Professional Documents
Culture Documents
TRANSISTOR MOTOR
CONTROLLERS
(SR AND SP)
DESCRIPTION, CHECKS, ADJUSTMENTS,
TROUBLESHOOTING, REPAIRS, AND
THEORY OF OPERATION
ERC70-120HG [A839]
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Transistor Motor Controllers (SR and SP) Table of Contents
TABLE OF CONTENTS
Description .......................................................................................................................................................... 1
Model Number Data for Transistor Motor Controllers (SR and SP)................................................................. 2
Motor Controller Checks and Adjustments .......................................................................................................... 5
Checks and Adjustments Using a Handset ......................................................................................................... 5
General ........................................................................................................................................................... 5
Connect Handset ............................................................................................................................................ 6
Start Sequence ............................................................................................................................................... 6
Check or Delete Stored Status Codes ............................................................................................................ 7
Returning Lift Truck to Normal Operation........................................................................................................ 8
Checks and Adjustments on Workbench ........................................................................................................ 8
How to Check and Adjust Registers................................................................................................................ 9
Function Parameters Adjustments....................................................................................................................... 10
General ........................................................................................................................................................... 10
Function Numbers........................................................................................................................................... 11
When Handset is Connected to Motor Controller in Lift Truck ........................................................................ 11
Function Numbers 1 through 15.............................................................................................................. 11
Function Numbers 16 through 30............................................................................................................ 11
Function Numbers 48 through 63............................................................................................................ 12
Function Number Descriptions ............................................................................................................................ 12
Traction Motor Controller (Label Letter - SR)....................................................................................................... 13
Functions with Premium Display Panel Only................................................................................................... 17
Pump Motor Controller (Label Letter - SP) .......................................................................................................... 20
Functions With Premium Display Panel Only .................................................................................................. 22
Troubleshooting ................................................................................................................................................... 28
General ........................................................................................................................................................... 28
Status Codes................................................................................................................................................... 28
Status Code Charts ............................................................................................................................................. 31
Transistor Motor Controllers Repairs ................................................................................................................... 65
General ........................................................................................................................................................... 65
General Maintenance Instructions .................................................................................................................. 67
Special Precautions .................................................................................................................................... 67
Fuses .............................................................................................................................................................. 67
Contactors....................................................................................................................................................... 68
Repair ......................................................................................................................................................... 68
Contactor Driver Module ................................................................................................................................. 70
Contactor Driver, Replace........................................................................................................................... 70
Motor Controller Plug ...................................................................................................................................... 70
Brush Wear Indicators..................................................................................................................................... 72
Thermal Sensors............................................................................................................................................. 73
Motor Controller, Replace ............................................................................................................................... 73
Parameter Tables................................................................................................................................................. 76
General ........................................................................................................................................................... 76
Function Numbers ...................................................................................................................................... 76
Motor Controller Checks and Adjustments...................................................................................................... 76
Parameter Tables ............................................................................................................................................ 76
Theory of Operation ............................................................................................................................................ 83
General ........................................................................................................................................................... 83
SEM System Description ................................................................................................................................ 83
SEM System Operation (SR Motor Controller) ............................................................................................... 84
Reverse Circuit ........................................................................................................................................... 84
Performance and Efficiency ........................................................................................................................ 85
ERC70-120HG [A839]
ii
2200 YRM 808 Description
Description
This section describes the operation and the functions This YRM section has the following components:
of the Transistor Motor Controllers (SR and SP). The SR a. A description of the Transistor Motor Controller.
letters are used to identify the transistor motor controller b. A series of Status Codes that describes an indica-
that uses the SEM (Separately Excited Motor) technol- tion of a malfunction or operation that is not correct
ogy. This motor controller is used to control the opera- and its possible causes. These status codes can
tion of the shunt traction motor. The SP motor controller be shown on the LCD screen of the display panel.
is a transistor motor controller that controls the series c. Checks and replacement of the motor controller are
lift pump motor and does not use the SEM technology. described in Repairs.
