BRJ 7 PDF
BRJ 7 PDF
BRJ 7 PDF
7-3
2. BATTERY
1) STRUCTURE
1
4 2
5
6
BRJ7EL03
1 Cells 7 Plug
2 Steel box 8 Spacer
3 Cell connector 9 Handle (Red)
4 Row connector 10 Screw
5 Positive leading cable 11 Spring washer
6 Negative leading cable
7-4
2) GENERAL
As in the battery forklift, the battery is an
energy source, the handling of the battery
is very important. The life and performan-
ce of the battery greatly depend on the
ordinary handling and maintenance.
Therefore, be sure to check and maintain
the battery so that it may be kept best.
BRJ7EL04
7-5
4) SAFETY PRECAUTIONS
(1) When a sulfuric acid contact with skin
For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large
amount of water or milk. Seek medical attention immediately. When handling acid, always wear
eye goggles or a face shield and rubber gloves.
(2) Strict prohibition of fire and ventilation
Since batteries generate explosive hydrogen gas, no fire should be drawn near. Before the battery
charging, keep the battery cover open and check the ventilation status. Charging in an enclosed
space can cause a explosion.
(3) Never place metallic articles on the batteries
If done so, it may cause “short circuit” accidents(dangerous especially while charging).
Sparks will be generated which is equally dangerous as open fires.
(4) Handling of charger
When connecting or disconnecting a battery from a charger or attempting maintenance, make
sure switches are all off. Ensure that the charger and the battery are matched. If a 300Ah battery
is used with a charger designed to charge a 500Ah battery, it will severely overcharge the battery.
5) OPERATION PRECAUTIONS
(1) Avoid over-discharge
If over-discharged, it will be difficult to restore the batteries to the original state by recharge. In
order to maintain the batteries in use for long period of time, it is recommended to use the
batteries with discharge amount not exceeding 80% of the rated capacity. Further care should be
taken for preventing the unit cell voltage from falling below 1.5V.
(2) Avoid over-charge
If overcharged, the rise in battery temperature will become excessive, resulting in deterioration of
plates and other parts and markedly shortening of battery life.
(3) Avoid excessive elevation of temperature
Be sure to open the cover of battery housing tray before charging. If there is a possibility of
temperature to exceed 55。C, discontinue the charge operation temporarily, or reduce the charge
current.
6) INSTRUCTION
(1) Unpacking
Electric traction storage batteries(herein after refer to as “batteries”) are delivered to customers in
dry-charged condition. At unpacking, check whether the batteries and accessories have been
damaged. If there are observed defects, you should notify the condition to our branch office or
agent. Never remove the sealing plug until the battery is put into service.
7-6
(2) Performance and maintenance of batteries
① Initial charge
Wet-charged battery gradually decrease its capacity during storage. In order to provide sufficient
discharge capacity in the first discharge, the good initial charge is required. The conditions of
initial charging are seen as below at room temperature.
a. By modified constant voltage charger
Connect the battery to the charger and turn on the equalizing charge “ON”. The battery will be
fully charged and terminated automatically.
b. By constant voltage constant current charger
Connect the battery to the charger and turn on the equalizing charge “ON”. The battery will be
fully charged and terminated automatically.
c. By constant current charger
Connect the charger to the battery and charge the battery by 0.1C×5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
condition is identified.
·When a constant value is indicated for more than 1 hour after the battery voltage has reached
the maximum value.
·When more than 1 hour of charge is continued after the electrolyte specific gravity has risen
fully and becomes constant.
② Discharge and capacity
The capacity of batteries is indicated at 5 hour rate capacity which means the battery can be
discharged for 5 hours with the discharge current calculated by dividing the capacity value by 5
until the unit cell mean voltage reaches down to 1.7V at the electrolyte temperature of 30。C.
That is, the capacity is indicated by AH(ampere hour) being calculated as the product of
ampere(A) and time(H). However, even in the same type of batteries, the capacity varies with the
discharge conditions(discharge current, battery temperature and specific gravity of electrolyte)
Even if the batteries discharged its full capacity, if immediately charged to full, there will be no
harmful effects remained. Ideal charging amount(AH) is 110-125% of the amount of previous
discharge.
③ Specific gravity of electrolyte
Specific gravity of electrolyte drops at discharge and rises at charge. When the batteries are fully
charged, it becomes almost constant and shows no further rise. The specific gravity value varies
with the change in temperature. Therefore specific gravity measurement should be made with
temperature of electrolyte at the same so the measured specific gravity value could be corrected
to that at the standard temperature of 25。 C by the following formula.
S25 = St + 0.0007(t-25)
Where, S25 : Specific gravity at 25。
C
St : Actually measured specific gravity at t 。
C
t : Electrolyte temperature (。C)
The standard specific gravity for this type of battery is 1.280±0.01(25。 C) at full charge condition.
If the electrolyte is decreased naturally while using, distilled water shall be replenished up to the
specified level. (Never refill sulfuric acid)
Only when large quantity of electrolyte is lost due to spillage, etc., dilute sulfuric acid specified in
gravity shall be added.
7-7
④ Normal charge
Charge the discharged batteries as quickly as possible. The temperature of electrolyte before
starting the charging operation shall preferably be below 45。 C, and the temperature during the
charge should be maintained at no higher than 55。 C. (Under any unavoidable situations, it should
never be above 55。 C). Methods of charging varies in precise meaning with the types of chargers
used. A standard charging method is described hereunder. (If a special method is mentioned to
be adopted, follow that instruction).
a. Charging by modified constant voltage automatic charger
There is almost automatic charger today which complete the charging just only connecting the
plug between battery and charger without outer operating timer but if your charger has it, after
setting the timer for 3-4 hours and turn on the charger and the charger is left as it is, then the
charge will be made automatically. In principle, regardless of the amount of previous discharge,
it is not required to alter the setting of timer time. The recommendable current value of this type
of charger is “5 hour rate current ×1.0~1.5” at the start of charging, and at the final stage it is “5
hour rate current ×0.15~0.25”. Normally the charge is terminated within 8~12 hours
automatically.
b. Charging by constant current constant voltage automatic charger
After a lapse of specified charging time after the switch is turned on, the charge will be
completed by turning off the switch. The charging time can be calculated by the following
formula.
Amount of previous discharge(AH)
Charging time = + 2~3(H)
Capacity of charger(A)
When the amount of previous discharge is not known, use the 5 hour rate rated capacity of the
batteries. At immediately after charging, the charge current is allowed up to 3 times 5 hour rate
current. For charger provided with a timer, the charge will terminate automatically if the timer is
set at the specified time according to the operation manual.
⑤ Equalizing charge
When large number of cells are used in a set of battery, the voltage and specific gravity of
respective cells tend to become unequal, resulting in necessity of charging all the cells at an
appropriate time in order to equalize them. This is called equalizing charge. Normally the
equalizing charge should be carried out once every month. The methods are in normal type
charger, extend the charge for 5 more hours after full charge at the final stage current, and in
automatic charger which are in most cases provided with timer, extend the time setting for 3-6
more hours.
⑥ Water replenishment
Only the water content of electrolyte is decreased due to electrolysis of water during charge and
natural evaporation. If a battery used with the electrolyte decreased excessively, plates will
deteriorate resulting in markedly shortening of battery life. Be sure to check the electrolyte level
once every week. If the electrolyte level is lowered, replenish distilled water up to the specified
level. In this case, never attempt to replenish sulfuric acid or tap water. Use only distilled water
for battery replenishment. If the amount of water required for weekly addition to a unit cell for
100AH of battery capacity is in excess of 45cc, it is assumed that the cell is receiving overcharge.
Accordingly, be sure to reduce slightly the daily charge amount. Under the normal conditions, the
addition of water per week is 45cc or less. Incidentally, water replenishment should be made
before charging to the contend of minimum level.
7-8
(for the purpose of uniform stirring of electrolyte by charging). If the electrolyte level is improper
after completion of charging, you may topping up the electrolyte level to the maximum level .
a. Determination of replenishment time and methods(cell with ONE TOUCH CAP)
Confirm the electrolyte level by looking at the float in the ONE TOUCH CAP. If too low as shown
in figure, replenish water. Replenishment shall be performed after opening the cover of the plug
using syringe and jug. When refilling is completed, close each cover completely until “click”
sound is heard.
Cell cover
Cell cover
Float Float
B153EL041 B153EL042
⑦ Cleaning
If electrolyte spills or the cells are polluted with dust or stains, it will cause generation of leak
current. Wipe off dust and stains with moist cloth and clean in such a manner that the cells are
kept in dry condition. In the case of plastic containers or covers, never use such organic solvents
as paint thinner and gasoline. If used, the plastic containers or covers may suffer cracking. If you
are forced to use them, be sure to use white kerosene.
⑧ Notice on charging
The charging area must be well ventilated to facilitate exhaust of gas generated from the battery
during charging. Charge the battery in an area free from iron working, welding, etc. Further the
battery generates hydrogen, oxygen, acid mist and on rare occasions, hydrogen sulfide during
charging depending on the case. Special care may be required in the case of equipment and
objects near the battery that may contaminated or damaged. Do not pull out the charging plug
during charging, as it will cause sparks. Since hydrogen gas generated during charging may
remain in the area surrounding the battery after charging, never bring fire or flame close to this
area. In case of counter-balance type vehicles, open the battery cover before charging.
⑨ Repair of failure cell
a. To remove a cell from the circuit or battery from steel tray, it is first necessary that the intercell
connector be removed.
b. Before performing any repairs, you must open one-touch caps for gas purging of all cells. After
you have finished that, must remove connector covers and on-touch caps from failure cell
including surrounding cells. All vent holes of cells removed of one-touch caps must cover by
four layers of water dampened cloth and then proceed with repairs. Using an acid syringe
withdraw sufficient electrolyte from failure cell to reduce the liquid levels until minimum level
indicating of one touch caps.
c. The safe and most efficient method of removing a connector is with hand or electric drill(Ø25mm)
from failure cell as well as all surrounding cells.
7-9
You must make sure to clear of explosive hydrogen gas in the cells before repairs. Be
careful not to drill to far into the cell and damage the unit. During drilling operation make
sure lead curls produced do not contact opposite cell poles and cause a spark.
d. Upon completion of drilling the intercell connectors, can be lifted off.
e. Lifted off the failure cell from circuit after removing of intercell connector.
f. Installing new cell and connector.
g. With surfaces properly cleaned and neutralized, position the connectors.
h. Place damp rags around each lead head. Hold tip of the welder in center of post move welder
completely around top of post and out to the area where the post meets the connector. Move
welder back to center of post and add molten lead until area is filled to top of connector. Again,
move welder completely around area, with tip on molten lead. If you have jig for welding
connector, have easier and better welding work.
i. When replacing electrolyte in a repaired cell, use sulphuric acid of the same specific gravity that
is found in the balance of the battery.
j. Finally, rejoin connector covers and one-touch caps to the cells.
⑩ Summary of daily maintenance
a. Avoid overcharge. After discharge, charge the batteries immediately. The standard frequency
of equalizing charge is more than once every month.
b. Check the electrolyte level once a week. If found decreased, replenish distilled water up to the
specified level.
c. The top surface of battery cells should be kept clean and dry.
d. Be sure to keep open the cover of battery housing tray during charge.
e. Never draw near open fires such as lighted cigarettes or burning matches during charge.
(3) Others
① Storage of batteries
When batteries are stored, keep them distant from room heaters or other heat generating
sources. Clean, cool and dry place where no direct sunlight is directed is suited for battery
storage. Before putting into storage, it is important to charge the batteries and keep the
electrolyte level at the specified level. When the temperature in storage location is higher than
20。C, check the specific gravity once a month, and when lower than 20。 C, check it once every
two months. If the measurements show values lower than 1.230(20。 C), it is required to charge
the battery in accordance with the method described in NORMAL CHARGE.
② Maintenance record
It is recommended to keep maintenance record in order to know the operational conditions of
batteries. Daily charge and discharge, equalizing charge requirements, and water replenishment
requirements can be clarified at a glance. Measurements of specific gravity and temperatures
once every two to four months after equalizing charge and maintenance thereof will serve for
battery health diagnosis.
③ Electrolyte temperature
The operating temperature range of batteries is -10~45。 C(temperature of electrolyte). If the
batteries are exposed to cold atmosphere in discharged condition, the electrolyte may freeze, and in
extreme cases, the capacity will be decreased, but, if not frozen, no adverse effects will be exerted
over the life. Contrarily if the temperature is high, especially if used at above 55。
C, the battery life
will be considerably shortened. Care must be taken so that the temperature during charge will be
maintained at 55。 C or lower. Even under unavoidable circumstances it should not exceed 55。 C.
