Supersigma2 Handleiding

SuperSigma2 QRM for PMS motors
This user manual details the features of the standard controller range:
(for more detailed information contact DMC)
1. PMS range for Permanent Magnet Synchronous Motors 24-96V, 250-600Arms
Modification History:
Revision Issue Date Author Changes

01.00.05 23-12-2014 RP First Release
01.00.06 17-04-2015 RP Match latest firmware V02.03.xx
01.00.09 20-04-2016 RP Match Firmware V02.06.01
Preliminary information, we reserve the right to updates and/or modifications at any time without prior notice
Contents
1 DMC PHILOSOPHY – INTRODUCTION ..................................................................................................................... 4
2 SUPERSIGMA2 VARIANTS ...................................................................................................................................... 5
3 CONTROLLER FEATURES ........................................................................................................................................ 6
4 TECHNICAL SPECIFICATIONS .................................................................................................................................. 7
4.1 ELECTRICAL................................................................................................................................................................ 7
4.1.1 Voltage specifications: ................................................................................................................................... 7

4.1.2 Current specifications: ................................................................................................................................... 7
4.2 ENVIRONMENTAL........................................................................................................................................................ 7
4.3 MECHANICAL ............................................................................................................................................................. 7
5 INSTALLATION INSTRUCTIONS ............................................................................................................................... 8

5.1 SAFETY ................................................................................................................................................................... 8
5.2 MECHANICAL INSTALLATION AND COOLING ...................................................................................................................... 8
5.3 POWER WIRING .......................................................................................................................................................... 8
5.4 LIGHT WIRING ............................................................................................................................................................ 8
5.5 SPEED SENSOR CABLING ............................................................................................................................................... 8
5.6 CONTACTORS ............................................................................................................................................................. 8
5.7 FLASHING NEW SOFTWARE ........................................................................................................................................... 9
5.8 POWER UP DELAY ....................................................................................................................................................... 9
6 EMC GUIDELINES ................................................................................................................................................... 9

6.1 POWER CABLES .......................................................................................................................................................... 9
6.2 SIGNAL CABLES .......................................................................................................................................................... 9
6.3 CONTROLLER ............................................................................................................................................................. 9
7 CALIBRATOR .........................................................................................................................................................10
7.1 THE CALIBRATOR ...................................................................................................................................................... 10
7.2 CALIBRATOR MAP ..................................................................................................................................................... 10
7.3 DMC PC PROGRAMMER ........................................................................................................................................... 10
8 DASHBOARD DISPLAY ...........................................................................................................................................11

8.1 GENERAL INFORMATION............................................................................................................................................. 11
8.2 DISPLAY SETUP MENU ................................................................................................................................................ 11
8.3 DISPLAY FEATURES SETUP .......................................................................................................................................... 11
8.4 DISPLAY ICONS ......................................................................................................................................................... 12
9 PARAMETERS ........................................................................................................................................................13
9.1 MENU 1 “TRACTION ADJUSTMENTS” ........................................................................................................................... 13
9.1.1 Neutral braking setup options ..................................................................................................................... 14

9.1.2 Neutral braking setup in speed control mode (control mode 0) .................................................................. 14
9.1.3 Neutral braking setup in torque control mode (control mode 1) ................................................................. 14
9.1.4 Neutral braking setup in torque control mode (control mode 2) ................................................................. 14
9.1.5 Hill Hold ....................................................................................................................................................... 14
9.2 MENU 1 “PUMP ADJUSTMENTS” ................................................................................................................................ 15

9.3 MENU 2 “STATUS” ................................................................................................................................................... 16
9.3.1 Status tables ................................................................................................................................................ 17

9.3.2 Drive and brake limits tables ....................................................................................................................... 17
9.4 MENU 3 “CONTROLLER SETUP” .................................................................................................................................. 18
9.4.1 Controller Setup for Traction ....................................................................................................................... 18

9.4.2 Controller Setup for Pump ........................................................................................................................... 19
9.5 PMS MOTOR AUTO TUNING ...................................................................................................................................... 20
SuperSigma2 QRM PMS – V1.00.09 20-4-2016 Page 2 (44) ©2016 DMC GmbH Herten Germany
9.5.1 Menu 4 “PMS Motor Auto Tuning” .............................................................................................................. 20
9.5.2 Setting up auto tuning ................................................................................................................................. 21
9.5.3 Initiating auto tuning ................................................................................................................................... 21
9.5.4 Auto tuning errors ........................................................................................................................................ 23
9.5.5 Recalculation................................................................................................................................................ 23
9.6 MENU 5 “PMS MOTOR SETUP” ................................................................................................................................. 24

9.7 MENU 6 “PMS MOTOR ADVANCED” ........................................................................................................................... 25
9.8 MENU 7 “LIMITS SETUP” ........................................................................................................................................... 26
9.9 MENU 8 “BDI” BATTERY DISCHARGE INDICATOR............................................................................................................ 27
9.10 MENU 9 “CAN BUS SETUP” ....................................................................................................................................... 27
9.11 MENU 10 “FAULT LOG” ............................................................................................................................................ 28
9.13 MENU 11 “TEST” ..................................................................................................................................................... 29
9.13.1 Test menu for Traction ................................................................................................................................. 29

9.13.2 Test menu for Pump ..................................................................................................................................... 30
9.14 MENU 12 “DEBUG”.................................................................................................................................................. 31

9.15 .MENU 13 “ABOUT” ................................................................................................................................................. 31
9.16 AVAILABLE APPLICATION NOTES .................................................................................................................................. 31
9.17 THERMAL MOTOR MANAGEMENT & PERFORMANCE TABLE.............................................................................................. 32
9.17.1 Current roll back on motor temperature ...................................................................................................... 32

9.17.2 Option to disable current roll back functions ............................................................................................... 32
10 DIAGNOSTICS ................................................................................................................................................... 33
10.1 GENERIC PMS MOTOR MODULE SUB ERROR CODES ........................................................................................................ 36
11 GRAPHICS & SCHEMATICS ................................................................................................................................ 37

11.1 ACCELERATOR CHARACTERISTICS .................................................................................................................................. 37
11.2 CONTROLLER THERMAL CUTBACK CHARACTERISTIC ......................................................................................................... 37
11.3 LIGHT WIRING PMS TRACTION ................................................................................................................................... 38
11.4 LIGHT WIRING PMS PUMP ........................................................................................................................................ 39
11.5 CAN BUS WIRING ..................................................................................................................................................... 40
11.5.1 CAN bus wiring example with DMC Display: ................................................................................................ 40

11.5.2 CAN bus wiring example without DMC Display: .......................................................................................... 40
11.6 IGAUGE DISPLAY – CONNECTION DIAGRAM .................................................................................................................... 41

11.7 POWER WIRING ....................................................................................................................................................... 41
12 MECHANICAL DRAWINGS ................................................................................................................................. 42

12.1 SUPERSIGMA2 CONTROLLERS ..................................................................................................................................... 42
12.2 DMC ADVANCED DISPLAY.......................................................................................................................................... 42
13 CONTACT INFORMATION ................................................................................................................................. 44
1 DMC Philosophy – Introduction
DMC (Digital Motor Control) GmbH, is a company with a dedicated team of individuals with many years’ experience in the design,
manufacture, sales and aftermarket support of controllers predominately utilised in the electric vehicle industry. The Company has
been formed with enthusiasm and professionalism to create and develop unique products for this particular "niche" industry where
specialist knowledge and experience are essential for success.
A full range of associated accessories and support infrastructure completes the DMC service. To conclude, a fusion of creative
thinking, collective experience and latest state of the art technology, has produced what we believe to be the most flexible and
thermally advanced controller ranges available in the market place to date.
Next Generation: The SuperSigma2 Controller Range
After the success of the Sigmadrive controller range, DMC has developed a new controller range, specially designed to control AC
induction and PMAC (PMS) motors, running on nominal battery voltages in the range of 24V up to 120V, at nominal powers up to
30kW and peak powers up to 60kW.
The power board design fundamentals are similar to the previous Sigmadrive design, combining superior heat sinking of components
and connections with unmatched vibration protection. The mechanical design is improved to IP65 and we incorporated the industry
standard 35 way AMP-seal connector.
Nonetheless we had to leave the single PCB design philosophy in favour of a separate logic PCB to utilise 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.
New Features on SuperSigma2 are for example fully automated tuning of AC induction motors 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 smoothly!
On PMAC we introduce automated motor sensor setup for 8bit sin/cos absolute position encoders and hall sensors, which
significantly eases the production of PMAC motors, eliminating the costly need for adjusting sensor offsets.
Vehicle constructers now have the choice to use control via CAN or use the flexibility of software selectable active high or active low
inputs. Optimized interfacing with battery management systems completes the SuperSigma2 controller range, allowing limiting
battery current, especially useful for vehicles using Lithium batteries.
Sigmadrive Controller Range
The first generation of DMC controllers, today known as the ‘Sigmadrive controller range’ was designed in the year 2000. Utilising
revolutionary power heat sinking technology called IMS (Insulated Metal Substrate) a new generation of highly efficient controllers
for all popular motor types is offered from a single core design, in the 24V - 96V, 1KW - 24KW power range. Using 'flash memory' in
the control electronics coupled with a unique design architecture, all powers and motor types including AC, PMS (PMAC), SEM, PM4
and Series, can be accommodated within 3 standard power frames. Particular attention has been placed on providing high-resolution
control circuitry and software, to provide fully optimised, highly efficient motor control.
The principle advantage of IMS technology (which can be visualised as a metal PCB) is that cost effective SMD Mosfet power devices
can be mounted and soldered directly onto the IMS PCB, which provides immediate and excellent 'integral' heat sinking.
Consequently, reliability and efficiency are significantly enhanced due to the power switching devices running cooler and therefore
inherently more efficiently. This approach also leads to significantly improved continuous power delivery (1 hour current rating), as a
ratio to peak power, with the controllers continuous rating normally being one of the most important aspects in determining the
vehicles performance.
By using an innovative patented technique, DMC has fully exploited IMS technology to realise a unique controller design. The
construction provides manufacturing simplicity and reliability by removing the need for any interconnections and using a minimal
number of mechanical and electronic components. This gives a totally robust and environmentally sealed, space efficient controller.
©2015 DMC GmbH
2 SuperSigma2 variants
Model Number Description Model Nr. Power

