PG Drives Technology I-DRIVE Series Manuals

PG Drives Technology I-DRIVE Series Manuals

Manuals and User Guides for PG Drives Technology I-DRIVE Series. We have 1 PG Drives Technology I-DRIVE Series manual available for free PDF download: Technical Manual

PG Drives Technology I-DRIVE Series Technical Manual

PG Drives Technology I-DRIVE Series Technical Manual (115 pages)

Brand: PG Drives Technology | Category: Controller | Size: 5.48 MB

Table of Contents

Table of Contents
3
About this Manual
8
Icons
8
Chapter 1 - Operation

9
- Introduction
  11
- General
  11
  - Handling
    11
  - Operating Conditions
    11
- Controls
  11
  - On/Off Switch
    11
  - Status Indicator
    12
  - Throttle
    12
  - Wig-Wag Throttle
    12
  - Single-Ended Throttle
    12
  - Unipolar Throttle
    12
  - Tiller Switch
    12
  - Direction Switches
    12
  - Reverse Switch
    12
  - Speed Limiting Potentiometer
    12
  - Belly Button
    12
  - Slow/Fast Switch
    13
  - Audible Alarm
    13
- Getting Ready to Drive
  13
- Tips for Using Your Controller
  13
  - Driving - General
    13
  - Driving Technique
    13
- Precautions for Use
  14
  - Hazards
    14
- Safety Checks
  15
  - Daily Checks
    15
  - Weekly Checks
    15
  - Servicing
    15
- Status Indication
  16
- Battery Gauge
  19
  - How to Read a Single Bulb (or LED) Battery Gauge19
    19
  - How to Read a Trucharge Battery Gauge
    19
- Pushing Your Machine
  19
- Programming
  20
- Warranty
  20
- Servicing
  21
Chapter 2 - Installation

23
- Documentation
  25
  - I-Drive Versions
    25
  - I-Drive Operation
    25
  - Dimensions
    26
  - I-Drive 45A and 70A Controllers
    26
  - I-Drive 140A and 180A Controllers
    27
  - Program Settings
    27
  - Soft-Stop
    28
  - Other Information
    28
- Immobilizing the Machine
  28
  - Prevention of Unauthorized Use
    28
  - Charger Interlock
    28
- Connections
  28
  - General
    28
  - Wiring Configuration I45 & I70
    29
  - Wiring Configuration I140 & I180
    30
  - Connectors & Connector Kits
    30
  - Motor and Battery
    30
  - I45 & I70
    30
  - I140 & I180
    31
  - Aux 1 Connector
    31
  - Tiller Interface Connector
    31
  - Programming Connector
    31
  - Crimping
    32
  - Wire Gauge and Types
    32
  - Battery Connection
    33
  - Motor Connection
    33
  - Auxiliary 1 Output
    33
  - Solenoid Brake
    33
  - Auxiliary 1 Other Modes
    33
- Tiller Interface
  35
  - Throttle Potentiometer Configuration
    35
  - Speed Limiting Potentiometer / Belly Button Input
    36
  - Speed Limiting Potentiometer Configuration
    36
  - Belly Button Configuration
    37
  - Fused B+ Supply
    38
  - On/Off Switch
    38
  - Status Indicator
    38
  - Status Indicator Diagnostic Setting
    39
  - Slow/Fast Switch
    40
  - Reverse Switch / Auxiliary 3 Input / Reverse Direction Switch
    40
  - Reverse Switch
    40
  - Auxiliary 3 Input
    40
  - Reverse Direction Switch
    41
  - Auxiliary 2 Output
    41
  - Diagnostic/Reverse Alarm
    41
  - Brake Light
    42
  - Auxiliary 2 Other Modes
    42
  - Auxiliary 3 Output
    43
  - Volts
    44
  - Inhibit 1 / Forward Direction Switch
    44
  - Inhibit 1
    44
  - Inhibit 1 Debounce
    44
  - Inhibit 1 Mode
    44
  - Inhibit 1 Target
    45
  - Inhibit 1 Speed
    45
  - Inhibit 1 Operation
    45
  - Forward Direction Switch
    46
  - Inhibit 2 / Tiller Switch
    46
  - Inhibit 2
    46
  - Inhibit 2 Debounce
    47
  - Inhibit 2 Mode
    47
  - Inhibit 2 Target
    47
  - Inhibit 2 Speed
    48
  - Inhibit 2 Operation
    48
  - Tiller Switch
    48
  - Drive Motors
    49
    