7-10
7) TROUBLESHOOTING
7-11
3. DRIVE MOTOR
1) STRUCTURE
17
14
13
17
15
12
16
18
19
11
10
2
7
6
4
5
8
1 9
20
BRJ7EL06
7-12
2) SPECIFICATION
Type - TSA200-160-104
Rated voltage Vac 30
Rated output kW 6.8
Insulation - Class F
3) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-12)
7-13
4. PUMP MOTOR
1) STRUCTURE
8
7
1 2 12
9 3
13 14
10
11
BRJ7EL07
7-14
2) SPECIFICATION
Type - TSA170-210-009
Rated voltage Vac 30
Rated output kW 15.8
Insulation - Class F
4) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-14)
7-15
5. EPS MOTOR
1) STRUCTURE
12
5 7
10
12
11
14
8
15 16
13
6
4
1
9 8
BRJ7EL08
7-16
2) SPECIFICATION
Type - G104087A
Rated voltage Vac 23
Rated output W 400
Insulation - Class H
3) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-14)
7-17
6. CONTROLLER SYSTEM
1) STRUCTURE
BRJ7EL11
(1) Specifications
Model Model Application Type Power Current limit
AC2 Traction AC 36-48V, 450A 450A/3min
14/16/20/25BRJ-7
AC2 Pump AC 36-48V, 450A 450A/3min
7-18
2) OPERATIONAL FEATURES
(1) Features
① Speed control.
② Optimum behavior an a slope due to the speed feedback:
·The motors speed follows the accelerator, starting a regenerative braking if the speed overtakes
the speed set-point.
·The system can perform an electrical stop on a ramp (the machine is electrically hold on a
slope) for a programmable time.
③ Electronic differential feature with torque balance between external and internal wheel.
④ Regenerative release braking based upon deceleration ramps.
⑤ Regenerative braking when the accelerator pedal is partially released (deceleration).
⑥ Direction inversion with regenerative braking based upon deceleration ramp.
⑦ Regenerative braking and direction inversion without contactors: only the main contactor is
present.
⑧ Optimum sensitivity at low speeds.
⑨ Voltage boost at the start and with overload to obtain more torque (with current control).
⑩ Hydraulic steering function:
·The traction inverter sends a "hydraulic steering function" request to the pump inverter on the
can-bus line.
⑪ Backing forward and reverse options are available, with the tune and the speed of the function
programmable with a console or buttons on a display.
⑫ High efficiency of motor and battery due to high frequency commutations.
⑬ Modification of parameters through the programming console or buttons on a display.
⑭ Internal hour-meter with values that can be displayed on the console.
⑮ Memory of the last five alarms with relative hour-meter and temperature displayed on the console.
16 Diagnostic function with a console for checking main parameters.
17 Built in BDI feature.
18 Flash memory, software downloadable via serial link and via CANBUS.
(2) Diagnosis
The microcontrollers continually monitor the inverter and carry out a diagnostic procedure on the
main functions. The diagnosis is made in 4 points.
① Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging,
phase's voltages, contactor drivers, can-bus interface, if the switch sequence for operation is
correct and if the output of accelerator unit is correct, correct synchronization of the two μCS,
integrity of safety related inputs hardware.
② Standby diagnosis in standby that checks: Watchdog circuit, phase's voltages, contactor driver,
current sensor, can-bus interface.
③ Diagnosis during operation that checks: Watchdog circuits, contactor driver, current sensors, can-
bus interface.
④ Continuous diagnosis that checks: Temperature of the inverter, motor temperature.
Diagnosis is provided in two ways. The digital console can be used, which gives a detailed
information about the failure; the failure code is also sent on the Can-Bus.
7-19
3) DESCRIPTION OF THE CONNECTORS
(1) Traction controller
BRJ7EL12
7-20
No. of Pin Function Description
E6 REVERSE Reverse direction request input. It must be connected to the reverse
direction microswitch, active high.
E7 PB Brake request input. It must be connected to the brake pedal switch,
active high.
E8 CPO TB Brake potentiometer wiper.
E10 NPO TB -BATT.
E14 ENABLE Accelerator enable function input. It must be connected to the accelerator
enable switch. Active high.
F1 KEY Connected to the power supply through a microswitch (CH) with a 10A
fuse in series.
F2 PMC Positive of main contactor coil.
F3 PBRAKE Positive of the electro mechanical brake coil.
F4 PEDAL S/W PEDAL S/W ; It must be connected to the PEDAL microswitch ; It is active high.
F5 SAFETY If not connected to -Batt the MC coil power output will be disabled. It can
also be used as a general purpose input.
F6 PTHERM Input for motor temperature sensor.
F8 NMC Negative of main contactor coil.
F9 NBRAKE Output for driving a brake or an hydraulic steering contactor coil ; It drives
the load to -Batt maximum current : 3A.
F10 SR/HB Speed reduction (hand brake) input. Active low (switch opened). See also
option chapter.
F11 GND -Batt.
F12 NTHERM -Batt.
7-21
Encoder installation
① Traction controller card is fit for different types of encoder. To control AC motor with a inverter, it is
necessary to install an incremental encoder with 2 phases shifted of 90。. The encoder power
supply can be +12V. It can have different electronic output.
D1 : +12V - Positive of encoder power supply.
D2 : GND - Negative of encoder power supply.
D3 : A - Phase A of encoder.
D4 : B - Phase B of encoder.
BRJ7EL26
7-22
(2) Pump controller
BRJ7EL12
7-23
No. of Pin Function Description
D1÷D6 Incremental ENCODER connector.
E1 TILT DOWN Tilt down analog input
E4 CM Positive of height limit microswitch
E8 TILT UP Tilt up analog input
E13 HEIGHT LIMIT Speed reduction input. Active low (switch opened).
F1 KEY Connected to the power supply through a microswitch (CH) with a 10A
fuse in series.
7-24
4) FUNCTION CONFIGURATION
■ TRACTION CONTROLLER
Using the CONFIG MENU of the programming console, the user can configure the following
functions (see "OPERATIONAL FEATURE" chapter for an explanation of "hydraulic steering
function") :
(1) Submenu "SET OPTIONS"
① Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
② Battery check
- ON : The battery discharge level check is carried out; when the battery level reaches 10%, an
alarm is signalled and the maximum current is reduced to the half of the programmed
value.
- OFF : The battery discharge level check is carried out but no alarm is signalled.
③ Cutback mode
- PRESENT : Input F10 is managed as a cutback speed input.
- ABSENT : Input F10 is managed as a handbrake input.
④ Traction cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the traction
maximum speed is reduced to 60Hz.
⑤ Lift cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the lift function is
disabled.
⑥ Stop on ramp
- ON : The stop on ramp feature (truck electrically hold on a ramp) is managed for a fixed time (6
sec.).
- OFF: The stop on ramp feature is not performed.
⑦ Pedal brake
- ANALOG : The mechanical brake pedal has a switch and a potentiometer installed. When the
accelerator is released and the pedal brake is pushed the inverter performs an
electrical braking whose intensity is proportional to the brake pedal potentiometer.
The minimum intensity is established by the "Release braking" parameter, when the
brake pedal is slightly pressed (brake switch close but brake potentiometer at the
minimum). The maximum intensity is established by the "Pedal braking" parameter
when the brake pedal is fully pressed (brake potentiometer at the maximum). In the
middle positions, the electrical braking intensity is a linear function between
minimum and maximum intensity.
- DIGITAL : The truck does not have a potentiometer installed on the mechanical brake pedal, but
only a microswitch; when the accelerator pedal is released and the brake pedal is
pushed (brake switch closed), the inverter performs an electrical braking following
"Pedal braking" parameter.
⑧ Set temperature
- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to C25 (C35) input.
- ANALOG : An analog motor thermal sensor is connected to C25 (C35) (the curve can be
customized on a customer request).
- NONE : No motor thermal sensor switch is connected.
7-25
⑨ EPS
- ON : If this option is set to ON, electric power steering function is used.
- OFF : If this option is set to OFF, electric power steering function isn't used.
⑩ Display
If this option is set to on the communication with the graphic display is enabled.
⑪ S.R.O.
If this option is set to on the static return to off is requested for starting the truck.
The required sequence is :
- Seat-direction lever-accelerator pedal or :
- Seat-accelerator pedal-direction lever within the weq. delay time
If this option is set to off the required sequence to start the truck is :
- Direction lever-accelerator pedal or :
- Accelerator pedal-direct lever within the seq. delay time
⑫ Pedal type
- OPTION #1 : The pedal position is sent to the display for graphic indication.
- OPTION #2 : The speed set-point is sent to the display for graphic indication.
⑬ Pedal brake stop
If set to on the truck is stopped when the pedal brake is pressed.
If set to off the traction current is reduced to the half of the maximum current.
⑭ Model selection
There are 2 options, 16/25.
In case of BRJ truck, it has to be selected 16 or 25(14/16BRJ→16, 20/25BRJ→25).
⑮ Lift limit
If the mast is lifted preset height, traction speed reduction is working depends on the setting status
of this function.
- ON : If set to on this function, traction speed control is performed.
- OFF : If set to off this function, traction speed control isn't performed.
7-26
⑤ Throttle 0 zone
It establishes a deadband in the accelerator input curve (see also curve below).
⑥ Throttle X point
This parameter changes the characteristic of the accelerator input curve.
⑦ Throttle Y point
This parameter changes the characteristic of the accelerator input curve.
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.
⑧ Adjustment #2 bdi
It adjusts the lower level of the battery discharge table.
⑨ Adjustment #1 bdi
It adjusts the upper level of the battery discharge table.
BRJ7EL13
⑩ Adjustment #03 :
Set an increment of battery charge above actual value. If battery voltage exceed this total value
the software recognize charging, and battery charge percentage increase to correct value also if
battery isn't fully charged.
7-27
⑪ PWM on main contactor
- OFF : The inverter applies the battery voltage to the coil on F8 output.
- ON : The PWM reduces the voltage to the set value.
⑫ PWM on aux output
- OFF : The inverter applies the battery voltage to the coil on F9 output.
- ON : The PWM reduces the voltage to the set value.
⑬ MC/AUX PWM : It sets the PWM level in % on the outputs F8 and F9. Here is used to drive a
main contactor.
⑭ Adjustment #04 : This parameter determines the motor temperature level at which the "MOTOR
TEMPERATURE" alarm is signalled. This parameter must be adjusted only if
the "SET TEMPERATURE"(menu "SET OPTION") parameter is programmed
"ANALOG"
⑮ Speed factor
It adjust the speed coefficient to have the correct speed indication on the display. This coefficient
has to be regulated depending on truck mechanic characteristics. It results from the following
formula :
Speed factor = 88*rr*p/Ø
Where : rr = total gearbox ratio
Ø= traction wheel diameter(cm)
P = number of pair poles of the motor
7-28
standard
f acceleration ramp
Stop
Smooth
BRJ7EL14A
17 Seat delay time : It sets the delay time after the seat switch is off.
18 Sequence delay : It sets the delay from the accelerator enable to direction signal input.
19 Chat time : It sets the time from the time main contactor is on to the time seat switch is on.
20 Curve cutback : Speed reduction when the truck is doing a curve. The parameter sets the speed
setpoint when the truck driving wheels are running in opposite direction or when the maximum
steering angle is reached.
21 Dead angle : It determines the tire angle range be able to get full speed.
22 Lift limit CTB : It sets the traction speed when lift limit is on.
■ PUMP CONTROLLER
Using the config menu of the programming console, the user can configure the following functions.
(1) Submenu "SET OPTIONS"
① Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
② Set temperature
- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to A25 input.
- ANALOG : An analog motor thermal sensor is connected A25 (the curve can be customized on
a customer request).
- NONE : No motor thermal sensor switch is connected.
③ Electrical distribution
In case of BRJ truck that has electro solenoid valves, It is set to On.
In case of BR truck that has manual valves, It is set to Off.
④ Model selection
There are 2 options , 16/25.
In case of BRJ truck, It has to be selected 16 or 25(14/16BRJ→16, 20/25BRJ→25)
⑤ Digital lift
- OFF : The lift sensor includes a lift switch and an analogue lift sensor. Lift speed can be
controlled proportionally with lever position.
- ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled proportionally.
7-29
⑥ Lifting Cutback
If the mast is lifted preset height, Lift speed reduction is working
depends on the setting status of this function.
- ON : If set to on this function, Lift speed control is performed.
- OFF : If set to off this function, Lift speed control isn't performed.
⑦ Side shift Function
- OFF : The truck doesn't have the side shift function (default)
- ON : The truck has the side shift function (Option)
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC MIN and VACC MAX are values programmable by the "PROGRAM VACC" function.
