Fimap MMg base Instructions d'installation

ADJUSTMENT

AND

INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 1 di 15

READ THE USE AND MAINTENANCE MANUAL

CONSOLE CONFIGURATIONS AND SETTINGS

Console Services

The console allows you to:

-Program the chopper card to ensure the correct behaviour of the machine;

-Test the electric components and circuit regarding the traction system.

-Read the alarms to identify the error code easily.

Console use

The correct sequence to connect the console is:

1. TURN OFF the machine by turning the main key.

2. Connect the console to the chopper card via the connector on the board.

3. Turn on the machine and operate with the console.

4. When finish TURN OFF the machine.

5. Disconnect the console from the machine.

A BAD SEQUENCE IN CONNECTING AND UNCONNECTING THE CONSOLE CAN EASILY

DAMAGE THE CARD OR THE CONSOLE.

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 2 di 15

ALARM TABLE

Message Alarm What to do

ALARM A1

FW Switch ON Forward micro-switch on

in turning on.

Put the potentiometer in idle position and

verify that the forward micro-switch is

open.

ALARM A2

BW Switch ON Backward micro-switch

on in turning on. Let the pedal stay in idle position and

open the backward micro-switch.

ALARM A3

Pot. FAULT Potentiometer error Check the potentiometer harness.

ALARM A4

Ref OUT Neutral Potentiometer not

correclty positioned

Put the potentiometer in the idle position

or if it already is in the right position,

make the potentiometer programmation.

ALARM A5

Over temperature Thermal protection Wait for 5 minutes and then verify the

traction motor absorption rate.

ALARM A6

POWER STAGE Damaged power stage Replace the chopper card.

ALARM A7

OVERCURRENT Overcurrent Check the motor cables: If connections

are regular and repeat the alarm, replace

the chopper card.

ALARM A8 POWER

FUSE/RELAY Power fuse or internal

contactor damaged

Check the fuse on the + battery and

wiring, replace the chopper card if it

persists (General relay damaged).

ALARM A9

UNDERVOLTAGE Undervoltage Check the batteries for poor voltage.

ALARM A10

OVERVOLTAGE Overvoltage Battery voltage greater than 45V: check

battery status

ALARM A11

Overload Current Current protection Check the motor current and possibly trim

the electronic current control

ALARM A12

DISABLE ON Disabling active Check the status of the disabled.

ALARM A13

KEY-OFF Turn off sequence active Check the wiring on the ignition power

key.

ALARM A14

EEPROM FAIL E²prom data reading

failed Check the settings: if the alarm is

repeated, replace the chopper card.

ADJUSTMENT

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 3 di 15

CHOPPER CARD CONFIGURATION

Console Code: 431320

To enter the parameter list:

1. Press the “MODE” button.

2. The first parameter description will appear, pressing up or down it is possible to scroll the

parameter list.

3. Once on the parameter you want to change, press the “MODE” button to enter into the

parameter to modify the configuration (in modification condition the parameter

description will blink).

4. Change the value using the “UP” and “DOWN” buttons. Once configured correctly confirm

the changes by pressing the “MODE” button, this will confirm the changes.

ADJUSTMENT

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 4 di 15

PARAMETERS:

PARAMETER DEFAULT

MMG

RESET TO DEFAULT DISABLE DISABLE

ACCELERATION RAMP

3 3

REVERSE RAMP 1,5 1,5

NEUTRAL RAMP 1 1

FORWARD SPEED 100 100

BACKWARD SPEED 60 60

MINIMUM SPEED 0 0

BATTERY VOLTAGE 24 24

SPEED REFERENCE single-ended single-ended

REF. DEADBAND 0,2 50mV

BRAKE DELAY 2 0,5

MULTIMODE SPEED 50 50

MULTIMODE CURRENT

25 45

BW SAFETY TIME 0 0

BW SAFETY SPEED 0 0

LOW BATTERY 19 19

TIMEOUT RUN AWAIT

0 60

RUN-AWAY 0 14

CURRENT LIMIT 45 90

RATED CURRENT 15 25

OVERLOAD TIME 60 60

5-J1 HW CONFIG N.C. switch N.O. switch

6-J1 HW CONFIG N.O. switch N.C. switch

11-J1 HW CONFIG N.O. switch N.O. switch

ENABLE ALARM 1 ENABLE ENABLE

ENABLE ALARM 2 ENABLE ENABLE

ENABLE ALARM 3 ENABLE ENABLE

ENABLE ALARM 4 ENABLE ENABLE

ENABLE ALARM 12 ENABLE DISABLE

PASSWORD 0 0

ADJUSTMENT

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 5 di 15

POTENTIOMETER SETTINGS

(Resister Settings)

1) Ensure the machine is TURNED OFF.

