Scan
Scan
Scan
_DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to C25 (C35) input,
- ANALOG : An analog motor thermal sensor is connected to c25 (CSS) (the curve can be
customized on a customer request).
- NONE : No motor thermal sensor switch is connected.
@ Steer table
This parameter is used to set the correct steering table.
- OPTION #4 : The steering table is the one for 4 wheels truck.
@Display
lf this option is set to on the communication with the Zapi graphic display is enabled.
7-26
@Throttle Ozone
lt establishes a deadband in the accelerator in ut
®Throttle X point P curve (see also curve below).
This parameter changas the characteristic of th .
@Throttle Y point e accelerator input curve.
This parameter changes the characteristic of th .
e accelerator input curve.
SPEEDl(Hz)
MAXSPEED - - ------
TROTTLE Y
POINT
FREO. CREEP i • •
VACC
i
THROTTLE0
1
THROTTLEX
1
VACC
V
VACC MIN and VACC MAX are values programmable by the "Program vacc" function.
@Cooling tan work
Cooling fans installed on nearby motors and controllers will work as follows;
Option #1 : fans work always
Option #2 : fans work in case a temperature of controller or motor exceeds a temperature set in
START TEMP. FAN menu
Options #2 : fans work when motors work.
@Start TEMP. FAN
tt COOLING FAN WORK menu is set as option #2, This menu is used to set a temperature
limitation which allows fans to work when a temperature of controller or motor exceeds the
limitation.
@Adjustment #2 bdi
lt adjusts the lower level of the battery discharge table. Higher level means higher voltage.
® Adjustment #1 bdi
lt adjusts the upper level of the battery discharge table. Higher level means higher voltage.
@Adjustment #03 :
Set an increment of battery charge above actual value. lf battery voltage exceed this total value
the software recognize charging, and battery charge percentage increase to correct value also if
battery isn~ fully charged.
®Main cont. voltage
This parameters adjusts the line contactar coil voltage (PWM output C26).
@Aux output voltage
This parameters adjusts the solenoid coil voltage (PWM output C28).
@) 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".
7-27
@) Speed factor . . . .
lt adjusts the speed coefficient to have the correct speed 'nd'c~ti~n on the display. This coefficient
has to be regulated depending on truck mechanic charactenst1cs. lt results from the following
formula:
Speed factor = 88 * rr * p / fi5
where:
rr = total gearbox ratio
fi5 = traction wheel diameter (cm)
P = number of pair poles of the motor
@Load sensor (option)
ON : Load Sensing Function is activated
OFF : Load Sensing Function is disactivated
@REF. load weight (option)
This parameter is used to show and configurate the reference load weight.
@Overload weight (option)
This parameter is used to show and configurate the trigger condmon far OVER LOAD alarm.
lf the loaded weight exceeds the weight indicated in this paramter, OVER LOAD alarm and
function limitation will occur accroding to OVERLOAD TYPE paramter.
@Overload type (option)
This option specifies how overload alarm works in overloaded situation.
NONE : There would'n be any kind of alarms or limitations.
lf re-configuration of V.A.S.S LOAD is required, please set this parameter as NONE, then
proceed re-configuration.
Option #1 : lf the weight of load filed on forks exceeds the overload weight set in overload
parameter, OVER LOAD alarm will be displayed and followed by traction & pump limitation
except lift down & steering function.
Option #2 : lf the weight of load filed on forks exceeds the overload weight set in overload
parameter, OVER LOAD alarm will be displayed.
@Load speed UPD (option)
Far accuracy, Load Sensor only works when the traction motor speed is lower than as set in this
parameter.
7-28
.....,.,,,..,-
y
7-29
@ Frequency creep
Minimum speed when the torward or reverse switch is closed, but the accelerator is on a
minimum posnion.
@ Maximum current
This changes the maximum current of the inverter.
® Acc. smooth
lt gives a parabolic shape to the acceleration ramp.
® lnv. smooth
lt gives a parabolic shape to the acceleration ramp after a direction inversion.
®Stop smooth
Hz. lt sets the frequency where the smooth effect of the parabolic acceleration ends.
@Seat delay time
lt determines the delay time between the opening of the seat swnch on CNC#5 dignal input and
the start of the truck electrical braking.
@Sequence de. time
lt sets the maximum delay time between the accelerator is pressed and the direction lever is
moved out of the neutral posnion.
lf this time is expirad the truck stops wnh warning : "SEQUENCE FAULT'.
@>CHATTIME
After no travel or pump request is active for the chat time the line contactar is automatically
opened. To restart, the the operator needs to press the accelerator pedal or activate the hydraulic
levers.