⑥ Adjustment #04 : This parameter determines the motor temperature level at which the "MOTOR
TEMPERATURE" alarm is signalled. This parameter must be adjusted only if
the "SET TEMPERATURE" (menu "SET OPTION") parameter is programmed
"ANALOG"
⑦ PWM on main contactor
-OFF: The inverter applies the battery voltage to the coil on F8 output.
-ON: The PWM reduces the voltage to the set value.
⑧ PWM on aux output
-OFF: The inverter applies the battery voltage to the coil on F9 output.
-ON: The PWM reduces the voltage to the set value.
⑨ MC/AUX PWM: It sets the PWM level in % on the outputs F8 and F9.
⑩ Min lift(Option): Volts. It sets the minimum value for the lift sensor.
⑪ Max lift(Option): Volts. It sets the maximum value for the lift sensor.
7-30
⑫ Min lower(Option): Volts. It sets the minimum value for the lowering sensor.
⑬ Max lower(Option): Volts. It sets the maximum value for the lowering sensor.
⑭ Min reach in(Option): Volts. It sets the minimum value for the reach in sensor.
⑮ Max reach in(Option): Volts. It sets the maximum value for the reach in sensor.
16 Min reach out(Option): Volts. It sets the minimum value for the reach out sensor.
17 Max reach out(Option): Volts. It sets the maximum value for the reach out sensor.
18 Min shift right(Option): Volts. It sets the minimum value for the side shift right sensor.
19 Max shift right(Option): Volts. It sets the maximum value for the side shift right sensor.
20 Min shift left(Option): Volts. It sets the minimum value for the side shift left sensor.
21 Max shift left(Option): Volts. It sets the maximum value for the side shift left sensor.
22 Min tilt up(Option): Volts. It sets the minimum value for the tilt up sensor.
23 Max tilt up(Option): Volts. It sets the maximum value for the tilt up sensor.
24 Min tilt up(Option): Volts. It sets the minimum value for the tilt down sensor.
25 Max tilt up(Option): Volts. It sets the maximum value for the tilt down sensor.
7-31
5) PROGRAMMING & ADJUSTMENTS
There are two ways to adjust parameter via a console or buttons on a display.
※ Adjustments via buttons on a display, please refer to the display section. (page 7-44)
ADJUSTMENTS VIA CONSOLE (Option)
Adjustment of parameters and changes to the inverter's configuration are made using the digital
console. The console is connected to the "B" connector of the inverter.
(1) Descriptions of console
Inverter B
connector
Console connector
Display
Buttons
20B7EL15
※ Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK
ULTRA, minimum "Release number 3.02".
7-32
(2) Description of standard console menu
① Traction controller
FORWARD
BRJ7EL15
7-33
② Pump controller
BRJ7EL16
7-34
(3) Description of ALARMS menu
The microprocessor in the controller records the last five alarms that have occurred. Items
remembered relative to each alarm are: the code of the alarm, the number of times the particular
Alarm occurred, the hour meter count, and the inverter temperature.
This function permits a deeper diagnosis of problems as the recent history can now be accessed.
Flow chart showing how to use the ALARMS function via the digital console.
BRJ7EL23
7-35
(4) Description of console PROGRAM VACC function
This function looks for and remembers the minimum and maximum potentiometer wiper voltage
over the full mechanical range of the pedal. It enables compensation for non symmetry of the
mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM VACC function.
Flow chart showing how to use the PROGRAM VACC function of the digital console:
7-36
6) TESTER MENU
(1) Traction controller
The most important input or output signals can be measured in real time using the TESTER
function of the console. The Console acts as a multimeter able to read voltage, current and
temperature. In the following chapter a list of relative measurements for different configurations.
① Motor voltage
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
voltage (which depends of the battery voltage).
② Frequency
This is the frequency of the voltage and current supplied to the motor.
③ Encoder
This is the speed of the motor, expressed in the same unit of the frequency; this information
comes from the speed sensor.
④ Slip value
This is the difference of speed between the rotating field and the shaft of the motor, expressed in
the same unit of the frequency.
⑤ Current rms
Root Mean Square value of the motor current.
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFET devices.
⑦ Motor temperature
This is the temperature of the motor; if the option is programmed "None" it shows 0。.
⑧ Accelerator
The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is shown on the
left hand side of the console display and the value in percentage is shown on the right hand side.
⑨ Forward switch
The level of the forward direction digital entry FW.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑩ Backward switch
The level of the reverse direction digital entry BW.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch
⑪ Seat switch
The level of the seat microswitch digital entry.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑫ Cutback switch
The level of the speed reduction microswitch.
- ON / GND = Input active, switch opened
- OFF / +VB = Input non active, switch closed.
⑬ Brake switch
The level of the pedal brake microswitch.
- ON / +VB = Input active, switch closed.
- OFF / GND = Input non active, switch open.
7-37
⑭ Brake pedal pot.
Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL
BRAKING parameter is set ANALOG.
⑮ Hand brake
The level of the handbrake microswitch.
- ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
16 Voltage booster
This is the booster of the voltage supplied to the motor in load condition; it is expressed in a
percentage of the full voltage.
17 Battery voltage
Level of battery voltage measured at the input of the key switch.
18 Battery charge
The percentage charge level of the battery.
19 Speed value
This is the speed value of drive.
7-38
⑩ Tilt up switch
Status of the tilt up switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑪ Tilt down switch
Status of the tilt down switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑫ Shift left switch
Status of the shift left speed switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑬ Shift right switch
Status of the shift right speed switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑭ Aux in switch
Status of the aux in switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑮ Aux out switch
Status of the aux out switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
16 Reach in switch
Status of the reach in switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
17 Reach out switch
Status of the reach out switch of the pump.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
18 Lift/lower request
Level of the lift and lower analogue signal. The voltage is shown on the left hand side of the
display and the value in percentage on the right hand side.
19 Tilt request
Level of the tilt analogue signal. The voltage is shown on the left hand side of the display and the
value in percentage on the right hand side.
20 Shift request
Level of the shift analogue signal. The voltage is shown on the left hand side of the display and
the value in percentage on the right hand side.
21 Aux request
Level of the auxiliary analogue signal. The voltage is shown on the left hand side of the display
and the value in percentage on the right hand side.
22 Reach request
Level of the reach analogue signal. The voltage is shown on the left hand side of the display and
the value in percentage on the right hand side.
7-39
23 Cutback switch
The level of the speed reduction microswitch.
- ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
24 Voltage booster
This is the booster of the voltage supplied to the motor in load condition; it is expressed in a
percentage of the full voltage.
25 Battery voltage
Level of battery voltage measured at the input of the key switch.
7-40
7) GENERAL SUGGESTION FOR SAFETY
For a proper installation take care of the following recommendations:
After operation, even with the key switch open, the internal capacitors may remain charged for
some time. For safe operation, we recommend that the battery is disconnected, and a short circuit
is made between battery positive and battery negative power terminals of the inverter using a
resister between 10 ohm and 100 ohm.
Do not connect the inverter to a battery with a nominal value different from the value indicated on
the controller plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit
does not "power up"
During battery charge, disconnect the controller from the battery.
Do not connect the controller to a battery with a nominal voltage different than the value indicated
on the controller label. A higher battery voltage may cause power section failure. A lower voltage
may prevent the logic operating.
Before doing any operation, ensure that the battery is disconnected and when all the installation is
completed start the machine with the drive wheels raised from the floor to ensure that any
installation error do not compromise safety.
Take care all the inductive devices in the truck (horn, solenoid valves, coils, contactors) have a
proper transient suppression device.
7-41
7. EPS CONTROLLER
1) STRUCTURE
BRJ7EL51
(1) Specifications
Model Model Application Type Power Current limit
14/16/20/25BRJ-7 AC0 EPS AC 36-48V, 45A 45A/2min
7-42
2) OPERATIONAL FEATURES
(1) Features
A list of eps-ac0 operational features follows below:
① Static sensitivity boost in open loop (steering sensitivity increases for a slow moving steering
wheel).
② Static numbness in closed loop (steering sensitivity decreases for handle steer close to the
straight-ahead direction).
③ Dynamic numbness in open loop (steering sensitivity reduces when the truck speed increases).
④ Dynamic numbness on request in closed loop (steering sensitivity reduces when the truck speed
increases).
⑤ Truck speed reduces when the steering angle increases.
⑥ Alignment at the rest position in open loop application (to avoid the drift of the steered wheel when
travelling with released steering wheel).
⑦ Embedded PID algorithm for automatic functions (AUTC).
⑧ Special debugging & troubleshooting system makes easier the fault catching.
⑨ Possibility to run in a stand-alone (not CAN Bus supported) configuration.
⑩ Motor control may be performed with encoder.
⑪ Redundant processing (two microprocessors aboard) fulfils the category #3 requirement including
the set-point comes via CAN Bus from a remote unit.
⑫ Redundant set point and feedback sensors fulfil the category #3 requirement.
(2) Diagnosis
According to EN1175, most of the diagnoses deenergize steer and traction in less then 100 msec.
Few secondary alarm conditions require longer time for detection. They too deenergize steer and
traction.
Diagnosis is provided in two ways. The digital console and a display can be used, which gives a
detailed information about the failure; the failure code is also sent on the Can-Bus.
7-43
3) DESCRIPTION OF CONNECTORS
(1) EPS controller
W
V - U
EP
AC
-
S
CN
CN CN
BRJ7EL52
7-44
No. of Pin Function Description
C1 PCLRXD Positive serial reception.
C2 NCLRXD Negative serial reception.
C3 PCLTXD Positive serial transmission.
C4 NCLTXD Negative serial transmission.
C5 GND Negative console power supply.
C6 +12 Positive console power supply.
C7 FLASH It must be connected to A8 for the flash memory programming.
C8 FLASH It must be connected to A7 for the flash memory programming.
7-45
4) FUNCTION CONFIGURATION
Using the config menu of the programming console, the service engineer can configure the
following functions.
7-46
⑦ AUX FUNCTION 1
This option sets the steering mode after the feedback sensor has reached the commanded
position (it is used only in closed loop configurations (i.e. automatic centering).
It can be set one of three:
- LEVEL 0 : The steering control is always active when a travel demand is active. The steer control
is turned off when the travel demands are deactivated (after a 3 sec delay).
- LEVEL 1 : The steering control is alternatively turned off (15 secs long plus the AUXILIARY
TIME) and on (3 secs long).
- LEVEL 2 : The steering control is alternatively turned off (15 secs long plus the AUXILIARY
TIME) and on (3 secs long) but only when a travel demand is active.
AUXILIARY TIME is the delay (in secs) the DC standing current takes to arrive to 0.
⑧ DIAG MOTOR TEMP
This option enables the diagnosis of the motor temperature. When it is set on and the motor
temperature overtakes 150。, a MOTOR TEMPERAT alarm occurs.
The KTY84-130 motor thermal sensor must be connected between CNB#3 and a minus battery
(CNA#13).
⑨ COMBI CAN PROT.(N/A)
This option isn't used BRJ truck. It's always set to absent.
7-47
⑨ MAXIMUM SLIP
(Factory adjusted). MAXIMUM SLIP modifies the acceleration and deceleration ramp for the
frequency in the motor. Higher MAXIMUM SLIP gets faster acceleration and deceleration ramp.
If the encoder is used for the motor control (ENCODER CONTROL is On), MAXIMUM SLIP has
another meaning: it is the slip to be applied when the control is sourcing the maximum current.
⑩ AUX VOLTAGE #1
(Factory adjusted). This is the self-acquired offset value of the stepper motor line connected to
CNA#9. The default value is 2.500 mV and can be re-acquired by rolling the DEBUG OUTPUT to 0
⑪ AUX VOLTAGE #2
(Factory adjusted). This is the self-acquired offset value of the stepper motor line connected to
CNA#8. The default value is 2.500 mV and can be re-acquired by rolling the DEBUG OUTPUT to 0
⑫ NO LOAD CURRENT
In order it shall be possible to weaken the steering motor when lightened (reducing power loss in
the motor), it is necessary to specify the current the motor drains when working full flux and
without load (NO LOAD CURRENT). To find this value it is necessary to set the DEBUG OUTPUT
to level 10 and to measure the current in the motor when running without load and a frequency
close to SET SAT FREQ/2.
⑬ ZERO SP POT
(Twin Pot version only). This adjustment is used to self-acquire the voltages on the twin
potentiometers when the steer handle is released in its straight ahead position. Just push the
enter button with a released steer handle to record the new ZERO SP POT value.
⑭ SET STEER 0-POS
It must be set to the FEEDBACK ENC value corresponding to a perfectly straight-ahead steered
wheel inside the first and fourth quadrant (i.e. it must be set to the value of FEEDBACK ENC for a
steered wheel that is straight ahead around the null WHEEL ANGLE position). The steered wheel
will be positioned to SET STEER 0-POS either when an AUTC is demanded (in case the steered
wheel angle is electrically limited or in case the steered wheel is the first and fourth quadrant).