AC Traction
Example: PAC960T4-** 60-96V 600Arms
PAC945T3-** 60-96V 450Arms
PAC960T4-01
PAC927T2-** 60-96V 270Arms
PAC914T1-** 60-96V 140Arms
Firmware Number PAC460T3-** 24-48V 600Arms
PAC445T2-** 24-48V 450Arms
Frame Size PAC425T1-** 24-48V 250Arms
1 = Size 1 (160x200x72mm) (small) AC Pump
2 = Size 2 (200x200x72mm) (medium) PAC960P4-** 60-96V 600Arms
3 = Size 3 (250x200x72mm) (medium+) PAC945P3-** 60-96V 450Arms
4 = Size 4 (320x200x72mm) (large) PAC927P2-** 60-96V 270Arms
PAC914P1-** 60-96V 140Arms
Configuration PAC460P3-** 24-48V 600Arms
T = Traction PAC445P2-** 24-48V 450Arms
P = Pump
PAC425P1-** 24-48V 250Arms
E = Power steer
PMS Traction
Maximum Current (Arms) PMS960T4-** 60-96V 600Arms
14 = 140 Arms PMS945T3-** 60-96V 450Arms
25 = 250 Arms PMS927T2-** 60-96V 270Arms
27 = 270 Arms PMS914T1-** 60-96V 140Arms
45 = 450 Arms PMS460T3-** 24-48V 600Arms
60 = 600 Arms PMS445T2-** 24-48V 450Arms
PMS425T1-** 24-48V 250Arms
Nominal Battery Voltage: PMS Pump
4 = 24/48V PMS960P4-** 60-96V 600Arms
9 = 60/96V PMS945P3-** 60-96V 450Arms
1 = 120V (future)
PMS927P2-** 60-96V 270Arms
PMS914P1-** 60-96V 140Arms
Motor Technology PMS460P3-** 24-48V 600Arms
PAC = 3 phase AC Induction
PMS445P2-** 24-48V 450Arms
PMS = Permanent Magnet Synchronous
PMS425P1-** 24-48V 250Arms
3 CONTROLLER FEATURES
Feature
Number of digital switch inputs. 7
Number of digital inputs, sensor related 3
Number of analogue inputs 6
Number of contactor driver outputs (2.5 Amps as limited by interconnect current carrying capability) 3
(build in contactor coil suppression)
Number of low power output (Can be amplified with a DMC external driver module 830/DRV) 1
24V - 120V Operation 
100% on Mosfet technology 
IMS power PCB for superb thermal conduction 
Cooled power terminals 
Updatable firmware / flash memory, easy software updates 
Environmental protection IP65 
Powerful, State of the art 32 bit microprocessor control 
High frequency 16kHz (Silent Operation) 
Internal watchdog monitoring microprocessor operation 
Arc less contactor switching and built in coil suppression 
Low impedance, active low inputs switched to B-ve 
Active high inputs available on request 
Thermally compensated current limit 
Selectable accelerator characteristics 
Adjustable creep speed 
Seat switch timer 
Power steer timer 
Electro brake timer 
Belly switch operation 
Regenerative braking 
Direction braking proportional to accelerator position 
Braking in neutral 
Braking with brake pedal – proportional or switched 
Under and Over-voltage protection 
Accelerator wire off detect 
Inching facilities 
Short circuit and open circuit contactor detect 
3 traction cutback speeds 
6 Pump speeds with Additive & Priority 
Input to disable pump operation 
Independent power steer speed and compensation settings 
Hardware and Software fail-safe systems 
+ 12V or +5V selectable output pin supply 
Diagnostics with LED indication 
Remote diagnostic LED 
Adjustments made via a calibrator or PC programmer 
CAN Open compatible 
Hours count displaying key & pulsing hours on calibrator 
BDI on Calibrator 
Dashboard display connectable 
Easy to use ‘icons’ for display information 
Resettable Service and Fault logs 
Setup menu on calibrator to enable various options 
4 TECHNICAL SPECIFICATIONS
4.1 Electrical
4.1.1 Voltage specifications:
Model Nominal battery Absolute operating voltage Reduced braking High Voltage cut out
voltage range voltage levels (F4) level (F22)
PXX4xx-XX 24 V – 48 V 12.0 V – 72.5 V 60.0 V – 67.5 V 70 V
PXX9xx-XX 60 V – 120 V 12.0 V – 144.0 V 130.0 V – 138.5 V 140 V
Note: These voltage levels are used to set the voltage levels in the Limits menu.
4.1.2 Current specifications:

Model Power Current limit Continuous current 1 hour rating. Controller frame size
(1 min) Unit mounted on an sufficient heat
sink, at 20C ambient.
PXX425XX 24/48V 250A 250Arms 130A Size 1
Switching Frequency: Controller frequency is 8KHz (centre aligned PWM switching). Motor frequency 16KHz.
Electrical Isolation: Enclosure to any live part = 1KV. Controller internal insulation specified at >10MΩ @500V DC.
Reverse Battery Polarity: If line contactor installed according to the manual, yes
I/O details: See light wiring diagram.
4.2 Environmental
Impact Protection (IP):The enclosure is protected to IP65 (when AMP seal Connector fitted)
Vibration: 6G, 40-200Hz for 1 hour, in x, y and z planes.
Operating Temperature: -30oC to +40oC ambient around controller.
Storage Temperature: -40oC to +70oC.
Humidity: 95% maximum, non-condensing.
Humidity Resistance: Ingress protected, watertight AMP seal connector
Safety: Designed to the requirements of machine directive 2006/42/EC, safety of industrial trucks
EN1175-1:1998+A1:2010, EN13849-1, UL94.
The vehicle manufacturer is responsible for the compliance of the complete system with the
appropriate regulations.
EMC: EN61000-6-2 (industrial immunity), EN61000-6-3 (residential emissions, Class B)
4.3 Mechanical
Details: See mechanical drawings.
Enclosure: Aluminium heat sink with ABS plastic cover.
Power connections: Vertical Copper studs.
Hexagonal: Fixing torque 9.5Nm (Slot screws are recommended!)
Slot screw: Recommended, fixing torque 9.5Nm (Brass)
Bolt length: Max 20mm incl. washer and spring washer
Weight: Size1: 3.25kg; Size2: 4.1kg; Size3: 4.9kg; Size4: 6.2kg;
Always use a torque wrench when fixing the power terminals.

Exceeding the maximum specified torque can cause serious damage to the
controller and warranty might be void.
Too long bolts damage the controller.
5 INSTALLATION instructions
5.1 SAFETY
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. THE VEHICLE
MANUFACTURER’S MANUAL SHOULD BE CONSULTED BEFORE ANY OPERATION IS ATTEMPTED.
THE BATTERY MUST BE DISCONNECTED AND THE INTERNAL CAPACITORS MUST BE DISCHARGED BEFORE REPLACING,
MODIFYING OR ATTEMPTING ANY REPAIRS OF THE CONTROLS.
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.
5.2 Mechanical installation and Cooling

The controller should be bolted down to a flat (0.2mm max. Deviation) paint free surface, eventually lightly coated with
a thermal transfer compound, by the 4 fixing 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.
5.3 Power wiring

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).
Fixing torque for power connectors M8 terminals is 9,5Nm, for M6 power connectors 9,5Nm.
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 an 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.
5.4 Light wiring

The controller may be supplied as a stand-alone unit or pre-wired onto a base-plate with contactors etc.
Control 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.
The main battery cable should be fused with a suitable air-break fuse. The key switch line must also be fused at a level
not exceeding 10 A when using the specified Ametek or Albright contactors.
The return wiring for the accelerators should be connected to pin A10 on the controller to guarantee wire off
detection..
5.5 Speed sensor cabling

Avoid routing the sensor cabling along with high power motor or battery cables.
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 @ pin A31). When connected also to the motor side, current will flow over the screen,
disturbing the signal from the sensor to the controller, this can result in dangerous situations.
5.6 Contactors
The contactor mounting plane can affect performance, contactors should never be mounted with their terminal studs
vertically down. For further applications information on contactors, please consult DMC GmbH in Herten.
As blow-out magnets are fitted to contactors (except 24V) ensure that no magnetic particles can accumulate in the
contact gaps and cause malfunction. Ensure that contactors are wired with the correct polarity to their power terminals
as indicated by the + sign on the top moulding.
The SuperSigma2 must NOT be used with permanently-connected on-board chargers or damage to the system may
result. Using a change-over contactor as line contactor is a good solution to fit both the charger and the controller in the
truck.
5.7 Flashing new software
When flashing the controller with a new software version, ALWAYS carefully check ALL parameters after flashing to be
correct. Only qualified engineers are allowed to update the controllers firmware.
5.8 Power up Delay

At first 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.
Specially at 24V systems using a Large size controller, the time delay to charge the capacitor bank can by longer.
6 EMC GUIDELINES
The following guidelines are intended to help vehicle manufacturers to meet the requirements of the EC directive
Electromagnetic Compatibility. The SuperSigma2 controller range is designed to meet EN61000-6-2 (industrial
immunity), EN61000-6-3 (residential emissions, Class B).
Any high speed switch is capable of generating harmonics at frequencies that are many multiples of its basic operating
frequency. It is the objective of a good installation to contain or absorb the resultant emissions.
All wiring is capable of acting as a receiving or transmitting antenna. Wiring should be arranged to take maximum
advantage of the structural metal work inherent in most vehicles. Vehicle metalwork should be electrically linked with
conductive braids.
6.1 Power Cables

All cables should be routed within the vehicle framework and kept as low in the structure as is practical – a cable run
within a main chassis member is better screened from the environment than one routed through or adjacent to an
overhead guard. Power cables should be kept short to minimize emitting and receiving surfaces. Shielding by the
structure may not always be sufficient – cables run through metal shrouds may be required to contain emissions.
Parallel runs of cables in common circuits can serve to cancel emissions – the battery positive and negative cables
following similar paths is an example.
Tie all cables into a fixed layout and do not deviate from the approved layout in production vehicles. A re-routed battery
cable could negate any approvals obtained.
6.2 Signal Cables

All wiring harnesses should be kept short. Wiring should be routed close to vehicle metalwork. All signal wires should be
kept clear of power cables or made from screened cable. When using screened cable, make sure only to earth it to one
point! Control wiring should be kept clear of power cables when it carries analogue information – for example,
accelerator wiring. Tie all wiring securely and ensure wiring always follows the same layout.
6.3 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”.
7 CALIBRATOR
7.1 The Calibrator
General
The DMC Calibrator is designed for Setting up the SuperSigma2 controller
range. It also has a build-in interface calibrator software updates via USB.
This guarantees maximum flexibility and no waste of hardware when only
the software must be updated.
CAN Node Setup