7-30
1 TRACTION CONTROLLER-SLAVE
Using the config menu of the programmin . .
following tunctions. g console, or us1ng a display, the user can configure the
• PUMP CONTROLLER
Using the config menu of the programming console, the user can configure the following tunctions.
(1) Submenu "SET OPTIONS"
(D Hour counter
- RUNNING :Toe counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
® Set temperatura
- 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.
@Joystick (Option)
- OFF : Toe truck model includes rnechanical lever distributor (default)
- ON : Toe truck model includes electro-hydraulic distributor and finger tips. Can communication
with Can tiller and Hydro CB zapi modules is enabled.
© Shift function
- ON : Fingertip Side Shift tunction is activated.
- OFF : Fingertip Side Shift function is disactivated.
@ Aux function
- ON : Fingertip Aux function is activated.
- OFF : Fingertip Aux function is disactivated.
® Digital lift . .
- OFF : The lift sensor includes a lift switch and an analogue hft sensor. L1ft speed can be
controlled proportionally with lever position. .
_ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled proporttonally.
7-31
(2) Submenu "AOJUSTMENTS"
h inal battery voltage.
<D Set battery type : ~elect~ t 0 nom f the battery voltage measured by the controller. Pleas
® Adjust battery : Fine ad¡ustment O 1 by 1 and check the voltage. e
increase or decrease the va1ue .
. . deadband in the accelerator input curve (see also curve below).
@ Throttle O zone • Estabhshes ª h teristic of the accelerator input curve
/A\ • Th. meter changes the c arac ·
w Throttle X zone . _is para h es the characteristic of the accelerator input curve.
@ Throttle Y zone : Th1s parameter e ang
SPEED f(Hz) A
MAX SPEED
TROTTLEY
POINT
FREQ.CREEP i i V
VACC MIN and VACC MAX are values programmable by the "PROGRAM VACC" function.
@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 OPTIONª) parameter is programmed "ANALOG"
(J) PWM on main contactor
- OFF: The inverter applies the battery voltage to the coil on A27 output.
- ON: The PWM reduces the voltage to the set value.
@ PWM on aux output
- OFF: The inverter applies the battery voltage to the coil on A28 output.
- ON: The PWM reduces the voltage to the set value.
® MC/AUX PWM: lt sets the PWM level in % on the outputs F8 and F9. Here is used to drive a
main contact for pump.
@) Fork leveling
- ON : AUTO TILT LEVELING function is activated.
- OFF : AUTO TILT LEVELING function is disactivated.
7-32
(3) parameter changa
(I) Acceler delay .
determines the accelerat,on ramp.
~ore value means better deceleration performance.
®oeceler delay .
lt determines the accelerat,on ramp.
More value means better deceleration performance.
® Max speed up . . . .
Determines the max1mum lift1ng speect with a potentiometer control.
© Min speed up . . . . . .
Determines the m1rnmum hft1ng speed with a potent1ometer control when the lifting enable switch
isclosed.
@Cutback speed
Determines the lift speed reduction in percentage when the speed reduction switch is activated.
@Tiltspeed
Tilt speed, fine regulation.
(J) Shift speed
Shift speed, fine regulation.
@Aux speed
Auxiliary function speed, fine regulation.
® Hyd speed fine
Hydro speed, fine regulation.
@I Maximum current
Toe maximum current of the inverter.
@ldletime
Time delay when an hydraulic steering function request is switched off.
7-33
5) PROGRAMMING & ADJUSTMENTS
There are two ways to adjust paramatar via a consola or buttons on a display.
* Adjustments via buttons on a display, plaasa refer to tha display section. (page 7-47)
ADJUSTMENTS VIA CONSOLE (Option)
Adjustment of paramaters
. and changas to the inverte~s configuration
. are made using the d"1g1ta1
.
console. Toe console 1s connected to the "B" connector of the 1nverter.
lnverter B
I· • • • • º • ·I connector
' Console connector
Display--
íl I]
? MOTOR DATA
Buttons- [
t[I]
ROU.
m
ENTER
Glt
SET
-im mi
ROU. OUT SET
2001a1s
* Please connect and disconnect it from the inverter aftera key switch
. off.
7-34
(2) oescription of standard consola menu
<D Traction controller-Master
HEADING
MAIN MENU
22B9El.18
7-35
® Traction controller-Slave
HEADING
MAIN MENU
SAVE
PARAMETER
RESTORE
PARAMETER
CODE,
ALARMS h , Nº , ·e
P ROGRAM
VACC SETTING MIN/MAX
VACC
NOT
MOTOR DATA
AVAILABLE
22B9R19
7-36
®pumP controller
HEAOING
MAIN MENU
2289820
7-37
(3) Description of the consola SAVE functlon
Toe SAVE function allows the operator to transmtt the paramet~r values and configuration data of
the chopper into the consola memory. lt is possible to load 64 d1fferent programmers.
