SME AC Panel Manual 052005 en

User’s manual
SME
AC PANEL
Edition
Edition May
May 2005
2005 rev1.0
rev1.0
SME company info:
Address: Via della Tecnica, n° 40 Z.I.

36071, Arzignano (VI) ITALY
Phone number: 0039-0444-470511
Fax number: 0039-0444-451803
e-mail: info@grupposme.com
chiara.pace@grupposme.com
web site www.grupposme.com
2
AC Torque control system
OPERATION & MAINTENANCE MANUAL
3
LIST of CONTENTS
Chapter 1: OVERVIEW page 5

1.1 Advantage of AC motor page 5
1.2 Comparison between AC and DC motor systems page 6
1.3 AC induction motor operation page 8
1.4 Principles of AC drive systems page 9
1.5 Basic operation of ITC vector drive system page 10
Chapter 2: GENERAL DESCRIPTION page 12

2,1 Main ITC features page 12
2.2 Basic ITC functions page 15
2.3 ITC system characteristics page 16
Chapter 3: INSTALLATION and WIRING page 17

3.1 GENERAL DESCRIPTION page 17
3.2 K1 connector: list of ALL TERMINALS page 21
3.3 K1 connector: list of UNUSED TERMINALS page 26
Chapter 4: PROGRAMMABLE PARAMETERS page 27

4.1 ADJUSTABLE PARAMETERS DESCRIPTION page 27
4.2 PARAMETERS RELATIVE TO A 48 V SYSTEM page 30
4.3 PARAMETERS RELATIVE TO A 36 V SYSTEM page 32
4.4 E-S-H ENERGETIC MODES PARAMETERS page 34
Chapter 5: SOME FUNCTIONS MANAGEMENT page 35

5.1 STATIC RETURN TO OFF page 35
5.2 PUMP MOTOR MODES page 35
5.3 BUZZER MANAGEMENT page 36
5.4 B.D.I. MEASURE MANAGEMENT page 36
Chapter 6: EYE SOFTWARE INTERFACE page 37
4
Chapter 7: COMPACT DISPLAY page 38
Chapter 8: DIAGNOSTIC AND TROUBLESHOOTING page 39

8.1 GENERAL DESCRIPTION page 39
8.2 ALARM LIST page 40
Appendix A : SYSTEM COMPONENTS TECHNICAL DATA page 54
Appendix B : K1 CONNECTOR SPARE PARTS page 63
Appendix C: INTERCONNECTION CABLE page 64
Appendix D: GENERAL INTERCONNECTION SCHEMATA page 65
5
1 OVERVIEW
1.1 Advantage of AC motor
AC induction motors are the most dif-

fused for power conversion in indus-
trial application.
In the battery-fed lift-truck applications

DC motors are more used, because
they are easy to control in torque with

a simple chopper drive with a current
limitation.
To reach the traction requirements the AC control has to be very advanced and the motor
parameters have to be known by the control algorithms.
The reason of their recent diffusion are related to the technological development and to
deeper studies about this matter.
The advantages of using AC motors instead of DC motors are many:

- more robust and easy to build
- less complex and more reliable
- practically maintenance free (no continuous brush maintenance)
- higher speed
- more performance at high speed especially in regeneration
- absence of contactors for speed inversion
- continuous torque control during inversion (no delay with zero torque)
- safer because AC motor is not supplied and it doesn’t work in case of short circuit
See following tables and relative explanation for a comparison between AC and DC motor
systems.
6
1.2 Comparison between AC and DC motor systems
MOTOR CHARACTERISTICS
AC Motor systems DC Motor system

1 Little components More complex
2 Decreasing price Increasing price
3 More reliable Less reliable
4 Practically maintenance free Continuous maintenance to brushes
5 High speed Low speed

6 High torque performance at high speed Low torque performance at high speed
7 High braking performance at high speed Poor braking performance at high speed
8 Safer Less safe
CONTROLLER CHARACTERISTICS
AC Motor systems DC Motor system

9 Complex controller Simple controller
10 No auxiliary contactor Presence of auxiliary contactors
11 4 quadrants continuous transition Torque discontinuity and delay
12 Precise and smooth regulation Poor regulation
AC and DC MOTORS DIFFERENCE EXPLANATION
DC motor is made with a rotor with power windings and a stator with excitation windings and
brushes. The AC motor is composed by a rotor and a stator with windings.
Because of great diffusion of AC motors and the automatic industrial production process, their
prices continue to decrease.

Because of DC motor more complexity, brush presence and poor environmental protection, the life
of DC motor is greatly reduced, compared with AC motor.
The maintenance of DC motor must be continuous because of consumption of brushes.
The most critical component for AC motor are the bearings.
AC motor reaches higher speed because of DC sparkling limitation of brushes.
7
AC motor has higher torque at high speed because of DC sparkling limitation of brushes.
AC motor has much more regenerative braking torque at high speed because of DC sparkling
limitation of brushes.
AC motor is safer than DC because if a short circuit happens in armature, DC motor acceler-
ates. The AC motor needs an AC voltage to accelerate.
The AC controller is much more complex of a DC one.
The reason why is the AC control algorithms requires the use of a very powerful microproces-
sor which performs a fast real time control.
In most of DC controllers are present auxiliary breakers which operate every drive inversion,
introducing delays and compromising the controller life.
Most of DC controller systems has zero torque delays during inversion causing a poor driving
performance. In AC the transition between forward and reverse and acceleration and braking
is continuous giving an optimum performance even at very low speed and in sharp ramp.
Because of 4 quadrants continuous transition and the presence of a sophisticated controller

the regulation of AC system is superior in precision, stability, smoothness and safety to DC
one.
8
1.3 AC induction motor operation
AC motor is composed by a stator with 3 phase windings and a rotor with speed and ther-
mal sensors.
The 3 phase AC source voltage generates a stator rotating field which is coupled with
rotor conductors generating a magnetic force.
The typical torque-speed curve shows how a motor fed by its rated frequency has
synchronous speed = 2*f*60/p
Where: speed [rpm] f [Hz] p motor poles.

The speed decreases with load increasing. The normalised difference between the syn-
chronous and the rotor speed is called slip.
In diagram below you can see the mechanical characteristic of an AC engine.

