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Manual Title

272486700

Controller Electronic COMBI

272487200

Multifunction Digital Instrument (MDI)

272490600

Reducer

272491100

EPS-DC / Wire Guidance

272495600

Service Repair Manual

©2011 Yale Axcess Online

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P.N. 272486700

Technical Information for YALE Service Centres

This manual is addressed exclusively to the specialised technicians of the Yale service network CONTROLLER ELECTRONIC

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COMBI Section: INDEX

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INDEX 1.0 MECHANICAL DIMENSIONS 2.0 ELECTRONIC CONTROLLER 3.0 INTRODUCTION 3.1 MOTOR CURRENT ABSORPTION TABLE 3.2 FUNCTIONAL CHARACTERISTICS 3.3 SCHEMATIC DIAGRAM 3.4 PROTECTION DEVICES 3.5 CONTROLLER DIAGNOSTICS 3.6 OPERATING PRINCIPLE 3.7 DEFINITION OF TRAVEL DIRECTION 3.8-3.8.1 INTRODUCTION TO THE PROGRAMMING CONSOLE 3.8.2 USE OF THE PROGRAMMING CONSOLE 3.8.3 CONNECTION TO THE CHOPPER 3.8.4 DESCRIPTION OF THE CONSOLE MENU 3.9 DESCRIPTION OF CONNECTOR INPUTS 3.9.1 CONNECTOR WIRING DIAGRAM 3.9.2 PROGRAMMING OF CONNECTOR “E” INPUTS 3.9.3 DESCRIPTION OF CONNECTOR “B” FUNCTIONS 3.10 PROGRAMMING TABLE 3.11 PARAMETER CHANGE, DESCRIPTION OF THE PARAMETERS 3.12 CONFIG. MENU ADJUSTMENTS 3.13 CONFIG. MENU SET OPTIONS 3.14 PROGRAMMING LEVEL EQUIVALENCE TABLE 3.15 TESTER MENU TABLE 3.16 DESCRIPTION OF TESTER FUNCTIONS 3.17 DESCRIPTION OF ALARMS 4.0 DESCRIPTION OF SERIAL TILLER 4.1 SCHEMATIC DIAGRAM 4.2 DESCRIPTION OF HALL EFFECT SENSORS

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1.0 MECHANICAL DIMENSIONS OF THE COMBI CONTROLLER

2.0 COMBI ELECTRONIC CONTROLLER

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2.1 TABLE OF COMPONENTS

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3.0 ELECTRONIC CONTROLLER FOR DRIVE MOTOR AND PUMP MOTOR INTRODUCTION The COMBI controller, used for control of the drive motor, is the latest evolution of high-frequency MOS technology and operates at a frequency of 16 KHz. It is an electronic system for the control of separately excited motors.

The armature and field are separately controlled by the system and so the current flowing in the field is not the same as that flowing through the armature.

No starting contactors: the armature and the field are controlled directly by MOSFET. The high commutation frequency of the MOSFETs, the separately excited motor connected to the COMBI controller make it possible to maintain the same speed even under load: A) Demand for higher torque B) Higher current draw from the motor Control also the lifting pump motor as standard.

Control of a series of solenoid valves (SOLENOID CONTROL VALVE) for directional control of the hydraulic oil flow and lowering control by way of a proportional valve.

This system includes only one power contactor.

TECHNICAL SPECIFICATIONS FOR THE DRIVE MOTOR AND THE PUMP MOTOR -

Operating voltage 24 Volt Maximum field current (drive motor) 50 A Maximum armature current (drive motor) 200-400 A Armature commutation frequency 16 KHz Field commutation frequency 1 KHz Minimum ambient temperature -30 °C Maximum ambient temperature +80 °C Maximum current (pump motor) 250-300 A

3.1 MOTOR CURRENT ABSORPTION TABLE

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3.2 FUNCTIONAL CHARACTERISTICS OF THE COMBI CONTROLLER - Speed control - Excellent sensitivity at low speeds - Speed reduction: maximum speed in both directions can be adjusted using the programming console.