When connecting the Calibrator to a controller it will ‘scan’ the CAN bus for
all available Nodes, to enable calibration of all DMC controllers on the same
bus. All controllers are by factory default set to Node 0. Therefore before
using this feature, give all controllers on the bus a unique Node number. To
do this, the calibrator must be plugged in to the controller you want to
adjust the Node number on (menu item 9.1)
Adjustments
The calibrator is easy to use. The up and down buttons are used for scrolling
up and down. Selections can be made with the SEL-button. The plus- and
minus-buttons are used to increase or decrease the parameters.
Firmware updates
On the top-right-hand side a 3-way switch is used to select the operating
mode. For normal operation it must be in position 2.
For flashing new calibrator firmware the switch must be moved to position 3.
To be able to update the calibrator firmware it is necessary to have a PC
software package installed and a copy of the calibrator firmware.
For detailed information on updating firmware please contact your DMC
supplier. SuperSigma2 controller firmware updates are done with a separate
dongle, please contact DMC for details.
7.2 Calibrator map
 Press and hold the select button for 3 seconds to return to the first screen.
 The calibrator remembers the cursor position in the submenus until key-off.
 When connecting more than 1 node to the CAN bus, the calibrator will react slightly slower.
7.3 DMC PC Programmer

The PC programmer is available for download from our website in the download section (register first).
To be able to use the PC programmer software, the latest version of the DMC calibrator with USB connectivity is
required. The PC programmer let you edit, store and print controller parameters on a windows based PC running XP,
Vista or Windows7. All SuperSigma2 controllers are compatible with the PC programmer.
The installation package includes a manual describing the features and functionality.
The PC programmer updates it’s data dictionary automatically when new parameters are available. For the automatic
update of the data dictionary on Windows Vista, 7 and 8, the DMC PC programmer must be started as administrator.
8 DASHBOARD DISPLAY
The DMC dashboard display is specially

1 designed to be as flexible as possible to meet
6 2 customer requirements.
5 7 The display is CAN-Bus driven and gets its
information from the DMC controllers and
eventually from auxiliary equipment.
In the future the membrane buttons will allow

selecting different performance settings to be
selected.
4
Faults are indicated with Icons.
The Icons can be modified and even the
3 customer’s brand name and logo can be
displayed to match the truck-identity.
8.1 General information

<1> Brand name window. When required DMC can fit the customer’s name and logo here during production.
<2> Membrane buttons. Used for setting functions as Service interval timer, Hours counter and the Customer
information field <6>.
<3> Battery Discharge Indicator. Indicates the battery discharge state set by CAN-Node 0 (master)
<4> Fault indication fields. Indicates the status of the traction- and pump controllers and other CAN-Nodes.
The CAN node number is displayed in the Icons to indicate which controller has a problem.
When a fault is indicated it replaces the ‘OK’ below the CAN-Node indicator with a fault icon.
Via the calibrator it is possible to select what failure types are displayed or ignored.
<5> General indication field. Calibrator selectable indicators for speed, motor voltage, accelerator demand and
steering (from master)
<6> Free 2x9 character field to show a text. The text can be edited with the display buttons.
<7> Hours counter. Here either Work or Key hours are displayed, selectable with the display buttons.
The hours counter value is stored in the display. The controllers have their own separate counter.
8.2 Display setup menu

To access the display setup menu, hold the select button for 3 seconds.
Features as the Service interval timer, Hours counter and the Customer information field can be adjusted and optionally
protected with a pin code.
Use the up and down arrows (↑↓) to choose the option, press SEL, then use the + and – buttons to change the value.
8.3 Display Features Setup

Ref Parameter Submenu ref. Sub menu description Range & Action
1 Service timer 1. Svc interval Set the time interval for next service. 0– 32767 Hr.
(40 Hours before service is needed a
spanner icon is shown at power up
indicating service is required)
2. Count hours Set to count work or key hours Work / Key Hrs.
3. Reset timer Resets the service interval timer To confirm press SEL
4. Svc time Indication of the actual counter value Indication only
2 Hours counter 1=Key, 2=Work Select to indicate work or key hours Select ↑↓ and confirm SEL
3 Information 1. Adjust field Free 2x9 character field to show a
field customised text.
↑↓ for position, + / – change
4 Pin codes 1. Service timer Sets pin code for service timer access
value, SEL to return to menu
2. Information field Sets pin code for information field
access
3. Reset all pin codes Reset all pin codes (Only with DMC master code)
5 About SW version & date Indication of the software version & Indication only
date
6 Return to main - Select to return to the main menu Select ↑↓ and confirm (SEL)
screen
8.4 Display Icons
LED Calibrator Message Display
code Icon
0 None (lowest priority)
Handbrake on
2 Voltage getting low
3 Pump inhibit
4 Voltage getting high
5 Motor hot
6 Controller hot
7 Adjustments out of range

8 Default settings restored
9 E-eprom cannot be accessed
10 2 Direction fault
11 Seat- or tiller switch open
12 Sequence fault
13 Accelerator high at first power up
14 Inching or belly fault
15 Voltage too low
16 N/A
17 Voltage too low
18 High sided Mosfet short circuit
19 N/A
20 Hardware over current
21 Contactor coil short circuit
22 Voltage too high

23 Low sided Mosfet short circuit (neutral)
24 HWFS not working
25 Contactor fault
26 Thermal shutdown fault

27 Low side Mosfet short circuit
28 Wire off detected
29 CAN Node time out
30 Over speed
31-40 Motor fault
9 Parameters
9.1 Menu 1 “Traction Adjustments”
Cal Parameter Calibrator Min. adjust Max. Step Default
Ref text adjust size
1 Acceleration delay Accel 0.1 s 10.0 s 0.1 s 2.5 s
2 Deceleration delay Decel 0.1 s 10.0 s 0.1 s 0.3 s
3 Creep speed Creep 0.0 Hz 10.0 Hz 0.1 Hz 0.0 Hz
4 Maximum speed forward SpdMaxF 0.0 Hz 400.0 Hz 0.1 Hz 100.0 Hz
5 Maximum speed reverse SpdMaxR 0.0 Hz 400.0 Hz 0.1 Hz 100.0 Hz
6 Cutback speed 1 Speed1 0.0 Hz 400.0 Hz 0.1 Hz 100.0 Hz
6a Inching speed InchSpd 0.0 Hz 25.0 Hz 0.1 Hz 10.0 Hz
7a Inching time InchTime 0.1 s 10.0 s 0.1 s 5.0 s
9 Speed limit ramp (torque control only) SpLimRmp 0.1 s 10.0 s 0.1 s 4.0 s
10 Direction Brake torque DBrake 0% 100 % 1% 85 %
11 Neutral Brake torque NBrake 0% 100 % 1% 25 %
12 Foot brake torque FBrake 0% 100 % 1% 65 %
13 Direction brake ramp time DBrkRamp 0.1 s 10.0 s 0.1 s 3.0 s
14 Neutral brake ramp time NBrkRamp 0.1 s 10.0 s 0.1 s 0.3 s
15 Foot brake ramp time FbrkRamp 0.1 s 10.0 s 0.1 s 0.3 s
16 Drive torque release time DTrqRLS 0.1 1.0 s 0.1 0.3
17 Brake torque release time BTrqRLS 0.1 1.0 s 0.1 0.3
18 Neutral brake-End delay NBrkEnd 0.0 s 10.0 s 0.1 s 0.0 s
19 Power steer delay PStrDly 0.0 s 50.0 s 0.1 s 5.0 s
20 Electric brake delay EBrkDly 0.0 s 50.0 s 0.1 s 0.5 s
21 Accelerator pot minimum AccMin 0.0 V 10.0 V 0.1 V 0.2 V
22 Accelerator pot maximum AccMax 0.0 V 10.0 V 0.1 V 4.6 V
23 Brake pot minimum BrkMin 0.0 V 10.0 V 0.1 V 0.2 V
24 Brake pot maximum BrkMax 0.0 V 10.0 V 0.1 V 4.6 V
25 Steer pot minimum StrMin 0.00 V 10.00 V 0.01 V 0.20 V
26 Steer pot middle point StrMid 0.00 V 10.00 V 0.01 V 2.30 V
27 Steer pot maximum StrMax 0.00 V 10.00 V 0.01 V 4.80 V
28 Wig/Wag fwd threshold FwdTH 0.0 V 10.0 V 0.1 V 3.0 V
29 Wig/Wag rev threshold RevTH 0.0 V 10.0 V 0.1 V 2.0 V
30 Speed ratio (display Kph) SpdRatio 1.0 999.9 0.1 120.0
31 Vehicle max. Speed VmaxSpd 0.0 KPH 999.9 KPH 0.1 KPH 20.0 KPH
32 Dual motor cut out DMcut 0% 100 % 1% 10 %
33 Dual motor angle 1 DMang1 0% 100 % 1% 60 %
36 Dual motor speed 1 DMspd1 0% 100 % 1% 10 %
37 Dual motor speed 2 DMspd2 0% 100 % 1% 5%
38 Dual motor speed 3 DMspd3 0% 100 % 1% 30 %
39 Speed threshold to enter speed control SpdThSpC 0.1 % 50.0% 0.1% 5.0%
40 Ramp time from SpdThSpC to zero SpdRmpTm 0.0 S 10.0 S 0.1 S 2.5 S
41 Speed threshold to enter hill hold SpdTH_HH 0.1 % 10.0 % 0.1 % 1.0 %
42 Hill hold time HHTime 0s 60 s 1s 5s
43 Restraint hill hold speed HHspeed 0.0 Hz 5.0 Hz 0.1 Hz 3.0 Hz
44 Restraint hill hold torque threshold HHTrqTH 0.1 % 35.0 % 0.1 % 1.5 %
45 Hill Hold/positioning proportional gain KpPos 0.0 10.0 0.1 0.0
46 Hill Hold/positioning derivative gain KdPos 0.00 1.00 0.01 0.00
47 Hill Hold position dead band PosDBand 0 720 1 0
Depending on controller type and configuration some settings will be not available (N/A).
9.1.1 Neutral braking setup options
Neutral braking can be setup in three different modes, depending on the vehicle requirements.
The neutral braking mode can be selected in combination with the control mode setup in the controller setup menu:
 Control mode 0, speed control is selected with neutral braking operating in speed mode.
 Control mode 1, torque mode is selected with neutral braking operating in torque mode.
 Control mode 2, torque mode is selected with the end neutral braking operating in speed mode.
If the Hill-Hold feature is required, the choice for the end of neutral braking in speed mode is mandatory.
9.1.2 Neutral braking setup in speed control mode (control mode 0)
This feature is under development.
9.1.3 Neutral braking setup in torque control mode (control mode 1)
The following graph shows how the available neutral braking parameters work.
Use this graph as a reference to understand the meaning of the different parameters used to setup smooth neutral
braking to zero speed.
The neutral braking torque is set with parameter 1.11 (typical value between 10 and 25%). The torque is ramped with
parameter 1.14 Neutral brake ramp time (typical set to 2 to 4 seconds). When ‘speed threshold to enter end of braking
mode’ is reached the neutral braking torque will be reduced with speed to give a smooth end of braking feel (typical
value 10 to 14%). From the point ‘speed threshold ramp time to zero speed’ (typical 2 to 5%) a timer function (neutral
brake end delay – typical 5 to 10 seconds) is used to brake the vehicle to zero speed.
9.1.4 Neutral braking setup in torque control mode (control mode 2)
9.1.5 Hill Hold
If the Hill-Hold feature is required, the choice for ‘end of neutral braking in speed mode’ is mandatory.
9.2 Menu 1 “Pump Adjustments”
Cal Parameter Calibrator Min. Max. Step size Default