SET STEER 0-POS may be rolled up or down in 5 mV steps. 2492mV is the default value.
⑮ SET STEER 180
It must be set to the FEEDBACK ENC value corresponding to a perfectly straight-ahead steered
wheel inside the second and third quadrant (i.e. it must be set to the value of FEEDBACK ENC for
a steered wheel that is straight ahead around the 180 degrees WHEEL ANGLE position). The
steered wheel will be positioned to SET STEER 180 when an AUTC is demanded (in the second
and third quadrant and for any application without electrical angle limitation).
SET STEER 180 may be rolled up or down in 5 mV steps. 0mV is the default value.
16 SET ENC AT 180
This adjustment is used to acquire the encoder counting corresponding to a partial steered wheel
revolution (about a half) occurring between two falling edges of the straight ahead sensor : the first
falling edge occurs on incidence of the first iron plate limit; the second falling edge occurs on
incidence of the second iron plate limit .It is an important setting for applications without steered
wheel angle limitation. Procedure for SET ENC AT 180 consists of collecting the encoder counting
corresponding to that half steered wheel revolution on the tester reading ENC COUNT AT 180. To
do that two ways are available: autoteaching and manual teaching.
Autoteaching procedure automatically saves the new ENC COUNT AT 180 on SET ENC AT 180;
manual teaching procedures asks the ENC COUNT AT 180 being manually saved on SET ENC
AT 180.
7-48
17 SET ENC AT 360
This adjustment is used to acquire the encoder counting corresponding to a full steered wheel
revolution. It is an important setting especially for applications without steered wheel angle
limitation. Procedure for SET ENC AT 360 consists of collecting the encoder counting
corresponding to a full steered wheel revolution on the tester reading ENC COUNT AT 360. To do
that three ways are available: autoteaching , manual teaching and SET ENC AT 360 manual
setting.
Autoteaching procedure automatically saves the new ENC COUNT AT 360 on SET ENC AT 360;
manual teaching asks the ENC COUNT AT 360 being manually saved on SET ENC AT 360; SET
ENC AT 360 manual setting consists of writing directly the SET ENC AT 360 value in EEPROM .
18 AUTOTEACHING
This option (on/off) is used to launch the autoteaching procedure. Take care there is not
mechanical angle limitation before to turn it on. Then recycle the key and the steering motor starts
an automatic sequence to collect the ENC COUNT AT 360 and ENC COUNT AT 180. If the
collected couple is consistent ( ENC COUNT AT 180 stays inside the window from 3/8 to 6/8 of
ENC COUNT AT 360) they are automatically saved on the settings SET ENC AT 360 and SET
ENC AT 180. If the autoteaching procedure successful ends, the display switches from the DATA
ACQUISITION alarm to the collected values (in the range 0 to 5Vdc. Left side shows the ENC
COUNT AT 360 value; the right side shows the ENC COUNT AT 180 value). If the ouple of values
is not consistent they were not saved and the display switches cyclically from the collected data to
the DATA ACQUISITION inscription.
7-49
④ AUX FUNCTION #2
Level 0 to 9. This setting performs the dynamic numbness compensation: it consists of a reduction
in the steer sensitivity when the truck is driving at high speed. To get this goal, it is necessary to
attenuate the scaling factor between the speed of the steering wheel and the speed of the
steering motor. AUX FUNCTI ON #2 does that but only when the steering wheel is slow turning.
This attenuation must be proportional to the drive speed. At full drive speed the attenuation of the
scaling factor is maximum.
AUX FUNCTION #2 to Level 0 means no attenuation of the scaling factor with the truck speed.
AUX FUNCTION #2 to Level 9 means maximum attenuation of the scaling factor with the truck
speed.
Obviously, to perform the dynamic numbness compensation, it is necessary to know the drive
speed and so the eps-ac0 must be CAN Bus connected.
⑤ CREEP SPEED
Level 0 to 9. It sets a minimum amount of motor torque when the steering motor is slow turning. It
is useful (together with the ANTIROLLBACK parameter) to neutralize the recall torque generated
by the elastic tyre on the steered wheel.
⑥ KP
Level 0 to 9. It is used to set the proportional contribution to a PID algorithm for AUTC functions.
The proportional contribution is applied to the difference between the commanded position and
the real position (steered wheel angle). The accuracy of the pursuing between commanded and
real position increases if KP increases. It is used in closed loop applications.
⑦ POS. ACCURACY
Level 0 to 9. It is used to set the proportional contribution to a PID algorithm for AUTC functions.
The proportional contribution is applied to the difference between the commanded position and
the real position (steered wheel angle). The accuracy of the pursuing between commanded and
real position increases if POS.
ACCURACY increases. POS. ACCURACY is used only for closed loop applications. KP and
POS. ACCURACY are a coarse and a fine contribution to the same setting.
⑧ DYNAM NUMB SPEED
Level 0 to 9. This parameter handles the dynamic numbness vs. the steering error for AUTC
functions. This functions applies a linear correspondence between the steering motor speed and
the angle error between the actual commanded position and the latest steady state position of the
steered wheel. This parameter sets the percentage of the full steering motor speed is applied
when in the full dynamic numbness. The full steering motor speed is the sum of the SET SAT
FREQ and OVERSAT FREQ settings. When the angle between the actual commanded position
and the latest steady state position is less than 40% of the DINAM NUMB ANG setting, the full
dynamic numbness vs. the steering error is applied and the steering speed is clamped to the
DYNAM NUMB SPEED percentage below.
- LEVEL 0: At full dynamic numbness, the steering motor frequency is clamped to 40% (maximum
numbness)
- LEVEL 1: At full dynamic numbness, the steering motor frequency is clamped to 46%.
- LEVEL 2: At full dynamic numbness, the steering motor frequency is clamped to 53%.
- LEVEL 9: At full dynamic numbness, the steering motor frequency is clamped to 100% (no
numbness).
Each step more has a weight of 6.6 %.
7-50
⑨ DYNAM NUMB ANG
Level 0 to 9. This parameter handles the Dynamic Numbness vs. the Steering Error for AUTC
functions. This functions applies a linear correspondence between the steering motor speed and
the angle error between the actual commanded position and the latest steady state position of the
steered wheel: when this angle error is wider than the angle specified with this setting, there will
be no clamp on the steering motor speed (full speed steering motor is SET SAT FREQ plus
OVERSAT FREQ); when this angle error is smaller than 40% of the angle specified with this
setting, the maximum Numbness will be applied. This parameter sets the angle, between the
commanded position and the latest steady state position, at which the steering motor speed gets
its maximum value (SET SAT FREQ plus OVERSAT FREQ).
- LEVEL 0: No Numbness if the angle between tiller and latest steady state is higher than 5。.
- LEVEL 1: No Numbness if the angle between tiller and latest steady state is higher than 11。.
- LEVEL 2: No Numbness if the angle between tiller and latest steady state is higher than 17。.
- LEVEL 9: No Numbness if the angle between tiller and latest steady state is higher than 60。.
Each step has a weight of 6 degrees.
⑩ COMPENSATION
Level 0 to 2. This parameter applies a compensation for the drops in the motor connections to
have a real Emf/f control law.
- LEVEL 0: No compensation.
- LEVEL 1: Compensate the drop on power mosfets and cables.
- LEVEL 2: Compensate the drop on power mosfet, cables and motor resistance.
COMPENSATION to LEVEL 2 is strongly suggested (the correct setting of the motor resistance is
required when COMPENSATION is set to LEVEL 2)
⑪ 1ST ANGLE COARSE
This parameter regulates in coarse steps the maximum steered wheel angle in the direction
where FEEDBACK ENC is higher than 2.5 V.
Parameters 1st and 2nd ANGLE COARSE both to level 9 get the steered wheel angle unlimited. If
parameter change level 2 to level 9, it means that 180 angle system is changed to 360 angle
system.
⑫ 2ND ANGLE COARSE
This parameter regulates in coarse steps the maximum steered wheel angle in the direction
where FEEDBACK ENC is lower than 2.5 V.
Parameters 1st and 2nd ANGLE COARSE both to level 9 get the steered wheel angle unlimited. If
parameter change level 2 to level 9, it means that 180 angle system is changed to 360 angle
system.
⑬ AUXILIARY TIME
This parameter defines the time, after the steer handle is released and the travel demand
deactivated, for which the stand still torque is applied.
- LEVEL 0: No stand still torque.
- LEVEL 1: Brief application of the stand still torque (about 6 secs).
- LEVEL 9: Long application of the stand still torque (about 90 secs).
Intermediate levels are for proportionally increasing auxiliary time. The stand still torque reduces
with a ramp from the ANTIROLLBACK value down to zero with a delay specified with this setting.
⑭ ANTIROLLBACK
This parameter adjusts the stand still torque after the steer handle is released and the travel
demand deactivated.
It is in percentage of the maximum current. Injecting a continuous current in the motor generates
the stand still torque. It is useful (together with the CREEP SPEED parameter) to neutralize the
recall torque generated by the elastic tyre on the steered wheel.
7-51
15 LAG FB REGULAT
Level 0 to 9. It is used to set the integral (lag) contribution to a PID algorithm for AUTC functions.
The integral contribution is applied to the FEEDBACK ENC value only. It works like a low pass
filter to get smooth the pursuing next to the commanded position. The derivative (lead)
contribution generates dither that is possible to reduce by increasing this adjustment. Obviously
lag and lead regulations influence the stability of the closed loop and so different setting must be
empirically tried to avoid oscillations.
- LEVEL 0: lowest lag contribution (high cut off frequency low pass filter).
- LEVEL 9: highest lag contribution (low cut off frequency low pass filter).
16 LEAD FB REGULAT
Level 0 to 9. It is used to set the derivative (lead) contribution to a PID algorithm for AUTC
functions. The derivative contribution is applied to the FEEDBACK ENC value only. High LEAD
FB REGULAT value brakes the steering motor in advance respect to the commanded position so
avoiding the overshooting of the commanded position.
On the other side generates damping and dither, close to the commanded position. Obviously lag
and lead regulations influence the stability of the closed loop and so different setting must be
empirically tried to avoid oscillations.
- LEVEL 0: lowest lead contribution (overshooting is favorite).
- LEVEL 9: highest lead contribution (damping is favorite).
4) SPECIAL FUNCTIONS
(1) Acquiring the motor resistance
When it is possible, the steering motor is controlled sensorless. To get the best performance in
terms of the max torque generated, it is necessary to compensate for the drop in the motor
resistance. So the correct value of the motor resistance must be known.
Eps-ac0 provides a self-acquisition procedure to acquire the motor resistance.
It is just enough to connect the eps-ac0 to the battery, to the motor and to the wiring in order no
alarm occurs.
Then:
① Enter the ADJUSTMENTS menu searching for ADJUSTMENT #01 setting.
② Turn ADJUSTMENT #01 to Level 1. (A DATA ACQUISITION alarm occurs and a half Imax DC
current is automatically injected in the motor).
③ Wait about 2 secs.
④ Roll ADJUSTMENT #01 back to Level 0.
⑤ Save the new setting.
With this procedure the resistance between two motor terminals is automatically measured and
recorded (in milliohms) on the ADJUSTMENT #02.
It is also possible to adjust the motor resistance value without self-acquisition by rolling the
ADJUSTMENT #02.
The acquisition of the motor resistance should be performed to find the correct value when
developing a new truck prototype; the correct value will be the default setting for the mass
production of that truck.
7-52
(2) Alignment at the rest position
In the open loop applications (i.e. when the stepper motor is used in the steering wheel or the
steer command is a speed information coming via CAN bus) an alignment at the rest position is
automatically performed when the steered wheel has a drift with a released steering wheel. To
enable this function, turn RECOVERY AT REST to On and recycle the key. This alignment at the
rest position is handled closed loop.
(3) Straight ahead steering numbness
In closed loop applicant It is possible to reduce the steering sensitivity while the steered wheel is
close to be straight ahead by using the NUMBNESS setting in the PARAMETERS CHANGE
menu. Increasing the NUMBNESS parameter gets the steering less responsive when the truck is
driving next to the straight ahead direction (i.e. a certain increment of the steering wheel angle
gets a smaller increment of the steered wheel angle when the truck is driving straight ahead than
when it is angled).
Higher NUMBNESS setting results in higher numbness of the steering at low steered wheel angle.
NUMBNESS to Level 0 results in a linear relationship between the command and the steered
wheel angle(no sensitivity reduction in straight ahead).
(4) Overshooting and damping avoid
To optimize the steer performance in closed loop application, the following simple test should be
tried.
Turn the tiller in a shot from a limiting position to the straight ahead direction. The steered wheel is
expected to turn from the limiting position to the straight head at full steering motor speed. Then it
must suddenly stop in the straight ahead direction without overshooting or damping (overshooting
means the steered wheel temporary overtakes the commanded position; damping means the
steered wheel slows down in advance respect to the commanded position).
