speed, Acceleration, Deceleration Programming

Programs appropriate values for speed, acceleration, and deceleration.

Brake Time Adjustment Procedure

Sets the time delay for solenoid brake engagement.

Fine-Tuning for Incline Performance

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