Ref text adjust adjust
1 Acceleration delay Accel 0.1 s 10.0 s 0.1 s 2.5 s
2 Deceleration delay Decel 0.1 s 10.0 s 0.1 s 0.3 s
3 Creep speed Creep 0.0 Hz 10.0 Hz 0.1 Hz 0.0 Hz
4 Maximum pot speed 1 Potmax1 0.0 Hz 400.0 Hz 0.1 Hz 0.0 Hz
5 Speed 2 demand Pspeed2 0.0 Hz 400.0 Hz 0.1 Hz 0.0 Hz
9 Speed 6 demand (power steer) Pspeed6 0.0 Hz 400.0 Hz 0.1 Hz 0.0 Hz
10 Minimum motor speed in cutback conditions 0.0 Hz
MinSpeed 400.0 Hz 0.1 Hz 0.0 Hz
(usually for hydraulic pump protection (Disabled)
11 Acceleration delay for speed 6 demand (pwrStr) Paccel6 0.1 s 10.0 s 0.1 s 2.5 s
12 Power steer delay PStrDly 0.1 s 50.0 s 0.1 s 5s
13 Accelerator pot minimum AccMin 0.0 V 10.0 V 0.1 V 3.3 V
14 Accelerator pot maximum AccMax 0.0 V 10.0 V 0.1 V 0.2 V
15 Speed threshold to enter speed control SpdThSpC 0.1 % 50.0% 0.1% 5.0%
16 Ramp time from SpdThSpC to zero SpdRmpTm 0.0 S 10.0 S 0.1 S 2.5 S
17 Speed threshold to enter hill hold SpdTH_HH 0.1 % 10.0 % 0.1 % 1.0 %
18 Hill hold time HHTime 0s 60 s 1s 5s
19 Restraint hill hold speed HHspeed 0.0 Hz 5.0 Hz 0.1 Hz 3.0 Hz
20 Restraint hill hold torque threshold HHTrqTH 0.1 % 35.0 % 0.1 % 1.5 %
Depending on controller type and configuration some settings will be not available (N/A).
9.3 Menu 2 “Status”
The status menu shows various parameters from the controller which can be useful to help tune and optimize vehicle
performance.
Cal Item Calibrator Step size Service log info & Notes
Ref text
1 Drive hours counter Drive 0.1 Hrs shows key hours
2 Raw BDI value incl. BDI states (see BDI
Battery Discharge Indicator BDI 1%
state (WO & CO) States table)
3 Vehicle Speed Vehicle 1 Kph
4 Controller Temperature CtrlTmp 0.1 C Min. temperature Max. temperature
Shows N/A when disabled.
5 Motor Temperature MotTemp 0.1 C
Min. temperature Max. temperature
6 Battery Voltage BatVolts 0.1 V Max. Voltage
7 Capacitor Voltage CapVolts 0.1 V Max. Voltage
8 Accelerator demand Accel 0.1 % Steer pot demand Foot brake demand
9 Drive State DriveSta -- See drive and brake status table
10 Speed Limit SpeedLim -- See speed limits table
11 Torque Limit TrqLimit -- See torque limits table
12 Motor Limit MotorLim -- See motor limits table
13 Current Fault code CurFault Fxx Show fault time Show sub code
14 Target demand DemTrgt 0.1 % + CW − CCW
15 Ramped demand DemRampd 0.1 % + CW − CCW
Motor torque Sub code
16 Actual torque TrqAct 0.1 % capability
+ CW − CCW
17 Actual speed SpeedAct 0.1 % + CW − CCW
18 Actual Flux FluxDem 0.1 % Actual Flux
19 Stator speed StatorSpd 0.1 Hz
20 Rotor speed RotorSpd 0.1 Hz RPM speed
21 Motor current I_Motor 0.1 Arms Id Current Iq Current
22 Reactive Power Motor Power
Motor voltage V_Motor 0.1 Vrms -! Reached maximum
output voltage (VL)
23 Battery current I_batter 0.1 A
24 Filtered capacitor voltage V_CapFlt 0.1 V
25 Speed limit SpdLim 0.1 %
26 Drive torque limit DrvTrqL 0.1 % Torque limit CW
27 Brake torque limit BrkTrqL 0.1 % Torque limit CCW
To reset the service log data, press the + and – button at the same time when the controller is in neutral.
9.3.1 Status tables
BDI States Drive and brake status
BDI States Description Status Description

0 Initializing NC No Configuration
1 OK N Neutral, not pulsing
2 BDI is getting low  Warning (WO) FD Forward drive
RD Reverse drive
3 BDI is too low  Cut out (CO)
DB Direction braking
NB Neutral braking
FB Foot braking
FB Hill hold
HF Forward restraint hill hold
HR Reverse restraint hill hold
9.3.2 Drive and brake limits tables

Torque limits have precedence above speed limits.
Speed limits Torque limits

+
Limit Description Limit Description
MS Motor speed CT Controller temperature
SM Speed limit forward or reverse MT Motor temperature
S1 Speed 1 limit PT Performance table current limit
S2 Speed 2 limit TC Timed Current Limit
2
S3 Speed 3 limit T1 I t current limit step 1
2
2
S6 Speed 6 limit HV High Voltage limit
SI Inching LV Low Voltage limit
SB BDI speed limit
Motor Limits Shared Line Contactor Status
Limit Description Status Description

TL Torque Limit ST Starting up
SL Speed Limit RC Ready to close Line Contactor
TH Not able to hold torque CS Is closing line contactor
SH Not able to hold speed PS Start pulsing
FH Not able to hold flux KF Key fault is found
IH Not able to hold flux current NK Not known
CH Not able to hold circle limitation
HL Not able to hold hexagon limit
OL Circle limitation
9.4 Menu 3 “Controller Setup”
9.4.1 Controller Setup for Traction
Change these settings to select the required options and I/O.
Cal Parameter Calibrator Options Range

Ref text (defaults are in bold)
1 Accel. Characteristic Lin/Curv 0 = Accelerator linear 0–1
1 = Accelerator curved
2* Control mode Spd/Torq 0 = Speed mode 0–2
1 = Torque mode
2 = Torque mode & end of braking in speed mode
3 Proportional direction brake Off /Bpro 0 = Fixed, 1 = Proportional 0–1
4 Hill hold Off/HH 0 = Coast, 1 = Hill hold 0–1
5* I/O Pin 5 and 6 Spd/Inch 0 = Speed 1+2 , 1 = Inching Fwd/Rev 0–1
6 I/O Pin 7 Spd3/Hbk 0 = Speed3, 1 = Handbrake 0–1
(If handbrake selected, set the required max. speed
when handbrake applied at Speed 3
7 Power steer trigger PsF/FR/S 0 = FS1 0–3
1 = Fwd/Rev
2 = Seat switch
3 = FS1 and rotor speed
8* Vehicle type select Ride/Wlk 0 = Ride-on 0–2
1 = Walkie
2 = Walkie (allows to drive slowly @ speed 3 speed with
tiller switch open and only when speed 3 is active)
9* Tiller Function TillFunc 0 = Normal response 0–2
1 = fast response
2 = immediate response
10 Display Status field Of/D/V/K 0 = None 0–6
1 = Acc
2 = Motor V/RPM
3 =Speed in Kph
4 = Steering position
5 = Motor current
6 = Battery current
11* Accelerator type AccelTyp 0 = Normal accelerator, 1 = Wig-wag 0–1
12 Accelerator Damping Factor AccelDam 1 = No damping, 2 to 120 multiplies the acceleration and 1 - 120
(Torque mode only) deceleration delay, linear reduced to 1 at 75% demand.
13* Single or Dual Motor Si/DL/DR 0 = Single, 1 = Dual Left, 2 = Dual Right 0–2
14* Digital O/P 4 config RL/BL 0 = Remote LED, 1 = Brake light 0–1
15* Load Defaults LoadDefs 0 = Don't load defaults, 1 = Load defaults 0–1
16* Active low or high digital Actv L/H 0 = Active low digital inputs 0–1
inputs 1 = Active high digital inputs
17* Accelerator supply wire off SplyWrOf 0 = No supply wire off detection 0–3
detection 1 = 0V wire off detection enabled
2 = 5V wire off detection enabled
3 = Both 0V and 5V wire off detection
18 Standby timer StdByDly Adjustable from 0 to 10 Minutes. 0 - 10
Default is 0 (0=Off)
19 Line Contactor pull-in level LCPlInLv Adjustable from 50% to 100% Ubatt.to limit inrush 50-100%
current. Default is 75%
20 Line Contactor pull-in time LCPlInTO Line Contactor pull in time out.. 0-60sec
out Default is 10sec.
21 Drive torque during braking DTrq@Brk 0 = no drive torque allowed during brake 0-1
1 = drive torque is allowed during brake
• (*) Recycle the key switch to make changes active. (Also indicated on calibrator ‘key’)
• Irrelevant options show n/a
9.4.2 Controller Setup for Pump
A pump controller is always in speed control mode. Other changes to the Controller Setup compared to the traction
controller setup are:
Cal Parameter Calibrator Options Range