Actions to neutralize overshooting are :
① Increase parameter change LEAD FB REGULAT
② Reduce parameter change KP or POS ACCURACY. This action reduces also the accuracy of the
pursuing at the commanded position
Actions to neutralize damping are :
① Reduce parameter change LEAD FB REGULAT
② Increase parameter change KP or POS ACCURACY. This action increases also the accuracy of
the pursuing at the commanded position.
7-53
5) PROGRAMMING & ADJUSTMENTS
There are two ways to adjust parameter via a console or a buttons on a display.
※ Adjustments via buttons on a display, please refer to the display section.
ADJUSTMENTS VIA CONSOLE (Option)
Adjustment of Parameters and changes to the inverter¡¯s configuration are made using the Digital
Console.
The Console is connected to the CNC connector of the inverter.
Inverter B
connector
Console connector
Display
Buttons
20B7EL15
※ Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM
CK ULTRA, minimum "Release Number 3.02".
7-54
(2) Description of standard console menu
BRJ7EL53
7-55
6) TESTER MENU
The most important input or output signals can be measured in real time using the TESTER
function of the console. The Console acts as a multimeter able to read voltage, current and
temperature. In the following chapter a list of relative measurements for different configurations.
(1) Stepper motor
Voltage value with 2 decimal digit. Measurement of the stepper motor speed with sign in the range
0 to 5 Vdc.
(2) Feedback sector
Voltage value with 2 decimal digit. Measurement (scaled in the range 0 to 5 Vdc) of the actual
state of the toggle switches. The steered wheel revolution is divided into 4 quadrants (sectors)
corresponding to two toggle switches configurations:
The steered wheel is in the 1ST sector (FEEDBACK SECTOR to 3.13V) when the configuration of
the toggle switches is the one expected for a steered wheel angle in the range 0 to 90 degrees.
The steered wheel is in the 2ST sector (FEEDBACK SECTOR to 4.39V) when the configuration of
the toggle switches is the one expected for a steered wheel angle in the range 90 to 180 degrees.
The steered wheel is in the 3RD sector (FEEDBACK SECTOR to 0.62V) when the configuration
of the toggle switches is the one expected for a steered wheel angle in the range -180 to -90
degrees.
The steered wheel is in the 4TH sector (FEEDBACK SECTOR to 1.88V) when the configuration of
the toggle switches is the one expected for a steered wheel angle in the range -90 to 0 degrees.
(3) Feedback ENC
Voltage value with 2 decimal digit. Measurement (scaled in the range 0 to 5 Vdc) of the position of
the feedback encoder connected to CNB#7 and CNB#8.
(4) Temperature
Degrees. Temperature of the controller base plate.
(5) Motor temperature
Degrees. Temperature of the motor windings measured with the thermal sensor inside the motor
and connected to CNB#3.
(6) Frequency
Hertz value with 2 decimal digit. This is the frequency applied to the steering motor.
(7) SAT. FREQ HZ
Hertz value with 2 decimal digit. This is a real time magnetic flux measurement: Vbattery/ SAT.
FREQ HZ provides real time the linked flux in the motor. The flux in the motor is modulated from
75% to 100% of the maximum flux.
The maximum flux is Vbattery/SET SAT FREQ.
The minimum flux is Vbattery/(1.33*SET SAT FREQ). When the motor is loaded, SAT. FREQ HZ
is equal to SET SAT FREQ; when the motor is lightened the flux reduces and SAT. FREQ HZ
increases up to 1.33*SET SAT FREQ.
(8) Motor voltage
It is a percentage. 100% means the sine waves in the motor have the maximum PWM amplitude.
(9) Motor current
Ampere value. Root Mean Square value of the line current in the motor.
(10) ENC speed
Hertz value with 2 decimal digit. This is the speed of the motor measured with the encoder on the
motor shaft.
(11) Endstroke CW
Provides real time the active state (ON) or not of the CW toggle switch (connected to CNA#3). It is
On when CNA#3 is low.
7-56
(12) Endstroke ACW
Provides real time the active state (ON) or not of the CCW toggle switch (connected to CNA#2). It
is On when CNA#2 is low.
(13) CW limit level
When the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to
ON) and the FEEDBACK ENC overtakes the superior limit for the steered wheel angle limitation,
the steered wheel angle will be limited and CW LIMIT LEVEL turns ON (active).
(14) ACW limit level
When the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to
ON) and the FEEDBACK ENC is lower than the inferior limit for the steered wheel angle limitation,
the steered wheel angle will be limited and ACW LIMIT LEVEL turns ON (active).
(15) Auto in progress
Provides real time the information the eps-ac0 follows the manual command (AUTO IN
PROGRESS is OFF) or is executing an automatic centering (AUTO IN PROGRESS is ON).
(16) MM alarm switch
It is On when the safety contact belonging to the main uC is closed.
(17) SM alarm switch
It is On when the safety contact belonging to the slave uC (supervisor) is closed.
(18) Truck moving
It provides the state of the travel demand for driving the truck. This information is obtained either
with the travel demands directly connected to CNA#1 or via CAN Bus (depending by the state of
the CAN BUS setting).
(19) High resol AD
It turns ON when the set point potentiometer is processed with a high resolution AD (it occurs
when the set pot potentiometer is close to the straight ahead position and SET HI RESOL AD is
Level 1).
(20) Wheel angle
It provides the current angle of the drive wheel by the degree.
(21) Slope peak
This reading is just for debugging the maximum slope of the potentiometers connected to the eps-
ac0. Especially for not redundant sensor equipments (just a single command potentiometer or just
a single feedback potentiometer without encoder) a concern regarding the safety raises: if a single
potentiometer fails a sudden movement of the steered wheel may occur with danger. To avoid this
problem it is necessary to detect any failure in a single potentiometer. This is hard to do because
the failure mode can be quite different. Anyway, the best countermeasure we can take is to seek
for the wiper voltage changes faster than its physical limit. In fact, for the limited speed of the
steering motor(or of the steering wheel), the slope in the wiper voltage must be limited under a
certain threshold. When this slope threshold is overtook, the potentiometer may be assumed
broken. So, it is useful to measure the maximum slope occurring in your application when right
working, in order a right slope threshold can be chosen to avoid an alarm occurs when the
potentiometer is not failed.
The SLOPE PEAK reading in the tester menu is a real time measurement of the slope peak of the
potentiometers. In particular:
When the special adjustments DEBUG OUTPUT is other than Level 12 or 13, SLOPE PEAK
supplies the slope peak of the CPOC1 set point potentiometer (CNA#9).
When the special adjustments DEBUG OUTPUT is Level 13, SLOPE PEAK supplies the slope
peak of the CPOT feedback potentiometer (CNB#6).
7-57
When the special adjustments DEBUG OUTPUT is Level 12, SLOPE PEAK supplies the slope
peak of the CPOC2 set point potentiometer (CNA#8).
The SLOPE PEAK measurement is the difference between two AD conversions of the selected
potentiometer picked up with 16 msec long interval. The SLOPE PEAK reading can be converted
in a Voltage change (V in volts) of the wiper voltage in an interval 16 msec long, with the formula:
V = SLOPE PEAK*5/1024 = Voltage change in Volts in 16 msec
(e.g. When SLOPE PEAK is 61 it means the selected potentiometer, in the worst case, changes
61*5/1024 =0.3 V in 16 msec.).
Obviously the SLOPE PEAK reading must be compared with the threshold for the STEER
SENSOR KO alarmThe STEER SENSOR KO alarm may be adjusted.
(22) TRUCK SPEED
Percentage value. It represents the truck speed represented in percentage of the full drive speed.
It is used for the dynamic numbness (i.e. the steering sensitivity reduces when the truck speed
increases).
(23) ENC COUNT AT 360
Voltage value with two digits in the range 0 to +/-5Vdc value. This reading supplies the encoder
counting corresponding to a complete steered wheel revolution in the range 0 to +/- 5.00Vdc. At
rest it assumes a 5Vdc value, after a first valid falling edge on the straight ahead sensor it switches
from 5Vdc to 0Vdc.
After a second valid falling edge on the straight ahead sensor it switches to an intermediate value
(between 0Vdc and +/-5Vdc) corresponding to the encoder counting for a full steered wheel
revolution.
See also 10.5 and 10.6. This reading may be manually saved on the adjustments SET ENC AT
360.
(24) ENC COUNT AT 180
Voltage value with two digits in the range 0 to +/-5Vdc value. This reading supplies the encoder
counting corresponding to a quasi-half steered wheel revolution (measured between the first and
the seconds end of the iron plate in figure 4-4- and 4-5) in the range 0 to +/- 5.00Vdc. At rest it
assumes a 5Vdc value, after a first valid falling edge on the straight ahead sensor it switches from
5Vdc to 0Vdc. After a second valid falling edge on the straight ahead sensor it switches to an
intermediate value (between 0Vdc and +/-5Vdc) corresponding to the encoder counting for a side
to side iron plate rotation. See also 10.5 and 10.6. This reading may be manually saved on the
adjustments SET ENC AT 180.
ENC COUNT AT 180 is expected being about a half of the ENC COUNT AT 360.
7-58
8. FINGERTIP CONTROLLER
1) INTRODUCTION OF FINGER TIP
The general forklift performs lifting and tilting using the mechanical lever mounted on MCV (Main
Control Valve) by an operator.
A new system is designed in order to improve operator's convenience and match up with marketing
trend. That is what is called a finger tip or mini- lever system. The system is to apply electric levers
and proportional valve instead of mechanical levers and MCV. The attachments are operated as
controlling the solenoid of a proportional valve according to the voltage of an electric lever.
2) GENERAL CHARACTERISTIC
(1) Functional characteristics
Voltage [V] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24/36/48/80V
Output for ON-OFF valves [n。] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Output for proportional valves [n。] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Digital inputs [n。] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Analog inputs [n。] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
RS-232 [n。] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
CAN [n。] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IP65
(2) Input
Analog inputs : Mhyrio provides 1 analog input. The analog device can be supplied at +12. It is
necessary to specify in the order the voltage selected. The supply output is able to deliver max
100 mA.
Proportional valves are driven in current mode with programmable frequency. The valves voltage
supply is the same used for ON-OFF valves and the current range have to be defined. Via
console or display it is adjustable in a big range, but the shunts can be adapted to every types of
valves (minimum current 200 mA, maximum current up to 2 A).
7-59
BRJ7EL61
7-60
1 8
A (Connector Cdnsole)
B C
14 10 23 16
9 6 15 9
5 1 8 1
3) STRUCTURE
4) Description of connectors
No. of Pin Function Description
A1 PCLRXD Serial communication interface
A2 NCLRXD Serial communication interface
A3 PCLTXD Serial communication interface
A4 NCLTXD Serial communication interface
A5 GND Negative supply.
A6 +12 +12V supply.
A7 -
A8 -
B1 +KEY Mhyrio CB positive power supply
B2 PAUX Input of valves positive power supply
B3 -BATT Mhyrio CB negative supply
B4 CAN_L CAN low signal in
B9 CAN_T CAN termination : connect to CANH_OUT to insert a 120 ohm termination
resistance
B10 PPO_S Positive supply of analog devices (+12 V)
B13 CAN_H Can high signal in
B14 CANH_OUT Can high signal out
C1 NEVP1 Negative of the proportional electro valve lift up.
C2 PEVP1/2 Positive of the proportional electro valves lift up & lowering.
C3 NEVP2 Negative of the proportional electro valve lowering.
C4 NEVP3 Negative of the proportional electro valve reach in.
C5 PEVP3/4 Positive of the proportional electro valves reach in & reach out.
C6 NEVP4 Negative of the proportional electro valve reach out.
C7 NEVP5 Negative of the proportional electro valve tilt up.
C8 PEVP5/6 Positive of the proportional electro valves tilt up & tilt down.
C12 NEVP7 Negative of the proportional electro valve side shift right.
C13 PEVP7/8 Positive of the proportional electro valves side shift right & left.
C14 NEVP8 Negative of the proportional electro valve side shift left.
C15 NEVP6 Negative of the proportional electro valve tilt down.
C19 NEVP Negative of buzzer relay
C20 PEVP Positive of buzzer relay
C23 -BATT Mhyrio CB negative supply
7-61
Type Function Description
SET BATTERY 12/24/36 This parameter sets the battery nominal voltage, that is the key input voltage
TYPE /48/72/80 (MHYRIO supply)
V valves coil 12/24/36 This parameter sets the ON/OFF valves coil nominal voltage.
/48/72/80
Valves supply 12/24/36 This parameter sets the voltage of the valve's coil positive supply.