These motor controllers are made by General Electric d. Parameter Tables
Company. e. A basic Theory of Operation on how a transistor
• Troubleshooting and Adjustments With a Com- motor controller operates using the SEM technol-
puter for EV-100ZX, EV-T100, and SR/SP Transis- ogy.
tor Motor Controllers (DOS Version) 2200 YRM
597 An electronic diagnostic and adjustment device can
• Troubleshooting and Adjustments With a Com- also be used to check and adjust the motor controllers.
puter for EV-100ZX, EV-T100, and SR/SP Tran- This electronic diagnostic and adjustment device is
sistor Motor Controllers (Windows Version) 2200 called a handset and is described later in this section.
YRM 947 A PC, with the control software installed, has access to
• Electrical System Repairs, Checks, and Adjust- function registers of the motor controllers through the
ments 2200 YRM 560 SEM display panel. The handset has access to less
• SEM Display Panel (DOS Version) 2200 YRM 725 function registers of each motor controller and can only
• SEM Display Panel (Windows Version) 2200 YRM make changes to a limited number of the registers of
942 these SR and SP motor controllers. The handset can
only be connected to a motor controller at the motor
The motor controllers are similar, but control different controller 12-pin connector.
types of motors and have some different components.
Both motor controllers are connected to the display A short description and the replacement of the display
panel on the instrument panel (dash) of the lift truck. panel is in the section SEM Display Panel 2200 YRM
This display panel provides access to both motor con- 725.
trollers for adjustments and data display on the Liquid
These transistor motor controllers are covered units
Crystal Display (LCD) screen.
with no serviceable components. This section de-
The display panel has a connector for a serial cable that scribes the procedures for using the electronic di-
will connect to a serial port of a personal computer (PC) agnostic and adjustment devices for checking and
for checks, adjustments, and troubleshooting. adjusting the operation of the motor controller.
a. A Cable Kit, Display Panel to Computer, is required
Authorized technicians can adjust the controllers for
(Yale Part No. 580001632). See your dealer for
different units or types of operations. Self diagnostics
Yale lift trucks.
are provided to monitor internal components as well as
b. The SMARTSET™ software for a personal com-
to detect problems with certain inputs and outputs. Ad-
puter is available on a 3.5-inch diskette. See your
justable register values and status codes are accessed
dealer for Yale lift trucks.
using a handset or a personal computer (PC). See the
These motor controllers have logic circuits and func- section Troubleshooting and Adjustments With a
tions that control and keep a record of the operations of Computer 2200 YRM 597 for information on the use
the motor controller. The registers also store a record of a PC.
of potential malfunctions or operations that are not cor-
rect. for the motor controller. These malfunctions or
incorrect operations can indicate possible causes of a
problem during troubleshooting.
1
Description 2200 YRM 808
There are electrical components that are not part of the (05) These numbers indicate the armature current.
motor controllers but give input signals to them. These 22 = 220 Amps
components include the following: 33 = 330 Amps
a. Key switch 40 = 400 Amps
b. Start switch
c. Seat switch (06) This number indicates the field current.
d. Direction (FORWARD and REVERSE) switches
(07) This letter/number set indicates the revision.
e. Accelerator potentiometer
f. Lift, tilt, auxiliary, and hydraulic speed switches These motor controllers have signal outputs for the dis-
g. Motor brush wear and temperature sensor switches play panel on the dash. The display panel has a serial
port connector for a serial cable that will connect to a
The brake fluid switch and the park brake switch are in-
serial port of a personal computer for checks, adjust-
puts to the display panel for the attention of the operator.
ments, and troubleshooting. All of the control settings
Fuses are also located outside the case of the motor for the motor controllers and the display panel can be
controllers. Checks and replacement of these electrical set using a PC through this connector.
components are described in Electrical System Re-
A handset with a digital display is also available. The
pairs, Checks, and Adjustments 2200 YRM 560.
handset can be directly connected to a motor controller
to set or check some of the functions and to check the
MODEL NUMBER DATA FOR TRANSISTOR
status codes. This connection uses a different cable
MOTOR CONTROLLERS (SR AND SP) than the computer or display panel cable.