Electromagnetic torque is function of speed n (or of slip s ), and marked areas indicate
where your engine works in stable operating mode (both as motor and as generator).
In fact, an increase (decrease) of your engine torque corresponds to an increasing

(decreasing) external torque
Torque-speed curve
9
A simplified single phase electrical diagram shows how the motor works.
Increasing the frequency the voltage must be increased to keep flux constant, moreover in-
creasing the load torque the slip increases and so the torque current increases.
Simplified single phase electrical diagram
1.4 Principles of AC drive systems
AC motor supply systems based on DC/AC conversion are the followings:
- scalar control (with load compensation)

- slip control
- flux vector control
Scalar control is based on V/f characteristic. It’s very simple and it requires few
motor parameters but it has no zero speed range, lower maximum torque,
lower maximum speed, lower efficiency, slow dynamics.
Slip control is based on a voltage and slip compensation with load. It’s quite
simple drive, it has zero speed range, but it has less efficiency and lower preci-
sion.
Flux vector control that is based on a flux and torque control, depending on
motor parameters knowledge and speed and current measures. It is more com-
plex, but it has much more performance, zero speed control, fast and precise
response and more efficiency.
10
1.5 Basic operation of ITC vector drive system
Functional block diagram
11
The previous block diagram shows how the control board works. This is the meaning of the dia-
gram functional blocks :
SPEED
The reference speed is set by pedal accelerator, which is limited and interlocked with
other various signals such as:
- Seat
- Hand brake
- Pedal brake
- Start
- Forward
- Reverse
- Steering position
The resulting speed Nr is compared with the motor actual speed Nm calculated from
the motor speed sensor signal. A regulator sets a required torque Tr to correct the
speed error.
SPEED SENSOR
A quadrature pulse output encoder is installed in the AC motor as speed sensor sup-
plying to the logic the information of position, speed and direction of the motor.
TORQUE
The required torque Tr is compared with the estimated torque Te and the regulator
requires a desired voltage Usx. Moreover it’s done also a slip estimation to calculate
the Flux position.

FLUX
The required torque function of actual speed Fr is compared with the estimated torque
Fe and the regulator requires a desired voltage Usy.

FLUX POSITION
Flux position is estimated and output to PWM modulator, current decoupling.
INVERTER VOLTAGE
Combining the Usx and Usy voltage with Flux frequency are calculated the required
inverter voltage which is sent to a PWM modulator which generates drive commands
for power mos-fets
CURRENT DECOUPLING
The phase currents are measured, de-coupled and input to the FLUX and TORQUE es-
timators. There also used for protection purpose.
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2 GENERAL DESCRIPTION
This document scope is the description of inverter control unit, present on
electrical fork-lifts equipped with AC motors
2.1 Main ITC features
Most important features of Intelligent Torque Control system developed by SME

Company are the following:
- Control unit: One panel assembly containing three power inverters for drive and pump
and a control board; main board, wired directly to the power modules, could manage up
to 4 inverters. The presence of 2 DSP (Digital Signal Processors), working in mutual re-
dundant control, guarantees powerful software performance: in case of such a system,

managing both drive and pump motors, high dynamic performance in vectorial torque
control can be obtained (see Appendix A for technical data)
- Two asynchronous three-phase drive motors equipped with magnetic sensors(64 im-
pulses/rotation) (see Appendix A for technical data)
- An asynchronous three-phase pump motor for lifting equipped with magnetic sensor (64
impulses/rotation) (see Appendix A for technical data)
- COMPACT Display
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Software control algorithm is customised in order to best fit lift truck characteristics; you can set
the value of a wide range of parameters, in order to optimise system performance and to adjust
the settings of main functions in compliance with user’s needs.

User can interact with control board making use of a software application (named EYE) devel-
oped by SME Company, or with COMPACT display. In both cases, it’s possible to obtain an ex-
haustive “on line” diagnostic for all lift truck functional parameters and also to adjust them.
You can upgrade control board internal software connecting a PC via serial port (or via USB 1.x or
higher, inserting the appropriate serial port-USB adapter); in fact, working with RS232 communi-
cation standard, EYE application permit to load and upgrade panel software in any working con-
ditions, if only control board is correctly fed on .
COMPACT display
14
2.2 Basic ITC functions
Following basic hardware and software functions characterize SME Company sys-
tem:
- Protection against reverse battery polarity
- Anti-roll-back, with adjustable ramp stop time

- Anti-roll-down
- Regenerative braking
- Electrically assisted braking
- Management of static return to off function (SRO)
- Drive speed compensation (load/unload)

- Drive speed acceleration/deceleration
- Drive speed reduction

- Redundant control of acceleration pedal (applying a control switch or a double potentiome-
ter)
- Continuous lift speed control

- Pump speed compensation (load/unload)
- Lift speed acceleration/deceleration

- Continuous control of main contactor applied to DC power line
- Seat switch open check with delay time
- Battery discharged indicator with adjustable reset value

- Overtemperature protection for inverters and motors
- Low and high battery voltage limit

- Drive/pump speed feedback
- Zero speed drive in ramp
- Standby for supply

- Diagnostics and stored error code
- Power line fault detection (fuse/contactor)

- Continuous temperature measuring (Controller, drive/pump motor)
- Full protection against short or open circuits
15
2.3 ITC system characteristics
You can obtain high performance for the lift truck with SME system, thanks to follow-
ing specific features:
- DSPs high performance control with custom software: this is resident in the internal
FLASH memory, and allows to control 3 independent AC motors.

- One serial asynchronous RS232 interface for PC communication in order to obtain:
1. software update
2. diagnosis of truck functionalities
3. parameters modification, in order to customise the system
- One accelerator (0 - 12 V) and all on/off emergency micro-switches interface.
- One encoder (0 - 5 V) interface for traction and pump motors.

- Motor torque control by speed and current loop.
- Controlled acceleration and deceleration ramps of drive and pump motors in order to
avoid uncontrolled jolts of the load due to oversights of the operator.

- Automatic truck speed limitation depending on steering angle.
- Ramp stop of the lift truck.

- Automatic energy recovery at each truck braking.
- LIN (Local Interconnect Network) display interface.
- Automatic truck speed limitation, depending on the height of the load lifted.
- Automatic truck maximum speed limitation, in function of:
1. weight present on the forks
2. fork height
3. battery voltage level
4. any thermal alarm
- Full protection of drives against overcurrent of the motors, overheating of the power
transistors and both maximum and minimum battery voltage.

- Low maintenance costs by using A.C induction motors
16
3 INSTALLATION and WIRING
3.1 GENERAL DESCRIPTION

1. A metallic container encloses control board (Fig. 1).
( Refer to APPENDIX A for technical data and other details about control board)
2. There are three power modules (see fig 2 for single module) assembled to main board as
shown in Fig. 3 and Fig. 4; in Fig. 5 you can see a view of main contactors .
( Refer to APPENDIX A for technical data and other details about power inverters)
3. A 68 ways AMP connector (named K1), permits to interface control board to lift truck electri-
cal/electronic sub-devices. See Fig. 6 for a view of K1- 68 ways connector.
( Refer to APPENDIX B for technical data and other details about K1 connector and to AP-
PENDIX D for a generic interconnection schemata)
4. Three 26 ways connectors (named C1 C2 C4) permit to wire and control 3 power inverters.
No details are given about the pin-out of these connectors t, because they are not user ac-
cessible for maintenance or diagnostic operations. Power modules shall be connected also
to battery supply (wire named +B and -B) and to corresponding motor phases .
BEWARE!
Working on electrical systems is potentially dangerous; you should protect yourself against :
Uncontrolled operation: some conditions could cause the motor to run out of control: discon-
nect the motor or jack up the vehicle and get the drive wheels off the ground before attempt-
ing any work on motor control circuitry.

