PG DRIVES TECHNOLOGY AC TRACTION – INSTALLATION
5.2 Battery and Motor Wire Size and Type Selection
The wiring arrangement used on a particular vehicle can greatly affect the current carrying capacities of individual wires.
Ambient temperature, grouping and wire length can all significantly de-rate cable performance and other factors such as
vehicle duty cycles and airflow should also be taken into consideration when selecting vehicle wiring.
PGDT recommends the use of BS6231 (UL 1015, 1028, 1283 or 1284 dependent on wire gauge), Tri-rated wire due to its superior
flexibility and 90/105°C temperature rating. The table below shows the minimum recommended wire sizes for the various
connections on the Sigmadrive controllers.
Frame Size Motor Battery
Small 16 mm
2
16 mm
2
Medium 35 mm
2
35 mm
2
Large 70 mm
2
70 mm
2
It is the responsibility of the vehicle manufacturer to ensure that the vehicle’s wiring arrangement
is suitable for the intended application, and complies with all necessary standards that are
dictated by the relevant approvals of regulatory organizations. PGDT accepts no liability for
losses of any kind arising from an inappropriate wiring arrangement.
5.3 Battery and Motor Connection Crimps and Tooling
Good quality crimping is essential in ensuring the long-term reliability of the vehicle’s electrical system. Poor quality crimps may
initially appear satisfactory, but can deteriorate over time, ultimately causing the vehicle to break down. For the battery and
motor connections, the use of AMP
®
AMPower III or Solistrand copper tube leg terminals is recommended. It is absolutely vital
that the selected crimp terminal is designed to be used with the wire size and type being used.
It is also vital that for the selected crimp terminal the correct tooling is used for its installation onto the wire, and that the
procedure for doing so is followed correctly. Contact the crimp terminal manufacturer to ensure that the tooling employed is
suitable for use with the chosen combination of wire and crimp terminal.
If insulated crimps are used, ensure the insulation is firmly pushed into place. If uninsulated crimps are used, it is recommended
that heatshrink or similar sleeving is used to insulate the barrel of the crimp terminal.
Ensure that only fully trained and skilled operators perform the crimping procedure and that the
instructions provided by the crimp terminal manufacturer are followed. PGDT accepts no liability
for losses of any kind if the recommendations made in this section are not followed.
5.4 Control Connections
The low current control connections on the Sigmadrive are via Molex® SMD Micro Fit 3.0 Series connectors. These connectors are
labeled as A, B and C on the cover of the controller and provide the following functions.
A 16-way Vehicle Interface Connector
B 8-way Communications Connector
C 6-way Motor Feedback Connector
5.5 Control Connection Wiring
Use 0.5mm
2
/18AWG wire gauge for all control connections. It is also recommended that Tri-rated wire with a 105ºC insulation
rating is used.
SK79646-01 17
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