2) Connect the console to the machine.

3) Turn on the machine.

4) Enter into the parameter list using the “MODE” button.

5) Scroll down the list until you reach the parameter “Speed reference appears”

6) Press the “MODE” to enter into parameter to change the settings as below.

SPEED REFERENCE

single-ended Select the “single-ended” option and confirm with “MODE”

CALIBRATION

Stop pos = 0.6 V Put the pedal in the idle condition and confirm its value using

the “MODE” button.

CALIBRATION

Max pos = 2.7 V Press completely the potentiometer and confirm the value

using the “MODE” button.

7) Turn off the Machine.

8) Disconnect the console.

9) Turn on the machine and perform a functional test to verify the adjustment.

ADJUSTMENT

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 6 di 15

Electric installation tests

1. Check the electric installation functionality: switches,

contactors, motors, solenoid valve, power fuses and

thermal switches.

2. Check the functionality and the potentiometer conditions

and the conditions of the direction micro-switches.

3. Check that when the micro-switch is pressed there is about

0,5 mm of micro-switch lever movement clearance.

4. Check the conditions and the connections of the power

cables and battery charger (option).

ADJUSTMENT

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 7 di 15

Actuators pcb control

English

Version TBA

ADJUSTMENT

AND

INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 8 di 15

Battery check card adjustment

1. Check that when turning on the machine the battery check

card has the following starting sequence:

-Turning on of the LED which correspond to the set-up (red

LED = “0”).

-Turning on of all the LEDs (check of the lamps)

-Turning on of the LEDs depending on the charge of the

battery

2. Check the hour meter is functioning correctly.

To check the settings you simply need to turn on the machine

and check which is the first LED that turns on. Counting the

LEDs from the left side any LED correspond to a position and

the LED which turn on correspond to the current set-up.

Check that if the machine is using

wet cell batteries the

adjustment is on position 1.

Check that if the machine is using

GEL batteries the

adjustment is on position 4.

WARNING: A wrong set-up of the battery control card will

compromise the battery efficiency and damage them

permantely.

Battery charger adjustment

1. Verify that the battery charger set up is correct for the

battery type used on the machine.

ADJUSTMENT

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INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 9 di 15

2. To adjust the battery charger act as follow:

-Lift up the sticker on the front part of the battery charger.

-Set up the dip switches under the sticker following the

instructions of the table below.

-Put the sticker in its original position.

Battery charger with serial number from 470878.

Under the plastic cover you can see the dip switches as the

picture shows.

The dip switches has to be setted up as follow:

DP1 – DP2: Charge curve selection

DP1

DP2

GEL TROJAN ON ON

DP1

DP2

WET CELL ON OFF

DP1

DP2

GENERIC GEL o AGM OFF ON

DP1

DP2

GEL EXIDE SONNENSCHEIN

OFF OFF

Other switches UNCHANGEABLES

DP3 DP4 DP5 DP6 DP7 DP8

ON ON ON OFF OFF ON

Read carefully the battery charger use and maintenance manual

Charger warning codes:

ERROR

MESSAGE CAUSE WHAT TO DO

E01 Over voltage on the

battery Verify the battery installed on the machine, the

installation of the power connections and the quality of

the power cables.

E02 Over temp of an

external probe. Restart the battery charger if the problem is still there,

replace the battery charger.

E03 Charging phase issue Verify the battery conditions and, if necessary, replace it.

SCtCharging cycle taking

too long Verify the battery conditions and, if necessary, replace it.

SCrInternal short circuit Replace the battery charger

ADJUSTMENT

AND

INSPECTIONS MMG Doc. 10023983

Emesso Aprile 2010

Ver. AA

Pag. 10 di 15

Clean water installation testing

3. Check the cleanliness and functionality of the solution

filter under the solution tank plug.

4. Check the cleanness and sealing of the solution filter.

5. Fill up the solution tank.

6. Check the hoses sealing, solenoid valve and water

valve.

7. Check that when the water valve is open, the solution

arrive continuously onto the floor.

Traction and brakes adjustment

1. Move the brake lever to put it in parking position.

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