- Regenerative braking, based on deceleration ramps, and braking on release, on reversal and on partial release of the throttle.

- Speed control in descent: the motor speed follows the butterfly throttle control and regenerative braking is automatically activated if the motor exceeds the desired speed, thus making for optimum control on inclines.

- Hill starts with no roll-back even without using an electric brake.

- Antiroll-down function with keyswitch ON; the controller monitors the speed of the drive motor, and if the drive motor is found to be running in standby conditions, the controller activates the brake and controls the descent at very low speed.

- High motor and battery efficiency thanks to the high commutation frequency - Control of hydraulic functions with actuator speeds individually programmable and possibility to use proportional controls.

- Lowering control by proportional valve (can be replaced by ON/OFF valve).

Use of a proportional valve allows starting and stopping with controlled acceleration and deceleration ramps.

- Parameter editing via digital console (see specific description) - Internal hour counter (can be displayed on console) - Log of last 5 alarms with relative hour counter and temperature displayed on the console - Tester function on digital console to display the main parameters and characteristics of the machine - If the main contactor is out of service for more than one minute, it automatically returns to rest position; on selecting drive or operating the tiller, the contactor resets; on power up, it remains open until until either the drive control or the tiller switch is open.

3.3 SCHEMATIC DIAGRAM

3.4 PROTECTION DEVICES - Connection faults: The inputs are protected against connection faults.

- Thermal protection device: If the temperature of the COMBI exceeds 80°C, the maximum current is automatically reduced in proportion to the increase in temperature The temperature can never exceed 85°C, and is displayed on the MDI or the programming console - Driver protection: The drivers are protected against all possible short circuits. http://www.yaleaxcessonline.com/lib/service/itwservice/272486700/Y_naen/c1a.htm (4 of 17)19.09.2011 17:31:57

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- Battery discharged: When the battery is low, the maximum current is decreased in proportion to the degree to which the battery is discharged.

- Protection against accidental starts: Starting the machine requires a precise sequence of operations that, if not performed correctly, prevents starting.

The drive control must be open after the keyswitch and tiller microswitch (or dead-man microswitch if present).

- Protection against uncontrolled movements: The main contactor will not close if: - the power circuit is not functioning; - the logic circuit is not functioning perfectly.

- Main contactor: this must be installed to protect the controller against polarity reversal and for reasons of safety.

- External agents: The controller is protected against dust and splashes of liquids to an ingress protection rating of IP64.

3.5 COMBI CONTROLLER DIAGNOSTICS COMPONENT SELF-DIAGNOSIS The microprocessor runs diagnostic tests on the main components of the controller.

Diagnostic tests are structured into 4 main types.

1) Diagnostics on power-up : watch dog test, current sensor test, VMN test, contactor driver test, test for presence of drive request, accelerator high test.

2) Diagnostics in standby comprising: VMN test, contactor driver test, current sensor test.

3) Diagnostics during travel comprising: VMN test, current test, contactor control test, VMN in total conduction test.

4) Permanent diagnostics: temperature control, battery charge status control.

On the programming console it is possible to display the message relative to the alarm in progress.

3.6 OPERATING PRINCIPLE OF THE COMBI CONTROLLER Basic motor power supply circuit.

- As can be seen in the diagram on the right, the field and the armature are controlled by two separate circuits. The field is powered by a mosfet circuit designated “H-circuit” in which the mosfets are activated in pairs according to the selected direction of travel.

- circuit when drive is not selected

- The diagram on the right shows how the mosfet circuit activated for forward travels.

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- The forward travel power circuit is enabled via control of the mosfets: TARM. commutates at a frequency of 16 Khz (ARMATURE circuit).

T3-T4 commutates at a frequency of 1 KHz (field circuit).