Ref text (defaults are in bold)
1 Accelerator Characteristic Lin/Curv 0 = linear, 1 = Curved 0-1
2 Speed 6 input normally closed (low) or Spd6NO/NC 0 = Speed 6 input normally closed 0–1
normally open (high) 1 = Speed 6 input normally open
3 Inhibit input normally closed (low) or HibNO/NC 0 = Inhibit input normally closed 0–1
normally open (high) 1 = Inhibit input normally open
4 Enable power up checks Nchk/Chk 0 = Disable power up checks 0–1
1 = Enable power up checks
5 Enable pot with switch NoSw/Sw 0 = Disable pot switch (use pot only) 0–1
1 = Enable pot with switch
6 Display Status Field Of/D/V/K 0 = None 0–6
1 = Acc
2 = Motor V/RPM
3 =Speed in Kph
4 = Steering position
5 = Motor current
6 = Battery current
7 n/a
8 n/a
9 Digital O/P 4 (pin A18) RemoteLED 0 = Remote LED 0–0
10 Load Defaults LoadDefs 0 = Don't load defaults, 1 = Load defaults 0–1
11 Active low or high digital inputs Actv L/H 0 = Active low digital inputs 0–1
1 = Active high digital inputs
12 Accelerator supply wire off detection SplyWrOf 0 = No supply wire off detection 0–3
3 = Both 0V and 5V wire off detection
13 Line Contactor pull-in level LCPlInLv Adjustable from 50% to 100% Ubatt.to 50-
limit inrush current. Default is 75% 100%
14 Line Contactor pull-in time out LCPlInTO Line Contactor pull in time out.. 0-
Default is 10sec. 60sec
• (*) Recycle the key switch to make changes active. (Also indicated on calibrator ‘key’)
• Irrelevant options show n/a
9.5 PMS Motor Auto tuning
The SuperSigma2 is capable of performing auto tuning of the motor parameters and on PMS models it also does auto
setup the motor feedback sensor (both Sin/Cos and Hall sensors).
The auto tuning just needs a basic set of parameters to be entered. After initiating the auto tuning, the motor will spin.
It is therefore important to have the controller spin the motor freely. This is different from traction and pump:
 For traction the vehicle must be lifted such that the wheels can rotate freely.
 For pump the motor must be able to rotate freely (unloaded).
The auto tuning takes about 2 minutes to complete.

After a successful auto tuning, all the parameters in the motor setup and motor advanced menus will have new values.
It is possible to modify parameters in the PMS motor setup menu. In that case a recalculation must be performed.
Please read the next section for more details.
Parameters in the advanced menu are for indication only and cannot be changed manually.
 Traction controller auto tuning: THE TRACTION WHEELS MUST BE OF THE GROUND
 Pump controller auto tuning: THE PUMP MOTOR MUST BE ABLE TO SPIN UNLOADED
9.5.1 Menu 4 “PMS Motor Auto Tuning”

Cal Parameter Calibrator Min. Max. Step size DMC default
Ref text
1 Number of motor poles Nmotpole 2 48 2 8
0 = Sin/Cos, 1 = Hall sensors,
2 Sensor technology SensTech 1 0
2 = Sensorless
3 Sensor supply voltage SenSuppV 0 (=5V) 1 (=12V) 1 0
4 Reverse sensor reading SpdRever 0 1 1 0
5 Reverse motor direction MotorRev 0 1 1 0
6** Battery Voltage BattV AT 12. 0 V Units Umaxnom 1V 24V
7** Nominal RMS motor current For tuning Inom AT 1 Arms Units Imax Arms 1 Arms ½ max current
8* Maximum RMS motor current Imotmax 1 Arms Units Imax Arms 1 Arms Max current
9* Back e.m.f. constant (KeV) K emf 0.0 V/krpm 100.0 V/krpm 0.1 V/krpm 10.0 V/krpm
10* Motor phase to phase inductance L ph_ph 0 µH 32.000 µH 1 µH 80 µH
Maximum demagnetizing (Field 1 Arms
11* I demag 600 Arms 1 Arms 1 Arms
weakening) current (disabled)
12* Maximum Motor Frequency Fmotmax 0.0 Hz 400.0 Hz 0.1 Hz 100.0 Hz
13 Start Auto-tuning AutoTune 0 1 1 0
Recalculation after changing one of the
14 adjustment of this menu signed with Recalcul 0 1 1 0
one star *
15 Sin/Cos Sensor Delay Angle at 100 Hz SensDel 0,0 deg 15,0 deg 0,1 deg 3,6 deg
Auto tuning type 0 = tune only sensor
16 Atunetype 1 0
1 = tune sensor, Lphph & Ke
 * If a parameter with one star is changed, recalculation of the parameters is required.

Recalculation is performed after setting the recalculation parameter to 1 and recycle the key.
 VERY IMPORTANT: If a setting with two star ** is changed it is necessary to cycle the key and
perform the auto tuning process again.
 Reset to make changes active. Recycle the key switch (Also indicated on calibrator ‘key’)
9.5.2 Setting up auto tuning
The auto tuning algorithm needs a basic set of parameters in order to get the best results. Usually these values are
printed on the motor name plate or provided on a datasheet. This basic set consists of the following parameters:
Auto Tuning Parameter

Number of motor poles Set the number of poles
Sensor technology Choose analogue Sin/Cos sensor or Hall sensors
Sensor encoder supply voltage Choose 5 volt or 12 volt sensor supply
Reverse sensor encoder reading Try set to 1 if auto tuning diagnostics return an error 6
Try set to 1 if auto tuning diagnostics return an error 6 and motor direction
Reverse motor direction
is reversed (or counter clock wise)
Nominal Battery Voltage Set the nominal battery voltage
Nominal RMS motor current Set the nominal motor current (= continuous current)
Maximum RMS motor current Set the maximum required motor current
Back e.m.f. constant Set the Ke voltage (motor voltage per 1000rpm)
Motor phase to phase inductance Set the motor inductance in micro henry (µH)
Maximum demagnetizing current If field weakening is required, enter the maximum allowed motor current
in field weakening. Set to 1 to disable. To high values will damage the
motor magnets. Consult motor manufacture first!
Maximum desired motor frequency Set the maximum required motor frequency
9.5.3 Initiating auto tuning

After setting up the basic parameters for the auto tuning, the auto tuning can be initiated. This is done by setting the
auto tuning parameter to '1'. The calibrator will now show the following screen. These screens are shown to make the
user conscious that auto tuning is commencing.
*** AUTO TUNING ***
Have you set the

parameters?
********************
This can be confirmed by pressing and holding the + and - button for at least 5 seconds. Then the calibrator shows the
following screen:
For Traction controllers: For Pump controller:
*** AUTO TUNING *** *** AUTO TUNING ***
Are the wheels Is the motor able to spin

off the ground? unloaded?
******************** ********************
Again, confirm by pressing and holding the + and - button for at least 5 seconds.
*** AUTO TUNING ***
In progress 54 %
(select to cancel)
*********************
AUTO TUNING CAN BE DISABLED ANYTIME BY PRESSING THE SELECT BUTTON .
After the auto tuning process is finished, it will display the following screen:
*** AUTO TUNING ***
finished. Press
select to return
*********************
In case of errors, it shows the following screen:

*** AUTO TUNING ***
failed with code 4

(select to return)
*********************
9.5.4 Auto tuning errors
It is possible the auto tuning algorithm has encountered an error. This list provides the possible errors during auto
tuning.
Error Description
0 No errors in the Auto tuning Motor Module
The rated battery voltage set is not consistence with the measured one auto tuning cannot be performed
1
Solution: Set a proper number in ATMenu #6
The battery is too low auto tuning cannot be performed
2
Solution: Check power connections (+ and B+), check battery state of charge, check line contactor wiring.
3 An overcurrent is detected (maybe short circuit or wrong wiring)
4 No current is flowing in the motor: no or wrong motor connection.
No Sensor feedback reading: it means no sensor connected or motor locked
5 Solution: check for the sensor supply voltage setting being correct,
check sensor wiring and chech if motor is free to spin.
Error in speed measurement (only for Sin/Cos): direction measured is not consistent with motor direction
6 Solution: if motor spins in forward direction during autotuning change ATmenu #4
if motor spins in reverse direction during autotuning change ATmenu #5
7 Wrong number of poles set in ATmenu #1 (only for Sin/Cos)
8 Unable to finish calculation (rotor resistance too low or too high)
Unable to finish motor measurements
Probably causes:
9
1) Motor is loaded: remove mechanical load
2) Nominal current it is set to low: increase ATmenu#7
Motor inductance is too low
10 Sine/Cosine signal is not detected: check wiring or Sensor Supply ATMenu #3
11 Sine signal is not in the same range as the cosine signal: check wiring and sensor
12 Cosine signal is not in the same range as the sine signal: check wiring and sensor
13 Sine/Cosine signals are in range but very different: Check sensor mechanical alignment and wiring.
14 One of the three Hall sensor signal is missing
15 Two of the three Hall sensor signals are missing
16 All hall sensors signals are missing
Hall sensor configuration incorrect.
Probably causes :
17 1) the motor is loaded
2) sensors wrong wiring
Nominal current is set too low: increase ATmenu#7
Unable to calculate the PI gains: Perform auto tuning again starting from default values (if Autotune type 1
18
has been chosen), Check Ke and Lph-ph values.
19 Motor calculated maximum speed exceeds 500Hz: Refer to DMC
20 Unable to calculate limit curves. Check motor parameters (Fmotmax, I demag) in the auto tuning menu
21 An unknown error occurred: Refer to DMC
9.5.5 Recalculation
It is possible to alter one or more parameters, for example the maximum desired motor current. To gain advantage of
this change recalculation of the parameters should be performed. To initiate a recalculation, simply set the parameter in
the motor setup menu to 1 and recycle the key switch.
9.6 Menu 5 “PMS Motor Setup”
The AC motor setup menu define the motor characteristics for the controller.
Normally these parameters are calculated by the auto tuning procedure.
If it is necessary to tune these parameters, please consult DMC first.
Mistakes in the motor setup tables can cause serious accidents and/or defective controllers
and/or defective motors.
Cal Parameter Calibrator Min. Max. Step size DMC Actual