High current arcs: batteries can supply very high power, and arcs can occur if they are short
circuited. Always open the battery circuit ground before working on motor control circuit.
Wear safety glasses and use properly insulated tools to prevent shorts.
Lead acid batteries: charging or discharging generates hydrogen gas, which can build up and
go around the batteries. Follow the battery manufacturer’s safety recommendations and wear
safety glasses.
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Fig. 1: Logic control board, SME code IV055B
Fig. 2: Single power module
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Fig. 3: Power modules assembly with control board mounted, SME code IV045B
Fig4: Dimensions of half-bridge power modules
Fig. 5: Main contactors
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Fig. 6: View of accessible terminals on 68 ways connector
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3.2 K1 connector: list of ALL TERMINALS
Pin number Use Name Function

K1 – 1 IN -Battery Negative supply voltage of control board
K1 – 2 OUT + 24 V supply
K1 – 3 IN Lift pressure (optional) Proportional voltage signal (0-5V); you can connect a pres-
A sure linear sensor, made by SME cod B00ID160 working
correctly in 0¸250 bar pressure range

K1 – 4 IN start switch for accelerator START signal
D pedal N.O. with internal pull-up and Vmax(in)=24V

K1 – 5 IN accelerator pedal 2° Proportional voltage signal (0-5V) or (0-12V) managed as
A potentiometer accelerator pedal input
K1 – 6 IN park brake switch Park brake signal
D N.C., with internal pull-up and Vmax(in)=24V

K1 – 7 IN seat switch Seat switch signal
D N.O., with internal pull-up and Vmax(in)=24V

K1 – 8 IN reverse drive direction switch reverse drive direction di selezione signal
K1 – 9 IN forward drive direction switch forward drive direction signal

K1 – 10 IN accelerator pedal 1° Proportional voltage signal (0-5V) or (0-12V) managed as
A potentiometer accelerator pedal input

K1 – 11 OUT + 12 V supply +12V supply voltage (self-protected electronic component)
with:
Idc (nominal) =500mA; Imax = 1Adc

K1 – 12 IN/OUT LIN data line (Display I/0) Data line of LIN interface for COMPACT display
D
K1 – 13 IN not used - Digital input, for an optional encoder, Vmax(in) =5V
A/D - Analogue input (0-12V)
K1 – 14 OUT + 5 V encoder supply +5V supply voltage (self-protected electronic component)
with:
Idc (nominal) =500mA; Imax = 1Adc

K1 – 15 OUT GND Negative supply voltage for data type signals, with self-
protection against noises coming from DC power line;
Imax=500mA
K1 – 16 IN PHASE B of left drive motor PHASE B signal of the sensor bearing mounted into the left
D encoder drive motor; internal pull-up; Vin:(0 – 5V)
21
K1 – 17 IN PHASE A of left drive motor PHASE A signal of the sensor bearing mounted into the left
D encoder drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 18 OUT + coil main breaker Positive command of contactor coil; Inom=1A; Imax = 5A
K1 –19 OUT - coil main breaker Main breaker coil reference signal; Inom=1A; Imax = 5A
K1 – 20 OUT not used Self-protected open collector power output, you can apply it
A to an ON/OFF or proportional electrovalve coil; Vmax =Vali;
Inom=2A; Imax=6A
K1 – 21 OUT not used Self-protected open collector power output, you can apply it
D to an ON/OFF or proportional electrovalve coil; Vmax =Vali;
Inom=2A; Imax=6A
K1 – 22 IN + battery Control board supply voltage; V = Vsupply
K1 – 23 IN + battery key input Supply voltage of key and coils ; Vkey=Vsupply
K1 – 24 IN not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;

K1 – 25 IN not used Digital input , N.O., internal pull-up, Vmax(in)=24V
D
K1 – 26 IN not used Analogue input (0-12V)
A
K1 – 27 IN not used Analogue input (0-5V)
A
K1 – 28 IN PHASE B of pump motor PHASE B signal of the sensor bearing mounted into the pump
D encoder motor; internal pull-up; Vin:(0 – 5V)
K1 – 29 IN PHASE A of pump motor PHASE A signal of the sensor bearing mounted into the pump
D encoder motor; internal pull-up; Vin:(0 – 5V)

K1 – 30 IN Not used; Digital input for an optional encoder, motor; internal pull-up;
D PHASE A of an optional Vmax(in)=5V;
encoder
K1 – 31 IN/OUT Not used; - Digital input for an optional encoder, Vmax(in)=5V;

A/D PHASE B of an optional
- Open Collector power output, to command an ON/OFF
encoder
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 32 IN Asynchronous RS232 serial RX input for asynchronous RS232 serial communication stan-
D RX input dard
22
K1 – 33 OUT Asynchronous RS232 serial TX TX output for asynchronous RS232 serial communication
D output standard
K1 – 34 IN/OUT CAN – H (not used) H line input for CAN (Controller Area Network ) compo-
D nent; presence of internal termination resistance
K1 – 35 IN/OUT CAN – L (not used) L line input for CAN component; presence of internal ter-
D mination resistance
K1 – 36 IN PHASE B of right drive motor PHASE B signal of the sensor bearing mounted into the
D encoder right drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 37 IN PHASE A of right drive motor PHASE A signal of the sensor bearing mounted into the
D encoder right drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 38 IN AUX3 Digital input to activate pump motor auxiliary function
D AUX3; N.O., internal pull-up, Vmax(in)=24V
K1 – 39 OUT fans command (optional) Open Collector power output, to command fans (or other
A devices) Inom = 1A, Imax=3A; Vmax=60V;
K1 – 40 OUT Not used; Open Collector power output, to command an ON/OFF
D Electrovalve (or alike) command electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 45 OUT Not used; PWM supply voltage for electrovalve coils (or similar de-
Electrovalves supply voltage vices)
K1 – 46 IN lift high switch Voltage signal of lift critical high switch, N.O., internal
D pull-up, Vmax(in)=24V
K1 – 47 IN Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;

K1 – 48 IN pedal brake switch Activation signal for park brake, N.O., internal pull-up,
D Vmax(in)=24V
K1 – 49 IN Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;

23
K1 – 50 IN lift lever potentiometer voltage Proportional voltage signal (0-12V), input of lift lever po-
A tentiometer
K1 – 51 IN Not used Proportional voltage signal (0-12V)
A
K1 – 52 IN Not used Proportional voltage signal (0-12V)
A
K1 – 53 OUT buzzer command Open Collector power output, to command buzzer activa-
D tion; Vmax =24V; Inom=30mA; Imax=100mA.
K1 – 54 IN tilt switch Request of tilting, N.O., internal pull-up, Vmax(in)=24V
D
K1 – 55 IN Not used; - Digital input
D PHASE B of an optional encoder
- PHASE B signal for an optional encoder; internal pull-
up; Vin:(0 – 5V)
K1 – 57 IN digital input for 3 / 4 wheels - Digital input to select a lift truck with 3 wheels
D choice; (Closed ) or 4 wheels (Open);
PHASE A of an optional encoder
- PHASE A signal for an optional encoder; internal pull-
up; Vin:(0 – 5V)
K1 - 58 IN right drive motor thermal sensor/ Analogue input (or digital as optional) used for right drive
A/D switch motor thermal sensor (0-5V); internal pull-up;
K1 – 59 IN left drive motor thermal sensor/ Analogue input (or digital as optional) used for left drive
A/D switch motor thermal sensor (0-5V); internal pull-up;
K1 - 60 IN pump motor thermal sensor/ Analogue input (or digital as optional) used for pump mo-
A/D switch tor thermal sensor (0-5V)
K1 - 61 IN Not in use - Digital input , N.O., internal pull-up, Vmax(in)=5V;

K1 – 62 IN steering angle sensor voltage Proportional voltage signal (0-12V) or (0-5V), used as
A input to steering sensor circuit
D Electrovalve (or alike) command electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
24
K1 - 67 OUT Not used Power output, to command a proportional electrovalve
A coil; Vmax =Vsupply; Inom=2A; Imax=6A
Legenda:
D: digital signal, with boolean values (ON/OFF)
A: analogue signal, assuming values in [Vground -Vmax] range
A/D: signal that could be both analogue and digital
NO: normally open NC: normally close
IN: signal used as input OUT: signal used as output
Remember the controller contains ESD sensitive components.

