Professional Documents
Culture Documents
1
Learning objective
2
System Layout
MC Block Diagram
3
Major Components Location
Logic Unit
Pump Inverter
Tractors Inverter
4
Identification of Control Panel
5
Outline of Logic unit
6
Main Logic
Main Logic
Main Logic
• Improved serviceability
• Laptop socket via main logic
• DRS switch underneath footstep
• New drive features:
• Boost function
• Controlled roll back
• CAN bus electrical system
• GSE Connector Cap P/N 97005-18700
7
CAN-bus System
CAN-bus System
8
Model Information
NOTICE
• The data of a group 3 has no default value, but it needs to set data
by the actual truck type.
• When you set up for the first time, set up a group 3 first, and then set
default data of group 1 and group 2.
• If SUO data is not set, “| |” is displayed.
• The model information and various features are set during factory
shipment
Model Information
Notice:
1. The data of a group 3 has no default value, but it needs to set data by the actual
truck type. If the value and the truck model aren’t in agreement, the truck does
not operate normally.
2. When you set up for the first time, set up a group 3 first, and then set default
data of group 1 and group 2.
3. If SUO data is not set, “| |” is displayed.
4. The model information and various features are set during factory shipment.
9
Pictorial of Logic Card
10
Pictorial of Logic Power Supply Card
11
Traction Inverter Decal
Generation
Qty of Mosfet Mod.
12
Hydraulic Inverter Decal
Generation
Qty of Mosfet Mod.
13
Pictorial of Traction Inverter
14
Pictorial of Pump Inverter
15
Inverter Discharging Procedure
WARNING
Inverter discharging procedure :
1. Turn off the key switch.
2. Disconnect the battery plug.
3. Lift up the seat.
4. Place a 150Ω/25 W resistor
between P and N terminals in the
right traction inverter to discharge
electric charges stored in the
inverter.
5. After touching resistor to the P
and N terminals for approx. 5
sec., measure the voltage
between the terminals with a
multi-meter and confirm a reading
of 5 V or less.
6. Perform the same procedure for
left traction inverter and pump
inverter in order to discharge
electric charge from all inverters.
BEFORE you start to work on any of the inverters, you MUST discharge the integrated capacitors.
DO NOT underestimate the power of these “little” components. Together they can store between 300 ~
500Amp.
Therefore you MUST discharge the capacitors per module before working on them.
Now you are free to work safely with the controller modules.
Optional you can also use a 48V or 80V work light to discharge the capacitors. The light will also be an
indicator if the capacitors are discharged.
16
Removal and Installation Inverter Procedure
Removal
1. Raise the front wheels.
2. Perform step 1 to 5 in Inverter Discharging Procedure.
3. Disconnect all five power cables from P, N, U, V and W terminals. For the
pump inverter, leave P terminal as it is, and disconnect F terminal.
4. Disconnect the connector.
5. Remove M10 bolts (four places) fixing the inverter, then remove the inverter.
Installation
1. Wipe off the dirt and thermal paste from the inverter mounting surface once,
and also remove dirt from the mounting surface and the aluminum base plate of
the inverter.
2. Apply thermal paste approx. 1 mm (0.04 in.) thick to the area where the
aluminum base plate of the inverter comes into contact with the truck body.
3. Fix the inverter with M10 bolts.
4. Connect the power cables to P, N, U, V and W terminals. For the pump inverter,
include F terminal.
17
Replacing DSP Card
18
Power Board Heat Conducting Paste
CAUTIONS
This is for ALL controller models that are fitted to the counterweight.
Do not mix up. Result could be burned-out power boards ! Or overheating
conditions.
19
What is Inverter?
Traction Inverter
What is Inverter?
20
DSP Card
Traction Inverter,
DSP Card
DSP card
• Is a micro-processor card with digital signal processor.
• Performs adaptive control.
• DSPs have the speed capabilities to concurrently monitor the
system and control it.
• A dynamic control algorithm adapts itself in real time to
variation in system behaviour
21
Speed Control of Induction Motors
22
Insulated Metal Substrate (IMS) Module
U – Phase connection
MOSFET Banks
V – Phase connection [One for each phase]
V – Phase connection
The IMS module has plural MOS-FET modules and converts the battery DC
current to AC current for supplying to the drive and pump motors
The IMS module has plural MOS-FET modules and converts the battery DC
current to AC current for supplying to the drive and pump motors
As you see, a different lay-out than the hydraulic version.
The traction controller is smaller by dimensions.
There are only 3 power boards mounted on this base plate.
The U, V and W connections are also lined up differently compared with the
hydraulic inverter.
23
MOS-FET
MOSFET
A MOSFET is a switch with no moving parts that can be turned on and off a a very
fast rate.