T4 in total conduction (field circuit)

- The diagram on the right shows how the mosfet circuit is activated for reverse travel.

The reversing power circuit is enabled via control of the mosfets: TARM. commutates at a frequency of 16 Khz (ARMATURE circuit).

T2-T1 commutates at a frequency of 1 KHz (field circuit).

T4 in total conduction (field circuit)

3.7 DEFINITION OF MACHINE TRAVEL DIRECTION The microswitches for the direction of travel and quick inversion are wired in compliance with the definition of the direction of travel given in the following drawing:

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GENERAL WARNINGS AND PRECAUTIONS - Do not interface the controller with other electronic controls, especially those that operate at low frequency.

- Do not connect the controller to a battery with a different nominal voltage to that indicated on the module nameplate.

If the battery voltage is higher it may damage the MOS. If the battery voltage is lower, the module will not function.

- In the event of controller replacement, test the drive functions with the DRIVE WHEEL RAISED FROM THE GROUND, as connections errors can give rise to potentially dangerous situations.

3.8 PROGRAMMING CONSOLE 3.8.1 INTRODUCTION The programming console is designed to facilitate the calibration and fault diagnosis of the controller.

Featuring microprocessor technology, the programming console is connected to the controller by a cable that carries serial transmission data and the power supply.

Messages are displayed in alphanumerical characters on an LCD with 2 rows of 16 characters.

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The console offers the following advantages: - Quick and simple programming of operating parameters, obviating the need to access awkward parts of the machine to make adjustments on the trimmers; in addition, parameters can be edited in real time while the machine is running, thus allowing immediate verification.

- Rapid fault diagnosis.

The user can monitor the controller input signals in real time (potentiometer signal, currents, voltages, etc).

Furthermore, in the event of a controller malfunction, the console can display the type of alarm in progress. For more indepth diagnostics, the user can display the last 5 alarms to be activated.

- Standardized parameter settings: Once the parameters have been optimized on one machine, they can be saved in the console memory, from where they can be quickly and easily transferred to other machines.

- Special functions, such as acquisition of the potentiometer range.

3.8.2 USE OF THE PROGRAMMING CONSOLE

Take care to observe the correct polarity when plugging the console connector into the controller.

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3.8.3 CONNECTION TO THE CONTROLLER THECONNECTION MUST BE MADE WHEN THE MACHINE IS SWITCHED OFF as the controller and the console only perform the connection test on power-up.

1) Unplug the Multifunction Display panel connector from the controller connector B 2) Plug the console connector into connector B on the controller.

Take care to observe the correct polarity when plugging the console connector into the controller.

3.8.4 DESCRIPTION OF THE CONSOLE MENU

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3.9 DESCRIPTION OF CONNECTOR INPUTS AND OUTPUTS

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3.9.2 PROGRAMMING THE CONNECTOR “E” INPUTS

The inputs receive the battery + through a switch or a sensor with PNP output. At this point 4 negatives are supplied to power the sensors. The MAX current load for each switch is less than 50mA http://www.yaleaxcessonline.com/lib/service/itwservice/272486700/Y_naen/c1a.htm (12 of 17)19.09.2011 17:31:57

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3.9.3 DESCRIPTION OF CONNECTOR “B” FUNCTIONS

The positive to the MC is supplied by the keyswitch with anti-inversion protection diode.

The positive for the electromagnetic brake and for all the solenoid valves is taken from downstream of the main contactor, and consequently the currents of these loads do not pass through the keyswitch but the auxiliary circuit fuse.

The DOWN solenoid valve is programmed as either as a proportional valve or an On/Off valve: 1) if the solenoid valve control device is a potentiometer, it will be controlled as a proportional valve.

2) If the solenoid valve is open by an ON/OFF switch, it will controlled with an opening and closing ramp.

Right-left fork shift solenoid valves and fork up-down solenoid valves are present on some machines.

3.10 PROGRAMMING TABLE OF THE COMBI CONTROLLER

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