Use appropriate precautions in connecting, disconnecting and
handling it.
25
3.3 K1 connector: list of UNUSED TERMINALS
Pin number Use
13 digital input
20 power output
21 power output
24 digital input
25 digital input
26 analogue input
27 analogue input
30 digital input
31 digital input
34 CAN - H
35 CAN - L
40 power output
41 power output
42 power output
43 power output
44 power output
45 power output
47 digital/analogue input
51 analogue input
52 analogue input
63 power output
64 power output
65 power output
66 power output
67 power output
68 power output
26
4 PROGRAMMABLE PARAMETERS
4.1 ADJUSTABLE PARAMETERS DESCRIPTION

The possibility of interfacing by PC with the system allows to have an exhaustive real time analy-
sis of the system working and of the condition of its components; moreover, you can choose
among a wide range of parameters in order to reach the optimum operating of the system in com-
pliance with your needs.
Adjustable parameters are listed below, divided by functional groups, both for a 36 V and a 48 V
system. We briefly explain what’s the meaning of each programmable parameter, and which is
the effect of its changes in lift truck performance.
DRIVE MOTOR
PARAMETER PARAMETER DESCRIPTION

Drive acceleration ramp Lift truck acceleration with accelerator pedal pressed
Drive release ramp Lift truck deceleration with accelerator pedal released
Drive inversion ramp Lift truck deceleration in inversion
Pedal brake ramp Lift truck deceleration with pedal brake pressed
Drive limitation maximum speed Maximum lift truck speed with speed limitation (turtle active)
Maximum forward lift truck speed with no speed limitation

Forward maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no speed limitation
Reverse limitation speed
(no alarms present and turtle not active)
If the truck speed is greater than this threshold, the speed

Creep speed reference becomes a parabolic function of the accelerator po-
tentiometer voltage.
Maximum speed reference in the angle in which the internal

Steer limitation maximum speed
wheel is mechanically still.
Drive motors maximum current (expressed in per cent of high

Drive maximum current
energetic mode value)
Parameter that softens the drive inversion ramp if the traction

Partial release ramp
motors are working with low rpm
Critical height drive maximum Maximum lift truck speed when forks high is more than critical
speed (optional) one
27
SENSORS AND POTENTIOMETERS

Accelerator pedal minimum value Accelerator sensor voltage with pedal released
Accelerator pedal maximum value Accelerator sensor voltage with pedal completely pressed
Lift sensor minimum value Lift sensor voltage with lift lever released
Lift lever potentiometer voltage to which the lifting becomes

Lift sensor middle value
proportional to the shift of the lever
Lift sensor maximum value Lift sensor voltage with lift lever completely pressed
Steering sensor minimum value Steering sensor voltage with wheels turned on left
Steering sensor middle value Steering voltage with wheels straight ahead
Steering sensor maximum value Steering sensor voltage with wheels turned on right
PUMP MOTOR

Minimum lift speed Minimum lift speed
Maximum lift speed Maximum lift speed

Tilt speed Pump motor speed with lift function active
Pump motor speed with lateral shift function (1 st auxiliary)
Lateral shift (AUX 1 function) speed
active
AUX 2 function speed Pump motor speed with 2 nd auxiliary function active
AUX 3 function speed Pump motor speed with 3 rd auxiliary function active
Pump acceleration ramp Lift acceleration
Hydro speed Pump motor speed when steering

Pump motor speed with direction command lever not in
Hydro idle speed neutral, acceleration pressed and no pump command
active
Lift maximum current Pump motor maximum current with lift function active
Auxiliary maximum current Pump motor maximum current with lift lever released
28
TIMERS
Time interval between seat switch opening and drive and

Seat switch delay
pump motors stopping
Time interval when pump motor works (with hydro speed) af-
Hydro time
ter the end of a command
Time delay between last command given to a drive or pump

Chat time
motor and chat mode signalling
BATTERY

Minimum battery voltage necessary to reset battery dis-
Battery reset value
charged voltage alarm
29
4.2 PARAMETERS RELATIVE TO A 48 V SYSTEM
In following tables are listed maximum, minimum and default value for each programmable parame-
ter, in case of 48V system
DRIVE MOTOR
PARAMETER UNIT MINIMUM DEFAULT MAXIMUM
Drive acceleration ramp rpm/s 400 1150 2000
Drive release ramp rpm/s 400 900 2000
Drive inversion ramp rpm/s 400 1200 2000
Pedal brake ramp rpm/s 400 1000 2000

Drive limitation maximum speed rpm 500 2000 2500
Forward maximum speed rpm 1000 4500 4500
Reverse limitation speed rpm 1000 4500 4500
Creep speed rpm 100 300 2000
Steer limitation maximum speed rpm 400 1500 4500
Drive maximum current % 20 100 100
Partial release ramp rpm/s 10 50 500
Critical height drive maximum speed (optional) rpm 400 2000 4500

Accelerator pedal minimum value mV 200 1000 4500
Accelerator pedal maximum value mV 3000 5000 12000
Lift sensor minimum value mV 200 1000 12000
Lift sensor middle value mV 2000 7500 12000
Lift sensor maximum value mV 3000 11500 12000
Steering sensor minimum value mV 500 1200 11500
Steering sensor middle value mV 500 6300 11500
Steering sensor maximum value mV 500 10030 11500
30
PUMP MOTOR

Minimum lift speed rpm 500 700 1500
Maximum lift speed rpm 1500 3200 4500

Tilt speed rpm 500 900 2000
Lateral shift (auxiliary 1 function) speed rpm 500 900 2800
Auxiliary 2 function speed rpm 500 900 2800
Pump acceleration ramp rpm/s 1000 7000 10000

Pump deceleration ramp rpm/s 1000 7000 10000
Hydro speed rpm 400 500 800
Hydro idle speed rpm 200 300 500
Lift maximum current % 20 100 100

Auxiliary maximum current % 10 62 100
TIMERS
Seat switch delay s 1 3 9
Hydro time s 10 10 20
Chat time s 3 6 9
BATTERY
Battery reset value V 46 46.7 49.5
31
4.3 PARAMETERS RELATIVE TO A 36 V SYSTEM
In following tables are listed maximum, minimum and default value for each programmable parameter,
in case of 36 V system
DRIVE MOTOR
Drive acceleration ramp rpm/s 400 1150 2000
Drive release ramp rpm/s 400 900 2000
Drive inversion ramp rpm/s 400 1200 2000
Pedal brake ramp rpm/s 400 1000 2000