Ref text default setting
1 Proportional gain speed controller Kp Spd 0.1 63.9 0.1 1.0
2 Integral gain speed controller Ki Spd 0.1 1999.9 0.1 5.0
3 Enable double PI settings for speed
SpdPIx2 0 1 1 0
controller
4 Double PI speed threshold SpdPITH 0% 50 % 1% 5% %
5 Proportional gain speed controller
KpSpdLow 0.1 63.9 0.1 1.0
below threshold
6 Integral gain speed controller below
KiSpdLow 0.1 1999.9 0.1 5.0
threshold
7 Transition time between the two PI
TransTim 0.01 s 5.00 s 0.01 s 0.1 s s
settings for the speed controller
8 Extra field weakening level referred to
FWextra 0% 40 % 1% 10 % %
the ideal flux at maximum speed
9 Speed Threshold for beginning field
F_FW TH 20 % 100 % 1% 100 % %
weakening
10 Torque Reduction Map in field
TReduc1 10 % 100 % 1% 90 % %
weakening range point 1
TReduc2 10 % 100 % 1% 80 % %
TReduc3 10 % 100 % 1% 70 % %
TReduc4 10 % 100 % 1% 60 % %
TReduc5 10 % 100 % 1% 50 % %
15 Cap, Voltage ramp Time CapVTime 0,1 s 20,0 s 0,1 s 5,0 s s
16 Voltage Limiter Filter Frequency FVlimFlt 0,1 Hz 100,0 Hz 0,1 Hz 2,0 Hz Hz
9.7 Menu 6 “PMS Motor Advanced”
(indication only – not possible to modify without assistance of DMC engineers)
Cal Parameter Calibrator Min. Max. Step DMC Actual

Ref text size default setting
1 Decouple Iq and Id controllers Decouple 0 1 1 0
2 Enable software PWM algorithm delay
PWMDelay 0 1 1 0
compensation
3 Limit torque controller during Voltage limiting VoltSat 0 1 1 0
4 Speed Control Filter SCFilter 0 1 1 0
5 Enable Voltage Limiter VoltCtrl 0 1 1 0
6 Speed filter cut-off frequency Fspdfilt 4 Hz 400 Hz 1 Hz 80 Hz Hz
7 Percentage of correction for leakage inductance
DecoLeak 20 % 180 % 1% 100 % %
value
8 Back EMF correction factor BEMFCorr 20 % 180 % 1% 100 % %
9.8 Menu 7 “Limits Setup”
Cal Parameter Calibrator Min. Max. Step Default
Ref text size
1 Motor Temp Sensor Type MtempTyp 0 0 0 0=
KTY84-130
2 Motor Temp. Cutback start TempStrt 0 °C 151 °C 1 °C 120 °C
(disables) (enabled)
3 I²t Nominal Motor Current NomCurr 0 Arms Unit max. 1 0 Arms
(I2tInom Arms
4 I²t Start Motor Temperature I2tTemp 0 °C 100 °C 1 °C 0 °C
5 I²t Time I2tTime 0s 999 s 1s 0s
(disables) (disabled)
6 I²t Cutback1 I2tCutB1 0% 100 % 1% 100 %
9 Performance Table Speed 1 PTSpd1 0.0 Hz
400.0 Hz 0.1 Hz 50.0 Hz
(disables)
10 Performance Table Speed 2 PTSpd2 0.0 Hz 400.0 Hz 0.1 Hz 70.0 Hz
11 Performance Table Speed 3 PTSpd3 0.0 Hz 400.0 Hz 0.1 Hz 100.0 Hz
12 Performance Table Cutback 1 PTCutBk1 0% 100 % 1% 100 %
15 Low Voltage Cut Back start threshold LVCBstrt 16.0 V Unit max. 0.1 V 20.0 V
16 Low voltage cut back end threshold LVCBend 16.0 V Unit max. 0.1 V 16.0 V
17 Low voltage error threshold LVerror 14.0 V Unit max. 0.1 V 14.0 V
48 V units
18 High Voltage Cut Back start threshold HVCBstrt 24.0 V 67.5 V 0.1 V 60.0 V
19 High voltage cut back end threshold HVCBend 24.0 V 67.5 V 0.1 V 67.5 V
20 High voltage error threshold HVerror 24.0 V 70.0 V 0.1 V 70.0 V
96 V units
18 High Voltage Cut Back start threshold HVCBstrt 24.0 V 138.5 V 0.1 V 130.0 V
19 High voltage cut back end threshold HVCBend 24.0 V 138.5 V 0.1 V 138.5 V
20 High voltage error threshold HVerror 24.0 V 140.0 V 0.1 V 140.0 V
Generic
21 Absolute motor speed AbsMaxSp 0.0 Hz 400.0 Hz 0.1 Hz 125.0 Hz
22 torque threshold for stall protection (off when TrqTHLim 1% 100 % 0,1 % 100 %
100%)
23 timer for stall protection StallTim 0s 120 s 0,1 s 60 s
9.9 Menu 8 “BDI” Battery Discharge Indicator
Cal Parameter Calibrator Min. Max. Step Default Default

Ref text adjust adjust size 48V 96V
1 Battery type Batt Typ 0 0 1 0 0
2 Nominal battery voltage NomBatV 12. 0 V Uabsmax 1V 48 V 96 V
3 BDI reset level BDIreset 12. 0 V Uabsmax 0.1 V 50.2 V 100.3 V
4 BDI empty level BDIempty 12. 0 V Uabsmax 0.1 V 38.9 V 77.8 V
5 BDI warning level BDIwarn 0% 100 % 1% 20 % 20 %
6 BDI cut out level BDIcut 0% 100 % 1% 0% 0%
7 BDI speed limit (traction only) BDIspeed 0.0 Hz 400.0 Hz 0.1 Hz 100.0 Hz 100.0 Hz
9.10 Menu 9 “CAN Bus Setup”

SuperSigma2 uses our own CAN bus protocol for sending information to other CAN nodes and receiving control
messages from other CAN nodes. The system is designed for the SuperSigma2 to act as a slave in an existing CAN
environment. Detailed information about the protocol will be provided on request.
As default the CAN system is deactivated.
Cal Parameter Calibrator Options Default
text
Ref
1 CAN Node Number CAN node Node number 0 to 15 0
2 CAN bit rate CANbitRt CAN bus speed: 0
0 = 100kbps
1 = 125kbps
2 = 250kbps
3 Transmit CAN messages CANMsgs 0= DC & DS (Receive &Transmit) 4
1 = DC & DS & MS (Receive &Transmit)
2 = DC & DS & CS (Receive &Transmit)
3 = DC & DS & CS & MS (Receive &Transmit)
Used short descriptions: 4= no CAN message
5= DS only (Transmit only)
DC : drive command (receive) 6= MS only (Transmit only)
DS : drive status (transmit) 7= DS & MS (Transmit only)
MS : Motor status (transmit) 8= CS only (Transmit only)
CS : controller status (transmit) 9= CS & DS (Transmit only)
10= CS & MS (Transmit only)
11= CS & MS &DS (Transmit only)
4 Shared Line Contactor ShareLC 0 = No shared line contactor 0
1 = Shared line contactor
5 Last Node Sharing Line Contactor LstNode Node number 1 to 15 1
6 CAN motor status transmit rate CAN_MS 100 to 1000ms 100ms
7 CAN controller status transmit rate CAN_CS 100 to 1000ms 1000ms
8 CAN drive status transmit rate CAN_DS 100 to 1000ms 100ms
9 CAN controller timeout timer CAN_TO 100 to 500ms 150ms
Recycle the key switch to make changes active. (Also indicated on calibrator ‘key’)
9.11 Menu 10 “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.
To reset the fault log, press the + and – button at the same time when the controller is in neutral.
To reset the fault log data, press the + and – button at the same time when the controller is in neutral.
9.13 Menu 11 “Test”
9.13.1 Test menu for Traction
The test menu shows I/O information, useful for fault finding.
Cal Parameter Calibrator Unit Min. Max.

Ref Text Display Display
1 Forward switch Forward Input 0 1
2 Reverse switch Reverse Input 0 1
3 FS1 / Belly switch FS1/Bely Input 0 1
4 Seat / Tiller switch Seat/Til Input 0 1
5 Speed 1 / Inch Forward Spd1/InF Input 0 1
6 Speed 2 / Inch Reverse Spd3/InR Input 0 1
7 Speed 3 / Handbrake Spd3/Hbk Input 0 1
*8 Digital Output 1 DigOut 1 Output 0 1
9 Accelerator pot (%) AccelPot % Input 0% 100 %
10 Accelerator pot (V) AccelPot V 0.0 V 10.0 V Raw AD Raw AD Volts
11 Brake pot (%) BrakePot % Input 0% 100 %
12 Brake pot (V) BrakePot V 0.0 V 10.0 V Raw AD Raw AD Volts
13 Steer pot (%) SteerPot % Input 0% 100 %
14 Steer pot (V) SteerPot V 0.00 V 10.00 V Raw AD Raw AD Volts
15 Line contactor Line Output 0 1
16 Electric Magnet Brake contactor ElecMbrk Output 0 1
17 Power steer contactor PSteer Output 0 1
18 Speed Sensor SpeedSen Input 0 1
19 Speed Sensor Direction SpeedDir Input/ 0 1
output
20 Encoder 3 input Encoder3 Input 0 1
21 Positive hardware overcurrent PosOvrCr Input 0 1
trip
22 Negative hardware overcurrent NegOvrCr Input 0 1
trip
23 Internal temperature sensor IntTempS ˚C 0.00 ° C 120.00 °C Raw AD Raw AD Volts
24 Internal reference voltage IntVref mV 0 mV 3300 mV Raw AD
25 +5 V power supply +5V V 0.00 V 5.10 V Raw AD Raw AD Volts
26 +14 V power supply +14V V 0.00 V 14.00 V Raw AD Raw AD Volts
27 M1 current sensor output I_M1 V 0.00 V 5.10 V Raw AD Raw AD Volts
28 M3 current sensor output I_M3 V 0.00 V 5.10 V Raw AD Raw AD Volts
29 M1 voltage M1 Volts V 0.0 V 200.0 V Raw AD Raw AD Volts
30 N/A
31 M3 voltage M3 Volts V 0.0 V 200.0 V Raw AD Raw AD Volts
32 Power PCB identification PCB ID 0h Fh
33 Sensor supply output SensSuppl Output 0 1
9.13.2 Test menu for Pump
Changes to the Test menu compared to the traction test menu are:
Cal Parameter Calibrator Unit Min. Max.