/48/72/80
EVP type DIGITAL It sets EVP single to ON-OFF valve type
ANALOG It sets EVP single to proportional valve type
EVP1 type DIGITAL It ses EVP1 to ON-OFF valve type
ANALOG It sets EVP1 to PROPORTIONAL valve type
EVP2 type DIGITAL It sets EVP2 to ON-OFF valve type
ANALOG It sets EVP2 to PROPORTIONAL valve type
EVP3 type DIGITAL It sets EVP3 to ON-OFF valve type
ANALOG It sets EVP3 to PROPORTIONAL valve type
EVP4 type DIGITAL It sets EVP4 to ON-OFF valve type
ANALOG It sets EVP4 to PROPORTIONAL valve type
EVP5 type DIGITAL It sets EVP5 to ON-OFF valve type
ANALOG It sets EVP5 to PROPORTIONAL valve type
EVP6 type DIGITAL It sets EVP6 to ON-OFF valve type
ANALOG It sets EVP6 to PROPORTIONAL valve type
EVP7 type DIGITAL It sets EVP7 to ON-OFF valve type
ANALOG It sets EVP7 to PROPORTIONAL valve type
EVP8 type DIGITAL It sets EVP8 to ON-OFF valve type
ANALOG It sets EVP8 to PROPORTIONAL valve type
MODEL OPTION #1 It sets every parameter to counter balanced type truck
TRUCK OPTION #2 It sets every parameter to BRJ type truck
7-62
5) ADJUSTMENTS & FUNCTION
There are two ways to adjust parameter via a console or buttons on a display.
(1) Adjustments via console or buttons on a display
Adjustment of Parameters and changes to the controller's configuration are made using the Digital
Console or buttons on a display. The console can be connected directly to Mhyrio CB (connector
A), or it can be physically connected to another controller in the CANBUS net, then virtually
connected to Mhyrio CB (which is node 9 of the net). If you don't have the console, you can do
adjustments using the buttons on a display easily.
(2) Description of standard console menu
HEADING
MAIN MENU
BATTERY VOLTAGE V
TESTER
VALVES SUPPLY V
CAN POT EVP %
CAN POT GROUP 1 %
CAN POT GROUP 2 %
CAN POT GROUP 3 %
SAVE CAN POT GROUP 4 %
PARAMETER INPUT 0 ON/OFF
INPUT 1 ON/OFF
INPUT 2 ON/OFF
RESTORE
PARAMETER ANALOG INPUT 1 0/256
ALARMS CODE,
h, N, C
PROGRAM
VACC
BRJ7EL62A
7-63
(3) Description of parameters that may be programmed (parameter change)
In addition to the configuration, parameter settings can be factory set (default parameters), or the
customer can make changes according to the application, using a digital console or a display.
During the setting up procedure on the machine, the console can remain connected to the
controller during travel. The parameters can be modified in real time, during operation. Pay
attention to the polarity of the console connector. Refer to chapter 7.1 and 7.2 of this manual for
connection details.
CONNECTION OF THE CONSOLE TO THE CONTROLLER MUST BE MADE WITH THE KEY
SWITCH TURNED OFF.
The following parameters can be modified:
① Min EVP
This parameter adjusts the minimum current of the SINGLE valve, if it is set as proportional (see
"set option menu").
② Max EVP
This parameter adjusts the MAXIMUM current of the SINGLE valve, if it is set as proportional (see
"set option menu").
③ Min EVP1
This parameter adjusts the minimum current of valve 1, if it is set as proportional (see "set option
menu").
④ Max EVP1
This parameter adjusts the maximum current of valve 1, if it is set as proportional (see "set option
menu").
⑤ Min EVP2
This parameter adjusts the minimum current of valve 2, if it is set as proportional (see "set option
menu").
⑥ Max EVP2
This parameter adjusts the maximum current of valve 2, if it is set as proportional (see "set option
menu").
⑦ Min EVP3
This parameter adjusts the minimum current of valve 3, if it is set as proportional (see "set option
menu").
⑧ Max EVP3
This parameter adjusts the maximum current of valve 3, if it is set as proportional (see "set option
menu").
⑨ Min EVP4
This parameter adjusts the minimum current of valve 4, if it is set as proportional (see "set option
menu").
⑩ Max EVP4
This parameter adjusts the maximum current of valve 4, if it is set as proportional (see "set option
menu").
⑪ Min EVP5
This parameter adjusts the minimum current of valve 5, if it is set as proportional (see "set option
menu").
⑫ Max EVP5
This parameter adjusts the maximum current of valve 5, if it is set as proportional (see "set option
menu").
⑬ Min EVP6
This parameter adjusts the minimum current of valve 6, if it is set as proportional (see "set option
menu").
7-64
⑭ Max EVP6
This parameter adjusts the maximum current of valve 6, if it is set as proportional (see "set option
menu").
⑮ Min EVP7
This parameter adjusts the minimum current of valve 7, if it is set as proportional (see "set option
menu").
16 Max EVP7
This parameter adjusts the maximum current of valve 7, if it is set as proportional (see "set option
menu").
17 Min EVP8
This parameter adjusts the minimum current of valve 8, if it is set as proportional (see "set option
menu").
18 Max EVP8
This parameter adjusts the maximum current of valve 8, if it is set as proportional (see "set option
menu").
19 EVP Open delay
Single proportional valve current ramping up time: this parameter sets the single valve current
ramp, to change from 0 A to operating current.
20 EVP Close delay
Single proportional valve current ramping down time: this parameter sets the single valve closing
ramp, to change from operating current to 0 A.
21 EVP1 Open delay
EVP1 proportional valve current ramping up time: this parameter sets the EVP1 valve current
ramp, to change from 0 A to operating current.
22 EVP1 Close delay
EVP1 proportional valve current ramping down time: this parameter sets the EVP1 valve closing
ramp, to change the coil current from operating current to 0 A.
23 EVP2 Open delay
EVP2 proportional valve current ramping up time: this parameter sets the EVP2 valve current
ramp, to change from 0 A to operating current.
24 EVP2 Close delay
EVP2 proportional valve current ramping down time: this parameter sets the EVP2 valve closing
ramp, to change the coil current from operating current to 0 A.
25 EVP3 Open delay
EVP3 proportional valve current ramping up time: this parameter sets the EVP3 valve current
ramp, to change from 0 A to operating current.
26 EVP3 Close delay
EVP3 proportional valve current ramping down time: this parameter sets the EVP3 valve closing
ramp, to change the coil current from operating current to 0 A.
27 EVP4 Open delay
EVP4 proportional valve current ramping up time: this parameter sets the EVP4 valve current
ramp, to change from 0 A to operating current.
28 EVP4 Close delay
EVP4 proportional valve current ramping down time: this parameter sets the EVP4 valve closing
ramp, to change the coil current from operating current to 0 A.
7-65
29 EVP5 Open delay
EVP5 proportional valve current ramping up time: this parameter sets the EVP5 valve current
ramp, to change from 0 A to operating current.
30 EVP5 Close delay
EVP5 proportional valve current ramping down time: this parameter sets the EVP5 valve closing
ramp, to change the coil current from operating current to 0 A.
31 EVP6 Open delay
EVP6 proportional valve current ramping up time: this parameter sets the EVP6 valve current
ramp, to change from 0 A to operating current.
32 EVP6 Close delay
EVP6 proportional valve current ramping down time: this parameter sets the EVP6 valve closing
ramp, to change the coil current from operating current to 0 A.
33 EVP7 Open delay
EVP7 proportional valve current ramping up time: this parameter sets the EVP7 valve current
ramp, to change from 0 A to operating current.
34 EVP7 Close delay
EVP7 proportional valve current ramping down time: this parameter sets the EVP7 valve closing
ramp, to change the coil current from operating current to 0 A.
35 EVP8 Open delay
EVP8 proportional valve current ramping up time: this parameter sets the EVP8 valve current
ramp, to change from 0 A to operating current.
36 EVP8 Close delay
EVP8 proportional valve current ramping down time: this parameter sets the EVP8 valve closing
ramp, to change the coil current from operating current to 0 A.
7-66
(3-1) Description to change parameters by a console
The flow chart shows how to change parameters by a console.
BRJ7EL63
7-67
(3-2) Description to change parameters by a display
The flow chart shows how to change parameters by buttons on a display.
④ Press .
BRJ7EL64
7-68
① When the desired parameter appears, the display will
show a level number that will be between 0 and 9.
Press either M or Pto change the level value
7-69
⑩ Input 2
Level of digital input 2 :
- ON / +VB : input active, switch closed
- OFF / COND : input not active, switch open.
⑪ Analog input 1
Voltage of the analog input.
BRJ7EL66
Remember it is not possible to make any changes using TESTER. All you can do is measure as if
you were using a pre-connected multimeter.
7-70
(4-2) Description to check data by a display
The flow chart shows how to use the TESTER function of buttons on a display.
④ Press .
BRJ7EL67
7-71
① The first variable to be tested is shown on the
display
② Press either or .
BRJ7EL68
6) ANALYSIS OF ALARMS
① EEPROM KO
Fault in the area of memory where the adjustment parameters are stored. This Alarm does not
inhibit machine operation but operation goes on with default values; if fault is still present when the
Key Switch is re-cycled, replace the logic. If the fault disappears, the previously stored Parameters
will have been replaced by the default parameters.
② CAN BUS KO
There is a problem related to the CAN-BUS line. The error is signalled if the MHYRIO controller
does not receive any message from the CAN-BUS line. First of all, check the wiring. If it is ok, the
problem is on the logic board, which must be replaced.
③ Watchdog
The test is made in both running and standby. It is a self-diagnosing test within the logic. If an
alarm should occur, replace the logic.
④ WRONG SET BATTERY
This fault is signalled if the battery voltage is non consistent with the set battery programmed in
the 'set option' menu.
⑤ Undervoltage
This fault is signalled if an undervoltage condition is detected in the MHYRIO power supply.
⑥ FF valves
Flip-flop circuit, that manages on/off valve drivers short-circuit protection, does not reset in the
correct way. The problem is probably in the hardware circuit.
⑦ Coil shorted
ON/OFF valves drivers are protected against coil short circuit; if a short is present across the coil,
the flip-flop circuit is set and the alarm is signalled.
7-72
⑧ EV driver short
One of the on/off valves driver is shorted; check the external connection, if it is ok the driver is
probably damaged.
⑨ EVP driver short
The single proportional valve driver is shorted; check the external connection, if it is ok the driver
is probably damaged.
⑩ EVPG1 driver short
One of the Group 1 valves drivers is shorted; check the external connection, if it is ok the driver is
probably damaged.
⑪ EVPG2 driver short
One of the Group 2 valves drivers is shorted; check the external connection, if it is ok the driver is
probably damaged.
⑫ EVPG3 driver short
One of the Group 3 valves drivers is shorted; check the external connection, if it is ok the driver is
probably damaged.
⑬ EVPG4 driver short
One of the Group 4 valves drivers is shorted; check the external connection, if it is ok the driver is
probably damaged.
⑭ EV driver KO
One of the On/Off valves drivers is open (it does not close when it is commanded by the
microcontroller).
⑮ EVP driver KO
The single proportional valve driver is open (it does not close when it is commanded by the
microcontroller).
16 EVPG1 driver KO
One of the Group 1 valves drivers is open (it does not close when it is commanded by the
microcontroller).
17 EVPG2 driver KO
One of the Group 2 valves drivers is open (it does not close when it is commanded by the
microcontroller).
18 EVPG3 driver KO
One of the Group 3 valves drivers is open (it does not close when it is commanded by the
microcontroller).
19 EVPG4 driver KO
One of the Group 4 valves drivers is open (it does not close when it is commanded by the
microcontroller).
20 HI side driver KO
The high side driver which supply the valves coils positive is shorted or open.
21 Waiting for PEV
There isn't the valves positive power supply. Check B2 input then verify the VALVES SUPPLY
parameter is correctly set.
7-73
9. DISPLAY
1) STRUCTURE
The instrument panel has six built-in red LED, which provide the operator with an easy information
about the status of some truck devices.
13 7 10 8
HYUNDAI
M P
1 2 3 4 5 6 11 9 12
15B7OM65
7-74
2) WARNING LAMP
When the key switch is OFF, the display makes a general test lighting and switching OFF all the
LED in sequence.
(1) Oil level warning lamp (Option)
This LED lights when the measured oil level of the hydraulic
circuit is under the minimum acceptable mark.
To connect the oil sensor output to the Analogue Input #1.
16B7OM61
16B7OM62
16B7OM63
16B7OM64
16B7OM65
16B7OM66
7-75
3) TESTER MENU
Status of keyboard buttons can be monitored in real time in the TESTER menu.