    Gradient Performance
    49
    
    Freewheeling
    50
  - Programming Connection
    50
  - Batteries
    50
  - Mounting
    51
    
    Mounting the I-Drive
    51
    
    I45 & I70
    51
    
    I140 & I180
    52
    
    Orientation
    52
    
    Position
    52
    
    Cables
    53
    
    Mounting the I-Drive & I-Cover
    53
    
    I45 & I70 + I-Cover
    53
    
    I140 & I180 + I-Cover
    54
    
    Orientation
    54
    
    Position
    54
    
    Cables
    54
  - Battery Gauge
    55
  - Electromagnetic Compatibility (E.M.C.)
    55
    
    Emissions
    55
    
    Motor Suppression
    55
    
    Cables
    55
    
    Immunity
    56
  - Electro-Static Discharge (E.S.D.)
    56
    
    Electrical Masses
    56
    
    Prevention of Flashover
    56
    
    Control Panels
    57
    
    Electrical System to Chassis Paths
    57
    
    Electrical Components
    57
    
    Ensuring Repeatability
    58
    
    Drain Path Components
    58
  - Production Tests
    59
- Mounting
  59
- Cables and Connectors
  59
  - Preset Settings
    59
  - Operational Test
    59
- Test Drive
  59
- Soft-Stop Test
  59
Chapter 3 - Programming

61
- Introduction
  63
  - Sp1A & DTT
    63
- PC Programmer
  63
- Parameters
  63
- Speed Parameters
  65
  - Forward Acceleration
    65
  - Forward Deceleration
    65
  - Reverse Acceleration
    65
  - Reverse Deceleration
    66
  - Max. Forward Speed
    66
  - Min. Forward Speed
    66
  - Max. Reverse Speed
    67
  - Min. Reverse Speed
    67
  - Speed Limit Pot. Enabled
    67
- Operation Parameters
  68
  - Sleep Timer
    68
  - Throttle Invert
    68
- Throttle Parameters
  68
  - Throttle Type
    68
  - Throttle Deadband
    68
  - Throttle Gain
    68
  - Throttle Operated at Power-Up
    69
  - Throttle Reference Test
    69
  - ISO Tests Resistor
    69
  - Direction Switches
    70
- Battery Parameters
  70
  - Cable Resistance
    70
  - Calibration Factor
    70
  - Battery Lockout Parameters
    70
  - Battery Lockout Voltage
    71
  - Battery Lockout Voltage 2
    71
  - Battery Lockout Time
    71
  - Battery Lockout Type
    71
  - Battery Lockout Input Select
    71
  - Low Battery Alarm
    72
- Inhibit Parameters
  72
- General Parameters
  73
  - Soft-Stop
    73
  - Brake Time
    73
  - Output Voltage
    73
  - Status Output Type
    73
- Diagnostic Flash Sequence
  73
- Reverse Alarm
  74
  - Pulsed Reverse Alarm
    74
  - Diagnostic Alarm
    74
  - Brake Disconnected Alarm
    74
  - Brake Fault Detect
    74
  - Brake Light
    75
  - Freewheel Speed Limit
    75
  - Motor Parameters
    75
- Current Limit
  75
- Boost Drive Current and Boost Drive Time
  75
- Current Foldback Threshold, Current Foldback Time, Current Foldback Level and Motor Cooling Time
  76
  - Current Foldback Temperature
    77
  - Controlling a Machine on a Slope
    77
  - Motor Compensation
    77
  - Slope Factor
    78
  - Anti-Rollback Level
    78
  - Set-Up Procedure
    78
  - Pull-Away Delay
    79
  - Anti-Rollback Velocity
    79
  - Belly Button
    79
    