Ref Text Display Display
1 Speed 1 digital input Speed1 Input 0 1
7 Inhibit digital input Inhibit Input 0 1
*8 Digital Output 1 DigOut 1 Output 0 1
9 Accelerator pot (%) AccelPot % Input 0% 100 %
10 Accelerator pot (V) AccelPot V 0.0 V 10.0 V Raw AD Raw AD Volts
11 N/A
12 Analog input 2(V) Analog 2 V 0.0 V 10.0 V Raw AD Raw AD Volts
13 N/A
14 Analog intput 3 Analog 3 V 0.0 V 10.0 V Raw AD Raw AD Volts
… … … … … … … …
16 Digital output 2 DigOut 2 Output 0 1
9.14 Menu 12 “Debug”
(indication only)
The debug menu is for internal DMC use only.
9.15 .Menu 13 “About”

Cal Information Field Example
Ref
1 Customer name Cust. Standard
2 Application App. Standard
3 Controller type Ctrl. AC Traction
4 Software type Swtyp PAC960TL1-04
5 Software version SW V02.00.00
6 Software Date Date 26-08-2014
7 Hardware type HWtype Size 4 96 V
8 Hardware BOM HWbom V6.01b
9 BSP Version BSP V01.00.00
10 AC FOC version ACFOC V02.00.00
9.16 Available Application Notes

The following application notes are available upon request.
AN Title Version
120301 Flashing SuperSigma2 Controllers V1.0
130101 Performance Table V1.0
2
130102 It V1.0
130301 Low and High Voltage Limits and Cut Back V1.0
CAN DMC SuperSigma2 CAN protocol V2.0
CAN SuperSigma2 CAN Messages V2.0
Dual Motor Setup (document under development)

Shared line contactor setup (document under development)
9.17 Thermal Motor Management & Performance Table
The Performance Table sets a maximum current for a specified speed as shown in the table below:
Speed Maximum current allowed

Between PTSpd1 and Scale the set maximum current proportionally with speed between the speed points
PTSpd2 PTSpd1 and PTSpd2.
Between PTSpd2 and Scale the set maximum current proportionally with speed between the speed points
PTSpd3 PTSpd2 and PTSpd3.
The Performance Table collaborate with the other current roll back functions. The current roll back on controller
2
temperature, current roll back on motor temperature and the I t function.
2
The I t function have its settings in percentages, the same as the current roll back on controller and motor temperature.
The function that has the highest roll back percentage, will be applied to the applicable maximum current, and will
result in the effective maximum current as shown in the picture below (here the roll back is 50%).
Current [Arms] For normal operation, the

MaxCurr maximum current at boost speed is
CurBoost usually set the same as the
maximum current from the
Applicable Maximum current adjustments menu.
CurBase set by Performance Table This will then give a straight line
from zero speed towards boost
speed yielding maximum current at
low speeds.
CurMax
During operation, the controller will
show “PT” at row 9 in the status
menu.
Effective maximum current
Speed [rpm]
SpdBase SpdMax
SpdBoost
9.17.1 Current roll back on motor temperature

Motor Temperature
Current Fold back start setting The maximum current value is rolled back as soon as the motor
[A] temperature is above it’s starting point adjustment (parameter 2 in the
30 °C limits setup menu). It is cut back proportionally between the starting
point and 30 °C above the starting point as shown in the graph below.
Motor temperature [°C]
9.17.2 Option to disable current roll back functions

To disable the current rollback features:
 current roll back on motor temperature; by setting the motor temperature start adjustment at 151 °C,

2
I t function; by setting the I2tTime adjustment to 0.
 Performance Table; by setting the maximum current at boost speed adjustment to 0 A.
10 Diagnostics
Base Sub
fault Description fault Description
Code code
Controller warning faults - Reduces only performance - Fault will reset itself (if possible)
0 No error - -
1 N/A -
1 Battery voltage below absolute minimum
2 Capacitor voltage below absolute minimum
2 Voltage getting low
3 Battery voltage below minimum adjustment
4 Capacitor voltage below minimum adjustment
3 Pump inhibit -
1 Battery voltage above absolute maximum
2 Capacitor voltage above absolute maximum
4 Voltage getting high
3 Battery voltage above maximum adjustment
4 Capacitor voltage above maximum adjustment
5 Motor temperature high -
6 Controller temperature high -
< 999 First digit: menu number
> 100 Last two digits: item number within menu
999 Power PCB doesn't match firmware
1 Shared LC : master is not shared line contactor
7 Adjustment out of range 2 Shared LC : slave is not shared line contactor
3 Shared LC: not requested slave is shared LC
4 Wigwag is selected without walkie
5 Inching and walkie are both selected
6 Dual motor with speed mode selected
8 Default adjustments used -
Drive error faults - Commences graceful neutral brake - Requires a neutral recycle action to reset fault
9 Memory chip fault >0 Report to DMC.
10 Both forward and reverse inputs active -
Ride-on: Seat switch not closed or timed out
11 -
Walkie: Tiller switch not closed
1 Traction: FS1 switch active at power up
2 Traction: Forward switch active at power up
3 Traction: Reverse switch active at power up
4 Pump: Pump pot active at power up
12 Power up sequence fault 5 Pump: Speed 2 active at power up
6 Pump: Speed 3 active at power up
9 Inching: Forward switch active at power up
10 Inching: Reverse switch active at power up
1 Normal accelerator type high at power up
13 Accelerator more than 50% at power up
2 Wig-wag accelerator type high at power up
1 Foward switch active at inching
2 Reverse switch active at inching
3 FS1 switch active at inching
4 Seat switch active at inching
Traction: Inching sequence faults
14 5 Foot Brake switch active at inching
6 Hand Brake active at inching
7 Both inching buttons active at inching
8 Inching buttons active during normal drive
Walkie: Belly switch active -
Errors are continued at next page…
Error codes continued
Base Sub
code code
Soft error faults - Immediately stops pulsing - Requires a neutral recycle action to reset fault
15 Supply voltage too low >0 Report to DMC.
16 N/A -
1 Battery voltage below absolute minimum
2 Capacitor voltage below absolute minimum
17 Voltage is too low
3 Battery voltage below minimum adjustment
4 Capacitor voltage below minimum adjustment
1 M1 mosfets
18 High sided mosfets short circuit 2 M2 mosfets
3 M3 mosfets
19 N/A -
Hard error faults - Immediately stops pulsing and open line contactor - Cannot be reset (only by a key switch recycle)
Positive overcurrent detected during
1
initialization
Negative overcurrent detected during
2
20 Hardware over current detected initialization
3 Positive overcurrent detected
4 Negative overcurrent detected
<4 Contact DMC
1–3 Line contactor coil short circuit
4–6 EM-Brake contactor coil short circuit
21 Contactor coil driver fault (e.g. short circuit)
7–9 Power steer contactor coil short circuit
10 – 12 Digital output 4 short circuit
1 Battery voltage above absolute maximum
22 Voltage is too high 2 Capacitor voltage above absolute maximum
3 Battery voltage above maximum adjustment
4 Capacitor voltage above maximum adjustment
1 M1 mosfets
23 Low sided mosfets short circuit in neutral 2 M2 mosfets
3 M3 mosfets
24 Hardware fail safe fault >0 Report to DMC.
1 Could not discharge capacitor bank.
Capacitor bank did not charge sufficiently to
25 Line contactor fault 2
safely close the line contactor.
3 Line contactor opened inadvertently.
Pump motor speed below minimum speed
Let the system cool down for the power limit to
26 setting -when a system limit is active due to -
become inactive.
motor or controller power reduction
Low sided mosfets short circuit during power up 1 M1 mosfets
27 2 M2 mosfets
and before line contactor is closed
3 M3 mosfets
Errors are continued at next page…
Error codes continued
Base Sub
code code
1 Quadrature encoder sensor wire off detected
2 5 V supply wire off detected
28 Wire off 3 0 V supply wire off detected
4 Wig-wag out of safety range
5 Motor thermal sensor wire off detected
1 Shared LC slave time out fault
2 Shared LC Master fails to broadcast to slaves
3 Shared LC requested slave is not found by
29 Node fault
4 Shared
master LC master time out fault
5 CAN time out fault
6 CAN security bit check failure
Motor speed is too high to commence safe
1
pulsing
30 Motor over speeding
Motor speed is higher than absolute maximum
2
speed
31 Motor Fault
32 Motor Module initialization error See table below "Generic AC Motor Module
>0
33 Motor Module configuration inconsistency sub error codes"
34 Motor Module parameter inconsistency
1 Could not initialize calibration
35 Motor Calibration initialization fault
2 Time out during calibration
36 .. 38 N/A
1 Time out on configuration upload
39 Generic time out 2 Time out on getting stable inputs
3 Time out on motor ready
≥ 40 System fault. >0 Report to DMC.
10.1 Generic PMS Motor Module sub error codes
Sub
Description
Code
0 No errors in the motor module
1 The motor module could not be initialized
2 An overcurrent is detected
3 A wrong value of current offset is calculated
4 Wrong current: rated motor current is greater than max
5 Wrong poles number (is odd)
Wrong settings: rated motor voltage is too high in relation with the battery voltage capability
6
(0.93% Vbatt/sqrt(2))
7 Wrong settings: max trip current greater than max controller current
8 Wrong settings: max motor current lower than trip current
9 Sine signal is out of range: check connection and sensor
10 Cosine signal is out of range: check connection and sensor
11 No Hall sensor signal; check connection and sensor
12 Unable to perform recalculation: motor calculated maximum speed exceeds 500 Hz
Unable to perform recalculation: limit curves; check motor parameters (Ls, Ke, Fmax, Idemag) in
13
auto tune menu.
14 An unknown error occurred
11 Graphics & Schematics
11.1 Accelerator Characteristics
11.2 Controller Thermal Cutback Characteristic
11.3 Light Wiring PMS Traction
Connector A - Vehicle Interface - 35 Way (AMP SEAL Series)
In te rn a l c i rc u i ts :
Pin A1 to A7 12V
12K
Active Low circuit
PMS Traction Controllers - Connector A µP
B- 1 Forward i/p
B- 2 Reverse i/p Active High circuit
B- 3 FS1 i/p µP
B- 4 Seat i/p 47K 47K