24
MOS-FET
25
MOS-FET
26
MOS-FET
SOURCE (S) and DRAIN (D) are connected with a flexible tube.
There is NO flow of water between the GATE (G) and the other two
connections.
This model shows that the SOURCE (S) Collector and DRAIN (D) are fully
identical.
When the voltage pressure on the GATE (G) connection increases, the
flexible hose between the DRAIN (D) and SOURCE (S) is compressed.
Result will be a reduction of water flow from DRAIN (D) to SOURCE (S)
.
With many FET’s the DRAIN and SOURCE are allowed to be reversed.
27
MOS-FET
28
“PWM Inverter Principle No 1”
Inverter
DC AC
Lets take a closer look at the PWM inverter, and discuss some of basic
principles.
Inverter principle number 1 – A device that changes the battery DC current
into alternating current is generally called “Inverter”.
The inverter is comprised of two sections;
1.) Capacitor bank
2.) The Inverter section that changes the DC current to AC current.
29
“PWM Inverter Principle No 2”
(+)
S1 S3 S5
T1
Battery T2
T3
S4 S6 S2
(-)
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
30
“PWM Inverter Principle No 2”
(-)
S1 – on
S6 – on
S5 – on
0 60
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
31
“PWM Inverter Principle No 2”
(-)
S1 – on
S6 – on
S5 – on S2 – on
0 60 120
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
32
“PWM Inverter Principle No 2”
(-)
S1 – on
S6 – on S3 – on
S5 – on S2 – on
0 60 120 180
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
33
“PWM Inverter Principle No 2”
(-)
S1 – on S4 – on
S6 – on S3 – on
S5 – on S2 – on
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
34
“PWM Inverter Principle No 2”
(-)
S1 – on S4 – on
S6 – on S3 – on
S5 – on S2 – on S5 – on
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
35
“PWM Inverter Principle No 2”
(-)
S1 – on S4 – on
S6 – on S3 – on S6 – on
S5 – on S2 – on S5 – on
The output transistors of the inverter work like switches. They turn on and
off in a specific pattern to produce an output voltage waveform. What we
will do is move through the next few screen and watch the switch closures as
we progress through time.
Click on the mouse button and watch the switches close ( the closed
switches will turn red ).
36
“PWM Inverter Principle No 2”
Switch pattern
S1 – on S4 – on
S6 – on S3 – on S6 – on
S5 – on S2 – on S5 – on
T1-T2
T2-T3
T3-T1
0 360
The switch pattern that we just demonstrated will produce an output voltage
that looks like this, with each waveform being 120 degrees out of phase just
like a commercial power supply.
37
“PWM Inverter Principle No 3”
Volts
Time
30Hz 60Hz
The output of a PWM type inverter is both variable frequency and variable
voltage. This can be simply explained by what is called a V/f pattern. The
V/f pattern sets up a ratio of output voltage to output frequency. You will
see a little later that it is very important to keep this ratio constant for
optimum motor performance. What this shows me is at 60Hz the output
voltage will be 460V and at 1.5Hz the output voltage will be 23V.
Now this question probably comes to mind. A little while ago we said that
the DC bus of the PWM inverter was at a fixed level. So how does the
inverter vary the output voltage when the DC bus is fixed ?
38
“PWM Inverter Principle No 4”
To change the output voltage of the inverter when the pulse amplitude is
fixed, the width of the pulse must be adjusted ( or modulated). The
higher the ratio of turn on time as compared to the switching time of the
transistor, the higher the resultant voltage will be. This method is called
pulse width modulation.
39
“PWM Inverter Principle No 4”
40
“PWM Inverter Principle No 4”
41
“PWM Inverter Principle No 4”
42
“PWM Inverter Principle No 5”
Reference Reference
Sine Wave Sine Wave
Output Output
RMS Voltage RMS Voltage
The method used to produce this pulsed waveform can be simply described.
The first step of producing a PWM output waveform begins with the output
frequency reference. The output frequency reference is the commanded
frequency given to the inverter.
43
“PWM Inverter Principle No 5”
460V
460V
= 7.67 “This ratio does
60Hz not look
Volts constant to me”
23V
= 15.3
23V 1.5Hz
0
1.5Hz 60Hz
Frequency
So far we have talked about the V/f pattern of the inverter and that it is
important to keep a constant volts per hertz ratio. If we do some
investigation, we can see that the V/f ratio at 60Hz is about 7.67 and the
ratio at 1.5Hz is about 15.3. This does not look constant to me! Lets look at
this a little closer.