(1) Key 1 button
Status of keyboard button:
ON = Input active, button pushed
OFF = Input not active, button released
16B7OM67
16B7OM68
16B7OM71
16B7OM72
7-76
4) LCD FUNCTION
1 5 2 3
7 8 6 4 15B7OM77
7-77
(3) Turtle
The turtle symbol (3) is normally off; when it appears (fixed) it shows activation of the "soft" mode
of the truck, in which maximum speed and acceleration are reduced. The "soft" mode can be
activated pressing button .
(4) Hour meter
The number displayed on the bottom right side of the unit (4) shows the Hours Worked.
The letter present near the hour meter shows which hour meter is displayed:
- K : the key hour meter is displayed;
- T : the traction hour meter is displayed;
- P : the pump hour meter is displayed; it increases if pump control is working.
(5) Accelerator
The accelerator level indication is displayed on the central top side of the unit (5); it is shown by
ten notches. When the accelerator level is minimum only a notch is displayed, when the
accelerator level is maximum all the ten notches are displayed. Each notch represents 1/10 of the
difference between maximum and minimum accelerator level.
(6) Speed
The number displayed under the accelerator notches on the center of the unit (6) shows the truck
speed. The unit can be km/h or mph depending on the SPEED UNIT parameter setting.
(7) Wheel position
The notch displayed on the left of the hour meter (7) represents the wheel (only one of the nine
notches is displayed) and shows the steering angle (it corresponds to the relative truck direction if
the truck is running).
(8) Running direction
① Angle 180°(Default setting)
The arrow (8) shows the set truck rulling direction. The arrow point is up to when the truck is
forward running; the arrow point is down when the truck is reverse running. If the truck doesn't run
a dot is displayed instead of the arrow.
② Angle 360°(Selectable setting at parameter change menu of EPS controller)
If you select this function(please see the 7-51), you can steer to every direction.
When the wheel position is over 180°, the direction and wheel position display is reversed like
below.
7-78
5) DESCRIPTION OF PROGRAMMABLE FUNCTIONS
(1) Menu set model
① Connect to
Using CANBUS link, every module connected to can net can act as the "access node" to the
canbus net for the external world.
For example the ZAPI hand console (or the PC-Win console) can be physically connected to one
module and, by the canbus, virtually connected to any other module of the net.
This parameter is used to select the module to which the user wishes to be connected.
Following the numbers associated to each module in Zapi canbus system are showed.
7-79
⑦ Maintenance
The options are :
PRESENT : A maintenance hour-counter is incremented with key ON.
When the hours elapsed reach the programmed value with the display the warning
“SERVICE REQUIRED”is shown.
ABSENT : No“SERVICE REQUIRED”warning
⑧ Maintenance done
It can be ON/OFF. This parameter is normally off. Setting the“MAINT. DONE”on at next key-on
the maintenance hours are updated with the display’s hour meter contents. This operation erases
the“MAINTENANCE NEEDED”warning if it is present.
⑨ Seat belt status
It sets the“Seat belt”diagnostic LED indication in the following way:
OPTION #1 : No“Seat belt”indication. The diagnostic LED is not used.
OPTION #2 : If the seat belt are not fastened at Key-ON the diagnostic LED blinks for three times
than it turns off.
OPTION #3 : The diagnostic LED blinks until the seat belt is fastened than it turns off.
Delay display
0 1 2 3 4 5 6 7 8 9
off level
Service time
[sec] 1 3 5 7 9 11 13 15 17 20
7-80
6) DESCRIPTION OF CONSOLE USING
(1) Access to SET MODEL menu.
The only parameter present in SET MODEL function is CONNECTED TO.
By setting this parameter, operator can connect ZAPI console to every ZAPI product connected to
CAN-BUS line. This functionality allows completely control of every ZAPI product without changing
the position of the console connector.
20B7EL28
7-81
(2) Flow chart showing how to make changes to option menu:
20B7EL29
7-82
(3) Flow chart showing how to use the TESTER function of the digital console:
7-83
7) DESCRIPTION OF ALARM MENU
The microprocessor in the controller records the last five alarms that have occurred. Items
remembered relative to each alarm are: the code of the alarm, the number of times the particular
alarm occurred and the hour meter count. This function permits deeper diagnosis of problems as
the recent history can now be accessed.
Flow chart showing how to use the ALARMS function via the digital console:
7-84
8) STRUCTURE OF DISPLAY MENU
Graphic Smart Display present a software structure made by menus and submenus. It is possible to
have access to Graphic Smart Display menu structure by the six operator buttons integrated in a
membrane keyboard.
At turn on the display shows the HYUNDAI logo for some seconds, then asks the starting password
to have access to the main page (if "USER PASSWORD" option is ON), otherwise it shows directly
the main page (if "USER PASSWORD" option is OFF).
The main page, if there aren't alarms, shows battery charge, truck speed (in km/h or mph, it
depends on "SPEED UNIT" parameter) and key/traction/pump hour meter (see "HOUR
COUNTER" option); if alarms are present, it will show alarm code, node initials in which alarm has
occurred and alarm description.
From the main page it is possible to have access to the ALARM page (if alarms occur) and to
MENUS page. The CHANGE PASSWORD MENU is always accessible and visible, while the
others ones are accessible and showed, by entering service password. To enter this password is
necessary to push the out button (button #5) of membrane keyboard; this will show a entering
password page.
By using service password it's possible to enter in all menus (TRUCK, CHANGE PASSWORD,
MAINTENANCE).
It follows flow chart diagram of menu structure.
7-85
2 seconds
ENTER PASSWORD
ENTER USER PASSWORD
------------------------------- SERVICE / ENGINEERING
**** ****
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MENUS
CHANGE PASSWORD
16B7SM23
7-86
ZAPI CONSOLE
SET
MAINTENANCE HOURS
MAINTENANCE
00000
CHANGE PASSWORD
1 2 3 4 5 6 7 8 9
PASSWORD HAS
BEEN CHANGED
PRESS OUT
MAIN PAGE
20B7EL41
7-87
(1) Performance rolling
From MAIN PAGE using membrane keyboard numbers, it is possible to select the performance
mode which must be used in traction and pump controllers.
Performance can be chosen with button 4, and it is displayed in the top right side of the unit.
When one performance is selected, the related information will be sent via canbus to traction and
pump controllers that will manage this data. The standard functioning reduces truck performance
passing from high performance mode (H) to economy performance mode (E).
The real meaning, in terms of parameters level of these performances, depends on software
present on pump and traction controllers.
Button 4 Selects in sequence the truck performance (H → N → E).
7-88
9) ANALYSIS OF GRAPHIC SMART DISPLAY RELATED ALARMS
(1) Graphic Smart Display alarms
① WATCHDOG
Cause:
At start-up the watch dog signal is already active before the software has generated it. At standby
or running condition the watch dog signal is not active (in alarm status).
Troubleshooting:
The WD hardware circuit or microcontroller output port are damaged. In both cases no external
component are involved. Replace the logic board.
② COIL SHORTED
Cause:
This alarm occurs when there is a short circuit of the AUXILIARY coil connected to CNB#1
output. After the overload condition has been removed, the alarm exits automatically by releasing
and then enabling a travel demand.
Troubleshooting:
A) The typical root cause for this error code to be displayed is in the harness or in the load coil.
So the very first check to carry out concerns connections between dashboard outputs and
loads.
B) In case no failures/problems have been found externally, the problem is in the logic card, which
has to be replaced.
③ DRIVER SHORTED
Cause:
The driver of the auxiliary electro valve coil is shorted.
Troubleshooting:
A) Check if there is a short or a low impedance pull-down between NAUX (CNB#1) and -BATT.
B) The driver circuit is damaged in the logic board, which has to be replaced.
④ AUX DRIVER OPEN
Cause:
The AUX coil driver is not able to drive the load. The device itself or its driving circuit is damaged.
Troubleshooting:
This type of fault is not related to external components; replace the logic board.
⑤ HARDWARE FAULT
Cause:
At key-on the dashboard checks if the AUX driver is turned off by a not active (alarm status)
watch-dog signal. If it is not turned off then the alarm is generated.
Troubleshooting:
The problem is inside the logic, no external component are involved, replace the logic board.
7-89
⑥ CAN BUS KO
Cause:
Graphic Smart Display doesn't receive messages from canbus line or the hour meter
synchronization at key-on fails.
Troubleshooting:
A) If this fault code is displayed together with other alarm messages, the fault is probably to be
looked for in the Graphic Smart Display can interface, since the display seems to be unable to
receive any can message. So it is suggested to check Graphic Smart Display canbus wiring
and connection.
B) Otherwise, the fault is in the can interface of other modules present on canbus network.
M 245:
WRONG SET BAT
means that the alarm 245 - "WRONG SET BATTERY" occurred in the master traction controller
(M).
Here the table with the alarm codes and the respective meaning is shown.
7-90
10) DIAGNOSTIC FAULT CODES
7-91
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
31 VMN HIGH The test is carried out during initial diagnosis and in
standby.
Possible causes:
A) Problem with the motor connections or the motor
○ ○ power circuit; check if the 3 phases are correctly
connected; check if there's a dispersion of the motor
towards ground;
B) Inverter failure, replace it
32 VMN NOT OK This alarm occurs in the initial rest state after key on if
the outputs of the motor voltage amplifiers are not in the
○ window from 2.2 to 2.8 Vdc. It is necessary to replace
the controller.
38 CONTACTOR The main contactor coil has been driven by the logic
OPEN board, but the contactor does not close. Two possible
reasons:
○ A) The wires to the coil are interrupted or not well
connected.
B) The contact of the contactor is not properly working.
48 MAIN This alarm occurs only when the setting CAN BUS is
CONT.OPEN PRESENT. Then the eps-ac0 waits for a via CAN
information that the traction controller has closed the
○ main contactor. If this information lacks more than about
1.5 secs, this alarm occurs. Find, on the traction
controller, the reason for keeping the main contactor
open.
49 I=0 EVER ○ ○ Traction or Pump Controller current too low
53 STBY I HIGH Test carried out in standby. Check if the current is 0. If
not verified, an alarm is signalled which inhibits machine
○ ○ operations. Possible causes:
A) Current sensor failure;
B) Logic failure: first replace the logic; if the defect
persists, replace the power unit.
This alarm occurs two ways:
1) In the initial rest state after key on, if the outputs of the
current amplifiers are not comprised in the window 2.2 to
○ 2.8 Vdc.
2) After the initial diagnosis this alarm occurs when the
outputs of the current amplifiers at rest have a drift larger
than ±0.15 V. It is necessary to replace the controller.
60 CAPACITOR Follows the charging capacitor system:
CHARGE
power
capacitor
RES.
KEY
10A KEY
INVERTER
○ ○
When the key is switched ON, the inverter tries to charge
the capacitor through a power resistance, and check if
the capacitor are charged within a timeout. If this is not
true: an alarm is signalled; the main contactor is not
closed.
Possible reasons:
A) The charging resistance is opened; if it is opened.
B) The charging circuit has a failure.
C) There is a problem on the power modules.
7-92
Traction Pump Mhyrio EPS
Code Alarm Description
(T) (P) (V) (E)
7-93
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
7-95
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
7-96
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
228 POSITION This alarm occurs for an error in the redundant test of the
ERROR feedback sensors. Here we have an encoder and two
toggle switches. This alarm occurs whether the sector
(toggle switches configuration) and the encoder counting
are not matched. The sector is provided with the
FEEDBACK SECTOR reading in the tester menu ; the
encoder counting is provided with the WHEEL ANGLE
reading in the tester menu.
WHEEL ANGEL Admitted Admitted
(degrees) SECTOR PEEDBACK SECTOR
-22 to +22 1st or 4th 3.13V or 1.88V
+23 to +67 1ST 3.13V
+68 to +112 1st or 2nd 3.13V to 4.39V
○ +113 to +157 2nd 4.39V
WHEEL ANGEL Admitted Admitted
(degrees) SECTOR PEEDBACK SECTOR
+158 to -158 2nd or 3rd 4.39V or 0.62V
-157 to -113 3rd
0.62V
-112 to -68 3 or 4
rd th
0.62V to 1.88V
-67 to -23 4th
1.88V
When the FEEDBACK SECTOR and WHEEL ANGLE
don't meet the above correspondence, an alarm
POSTION ERROR occurs in less than 100msec. If the
alarm occurs when installing a new controller, be sure
the AUX FUNCTION 11 corresponds to the toggle
switches arrangement you have and SET ENC AT 360
was correctly set .
MODEL Model truck selected for the pump is not the same of
○
MISMATCH traction one
EVPG1 DRIV One of the group 1 valves drivers is shorted; check the
SHORT ○ external connection, if it is ok the driver is probably
damaged.
