Fimap MAGNA 65 Instrucciones de funcionamiento

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 1 di 19

READ THE OPERATING AND MAINTENANCE MANUAL

Service of the Console

The console allows to:

-set the chopper card for a personalised behaviour of the traction motor

-read the type of the alarm for a correct and easy trouble shooting

-test the different electric values and the state of the electric circuit relative to the traction

Use of the Console

The use of the instrument is very easy and comparable to one of the most common electronic devices

(such as mobile phones).

The sequence to follow always for the console connection is:

1. SWITCH OFF THE GENERAL KEY of the machine

2. take off the connector E from the chopper

3. connect the console in place of the connector E. If the operation connection results to be difficult,

check that the connector is positioned in the correct direction.

4. switch on the key and work with the console

5. quit from all the programs (main menu of the ignition) and SWITCH OFF THE GENERAL KEY of the

machine

6. disconnect the console connector and plug in the connector E

THE WRONG OPERATION SEQUENCE CAN EASILY COMPROMISE

THE FUNCTIONALITY OF THE CHOPPER CARD OR OF THE CONSOLE

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 2 di 19

Menu of the Console

HEADING: the features of the console and of the chopper card: voltage and maximum current of the

chopper card, the working hours of the chopper card.

PARAMETER CHANGE: in this menu the parameters can be changed to personalise the machine. The

parameters that can be modified are : CUT BACK SPEED 1 (minimum speed machine) and the CUT BACK

SPEED 2 (medium speed machine). All the other parameters are decided in Fimap and they are

related to the traction motor. It is forbidden to change them without previous Fimap

authorisation.

TESTER: the quantities of the electric characteristics (traction motor voltage, state of power switch =

closed/open ...) are showed in this menu.

SAVE: this permits, once the parameters have been changed, to enter the new setting in a storage

location of the console.

RESTORE: this permits to restore on the chopper card a parameter setting which has been entered in

the console.

ALARMS: indicates a list of the last five alarms occurred on the machine. According to the alarm a

specific corrective action is adopted (see following paragraph).

PROGRAM VACC: this section is used to teach the chopper about the potentiometer which is assembled

on the machine. It is an operation to be carried when there is the alarm Vacc not ok, when the

pedal accelerator is being replaced, when the chopper card is being replaced. A wrong relation

between the potentiometer and the chopper card causes the machine stop.

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 3 di 19

Flow chart of the console

HEADING

PROGRAM

TESTER

LIST OF PARAMETERS

ROLL to select

PARAM SET to change

enter

out

enter

out DO YOU WANT TO

SAVE DATA ?

ENTER = change

OUT

no change

enter

TEST LIST OF VALUES

to test

ROLL to select

PROGRAM

VACC

enter

out

Program for setting

pedal accelerator

MOTOR data

enter

out

L ente

out

enter

SAVE

enter

out

LIST OF free locations

Write on on a FREE

location

enter

RESTORE

enter

out

LIST OF locations

(programs) to load on

the chopper card

Enter: Are you sure ?

ENTER = restore

OUT= no restore

out

Out: Are you sure?

ENTER = change

OUT= no change

enter / enter

ALARMS List of the last 5

alarms occurred

Out

This menù has

not to be

modified

This menù has

not to be

modified

Enter: Are you sure ?

ENTER = save

OUT= no save

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 4 di 19

Alarms and Decoder

The chopper card visualises an anomaly on two levels of information

1. through a red alarm led which blinks for a quantity of times relative to the type of anomaly

2. through a message on the console that specifies more details on the nature of the anomaly.

Following table reports for each alarm the possible anomaly and of how to proceed on the machine.

DIAGNOSIS LIST ALARMS

(for better understanding of the list refer also to the electrical layout)

Number of

blinkings MESSAGE NOTES

1 WATCH DOG

The test of self-diagnosis of the chopper card carried

out both on rest as in drive verifies an anomaly

Possible causes

-the logic of the chopper card is damaged

Actions

-replace the chopper card

1 EEPROM DATA KO

The data of the hourmeter inside the chopper card

Actions

-switch off and on again the key. If the problem will be

solved the counter will be reset.