Toe information saved in the console memory can then be reloaded into another chopper using
the RESTORE function.
Toe data that is available via the SAVE function is as follows:
- AII parameter values (Parameter change).
- Options (Set. options).
Flow chart showing how to use the SAVE function of the digital console.
SELECT: MOD.D 1
FREE
® Press ENTER to commence SAVE routine.
2297E121
7-38
(4) Description of the consola RESTORE function
Toe RESTORE PARAM function allows transfer of the console's stored data into the memory of
the chopper. This is achieved in a fast and easy way using the method previously used wlth the
SAVE PARAM. function.
Toe data that is available via the RESTORE PARAM. function is as follows :
• AII Parameter Values (Parameter change).
• Options (Set options)
A When the RESTORE operation is made, all data in the chopper memory will be written ovar
and replace with data being restored.
Flow chart showing how to use the RESTORE function of the digltal console.
MAIN MENU
@The display will show:
PARAMETER CHANGE
MAIN MENU
@Toe display shows: RESTORE PARAM.
MAIN MENU
RESTORE PARAM.
7-39
(5) Description of alarms menu
The microprocessor in the controller records the last five alarms that hav~ occurred. ltems
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.
Row chart showing how to use the ALARMS function via the digital console.
2.2B7EJ23
7-40
(G) oescription of consola program vacc function
This function looks for and remembers the minimum and maximum potentiometer wiper voltage
over the full mechanical range of the pedal. lt 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.
Aow chart showing how to use the PROGRAM VACC function of the digltal consola:
MAIN MENU
@The display will show: PARAMETER CHANGE
•
© Press ROLL UP or ROLL DOWN button until
PROGRAM VACC. appear on the display. •
MAIN MENU
@The display shows: PROGRAM VACC
o ■ D
@ Press ENTER to go into the PROGRAM VACC o o D
routine.
(Z) The display will show the minimum and
VACC SETTING
maximum values of potentiometer wiper output. 4.8 4.8
CONNECTED TO
e. The display will shows the first option, only 16
CONNECTED TO option is present in this menu.
20078.28
7-42
lli\ floW chart showlng how to make changas to opt·
IJ:/ ion menu :
SET OPTIONS
......
11111
USER PASSWORD
k. New value far selected option appears.
OFF
YES=ENTER NO =- OUT
•
n. Press ENTER to accept the changes, or press
OUT if you do not accept the changes. • • •
1
CONFIG MENU
o. SET OPTIONS menu appears. SET OPTIONS
2087El29
7-43
@ Flow chart showing how to use the tester function of the digital consola:
MAIN MEt'sJU
c. Toe display will show: PARAMETEA CHANGE. PARAMETER CHAt'-lGE
KEY 2
i. Next variable for measurement appears. Q¡:-¡:- GNO
MAIN MEl's!U
k. Toe Display will show: TESTEA. TESTER
7-44
MORNITORING MENU
S) In console, This menu appears as ''TESTEA" MENU
( ) Traction controller-Master
1
CD Motor voltage .
This is the voltage supphed to the motor by the inverter; it is expressed as a percentage of the full
voltage (which depends of the battery voltage).
@Frequency
This is the frequency of the voltage and current supplied to the motor.
@Encoder
This is the speed of the motor, expressed in the same unit of the frequency; this information
comes from the speed sensor.
@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.
@Current rms
Root Mean Square value of the motor current.
@Temperatura
Toe temperatura measured on the aluminum heat sink holding the MOSFET devices.
(7) Temperatura #1
This is the temperature of the right motor; if the option is programmed "None" (see page 7-26) it
shows Oº .
@Temperatura #2
This is the temperature of the left motor; if the option is programmed "None" (see page 7-26) it
shows Oº.
® Accelerator
Toe voltage of the accelerator potentiomete~s wiper (CPOT).
® Steer angle
This is the indication of the angular position of the steered wheel.
@ Interna! wheel cutback
This is the indication of the speed reduction applied to the interna! wheel; in other words, it shows
the ratio of the two speeds.
@ Forward switch
Toe level of the forward direction digital input FW.
- ON / +VB = Input active, switch closed.
- OFF/ GND = Input non active, switch open.
@ Backward switch
The level of the reverse direction digital input BW.
- ON / +VB = Input active, switch closed.
- OFF/ GND = Input non active, switch open.
® Enable switch
Toe level of the enable digital input:
-ON / +VB = Input active, switch closed.
- OFF/ GND = Input non active, switch open.
7-45
® Seat switch
The level of the seat microswitch digital input.
- ON / +VB = Input active, swttch closed.
- OFF/ GND = Input non active, switch open.