Click
44
“PWM Inverter Principle No 6”
L1 L2
R1
M R2
S
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
45
“PWM Inverter Principle No 6”
L1 L2
R1
460V M R2
S
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
46
“PWM Inverter Principle No 6”
L1 L2
R1
12V DROP
460V M R2
S
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
47
“PWM Inverter Principle No 6”
L1 L2
R1
12V DROP
460V 448V M R2
S
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
48
“PWM Inverter Principle No 6”
L1 L2
R1
12V DROP
448V
= 7.46
60Hz
460V 448V M R2
S
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
49
“PWM Inverter Principle No 6”
L1 L2
R1
12V DROP
23V M R2
S
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
50
“PWM Inverter Principle No 6”
L1 L2
R1
12V DROP
11V
23V 11V M R2 = 7.34
S 1.5Hz
This is called an equivalent motor circuit. If you took a 3 phase motor you
could represent it with 3 separate equivalent motor circuits. The left portion
of the circuit is representative of the stator portion of the motor (consisting
of R1- stator resistance, L1-stator inductance , M-mutual inductance). And
the right portion of the circuit is representative of the rotor portion of the
motor ( consisting of L2-rotor inductance, R2/slip- rotor resistance divided
by the motor slip).
51
“PWM Inverter Principle No 6”
11V 448V
= 7.34 = 7.46
1.5Hz 60Hz
So the voltage and frequency ratios at 1.5Hz and 60Hz are basically the
same if you compare the voltage used for producing torque. This constant
voltage will produce a constant motor flux in the motor throughout the speed
range and
Click
52
“PWM Inverter Principle No 6”
If the V/f pattern is set improperly, the performance of the motor will suffer.
If the V/f ratio is set too low;
The motor flux will be reduced which will lead to a reduction of motor
torque. This can lead to problems starting the motor or running at low
speeds. As well as sluggish response to load changes.
Low voltage to the motor will also cause higher than normal current draw.
This condition may lead to motor overheating or inverter overload faults.
53
Hydraulic Pump Inverter
Hydraulic (Pump)
DC to AC Inverter
54
Hydraulic Pump Inverter – DSP Card
55
Hydraulic Pump Inverter – IMS Module
MOSFET Banks
[Two for each phase]
MOSFET Banks w
[Two for each phase]
MOSFET Banks
v [Two for each phase]
56
Hydraulic Pump Inverter – Capacitor Bank
Negative Positive
W-Phase
Capacitor
Banks
(Qty: 88)
V-Phase
Current
Sensor [V]
U-Phase
Current
Sensor [U]
57
Traction Inverter
Traction DC to AC
Inverter
58
Traction Inverter – DSP card
When ordering this part, you will also get the 4 plastic positioning
clips.
59
Traction Inverter – IMS Module
MOSFET Banks
[One for each phase]
U v w
Traction Inverter
60
Traction Inverter – Capacitor Bank
Current
Sensor [U]
U-Phase
V-Phase
Current
Sensor [W] W-Phase
Negative Positive
Capacitor
Bank
(Qty: 40)
61
Caution when working on the inverters
Go to next slide.
The Pump and Traction Inverters have three possible weak points!
62
Inverter’s weak points
63
Phases Terminal Torque!!
M8 Nut
11.77 ± 1.96 N.m
1.20 ± 0.20 kgf.m
8.68 ± 1.45 lb.ft
In case you over tighten the U, V and – or W terminal torque, the following
issue will happen:
64
Over Current to MOS-FET
65
Ribbon Cables Pinched
Be aware there is a chance for the flat cables to be pinched between the
plastic cover and
The base plate – heatsink.
66
Terminal on Contactor Coils
Wire 249 & 250 are joined and connected together to CN1-63 of the master
logics (con VE)
Wire 247 is connected to CN1-59
Wire 248 is connected to CN1-60
67
Correct Connection of wires
68
Connection for Main Harness & GSE plug
The fuse holder, the GSE connector and the logic card power & in-outputs
are all
Separate connectors to Harness B.
69
Know your forklift Truck
1.Lever regen.
When:(1)Direction lever is in F or R(opposite direction against the truck movement)
(2)Acceleration pedal is ON
(3)Regardless of BRAKE pedal
Regeneration: According to accel. pedal and SUO #22
2.Auto regen
You can select ACCEL. regen or BRAKE regen by SUO #21
2.1 ACCEl. regen
When:(1)Direction lever is in F or R
(2)Acceleration pedal is OFF
(3)Regardless of BRAKE pedal
Regeneration: Constant. According to SUO #23
2.2 BRAKE regen
When:(1)Direction lever is in F or R
(2)Acceleration pedal is OFF
(3)Press the BRAKE pedal
Regeneration: Constant. According to SUO #23
Basic Check
71
Any Questions?
72