Drive limitation maximum speed rpm 500 2000 2500
Forward maximum speed rpm 1000 3800 3800
Reverse limitation speed rpm 1000 3800 3800
Creep speed rpm 100 300 2000
Steer limitation maximum speed rpm 400 1500 4500
Drive maximum current % 20 100 100
Partial release ramp rpm/s 10 50 500
Critical height drive maximum speed (optional) rpm 400 2000 3800

Accelerator pedal minimum value mV 200 1000 4500
Accelerator pedal maximum value mV 3000 5000 12000
Lift sensor minimum value mV 200 1000 12000
Lift sensor middle value mV 2000 7500 12000
Lift sensor maximum value mV 3000 11500 12000
Steering sensor minimum value mV 500 1200 11500
Steering sensor middle value mV 500 6300 11500
Steering sensor maximum value mV 500 10030 11500
32
PUMP MOTOR

Minimum lift speed rpm 500 700 1500
Maximum lift speed rpm 1500 3200 4500
Tilt speed rpm 500 900 2000
Lateral shift (auxiliary 1 function) speed rpm 500 900 2800
Pump acceleration ramp rpm/s 1000 7000 10000
Pump deceleration ramp rpm/s 1000 7000 10000
Hydro speed rpm 400 500 800
Hydro idle speed rpm 200 300 500
Lift maximum current % 20 100 100

Auxiliary maximum current
% 10 62 100
TIMERS
Seat switch delay s 1 3 9
Hydro time s 10 10 20
Chat time s 3 6 9
BATTERY

Battery reset value V 34.4 34.9 37.3
33
4.4 E-S-H ENERGETIC MODES PARAMETERS
Some parameters value depend on selected energetic mode: in following tables are listed parame-
ter default values for each operating mode (economic, standard and high )
In case of 48 V system:
PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE

Maximum drive current 62 76 100
Maximum forward speed [rpm] 3000 3500 4500
Maximum reverse speed [rpm] 3000 3500 4500
Acceleration proportional to load 20 20 20
Drive acceleration ramp [rpm/s] 700 800 1150
Drive inversion ramp [rpm/s] 600 900 1200

Drive release ramp [rpm/s] 600 850 1000
Lift maximum current 70 80 100
Maximum lift speed [rpm] 2500 2750 2950
In case of 36 V system :
PARAMETER ECONOMIC MODE STANDARD MODE HIGH MODE

Maximum drive current 62 76 100
Maximum forward speed [rpm] 2800 3300 3800
Maximum reverse speed [rpm] 2800 3300 3800
Acceleration proportional to load 20 20 20
Drive acceleration ramp [rpm/s] 700 900 1100
Drive inversion ramp [rpm/s] 700 900 1100
Drive release ramp [rpm/s] 700 900 1200
Lift maximum current 70 80 100
Maximum lift speed [rpm] 1600 2500 2950
34
5 SOME FUNCTIONS MANAGEMENT
5.1 STATIC RETURN TO OFF
To ensure operator safety, when switching on the lift truck, a number of inputs are analysed; if
one of these signals indicates a wrong start condition or any likely danger situation, main
breaker is not closed and all system modes are disabled. If the anomalous input assumes the
correct value, main breaker is closed and it’s now possible go on with usual truck manage-
ment.
The analysed inputs are the followings:
1. Seat switch (the closing is checked)
2. Directional switch (the insertion of a selected direction is checked)

3. Accelerator (the system controls if the pedal is pressed)
5.2 PUMP MOTOR MODES
Control of a command lever moving when starting
When switching on the key, in case an hydraulic command is active, the lift, lateral shift, tilt
and auxiliary functions are disabled.
Only when the activated lever and/or the requested command assumes the released position,
operator can return to the usual operative condition .

Pump motor commands management
Switching on the key, the motor works at minimum speed ( idle speed, adjustable by PC ).
If the operator moves a command lever or the steering wheel, the speed takes on a value that
can be adjusted, depending on the type of the active command and on the possible presence
of limitations (caused by thermal or low battery alarms).

After the active command is switched off, motor speed assumes idle speed value for an ad-
justable time (idle time), relating to the start of hydro guide; if no command is activated during
this period of time, the speed returns to no operation value (0 rpm)
35
5.3 BUZZER MANAGEMENT
The buzzer is activated in the following cases:

1. Alarm condition
2. Switching your device on you find wrong start conditions:

- accelerator pedal pressed or directional (forward or reverse) switch inserted .
- one of pump motor command levers not released.
3. The seat switch is opened for almost “seat switch delay” seconds, when the park
brake is released. If the park brake is inserted, the buzzer is switched off.
5.4 B.D.I. MEASURE MANAGEMENT
To measure battery voltage one of the following conditions must be true :

- Chat mode
- Lift with drive and pump motors still

- Drive motors still and pump motor working to its minimum speed (idle speed)
If this conditions are fulfilled for at least 4 seconds, battery voltage begins to be evaluated,
using a low– pass filtering. After 15 seconds of voltage processing, the filter output signal is
uses to evaluate the battery charge level.
If the battery is discharged for at least two consecutive sampling periods, low battery voltage
alarm is signalled and following limitations are activated:
- limitation of drive motor speed and maximum torque

- limitation of maximum pump motor speed
- lift, tilt and auxiliary functions are disabled
If the alarm is observed switching on the key, the first received pump command is keep active
for 3 seconds and then is disabled. Battery voltage must exceed an adjustable limit value
(Battery reset value, see Chapter4) to return to normal operative condition after a low battery
voltage alarm.
36
6 EYE SOFTWARE INTERFACE
EYE is a diagnostic software environment designed to communicate with the forklift truck.
It can be run from a PC with serial or USB (1.x o 2.x)

port.
Connection between PC and SME Control board is
characterized by a 38,4 kBaud Baud-rate. (See AP-
PENDIX C for a schemata of interconnection cable)
User can communicate with lift truck during working op-

erations, and can analyse on line main electrical vari-
ables value/ status.
EYE software interface is user friendly and intuitive: it guides the operator through the proc-
ess of parameter setting and is an effective data analysis instrument, helping to identify
faults and causes of malfunctioning.
Following functions are in particular very useful:
- Diagnostic: User can receive relevant control data from the main board (such
as current, voltage, rpm, temperatures etc ) evaluating lift truck performance
and detecting any faulty circuit
- Calibration: User can transmit parameters and settings to the truck in order to
tune its performance.
To find further technical data and useful information about EYE software, refer its own
user manual .
37
7 COMPACT DISPLAY
LCD Compact display shows information about system main analogue and digital parameters,
as follows:
- Truck speed
- Park brake insertion
- Steering angle
- Seat switch closure
- Maintenance period expiry
- Low speed insertion

- Battery charge level
- Energetic operating mode

Compact display
- Alarm type
To find further technical data and useful information about Compact display refer its own
user manual .
We briefly mention two important functions:

DIAGNOSTIC MODE
This operating mode enables you to test main analogical and digital signals
managed by your system.
PARAMETER CALIBRATION
This procedure allows to adjust the main operating parameters of the system.
You can enter calibration mode before working as usual with your lift truck.
It is also possible to update the parameters with default values .
(Notice this way you loose calibration values).
38
8 DIAGNOSTIC AND TROUBLESHOOTING
8.1 GENERAL DESCRIPTION

Diagnostic information about anomalous working condition is provided by COMPACT display or
by PC (using EYE software utility). This chapter explains how to manage any detected fault and
how to return to a normal working situation; suggestions to be applied in case of each possible
alarm are listed in a growing order, i.e. from the least to the most serious one.
If an alarm condition is detected by main board, software control inhibits some lift truck functions,
to guarantee operator safety.

