Fimap MAGNA 85 BS Guida di riferimento

ADJUSTMENT

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 1 di 18

ADJUSTMENT AND INSPECTION

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

CHOPPER CARD TERMINAL

CONSOLE TERMINAL

ADJUSTMENT

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 2 di 18

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 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 3 di 18

Flow chart of the console

HEADING

PROGRAM

TESTER

enter

LIST OF PARAMETERS

ROLL to select

DO YOU WANT TO

SAVE DATA ?

out PARAM SET to change

enter

out

ENTER = change

OUT

no change

enter

TEST LIST OF VALUES

to test

This menù has

not to be

modified

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

Enter: Are you sure ?

ENTER = save

OUT= no save

OUT= no restore

ALARMS

Out

List of the last 5

alarms occurred

enter / en

ter

Out: Are you sure?

ENTER = change

OUT= no change

This menù has

not to be

modified

ADJUSTMENT

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 4 di 18

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

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 5 di 18

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 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 6 di 18

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

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

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Pag. 7 di 18

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 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 8 di 18

ADJUSTMENT FOR MOTORWHEEL

A2D1

108

CIMA

METALROTA

ATTENTION : In case of wrong direction, change the cable 7 and 8.

CHOPPER HO

MAGNA 85 - 100 CIMA WHEEL METALROTA

WHEEL

ACCELERATION DELAY 4 4

BRAKING 1 2

RELEASE BRAKING 2 4

CUTBACK SPEED 1 3 3

CUTBACK SPEED 2 6 6

COMPENSATION 9 9

CREEP SPEED 1 3

TRACTION IMAX 3 3

MAX SPEED FORWARD 9 9

MAX SPEED BACKWARD 7 7

SPEED LIMIT BRAKING 3 3

ADJUSTMENT

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 9 di 18

Adjustment using the console

Inserting the console

1. Check that all switches are off.

2. Lift the front wheel on the safety stand.

3. Insert the console into its connector with the key off.

4. Turn on using the key.

5. Either “HO AUTOSTOP V1.0 36V 200A 00000” or “*Alarm* abcdef …” will appear when it

starts up

6. Press seat.

7. Press ENTER to access the main menu.

Programming the chopper Console Display

1. Press ENTER to access the main menu.

2. The first item appears: “PROGRAM” = CHANGE PARAMETERS.

3. Press ENTER and check, scrolling with ROLL, if programming values

comply with the previous table.

* SELECT MENU *

1- PROGRAM

4. At the end press OUT and confirm with ENTER (in reply to “DO YOU

WANT TO SAVE DATA?”) if a parameter has been changed (using the

PARAM SET push-buttons on the console).

WARNING: SAFETY PARAMETERS CANNOT BE VARIED, SUCH AS

ACCELERATION, BRAKING, ETC.

ONLY SPEED CUTBACKS CAN BE VARIED (CUTBACK SPEEDS 1 AND

2).

5. If the chopper memory is lost use ROLL to select “RESTORE” =

REPROGRAM CHOPPER PARAMETERS: * SELECT MENU *

4- RESTORE

6. Press ENTER.

7. The PROGRAM 01 code appears (use ROLL to select the desired

PROGRAM): * SELECT PROGRAM *

PROGRAM 01

8. Press ENTER to confirm loading the program.

9. A request for confirmation appears, press ENTER = YES, OUT= NO : ARE YOU

SURE?

10. Press ENTER to confirm the loading procedure.

11. The stand-by message appears while loading the parameters: WAIT!

12. At the end the following message returns: * SELECT MENU *

4- RESTORE

ADJUSTMENT

AND

INSPECTION

MAGNA 85 – 100 BS

Doc.

Issued 12/2006

Rev. 00

Pag. 10 di 18

Acquiring accelerator pedal travel Console Display

1. Use ROLL to select: * SELECT MENU *

6- PROGRAM VACC

2. Press ENTER to display: FORW BACK

4.99 4.99

3. Press ENTER to zero the values: FORW BACK

0.0 0.0

3. Engage the 3rd forward gear and slowly press the pedal all the way

down without stopping and values of the following type will

appear:

FORW BACK

4.84 0.0

4. Repeat the procedure with reverse gear: FORW BACK

4.84 4.84

5. Press ENTER to display: ARE YOU

SURE?

6. Press ENTER to confirm and go back to the initial heading: * SELECT MENU *

6- PROGRAM VACC

Tester

1. WARNING: make sure the front wheel is lifted on the safety

stand.

2. Use ROLL to select: * SELECT MENU *

2- TESTER

3. Press ENTER and various parameters of the following types

appear: VMN

VMN > 30%

4. Use ROLL to select: BATTERY

VOLT=36 36V

5. Use ROLL to select: MOTOR VOLTAGE

VOLT = 00.0

6. Engage forward gear and 3rd gear and the following will appear: MOTOR VOLTAGE

VOLT = 26

7. Select 2nd gear and rotate the wheel at maximum speed and the

following will appear:

MOTOR VOLTAGE

VOLT = 21 - 22

(or similar values)

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