@Cutback switch
The level of the speed reduction microswttch.
- ON / GND = Input active, swttch opened.
- OFF/ +VB = Input non active, switch closed.
@Brake switch
The level of the pedal brake microswttch.
- ON / +VB = Input active, swttch closed.
- OFF/ GND = Input non active, swttch open.
@Exclusive hydro
Status of the exclusive hydro swttch.
- ON / +VB = Input active, swttch closed.
- OFF/ GND = Input non active, swttch open.
@Brake pedal pot.
Voltage of the brake potentiometers wiper (CPOTB). The parameter is active only if.the PEDAL
BRAKING parameter is set ANALOG.
@Hand brake
The level of the handbrake microswttch.
- ON / GND = Input active, swttch opened.
- OFF/ +VB = Input non active, swttch closed.
@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.
@Battery voltage
Level of battery voltage measured at the input of the key switch.
@Battery charge
The percentage Charge level of the battery.
@Load pot
Voltage value of load sensor.
7-46
@Temperatura
n,e temperature measured on the aluminum heat sink holding the MOSFETdevices.
(j) Voltage booster .
This is the booster of the voltage supphed to the motor in load condition; it is expressed in a
percentage of the full voltage.
@Battery voltage
Level of battery voltage measured at the input of the key switch.
®seat switch
The 1evel of the seat microswitch digital input.
• ON / +VB = Input active, switch closed .
• OFF/ GND = Input non active, switch opened.
@ Forward switch
Toe level of the forward direction digital input FW.
• ON / +VB = Input active, switch closed.
• OFF / GND = Input non active, switch opened.
@BackWard switch
The 1evel of the reverse direction digital input BW.
. oN / +VB = Input active, switch closed.
• OFF/ GND = Input non active, switch opened.
7-47
(3) Pump controller
<D 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).
®Frequency
This is the frequency of the voltage and current supplied to the motor.
@Encoder
This is the speed of the motor, expressed in the same unit of the frequency; this information
comes from the speed sensor.
© Slipvalue
This is the difference of speed between the rotating field and the shaft of the motor, expressed in
the same unlt of the frequency.
® Current rms
Root Mean Square value of the motor current.
@Temperatura
Toe temperature measured on the aluminum heat sink holding the MOSFET devices.
(7) Motor temperatura
This is the temperature of the motor; if the option is programrned "None" it shows Oº .
@ Lifting switch:
Status of the lifting switch.
- ON / +VB = Active entry of closed switch.
- OFF/ GND = Non active entry of open switch.
® Security switch:
Status of the SBR switch.
- ON / +VB = Active entry of closed switch.
- OFF/ GND = Non active entry of open switch.
® Hydro speed req.:
Status of the hydro speed request of the pump.
- ON / +VB = Active entry of closed switch.
- OFF/ GND = Non active entry of open switch.
® Lift/lower req.:
Level of the lift and lower analogue signa!.
@Tilt request:
Level of the tilt analogue signa!. Toe voltage is shown on the left hand side of the display and the
value in percentage on the right hand side.
@ Shift request:
Level of the shift analogue signa!. The voltage is shown on the left hand side of the display and
the value in percentage on the right hand side.
@Aux request:
Level of the auxiliary analogue signal. Toe voltage is shown on the left hand side of the display
and the value in percentage on the right hand side.
® Cutback switch:
Status of the speed reduction switch.
- ON / GND = Active entry of open switch.
- OFF/ +VB = Non active entry of closed switch.
7-48
®vo1taQ9 bOObsOOSte\er of the vottage supplied to the motor in load condition; it is expressed in a
, iS the
-n,,s of the full vottage.
rcentag8
pe vo\tage:
@Batterv b ttery vottage measured at the input to the key switch.
Level of a
7-49
7) GENERAL SUGGESTION FOR SAFETY
For a proper installation take care of the following recommendations:
A After operation, even with the key switch open, the interna! capacitors may remain charged f
~orne time. For safe operation, we recommend that th~ battery is disc~nnected, a~d a short circ~~
1s made between battery positive and battery negat1ve power term1nals of the 1nverter usin
. 9a
res1ster between 1Oohm and 100 ohm.
A Do not connect the inverter to a battery with a nominal value different from the value indicated 0
the controller plate. lf the battery value is greater, the MOS may fail; if it is lower, the control un;
does not "power up"
A During battery charge, disconnect the controller from the battery.
A 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.
A Before doing any operation, ensure that the battery is disconnected and when all the installation ¡8
completed start the machine with the drive wheels raised from the floor to ensure that any
installation error do not compromise safety.
A Take care all the inductive devices in the truck (hom, solenoid valves, coils, contactors) have a
proper transient suppression device.
7-50