Anomalous working conditions are indicated by different alarm levels, classified as follows, de-
pending on their effects on the system:
Level 1: main breaker is opened and both pump and drive motors are stopped; buzzer and red
led on the upper right corner of COMPACT display, signal the presence of such an
alarm.
Level 2: pump and drive motors are stopped.
Level 3: drive motors speed is limited to 2000 rpm. Moreover, in presence of such an alarm,
first command given to pump motor is inhibited 3 seconds after activation, together
with all pump motor functions (except hydro functions).
Level 4: drive and pump motors speed is limited to 800 rpm; buzzer signals the presence of
such an alarm.
Level 5: drive motors speed is limited to 800; over temperature alarms are signalled by. buzzer
activation.
Level 6: pump motor speed is limited to 800; buzzer signals the presence of such an alarm.
Level 7: no effects on system performance.
Notice : if more than one faulty condition is detected, Compact displays shows alarm code re-
ferring to the most serious one (the one characterized by lower alarm level).
Following section gives useful suggestions covering a wide range of possible faults, listing corre-
sponding alarm cause identified by its alarm code.
39
8.2 ALARM LIST
Maximum battery voltage
- Eye alarm code: 1

- Alarm level: 1
- Alarm cause: battery voltage, measured by a circuit inside control unit, exceeds following levels:
63 V, in case of systems working at 36 V
63 V, in case of systems working at 48 V
If the controller detects such a fault, refer to following troubleshooting procedure:
1. such an alarm can be caused also by the presence of regeneration currents; when lift truck is
on release or reverse braking ramp, motors work as generators, and battery voltage can ex-
ceed overvoltage limit. In a case like that, the battery condition should be verified ( if the bat-
tery is new it is necessary to do some charge-discharge cycles before reaching the rating de-
clared by the constructor) or has a high internal resistance.
If the case is the second and it is not possible to change the battery, the solution may be to
reduce the release and reverse braking ramp.
2. incorrect wiring to battery positive or negative terminals.
3. verify if battery is still in good conditions.

4. replace the control board .
Minimum battery voltage
- Eye alarm code: 2
- Alarm level: 1
- Alarm cause: battery voltage, measured by an internal circuit, is lower than following levels :
24 V , in case of systems working at 36 V
24 V , in case of systems working at 48V
40
In case of minimum battery voltage alarm, follow these steps:
1. incorrect wiring to battery, or corroded positive or negative terminals;

2. verify battery conditions: if the electrolyte inside is partially exhausted, an under voltage alarm
can sometimes be detected from the controller; even in case of low battery charge (<10%),
high current rates (i.e. both pump and drive motors working in full load conditions) could cause
an under voltage alarm, in particular in presence of an exhausted battery.
Pedal trimmer fault
- Eye alarm code: 3
- Alarm level: 2
- Alarm cause: voltage measured on accelerator circuit exceeds the value calculated averaging cali-
bration and reachable voltages; moreover, start switch seems to be open.
In case of such an alarm, follow these troubleshooting steps :
1. verify if the potentiometer initial set-up is correct; if not, repeat calibration procedure .
(You can use both PC with serial communication software and COMPACT display).
2. verify if the following 68 ways connector terminals are correctly wired to their correspondent
inputs in potentiometer circuit:

- K1-11 (12 V)
- K1-15 (ground)
- K1-10 (pedal input)
3. in case of correct wiring, replace the potentiometer itself.
4. replace control board
41
Eeprom alarm
- Eye alarm code: 5
- Alarm level: 1
- Alarm cause: eeprom does not work properly, or one of memorised values is out of correct limits.
In case of alarm follow this procedure:

1. load default values for eeprom variables, both using PC with serial communication software
and COMPACT display;

Pre-charge capacitors low voltage alarm (Capacitors not charged)
- Eye alarm code: 6

- Alarm level: 1
- Alarm cause: voltage level of pre-charge capacitors is less than 70 % of nominal battery level.
It could happen, in example, if the inverter is working with main breaker open.
Capacitors voltage decreases cause energy spent to keep motors in motion.

1. verify if main breaker coil and power terminals are in good conditions;
2. verify if supply lines power fuse is damaged;

3. verify if main breaker coils are correctly wired to their correspondent inputs :
- K1-18 (positive terminal)
- K1-19 (negative terminal)

4. replace main breaker;
5. replace control board.
42
Inverter desaturation or overcurrent alarm
- Eye alarm code: 8 for right drive motor power module

24 for pump motor power module
25 for left drive motor power module
- Alarm level: 1
- Alarm cause: actual current exceeds limits 929 A

1. With such an alarm present when you turn on lift truck, disconnect the power cable between
the malfunctioning inverter and the corresponding motor (first, turn off the system, of course).
If turning lift truck on again, alarm is not active, then:

1. replace the cable connecting control board and inverter.
2. replace the inverter;
If turning lift truck on again, alarm is active, then :

2. replace the motor.
Inverter capacitors pre-charge too fast
- Eye alarm code: 9

- Alarm level: 1
- Alarm cause: pre-charge capacitors voltage increases too fast when you turn the system on.
In case of too fast pre-charge alarm, follow this procedure:

1. replace main breaker.
2. replace cable connecting the CN1 output of the control board with the corresponding inverter;
3. replace the inverter connected with the CN1output of control board

4. replace control board
43
Pump motor inverter overtemperature
- Eye alarm code: 10
- Alarm level: 6
- Alarm cause: the inverter temperature (measured with a temperature probe), exceeds 100 º C, or
is inside [95 ºC, 100 ºC] range at least 30 s.

