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Learning objective
At the completion of this lesson, the student will be able to:
locate and Identify the control panel components
Understand the function of main logic and inverter controller.
Explain the purpose of using CAN-bus
Understand how to discharge an inverter controller.
Understand what is a MOS-FET
System Layout
MC Block Diagram
CAN-bus ensures quick and reliable and at the same time the CAN-bus
simplifies the wiring harness in the vehicle as well as the diagnostic
troubleshooting should anything go wrong. This makes maintenance
easier and less components are required.
The logic unit is the heart of the control system for the forklift truck, but
with a CAN-BUS system, there are more than one independent
controller on the Controller Area Network to communicate with each
other to control the truck.
Logics unit
Pump inverter
Input unit
Pump AC motor
AC Traction Motors
Traction inverter
2.
Pump inverter
3.
4.
Logic unit
5.
6.
7.
8.
9.
AC Traction motors
It controls all the jobs for the truck based on the operators input
The truck speed and residual battery power are monitored and shown on
this display unit.
The logic unit sets its model information and optional default data into
internal memory. The information is secured when the power supply is
turned off. This information is set at the factory.
If the truck model information is not set correctly, the truck will not
work properly.
Main Logic
Main Logic
DRS Switch
Improved serviceability
PDA or Laptop socket via
main logic
DRS switch underneath
footstep
New drive features:
Boost function
Controlled roll back
CAN bus electrical system
Main Logic
Improved serviceability
Boost function
CAN-bus System
CAN-bus System
Block Diagram of CAN Communication between components
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 arent 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.
4.
The model information and various features are set during factory shipment.
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11
Parallel Mosfet
Generation
InVerter
Generation
Qty of Mosfet Mod.
Parallel Mosfet
Generation
InVerter
Generation
Qty of Mosfet Mod.
Traction Inverter DSP (Digital Signal Processor) Right and Left Inverters with
Pin Connectors
CN2 Inverter card side
CN7 Traction right, Harness B side
CN6 Traction left, Harness B side
14
Hydraulic Pump Inverter DSP (Digital Signal Processor) with Pin Connectors
15
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.
The procedure is:
Use ceramic resistor 0358280 (150 / 25W) with two leads and crocodile clips and connect between
the + (POS) and (NEG) terminal pole.
16
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
18
CAUTIONS
The power board is mounted
directly to the counterweight.
There are two different types of
heat conducting paste for
following models:
3 wheeler, AC : Silicone paste
(White)
4 wheeler, AC : Heat Cement
(Non-hardening graying colour)
19
What is Inverter?
The inverter is a motor drive controller that
consists of:
Digital Signal Processor (DSP) card,
Insulated Metal Substrate (IMS) module
Drive boards
Using IMS to convert DC power to AC power
which features a transformer isolated sine
wave output.
It drives the AC induction motors according
to the motor control command from the logic
unit.
It also monitors malfunctions of motors and
its own condition. When a malfunction
occurs, it stops the motors and informs to the
logic unit.
Traction Inverter
What is Inverter?
The inverter is a motor drive controller that consists of:
Digital Signal Processor (DSP) card,
Insulated Metal Substrate (IMS) module
Drive boards
Using IMS to convert DC power to AC power which features a transformer
isolated sine wave output.
It drives the AC induction motors according to the motor control command
from the logic unit.
It also monitors malfunctions of motors and its own condition. When a
malfunction occurs, it stops the motors and informs to the logic unit.
20
DSP Card
Traction Inverter,
DSP Card
DSP card
21
22
U Phase connection
MOSFET Banks
[One for each phase]
V Phase connection
V Phase connection
23
MOS-FET
MOSFET
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 FETs the DRAIN and SOURCE are allowed to be reversed.
Note: The design of a transistor allows it to function as an amplifier or a
switch. This is accomplished by using a small amount of voltage to control a
gate on a much larger supply of electricity, much like turning a valve to
control a supply of water.
27
MOS-FET
28
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.