229 AUX FUCNT Potentiometer aux value and its complementer are not
○
KO matched
EVPG2 DRIV One of the group 2 valves drivers is shorted; check the
SHORT ○ external connection, if it is ok the driver is probably
damaged.
230 SHIFT Potentiometer shift value and its complementer are not
○
FUCNT KO matched
EVPG3 DRIV One of the group 3 valves drivers is shorted; check the
SHORT ○ external connection, if it is ok the driver is probably
damaged.
231 TILT FUCNT Potentiometer tilt value and its complementer are not
○
KO matched
EVPG4 DRIV One of the group 4 valves drivers is shorted; check the
SHORT ○ external connection, if it is ok the driver is probably
damaged.
7-97
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
232 LIFT FUCNT Potentiometer lift value and its complementer are not
KO ○
matched
EVP DRIVER One of the on/off valves driver is shorted; check the
SHORT ○ external connection, if it is ok the driver is probably
damaged.
233 AUX OUT OF Potentiometer aux value is out of range
RNG ○
7-98
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
241 CAN BUS KO There is a problem related to the CAN-BUS line. The
error is signalled if the MHYRIO controller does not
○ receive any message from the CAN-BUS line. First of all,
check the wiring. If it is ok, the problem is on the logic
board, which must be replaced.
ENCODER It occurs when ENCODER CONTROL is set ON and the
ERROR real frequency does not pursuit the commanded
frequency. This condition is several times due to either, a
mismatching between the Encoder resolution used in the
○ SW and the real encoder resolution, or a wrong
connection between the two encoder channels. In this
latest case swap the channels of the encoder (CNB#8
with CNB#7).
242 STEAR DEAD EPS Relay is open
○
ANGLE
MOTOR STALL ○ Encoder locked
COIL ON/OFF valves drivers are protected against coil short
SHORTED ○ circuit; if a short is present across the coil, the flip-flop
circuit is set and the alarm is signalled.
Q LINE This alarm occurs when the mean voltage on the
SENSOR KO quadrature line of the stepper motor (connection CNA#8)
is not null: the voltage on every stepper motor line is a
sine wave with null mean voltage. Check the continuity of
○ the stepper motor connections. In particular the
resistance between CNA#8 and the minus battery (with
the stepper motor at rest) is expected being very low
(close to 30 ohms).
243 SEQUENCE Wrong Sequence to begin traction(es. First pedal
○
FAULT activated and then forward switch activated)
EV DRIVER One of the On/Off valves drivers is open (it does not
○
KO close when it is commanded by the microcontroller).
D LINE This alarm occurs when the mean voltage on the direct
SENSOR KO line of the stepper motor (connection CNA#9) is not null:
the voltage on every stepper motor line is a sine wave
with null mean voltage. Check the continuity of the
○ stepper motor connections. In particular the resistance
between CNA#9 and the minus battery (with the stepper
motor at rest) is expected being very low (close to 30
ohms).
ANGLE NOT Angle from EPS is not valid
244 ○
VALID
EVPG1 One of the group 1 valves drivers is open (it does not
○
DRIVER KO close when it is commanded by the microcontroller).
7-99
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
7-100
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
7-101
Alarm Traction Pump Mhyrio EPS
Code Description
(T) (P) (V) (E)
7-102
10. BATTERY CHARGER
This explains basic information related to charger to help you easily understand and use it. This
includes the contents from the way to install a charger to tips for emergency situations. This is focused
on practices aiming to be usefully utilized in the field.
1) BASIC INFORMATION
(1) What is charger
Charger is a device which makes a battery accept D.C electricity under optimal condition as it
transforms A.C provided from external source of electricity.
The charger is a constant-current and constant-voltage way, SCR type charger that it has
advantages as follows
Η Even though A.C input voltage fluctuates within 10% of rated voltage (220/380/410/440V), the
current and voltage provided to the battery are stable.
Θ As minimizing the increase of temperature while charging a battery, it minimizes the stress on the
battery.
Ι The noisy of charger is minimal but the charging efficiency is very high.
Κ It prevents from under charging and overcharging.
Therefore, it helps the battery to maintain its performance for longer time and to prolong the life of
the battery.
7-103
(3) Names of each part (independent items)
1 5
3
6 9 10
7
2
11
BR7BAT30
7-104
2) CHARGER INSTALLATION METHOD
(1) Location for charger installation
Η Dry and well ventilated place.
Θ No inflammable and B7 fire are near by.
Ι Safe place where no collision possibility
with people or equipment is.
(2) Check points before installing charger
Η Enough capacity of AC input power
source to operate charger.
Θ Standard electric wire for power source
by capacity.
Display
3) HOW TO USE A CHARGER
(1) General charging method (Floating
charging) Θ
Η
Η Charging by this method supplies electric
power to the charger as operating Θ
external AC power switch of the charger. Ι
Θ Connect battery connecter and charger Η
connecter.
BR7BAT10
ÂAccording to charging condition
Η If there is no abnormality found when the
charger checks itself for 3-4 seconds
after inputting AC input power source, the
charger slowly increases the electric flow
for charging and the charging condition
lamp in the lower part of the front panel
for floating charging of "input" is on.
Θ When charging is processed about 80%,
yellow lamp in the middle of the front
panel, which shows that the charging
condition is in the middle, is on and then
green lamp is on when charging is
processed over 85% until charging is
completed.
Ι When charging is completed, "charging is
completed" lamp is on in the monitor and
other lamps of all monitors become off.
7-105
(2) Equalized charging
Η Equalized charging is
Equalized charging is to correct the
battery when it does not normally
perform its functions as the voltage
differences are too big between cells of a
battery.
When equalized charging is required?
- When re-operates the battery after
having left the battery for a long time.
- When a battery is over-discharged.
- When there is large deviation of voltage
and specific gravity between battery
cells.
- When change or supply electrolyte of
battery.
Θ Tips for equalized charging
If once push the equalized charging
button on the monitor in the beginning of
charging, the equalized charging lamp
becomes on and starts charging.
ö When the green charging condition
lamp is on ( over 85% charged), the
equalized charging switch is locked
that it does not operate even pushing
Equalized charging switch
the button. BR7BAT10
7-106
4) HOW TO CHECK THE CHARGER'S NORMAL OPERATION
After changing SCR module or PCB (SE-
5000SN), the charger's normal operation
should be checked.
ÂChecking order
(1) Separate the charger and battery
connector.
(2) Separate lower cover in the front of the
charger.
(3) Check the AV input voltage used from the
input switch terminal in the lower left side
of the inside of the charger.
Checking method between terminals.
Input voltage setting value Ą 220V 380V
- Between terminals No. 2 - No. 4 220V 380V
- Between terminals No. 2 - No. 6 220V 380V
- Between terminals No. 4 - No. 6 220V 380V
ö Above cases are under normal BR7BAT05
operations.
ö When installing charger for the first time
220V
or moving its location, check and make
it sure if the voltage is appropriately
connected.
Refer to No. 2 of the charger installation
method for the terminal connection
method.
- In case of 220V : (2), (4), (6), (8)
- In case of 380V : (1), (3), (5), (7)
It should be connected to the terminal.
380V BR7BAT06
7-107
(4) Convert the automatic / manual switch to
manual.
The automatic/manual switch is located in
the lower left part of the PCB
Be sure to check if battery connector is
separated in advance.
(5) MG/SW operation
(This switch is operated automatically.)
(6) Check the charging voltage soft start BR7BAT08
7-108
(7) If charger's out voltage is under 60V, it is
abnormal.
Please refer to the error sheet.
(8) When the charging voltage is indicated as
normal condition (63V), convert automatic
/ manual switch to automatic and start
charging.
ö Display error code on the front cover as BR7BAT11
following table.
7-109
5) CHECK POINTS BEFORE APPLYING
A/S
(1) AC input power source switch is input.
(2) Check if the battery connector of the
forklift truck and charger's connector are
connected.
(3) Check points when "Error" lamp is on in
the front monitor of the charger.
(4) Check the front cover indicator. BR7BAT10
7-110
6) ERROR DETECTION
(1) Error list
Η Only floating charge lamp is on in the
monitor but it is not charged.
Θ ON and OFF is repeated with a few
minutes intervals even after starting
charging.
Ι Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.V"
Κ Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.C"
Λ Charger TRIP is occurred after it started
charging and charging completion lamp
is on.
Μ Charger has no response even the
battery connector is connected.
7-111
(2) Troubleshooting
Η Only floating charge lamp is on after indicating "A.O", It's not charged.
PCB to manual.
NO NO
TH
Apply multi tester for input voltage change Change PCB Manual
over tab no. 6 /Auto S/W
Measure voltage between input tab no.8, CN4 contact fault
M/S
PCB CN4, and contact points with red reed PCB RY contact fault COIL FAN
NO putting black reed on the other side
Apply multi tester for input voltage change
TB.6
over tab no. 6
M/S electrical circuit
TH contact fault
7-112
Θ ON and OFF is repeated with a few minutes intervals after starting charging.
Indicate "O.C" on the monitor.
- TH is operated (AC input over-current TRIP).
OUTPUT
CURRENT
DE- IN-
CREASE CREASE
Serious
trans noisy Measure output Current Exceed Adjust output current
NO NO
under the current using DC value : 15~20A Standard within PCB
condition. current measure /100AH current Re-adjust to VR
Is MS
on? YES
 TH Setting fault
YES
 Re-adjust TH TH. TRIP Change TH
setting value
NO
* Refer to SCR Rated
Complete Current
YES Module checking
method SETTING
YES NO
NO Change
SCR MODULE
Separate the battery Check
connector and tune SCR
the charger off Module
YES Check
Check the normal
MAIN NO Change
operating condition
TRANS PCB
of the charger
VOLT
YES
7-113
Ι Charger TRIP is occurred after abnormality lamp is on.
In case error code is "O.V" Ą Over-voltage output / Set at 66Vdc (In case of BATT 48V)
After separating the battery connecter, Check Turning charging voltage volume in
turn on MS as converting the voltage of the NO the center of the right-hand side of
automatic/manual selection switch on output connecter PCB anti-clockwise rotation
lower part of PCB to manual 62-63V? Set the voltage same as 62.5V
Re-establish voltage
De- In-
establishment volume "17/0V" crease crease
YES
on the lower right side of PCB Measure
as turning it anti clockwise YES the voltage of the VOLT
rotation output connecter
62-63V?
Check contact error
or breaking of wiring NO Change
De- In- OK NO of the detect cable PCB
crease crease
Measure connecter pin
the voltage of the
output connector Check
62-63V? the detect
YES voltage of the J3 NO
NO YES
connector
Change PCB OK
7-114
Κ Charger TRIP is occurred after abnormality lamp is on.
In case error code is "O.C" Ą Output over current, established as 120% of the rated
current.
De- In-
crease crease
Measure
Re-establish the charging current
Restart the charger as pushing the output current by NO
volume in the center of PCB as turning
reset switch in the monitor. DC current measure
it anti clockwise rotation
AH÷8
YES
Change
OK
PCB
7-115
Λ Charger TRIP is occurred after it started charging and charging completion lamp is on.
(In case input voltage is normal - Refer to the error detection No. 1)
Restore the charger as pushing reset switch.
Measure
After separating battery connector,
the output current by NO Measure the output
put the automatic/manual selection
DC current measure voltage 62-63V
switch to manual
Is it normal?
YES
YES
NO YES
Change Change
SCR Module PCB
Decrease Increase
7-116
Μ Charger has no response even if the battery connector is connected.
- In case only floating LED is on, charger input power is cut off or doesn't connect. (In case
the input voltage is normal - Refer to the error detection No. Η )
NO Charger BATTERY
Connector contact fault
Battery
Measure Measure the
NO voltage
the battery voltage voltage within the is normal
Is it under RD of the charger (Over
35V? BATT(+) SHUNT 35V)
CN.6
YES RD PCB(+) YES
PCB(-)
BATT(-) Module
(-) PCB
(+)(-) Voltage Check the cable and contact
is over YES point status at PCB connector(J3)
12V
On the
Convert the automatic/manual selection switch
left side of PCB
to manual and turns it to automatic after 1/2~1
Is LP LED
hour and make it charge normally. NO NO
ON?
If the battery voltage is not increased after
automatic 1 hour charging is started, battery YES Change
check is required. PCB
RD
LED
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7) HOW TO CHECK THE SCR MODULE
Circuit Real diagram
K2 K2
G1
K1 G1
3 2 1 K1
* Before checking SCR MODULE, be sure to disconnect bus bar and wire on the terminal.
Measuring point
No. Measure value SURGE PCB
(Real diagram)
4 G1 ~ K2 Forward : Infinity ( ∞ )
Reverse : Infinity ( ∞ )
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8) PCB MAJOR PARTS NAME AND LOCATION
16
1
2
15
3
12 5
13 6
7 8 9 10 11
14
BR7BAT24
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