1. alarm could be caused by ineffective temperature dissipation.
Verify thermal coupling between inverter block and aluminium plate, and between aluminium
plate and truck ballast.
The presence of a correct amount of thermal grease in the coupling is essential to ensure an
efficient heat exchange;

2. replace cable connecting the output CN4 of the control board to the pump inverter;
3. if temperature readings seem too high in function of total time interval of lift truck using, re-
place pump inverter causing the alarm.
You can read temperature measures using “COMPACT” display or “EYE” communication soft-
ware.
4. replace main board.
Capacitors too charged on start

- Alarm level: 1
- Alarm cause: when you turn on the system, capacitors are not completely discharged by pump mo-
tor.
In fact, if you turn suddenly on the lift truck, after a turning off, capacitors voltage level is too high.
You have to discharge them before checking the presence of any fault (both of capacitors and of
main board)
1. verify the correctness of wiring from pump motor and relative inverter;
44
2. replace cable connecting the output CN4 of the control board with the corresponding
inverter;
3. replace the inverter connected to CN4 output of the control board;

4. verify if main breaker has stuck closed terminals: in such a case replace it;
5. replace the cable connecting the output CN1 of the main board to the right drive motor
inverter: a defective cable could give a wrong measure for capacitors voltage;
6. replace the right drive inverter;
Low battery alarm

- Alarm level: 3
- Alarm cause: battery voltage level is lower than minimum charge value expected, referred to
table 2 (for 36V system) and table 3 (for 48V system) in COMPACT display user manual.
In case of low battery alarm, follow this procedure:

1. measure battery voltage with a tester and, if different from the value reported on COM-
PACT display, replace main board;
2. otherwise recharge battery.
Drive motor overtemperature
- Eye alarm code: 13 for right drive motor

19 for left drive motor
- Alarm level: 5
- Alarm cause: The measure of drive motor temperature exceeds 155 ºC..
In case of alarm, follow this procedure:
45
Presence of alarm with cold motors:
1. with a handheld multimeter (in resistance operating mode) you have to measure a resis-
tance of about 10 kohm between the two wires of the temperature probe ( execute the
measure at ambient temperature of 25°C).
If the measure is not correct it is necessary to replace the temperature probe.
2. disconnect the temperature probe and check the wiring insulation between signal wire
and ground wire (towards control board);
Presence of alarm with hot motors:
1. If temperature value (you can read it from display or via PC) seems correct, verify if the
motor stator case are clean
Pump motor overtemperature
- Alarm level: 6
- Alarm cause: The measure of pump motor temperature exceeds 155 ºC .
Presence of alarm with cold motors:

1. with a handheld multimeter in resistance operating mode, you have to measure about
10kohm at ambient temperature of 25°C between the two wires of the temperature
probe. If the measure is not correct it is necessary to replace the temperature probe.
2. disconnect the temperature probe and check the wiring insulation between signal wire
and ground wire (towards control board);

Presence of alarm with hot motors:

1. If temperature value (you can read it from display or via PC) seems correct, verify if the
motor stator case are clean
46
Motor current offset alarm

36 for pump motor
- Alarm level: 1
- Alarm cause: non-zero phase currents when you turn lift truck on.
case of motor current offset alarm, follow this procedure:

1. replace the cable connecting the malfunctioning inverter to control board.
2. replace inverter.
Main breaker fault
- Alarm level: 1
- Alarm cause: overcurrent on main breaker coil.

1. replace main breaker
2. replace control board .
Watchdog timer alarm

- Alarm level: 1
- Alarm cause: improper communication between DSPs on control board, or/and defective control
board.

1. using EYE program interface, try to program control board flash memory;
2. replace control board .
47
Drive motor inverter overtemperature

- Alarm level: 5
- Alarm cause: inverter temperature, measured with a probe, exceed 100 ºC , or is inside
[95 ºC, 100 ºC] range at least 30 s.

1. alarm could be caused by ineffective temperature dissipation; verify thermal coupling be-
tween inverter block and aluminium plate and between aluminium plate and truck ballast.
The presence of the correct amount of thermal grease in the coupling are essential to ensure
a correct heat exchange;

2. replace cable connecting the output CN1 ( for right drive motor) or CN2 ( for left drive motor)
of the control board to the corresponding inverter;
3. if temperature readings seem too high in function of total time interval of lift truck using, re-
place inverter unit causing the alarm. You can read temperature measures using “COMPACT”
display or “EYE” communication software.

Serial communication alarm

- Alarm level: 1
- Alarm cause: error in serial communication between the two DSP; DSP present on main board
make a mutual software control, to insure fast diagnosis of such a fault.

1. program pump and drive DSP again; maybe software present in flash memory was cor-
rupted.
48
Alarm on 5 V encoder voltage

- Alarm level: 1
- Alarm cause: Main board K1-14 terminal (5 V output) voltage is lower than 4.3 V.
1. verify if 5 V output is grounded, cause an incorrect encoder wiring.

2. verify if 5 V output is grounded, cause any encoder malfunction.
In that case, replace the defective one.
Alarm on 12 V output voltage
- Alarm level: 1
- Alarm cause: Main board K1-12 terminal (12 V output) voltage is lower than 10.5 V.
In case of an alarm on 12 V output voltage, follow this procedure:

1. verify if 12 V output is grounded, cause an incorrect wiring to:
- Accelerator potentiometer
- Steering sensor
- buzzer
- display
2. replace defective device;
49
Pump motor commands active on start

- Alarm level: warning; while the fault condition is active, all pump motor functions (except hydro
functions) are inhibited.

- Alarm cause: you find a pump motor command active when you turn your system on.
1. before starting to operate, turn off any active command (both levers and switches);
2. be sure that lift, tilt and auxiliary command switches, are not active;
Seat switch open on start

- Alarm level: warning; main breaker is opened and pump and drive motors are stopped.
- Alarm cause: when you start working, you find seat switch open, or, after the main breaker is
closed, the seat switch remains opened for at least “ seat switch delay” s.
1. verify if seat switch is defective;

Wrong start

- Alarm level: warning; main breaker is opened and pump and drive motors are stopped.
- Alarm cause: when you start working, you find accelerator pedal pressed or a forward/ reverse
switch active.
1. verify if a switch was active or the pedal pressed, when you turn on the lift truck;
2. verify if start, forward or reverse switches are stuck close;
3. verify if pedal circuit voltage exceeds 1/3 its maximum range (measured in Volt);

50
Encoder alarm
- Eye alarm code: 74 (for right drive motor encoder)
75 (for left drive motor encoder)

- Alarm level: 1
- Alarm cause: an encoder channel is disconnected, and motor is working.
1. Verify if the encoder is correctly connected to:

- Motor itself
- Ground : K1- 15 terminal
- + 5 V: K1- 14 terminal
- A channel: K1- 37 terminal (for right drive motor encoder)
K1- 17 terminal (for left drive motor encoder)

- B channel: K1- 36 terminal (for right drive motor encoder)
K1- 16 terminal (for left drive motor encoder);

2. if correctly wired, replace the encoder;
Alarm of motor thermal probe
- Eye alarm code: 77 (for right drive motor thermal probe)

78 (for left drive motor thermal probe)
79 (for pump motor thermal probe).
- Alarm level: 7
- Alarm cause: Temperature difference between any two of the 3 motors results greater than 70 ºC
In case of alarm, follow this procedure:

1. verify if the wiring is correct;
2. replace the probe;
3. replace control unit.
51
Alarm of a inverter temperature probe
- Eye alarm code: 80 (for right drive motor power module probe)
81 (for left drive motor power module probe)
82 (for pump motor power module probe)

- Alarm level: 7
- Alarm cause: Temperature difference between any two of the 3 inverters is greater than 70 ºC.

1. check the wiring connecting control unit and inverter;

3. if alarm is still present, replace control unit.
CRC fault alarm
- Alarm level: 1
- Alarm cause: Faulty eeprom or mismatching software release.