1 EEPROM OFF LINE

The data of the hourmeter and of the alarm stored in

the chopper card are not correct

Actions

-switch off and on again the key. If the problem persists

replace the chopper card

-if the problem will be solved the data will be cancelled

1 EEPROM PAR KO

The memory of the chopper card has lost the

adjustment and operation data

Actions

-switch off and on again the key. If the problem persists

replace the chopper card

-if the problem will be solved the data will be replaced with

the standard data

ADJUSTMENT

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INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 5 di 19

Number of

blinkings MESSAGE NOTES

2 INCORRECT START

Incorrect starting sequence

Possible causes

-error in the sequence Key/drive selection made by the

operator

-the micro pedal and/or micro drive are stuck

-wiring not correct

Actions

check the starting sequence which is:

-switch on the key

-select drive (forwards/backwards)

-press the accelerator

-check that the drive microswitch and the manipulator

forward/backward traverse selector do not have the

contacts stuck and that they work correctly

-verify the continuity of the circuit that connects the micro

drive pedal, the chopper card and the drive manipulator.

3 VMN LOW

The first check recognises a voltage VMN lower than the

25% of the battery voltage

Possible causes

-wrong connections on the motor

-motor current leakage to the ground

Actions

-check that the motor terminals are well isolated from the

motor casing both inside and outside the motor. Verify that

there is not dirt that causes current leakage between the

terminals and the motor body

-verify that the motor is not wet and in case dry with an air

flow

-check that the connections on the motor and on the

chopper card are correct (verify the type of traction motor

assembled, the correct wiring and the connections on the

chopper VMN, positive and negative)

if the problem persists replace first the chopper card and, if

necessary, also the motor

3 VMN HIGH

Starting test check possible faults on the power circuit

branch .

Possible causes

-chopper power branch damaged

-MOSFET logic control damaged

Action

-replace the chopper card

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 6 di 19

4 VACC NOT OK

The chopper card recognizes an anomaly in the mechanical

stroke of the accelerator

Possible causes

-the operator switched on the machine with the

accelerator pressed down or he pressed down the

accelerator before the selection of forward or backward

traverse

-the seat microswitch does not work

-the potentiometer and/or the chopper card has been

changed and the relating values between the two

components are to be re-programmed

-a cable between the potentiometer and the chopper card is

interrupted

-the potentiometer is faulty

-the PROGRAM VACC (see chapter Adjustment and

Inspection) has not been carried out correctly

Actions

- check the correct sequence to get traverse

-check the continuity of connections between the

potentiometer accelerator and chopper card

-re-program the chopper card with PROGRAM VACC (see

chapter Adjustment and Inspection)

- check the functionality of the potentiometer (it could be

broken) and replace it if necessary (re-programming then

the chopper card)

5 I HIGH AT STAND

The chopper card tests if on rest the signal of the

current is zero. Otherwise, it blocks the traction

Possible causes

-defective current sensor

-fault in the feedback circuits, or in the logic or on the

chopper card

Actions

- replace the chopper card

6 NPOT NOT OK

Test on working condition: the negative point brings is

at a wrong

Possible causes

-the potentiometer is not well connected to the chopper card

-potentiometer defected

Actions

-check the good connections potentiometer – chopper card

-check the potentiometer efficiency

ADJUSTMENT

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INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 7 di 19

7 TH PROTECTION

The chopper card works out of the temperature range

(-30°C + 70°C)

Possible causes

-chopper card faulty

-the machine runs in braking condition and the chopper gets

overheated

Actions

-check the temperature of the site where the machine works

-check the consumption of the traction motor

8 DRIVER SHORTED

COIL SHORTED

The driver that controls the driver power switch do not

operate properly

Possible causes

-the driver is defected

Actions

-replace the chopper card

permanent

blink

BATTERY LOW

Battery level too low: the chopper card cuts the power to the

traction motor for its safeguard

Actions

check the charge of the batteries

check the cleanliness and the good connections on the

chopper card of the cable that come from the battery

permanent

switched on FORW BACK

The alarm is indicated when both the forward and backward

requests are activated simultaneously

Possible causes

-wiring not correct

-microswitch forward or backward stuck

Actions

-check the correct functionality of the contacts of the

manipulator

-verify the wiring relative to the manipulator

-if the defect persists replace the chopper card

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 8 di 19

Chopper card setting

1. Switch OFF the general key and plug in the special

connector. The OFF condition is necessary to save the

memory card from loss of data).