So when we call a variable frequency drive an inverter, this is technically
incorrect
29
S3
S4
S6
S5
Battery
S2
T1
T2
T3
(-)
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
(+)
S1
S3
S4
S6
S5
DC Bus
S2
T1
T2
T3
(-)
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
(+)
S1
S3
S4
S6
S5
DC Bus
S2
T1
T2
T3
(-)
S1 on
S6 on
S5 on
0
60
S2 on
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
(+)
S1
S3
S4
S6
S5
DC Bus
S2
T1
T2
T3
(-)
S1 on
S6 on
S5 on
0
60
S3 on
S2 on
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
(+)
S1
S3
S4
S6
S5
DC Bus
S2
T1
T2
T3
(-)
S1 on
S4 on
S6 on
S5 on
0
60
S3 on
S2 on
120
180
240
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
(+)
S1
S3
S4
S6
S5
DC Bus
S2
T1
T2
T3
(-)
S1 on
S4 on
S6 on
S5 on
0
60
S3 on
S2 on
120
180
S5 on
240
300
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
(+)
S1
S3
S4
S6
S5
DC Bus
S2
T1
T2
T3
(-)
S1 on
S4 on
S6 on
S5 on
0
60
S3 on
S2 on
120
180
S6 on
S5 on
240
300
360
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
S4 on
S3 on
S6 on
S5 on
0
60
S2 on
120
180
S6 on
S5 on
240
300
360
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
Volts
Typical Volt
per Hertz
Curve for a
Standard
460Volt
Motor
460V
230V
30Hz
Time
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 ?
Well this leads to our next topic, pulse width modulation.
38
Ton
Tc
Ton
Tc
= 50%
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
= 50%
Ton
Tc
= 75%
Ton
Tc
Ton
Ton
Ton
Tc
Tc
Tc
= 90%
40
41
42
Triangle
Carrier
Frequency
Reference
Sine Wave
Reference
Sine Wave
Output
RMS Voltage
Output
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
460V
460V
60Hz
= 7.67
Volts
23V
= 15.3
1.5Hz
23V
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
L1
L2
R1
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
L1
L2
R1
460V
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
L1
L2
R1
12V DROP
460V
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
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
L1
L2
R1
12V DROP
460V
448V M
R2
S
448V
= 7.46
60Hz
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
L1
L2
R1
12V DROP
23V
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
L1
L2
R1
12V DROP
23V
11V M
R2
S
11V
= 7.34
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
11V
= 7.34
1.5Hz
A constant V/f ratio
produces a constant
motor flux
448V
= 7.46
60Hz
A constant motor flux
produces a constant
torque
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
Over saturation
condition that leads to
high current but no
more torque production
Motor overheating
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)
DC to AC Inverter
54
55
MOSFET Banks
[Two for each phase]
MOSFET Banks
[Two for each phase]
56
Negative
Capacitor
Banks
(Qty: 88)
Positive
W-Phase
V-Phase
Current
Sensor [V]
U-Phase
Current
Sensor [U]
57
Traction Inverter
Traction DC to AC
Inverter
58
When ordering this part, you will also get the 4 plastic positioning
clips.
59
MOSFET Banks
[One for each phase]
Traction Inverter
60
V-Phase
W-Phase
Positive
Capacitor
Bank
(Qty: 40)
61
The Pump and Traction Inverters have three possible weak points!
62
63
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:
Fault code will be displayed on your operator display or even a burned
inverter could occur.
When you over-tighten, the thread-end could break inside the plastic stud,
resulting in bad contact with buss bar.
In the other case the buss-bar W phase will be forced out and the small PCB
(Printed Circuit Board) studs will bent and snap the board.
In these cases you will NOT have any warranty !! Be aware, these are
high costs repairs !!
64
65
Be aware there is a chance for the flat cables to be pinched between the
plastic cover and
The base plate heatsink.
66
67
68
The fuse holder, the GSE connector and the logic card power & in-outputs
are all
Separate connectors to Harness B.
69
70
Trouble Shooting
1.
2.
3.
4.
5.
6.
7.
8.
9.
71
Any Questions?
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