1. restore eeprom with EYE application software, using the “RESTORE” item present in main page
2. if alarm is still present, replace control board.
Bank CRC restored

- Alarm level: warning
- Alarm cause: there was an eeprom restore, caused by a CRC alarm.
1. switch on the system and the turn it on again
52
Steering sensor alarm

- Alarm level: 5
- Alarm cause: steer circuit voltage is out of nominal range.
In case of a steering sensor alarm follow this procedure:

1. verify correctness of wiring with :
- K1-11 (12 V),

- K1-15 (ground)
- K1-10 (steering sensor input);
2. if correctly wired, replace steering sensor;

Capacitors pre-charge too slow

- Alarm level: 1
- Alarm cause: pre-charge capacitor voltage grows too slowly, when you turn on the system.

1. replace cable connecting the CN1 output of the control board with the corresponding inverter
2. replace the inverter connected with CN1 output of the control board;
3. replace control board;
Capacitors pre-charge timeout

- Alarm level: 1
- Alarm cause: pre-charge capacitor voltage grows too slowly, when you turn on the system.

1. replace cable connecting the CN1 output of the control board with the corresponding inverter
2. replace the inverter connected with CN1 output of the control board;
3. replace control board;
53
APPENDIX A
POWER INVERTER TECHNICAL DATA
BATTERY VOLTAGE 24-60 V
MAXIMUM IMPULSIVE DRIVE INVERTER CURRENT 325 A
MAXIMUM IMPULSIVE PUMP INVERTER CURRENT 400 A
SWITCHING FREQUENCY 3-6-9 KHz
EFFICIENCY 95 %
PROTECTION LEVEL IP51
MECHANICAL SIZE 580 mm x 248 mm x187 mm
WEIGHT 24 Kg
VIBRATION 5g 10-500Hz in X,Y,Z axis
TEMPERATURE RANGE - 30 °C ¸ + 40 °C
MAXIMUM MODULE TEMPERATURE 95°C
CONTROLLER Complies with EN 1175-1 EN 12895-1
MAIN CONTACTOR 250A
MAIN FUSE 700A
KEY FUSE 6A
Fig.7: Single power module
54
LOGIC CONTROL UNIT
(SME Code IV055B)
55
SINGLE AC POWER DRIVE UNIT
(SME Code IV020B01)
56
POWER MODULES ASSEMBLY
(SME Code IV045B/6)
57
DRIVE MOTORS TECHNICAL DATA
POWER 5 KW
VOLTAGE 32 V
CURRENT 157 A
RATED SPEED 1500 RPM
MAXIMUM SPEED 4500 RPM
FREQUENCY 75 Hz
Cos f 0,72
SERVICE S2 60'
INSULATION CLASS F
PROTECTION DEGREE IP 10
BEARINGS 6206 2RS
WEIGHT 38,5 Kg
Fig.8: Drive motor
58
RIGHT DRIVE MOTOR
(SME Code MT329B)
59
LEFT DRIVE MOTOR
(SME Code MT317B)
60
PUMP MOTOR TECHNICAL DATA
POWER 12 KW
VOLTAGE 30,5 V
CURRENT 335 A
RATED SPEED 2200 RPM
MAXIMUM SPEED 4500 RPM
FREQUENCY 73 Hz
Cos f 0,84
SERVICE S3 15%
INSULATION CLASS F
PROTECTION DEGREE IP 20
BEARINGS 6206 2RS
WEIGHT 43,5 Kg
Fig. 9: Pump motor
61
PUMP MOTOR
(SME Code MT325B)
62
APPENDIX B
K1 CONNECTOR SPARE PARTS
K1 is an AMP 68 connector, with “POWER TIMER” terminals

See following list of component codes
- receptacle housing cod: 00-0963598-1
- cover for receptacle cod: 00-0964731-1
- cable clip cod: 00-0964732-1
- junior power timer terminal 1-2.5mm 2 cod: 00-0927766-1
- micro timer 2 terminal 0.5-1mm2 cod: 00-0962876-1
- rubber plug for junior timer 1-2.5mm2 cod: 00-0828905-1
- rubber plug for micro timer2 0.5-1mm2 cod: 00-0963530-1
- cavity plug cod: 00-0963531-1
63
APPENDIX C
INTERCONNECTION CABLE
(SME Code IV049A)
64
APPENDIX D
GENERAL INTERCONNECTION SCHEMATIC
65

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User’s manual

Address: Via della Tecnica, n° 40 Z.I.

Phone number: 0039-0444-470511

Fax number: 0039-0444-451803

web site www.grupposme.com

OPERATION & MAINTENANCE MANUAL

Chapter 1: OVERVIEW page 5

Chapter 2: GENERAL DESCRIPTION page 12

Chapter 3: INSTALLATION and WIRING page 17

Chapter 4: PROGRAMMABLE PARAMETERS page 27

Chapter 5: SOME FUNCTIONS MANAGEMENT page 35

Chapter 6: EYE SOFTWARE INTERFACE page 37

Chapter 8: DIAGNOSTIC AND TROUBLESHOOTING page 39

Appendix A : SYSTEM COMPONENTS TECHNICAL DATA page 54

Appendix B : K1 CONNECTOR SPARE PARTS page 63

Appendix C: INTERCONNECTION CABLE page 64

Appendix D: GENERAL INTERCONNECTION SCHEMATA page 65

1.1 Advantage of AC motor

AC induction motors are the most dif-

In the battery-fed lift-truck applications

they are easy to control in torque with

The advantages of using AC motors instead of DC motors are many:

AC Motor systems DC Motor system

2 Decreasing price Increasing price

3 More reliable Less reliable

4 Practically maintenance free Continuous maintenance to brushes

5 High speed Low speed

AC Motor systems DC Motor system

10 No auxiliary contactor Presence of auxiliary contactors

11 4 quadrants continuous transition Torque discontinuity and delay

12 Precise and smooth regulation Poor regulation

AC and DC MOTORS DIFFERENCE EXPLANATION

brushes. The AC motor is composed by a rotor and a stator with windings.

prices continue to decrease.

of DC motor is greatly reduced, compared with AC motor.

The maintenance of DC motor must be continuous because of consumption of brushes.

The most critical component for AC motor are the bearings.

AC motor reaches higher speed because of DC sparkling limitation of brushes.

ates. The AC motor needs an AC voltage to accelerate.

The AC controller is much more complex of a DC one.

Because of 4 quadrants continuous transition and the presence of a sophisticated controller

Where: speed [rpm] f [Hz] p motor poles.

In diagram below you can see the mechanical characteristic of an AC engine.

In fact, an increase (decrease) of your engine torque corresponds to an increasing

Simplified single phase electrical diagram

1.4 Principles of AC drive systems

AC motor supply systems based on DC/AC conversion are the followings:

- scalar control (with load compensation)

Functional block diagram

the Flux position.

Fe and the regulator requires a desired voltage Usy.

timators. There also used for protection purpose.

2.1 Main ITC features

Most important features of Intelligent Torque Control system developed by SME

dundant control, guarantees powerful software performance: in case of such a system,

control can be obtained (see Appendix A for technical data)

pulses/rotation) (see Appendix A for technical data)

the settings of main functions in compliance with user’s needs.

- Protection against reverse battery polarity

- Anti-roll-back, with adjustable ramp stop time

- Drive speed compensation (load/unload)

- Drive speed reduction

- Continuous lift speed control