1K
B- 5 Speed 1 i/p 12K
B- 6 Speed 2 i/p
B- 7 Handbrake (NO) i/p / Speed 3 (NC) Pin A8 20R 5V rail
8 Analogue supply 5V - 10mA max. 5Vpot
supply
9 Analogue AD1 - Accelerator pot
10 Analogue supply 0V Pin A10 39R
11 Analogue AD2 - Footbrake pot Pot Gnd
5K Pot
12 Analogue AD3 - Steer pot
Pin A9, 5K6
B+ 13 Key i/p A11,
Fuse 14 Contactor supply o/p A12 10K µP
10A K1
15 Contactor 1 o/p (line) Pot i/p
K2
16 Contactor 2 o/p (Magnet Brake)
Pin A12
K3
17 Contactor 3 o/p (Powersteer) 12V
CAN 12V rail
18 Digital o/p - Remote LED or Brake lights
Pin A23
19 Supply 12V - 70mA max.
CAN GND Polyfuse
20 CAN +12V
21 CAN H1
120R
22 CAN L1 Pin A24 CAN-L
23 CAN 0V Pin A27 5V
24 CAN 120R Link Encoder or
supply 12V
25 CAN H2
26 CAN L2 Pin A31
27 Motor sensor supply +5V / 12V (Software Encoder Polyfuse
28 Hall sensor 1 i/p selectable)
29 Hall sensor 2 i/p Pin A34 3,3V
30 Hall sensor 3 i/p &A35 2K2
31 Motor sensor supply 0V
µP
32 Motor sensor Sine AD5 i/p 34
33 Motor sensor CoSine AD6 i/p
34 Thermistor AD4 i/p 35 Polyfuse
35 Thermistor 0V
Connector B - Communications - 8 Way (Hidden) 35 Way pin layout:

Connector B (Hidden)
1 Rx - Flash
2 Tx - Flash
1 12
3 +12V Flash
4 N/C Connector B
13 23
5 CAN L 1 2 3 4
6 CAN H 24 35
5 6 7 8
7 +12V
8 0V MOLEX MFJ8 AMPseal 35 position
Most inputs are Normally Open (NO) except for the speed inputs, these are Normally Closed (NC)
11.4 Light Wiring PMS Pump
Connector A - Vehicle Interface - 35 Way (AMP SEAL Series)
In te rn a l c i rc u i ts :
Pin A1 to A7 12V
PMS Pump Controllers - Connector A 12K
B- 1 Pump Pot / Switch 1 i/p Active Low circuit
µP
B- 2 Pump Switch 2 i/p
B- 4 Pump Switch 4 i/p Active High circuit
µP
47K 47K
B- 6 Pump Switch 6 / Pwr Steer trigger i/p 1K
12K
B- 7 Pump Inhibit i/p
8 Analogue supply 5V - 10mA max.
Pin A8
9 Analogue AD1 i/p
20R 5V rail
5Vpot
10 Analogue supply 0V supply
5K Pot 11 Analogue AD2 i/p Pin A10 39R

12 Analogue AD3 i/p Pot Gnd
B+ 13 Key i/p
Pin A9, 5K6
Fuse 14 Contactor supply o/p
A11,
10A K1
15 Contactor 1 o/p (Line) A12 10K µP
K2
16 Contactor 2 o/p (Power Steer) Pot i/p
K3
17 Contactor 3 o/p (Remote LED)
Pin A12
18 Digital o/p 12V
CAN 12V rail
19 Supply 12V - 70mA max.
Pin A23
20 CAN +12V CAN GND Polyfuse
21 CAN H1
22 CAN L1 120R
Pin A24 CAN-L
23 CAN 0V
24 CAN 120R Link Pin A27 5V
Encoder or
25 CAN H2 supply 12V
26 CAN L2
27 Motor sensor supply +5V / 12V (Software Pin A31
selectable) Encoder Polyfuse
28 Motor Hall sensor 1 i/p
29 Motor Hall sensor 2 i/p
Pin A34 3,3V
30 Motor Hall sensor 3 i/p &A35 2K2
31 Motor sensor supply 0V
µP
32 Sine AD5 i/p
34
33 CoSine AD6 i/p
34 Thermistor AD4 i/p 35 Polyfuse
35 Thermistor 0V
Connector B - Communications - 8 Way (Hidden) 35 Way pin layout:

Connector B (Hidden)
1 Rx - Flash
2 Tx - Flash
1 12
3 +12V Flash
4 N/C Connector B
13 23
5 CAN L 1 2 3 4
6 CAN H 24 35
5 6 7 8
7 +12V
8 0V MOLEX MFJ8 AMPseal 35 position
For pump controllers pump switch 6 and pump inhibit are standard active low. Via the setup menu it is
possible to change to active high.
11.5 CAN bus wiring
CAN bus communication wires should be terminated at both ends with a 120Ω resistor.
All SuperSigma2 controllers the 120Ω termination resistor installed, it is up to the user to use it or not.
By linking pin A24 and A25 on a SuperSigma2 controller the termination resistor becomes active.
If a CAN bus network is installed in a machine, special care should be taken which 2 CAN nodes should have the build-in
termination resistor connected. Make sure that only 2 termination resistors are active.
Below 2 examples of a CAN bus network, with and without DMC CAN Display.
11.5.1 CAN bus wiring example with DMC Display:
The DMC advanced display has a CAN bus termination resistor installed. This resistor is fixed installed and cannot be
disconnected. Below schematic shows how the CAN bus termination should be wired when a DMC advanced display is
part of the CAN bus installation:
DMC Display CAN Connection Example With DMC Display

internal 120R
CAN H CAN L internal 120R internal 120R internal 120R

Alway s Connected A24
12V 0V
not used not used Connected
7 6 5 8
DMC Calibrator
7 A20 12V
6 A21 CAN H A25 A21 A25 A21 A25
5 A22 CAN L A26 A22 A26 A22
8 A23 0V
SuperSigma2 SuperSigma2 SuperSigma2

Controller 1 Controller 2 Controller 3
11.5.2 CAN bus wiring example without DMC Display:
If no DMC advanced display is installed, wire as followed:
CAN Connection Example Without DMC Display
internal 120R internal 120R internal 120R

A24 A24
Connected not used Connected

DMC Calibrator
7 A20 12V
6 A21 CAN H A25 A21 A25 A21 A25
5 A22 CAN L A26 A22 A26 A22
8 A23 0V
SuperSigma2 SuperSigma2 SuperSigma2

Controller 1 Controller 2 Controller 3
Always connect the 0V of the CAN bus to the B- of the largest power controller in the system
11.6 iGauge Display – Connection diagram
The iGauge is a 52mm diameter indicator.
It is capable of indicating lead acid battery discharge state, hours counter and the main SuperSigma2 fault messages.
iGauge Connector Connector B (8-Way)

Tx 4 1 Rx - Flash
Rx 3 2 Tx - Flash
12V Supply (+) 2 3 +12V Flash
0V Supply (-) 1 4 N/C
5 CAN L
6 CAN H
7 +12V
8 0V
11.7 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.
12 Mechanical Drawings
12.1 SuperSigma2 Controllers
S ize 4 ( L )
200mm
ABS Cover 72mm
150mm
S ize 3 ( M + ) Profile Example (Size 4) 30mm
Fuse
B+ + 200mm
150mm S ize 2 ( M )
200mm
S ize 1 ( S )
Fuse
B+ + 150mm
200mm
M1 M2 M3 Fuse
150mm
B+ +
303mm
320mm
M1 M2 M3
230mm
250mm
Fuse
M1 M2 M3 B+ +
180mm
200mm
M1 M2 M3
140mm
160mm
AMP
SEAL
35 AMP
SEAL AMP
B- B- B- SEAL B-
35
35 AM P SEAL
35
Power connections = M8 Power connections = M8 Power connections = M8 Power connections = M8

Controller mounting = M8 Controller mounting = M8 Controller mounting = M8 Controller mounting = M8
12.2 DMC Advanced Display
DMC Advanced Display
13 Contact information
DMC GmbH
Auf dem Hochstück 11
45701 Herten Germany
Tel: +49 (0) 2366 10070

Fax: +49 (0) 2366 100750
Email: [email protected]
Web: www.dmcde.de

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SuperSigma2 QRM for PMS motors

(for more detailed information contact DMC)

1. PMS range for Permanent Magnet Synchronous Motors 24-96V, 250-600Arms

Revision Issue Date Author Changes

4.1.1 Voltage specifications: ................................................................................................................................... 7

5 INSTALLATION INSTRUCTIONS ............................................................................................................................... 8

6 EMC GUIDELINES ................................................................................................................................................... 9

8 DASHBOARD DISPLAY ...........................................................................................................................................11

9.1.1 Neutral braking setup options ..................................................................................................................... 14

9.2 MENU 1 “PUMP ADJUSTMENTS” ................................................................................................................................ 15

9.3.1 Status tables ................................................................................................................................................ 17

9.4 MENU 3 “CONTROLLER SETUP” .................................................................................................................................. 18

9.4.1 Controller Setup for Traction ....................................................................................................................... 18

9.5 PMS MOTOR AUTO TUNING ...................................................................................................................................... 20

9.6 MENU 5 “PMS MOTOR SETUP” ................................................................................................................................. 24

9.13.1 Test menu for Traction ................................................................................................................................. 29

9.14 MENU 12 “DEBUG”.................................................................................................................................................. 31

9.17.1 Current roll back on motor temperature ...................................................................................................... 32

11 GRAPHICS & SCHEMATICS ................................................................................................................................ 37

11.5.1 CAN bus wiring example with DMC Display: ................................................................................................ 40

11.6 IGAUGE DISPLAY – CONNECTION DIAGRAM .................................................................................................................... 41

12 MECHANICAL DRAWINGS ................................................................................................................................. 42

13 CONTACT INFORMATION ................................................................................................................................. 44

Next Generation: The SuperSigma2 Controller Range

Sigmadrive Controller Range

©2015 DMC GmbH

Model Number Description Model Nr. Power

4.1.2 Current specifications:

EMC: EN61000-6-2 (industrial immunity), EN61000-6-3 (residential emissions, Class B)

Always use a torque wrench when fixing the power terminals.

5.2 Mechanical installation and Cooling

5.3 Power wiring

5.4 Light wiring

5.5 Speed sensor cabling

5.8 Power up Delay

6.1 Power Cables

6.2 Signal Cables

CAN Node Setup

7.2 Calibrator map

7.3 DMC PC Programmer

The DMC dashboard display is specially

In the future the membrane buttons will allow

8.1 General information

8.2 Display setup menu

8.3 Display Features Setup

7 Adjustments out of range

9 E-eprom cannot be accessed

22 Voltage too high

26 Thermal shutdown fault

9.1.2 Neutral braking setup in speed control mode (control mode 0)

This feature is under development.

9.1.3 Neutral braking setup in torque control mode (control mode 1)

9.1.4 Neutral braking setup in torque control mode (control mode 2)

This feature is under development.

9.1.5 Hill Hold

Cal Parameter Calibrator Min. Max. Step size Default

BDI States Drive and brake status

BDI States Description Status Description

9.3.2 Drive and brake limits tables

* AUTO TUNING *

* AUTO TUNING * * AUTO TUNING *

* AUTO TUNING *