2. Switch ON the general key

3. The model of the card (name, volts and amps) and the chopper

working hours appear on the display MX v.2.1

HOURS .0

4. press ENTER to get the main menu

5. you read the first option of the main menu: PROGRAM= CHANGE

PARAMETERS

6. press ENTER again to enter in this first branch of the main menu

where you can check and eventually modify the parameters of the

card. To move through the parameters use the button ROLL and

check if you have the situation below mentioned:

* SELECT MENU *

1- PROGRAM

CHOPPER MX BASIC PROFY/

KLINIK

1. ACCELERATION DELAY 6 6 ACCELERAZIONE SECONDI

2. CUTBACK SPEED 1 9 0 I RIDUZIONE DI VELOCITA' % VOLT

3. CUTBACK SPEED 2 6 6 II RIDUZIONE DI VELOCITA' % VOLT

4. COMPENSATION 9 4 COMPENSAZIONE DI POTENZA % AMP

5. TRACTION IMAX 9 9 CORRENTE MASSIMA % AMP

6. BRAKING 5 5 FRENATURA IN RALLENTAMENTO % AMP

7. RELEASE BRAKING 2 2 FRENATURA A RILASCIO % AMP

8. INVERSION BRAKING 1 1 FRENATURA INVERSIONE MARCIA % AMP

9. MAX SPEED FORW 9 9 MASSIMA VELOCITA' AVANTI % VOLT

10.MAX SPEED BACK 8 8 MASSIMA VELOCITA' INDIETRO % VOLT

11.CREEP SPEED 1 1 VELOCITA' MINIMA DI PARTENZA % VOLT

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 9 di 19

7. At the end press OUT and confirm ENTER if some parameter has been changed.

ATTENTION: PLEASE DO NOT CHANGE ANY PARAMETERS RELATED TO THE SAFETY

USE CONDITION OF THE MACHINE LIKE THE ONCE RELATED TO ACCELERATION,

BREAKING,. ECC. ONLY THE DIFFERENT SPEED VALUES CAN BE MODIFIED (CUTBACK

SPEED 1 – 2 and MAX SPEED FORWARD)

IN CASE OF LOSS OF DATA:

To set automatically the right values of all the parameters please

find out the menu "RESTORE PARAM." by using the ROLL button * SELECT MENU *

4 - RESTORE

1. Press ENTER

2. SELECT the program Mod. 03 (or the memory where the list has

been stored with the SAVE program). Use the ROLL button to run

through)

SELECT PROGRAM:

Mod. 03

3. Press ENTER to confirm the restore operation

4. Answer to the question “ARE YOU SURE?” by pressing ENTER to

confirm the operation (OUT to cancel and exit) ARE YOU SURE?

YES=ENTER NO=OUT

5. Press ENTER to confirm the restoring operation

6. Wait until the message WAIT stands still written on the display WAIT!

7. When all the parameters are refreshed and updated the heading

specified on the left appears on the display: SELECT MENU

RESTORE

ADJUSTMENT

AND

INSPECTION MAGNA 65-70-75-83 Doc. 10004978

Issued 27/03/2008

Rev. 00

Pag. 10 di 19

PROGRAM VACC

8. Run through the different menus moving from the menu RESTORE

to the menu PROGRAM VACC (to relate the pedal accelerator

stroke to the chopper card)

BE CAREFUL: EACH TIME YOU REPLACE THE CHOPPER CARD

AND/OR THE PEDAL ACCELERATOR THE FOLLOWING

INSTRUCTIONS MUST BE DONE

SELECT MENU

RESTORE PARAM.

9. Stop your run when you read “PROGRAM VACC”

10.Press ENTER to go into the menu

SELECT MENU

PROGRAM VACC

11.You read first the values set up on the chopper that have to be

refreshed. VACC SETTING

4,8 4,8

12.Press ENTER again to be ready to teach to the chopper card the new

stroke

13.Now you can start your operations: 0.0 0.0

14.Select the forward drive direction and press down slowly the pedal

from the top until the end of its stroke

15.Repeat the same operation with the backward drive direction

16.You can read now on the screen the new values FORW BACK

4,9 4,9

17.Press OUT

18.Read the two different choice to go ahead: ENTER to confirm the

new values, OUT to cancel and exit

ARE YOU SURE?

YES = ENTER NO =

OUT

19.Press ENTER to confirm

20.Run through the different menus to come back to the heading as

showed on the left SELECT MENU

PROGRAM

21.Press OUT to come back to the main heading. SWITCH OFF the

key and then disconnect the console. MX V.2.1

HOURS

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