    Belly Button Switch Type
    79
    
    Belly Button Speed
    79
    
    Belly Button Time
    79
  - Factory
    80
    
    Safety Fences
    80
    
    Supply Voltage
    80
  - Auxiliary Outputs
    80
    
    Auxiliary 1 Output Mode
    80
    
    Auxiliary 1 Output off Delay
    81
    
    Auxiliary 2 Output Mode
    81
    
    Auxiliary 2 Output off Delay
    82
    
    Auxiliary 3 Output Mode
    82
    
    Auxiliary 3 Input Type
    82
    
    Auxiliary 3 Output Voltage
    82
    
    Auxiliary 3 Output off Delay
    83
  - Memory Functions
    83
    
    Diagnostic Logs
    83
    
    Read System Log
    84
    
    Clear System Log
    84
    
    Read Control Log
    84
    
    Clear Control Log
    84
    
    Timer
    84
  - Read Timer
    84
  - Clear Timer
    84
Chapter 4 - Diagnostics

85
- Introduction
  87
  - Diagnostic Procedure
    87
  - Detecting a Trip Has Occurred
    87
- Trip Types and Possible Causes
  88
- Servicing of Defective Units
  92
Chapter 5 - Trucharge Module

93
- Introduction
  95
  - Surface Mount Variant
    95
  - Inset Variant
    95
- Dimensions
  96
- Surface Variant
  96
- Inset Variant
  96
- Mounting
  97
  - Handling
    97
  - Surface Variant
    97
  - Fixing
    97
  - Sealing
    97
  - Inset Variant
    98
  - Fixing
    98
  - Sealing
    98
- Wiring
  99
  - Wire Gauge
    99
  - Connectors
    99
  - Surface Mount Variant
    99
  - Inset Variant
    99
- Connections
  100
  - Surface Variant
    100
  - Inset Variant
    100
  - Controller Connections
    101
  - ESD Connection
    101
  - Surface Mount Variant
    101
  - Inset Mount Variant
    101
- Electromagnetic Compatibility (EMC)
  101
  - Immunity and Emissions
    101
  - Electro-Static Discharge (ESD)
    101
- Production Tests
  102
  - Mounting
    102
  - Cables and Connections
    102
  - Operational Test
    102
Chapter 6 - Warning Summary

103
- Introduction
  105
- Warnings
  105
  - Driving Technique
    105
  - Hazards
    105
  - Safety Checks
    106
  - Pushing Your Machine
    106
  - Programming
    106
  - Servicing
    106
  - Program Settings
    106
  - Charger Interlock
    107
  - General
    107
  - Motor and Battery
    107
  - I140 & I180
    107
  - Programming Connector
    107
  - Crimping
    107
  - Wire Gauge and Types
    108
  - Battery Connection
    108
  - Belly Button Configuration
    108
  - Fused B+ Supply
    108
  - Inhibit 1 & 2 Speed
    108
  - Drive Motors
    108
  - Freewheeling
    109
  - Programming Connection
    109
  - Position
    109
  - Production Tests
    109
  - Introduction
    109
  - Forward Acceleration
    109
  - Forward Deceleration
    110
  - Reverse Deceleration
    110
  - Max. Forward Speed
    110
  - Speed Limit Pot. Enabled
    110
  - Throttle Operated at Power-Up
    110
  - Soft-Stop
    110
  - Brake Fault Detect
    110
  - Freewheel Speed Limit
    110
  - Current Foldback Temperature
    111
  - Motor Compensation
    111
  - Pull-Away Delay
    111
  - Belly Button Time
    111
  - Safety Fences
    111
Chapter 7 - Specifications

113
- Electrical Specifications
  115

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