The model numbers for the Transistor Motor Controllers All of the electronic components of each motor con-
indicate the following information: troller are inside the case of the motor controllers and
Example: are fastened directly to the lift truck frame. The line con-
tactor, fuses, and steering contactor mount to a plate
IC3645 SR 4 W 60 6 N6 that is also fastened to the frame of the lift truck. See
Figure 1. If there is no motor controller for the lift pump,
(01) (02) (03) (04) (05) (06) (07) the lift pump contactor and contactor driver are also on
a mount plate. See Figure 2.
(01) The first series of letters and numbers indicate the
basic catalog number of the controller. The motor controller has a 12-pin connector, a 23-pin
connector, and four or six power terminals. The 12-pin
(02) The second set of letters indicate the control type. connector is used for handset connection. Jumper
SP = Series Control (Pump) wires in the plug cover of this connector make connec-
SR = Separately Excited Control (Regen to Zero) tions to the 23-pin connector. The 23-pin connector is
for control signal inputs and outputs. The functions of
(03) The next number indicates the operating voltage. each terminal pin are described in Table 5. The power
2 = 24 Volts terminals are for battery positive, battery negative, and
3 = 24 to 36 Volts the armature and field terminals of the motor.
4 = 24 to 48 Volts
2
2200 YRM 808 Description
3
Description 2200 YRM 808
Figure 2. Traction Motor Controller and Contactor Control for Lift Pump Motor
4
2200 YRM 808 Checks and Adjustments Using a Handset
5
Checks and Adjustments Using a Handset 2200 YRM 808
CONNECT HANDSET
WARNING
Prevent movement of the lift truck and possible in-
jury when making checks and adjustments. Before
the handset is connected or disconnected to the
display panel of the lift truck, do the following steps:
1. Raise the drive wheels as described in the Op-
erating Manual or the section Periodic Mainte-
nance of the Service Manual for this lift truck.
2. Turn the key to the OFF position, disconnect the
battery, and discharge the capacitor by operat-
ing horn for several seconds. Do NOT make a
short circuit at any of the motor controller ter-
minals.
CAUTION
Prevent damage to the motor controllers. The
motor controllers can be damaged if power is not
correctly connected or disconnected. Always dis-
connect the battery connector before connecting or
disconnecting connectors at the motor controllers.
Plug 8-Pin Plug 12-Pin NOTE: The lift truck can be operated with the handset
connected.
1 9
2 6 START SEQUENCE
3 3 NOTE: The term "Push CONT. Key" means to depress
4 4 the control key of the handset for approximately 1 sec-
ond.
5 5
6 8 Connect handset. Connect battery and turn key to ON
position. The display sequence is shown in Figure 4.
7 1
8 2
Figure 3. Handset
6
2200 YRM 808 Checks and Adjustments Using a Handset
Status codes for these functions are stored together Figure 5. Sequence for Access and Clearing of
with the battery charge at the time the malfunction or Status Codes
symptom occurred. The first of the 16 status codes
7
Checks and Adjustments Using a Handset 2200 YRM 808
All stored status codes can also be cleared by using the connected or disconnected. Always disconnect the
following procedure. power supply before connecting or disconnecting
the display panel or motor controller plugs.
1. Access the first stored status code. See Figure 5.
To exit the Setup mode, turn the key to the OFF posi-
2. While the first stored status code is being displayed, tion and push the ESC key for at least 1 second. The
push and hold the CONT and ESC keys. hourmeter reading will normally be displayed and then
after a few seconds, the display will go blank. Make
3. Hold the CONT and ESC keys depressed while the
sure to install connector cover at motor controller each
display scrolls through the 16 stored status code
time handset cable is removed.
registers.
The handset can also be used to check and adjust the
4. When the display goes blank, release the ESC key
functions of the motor controller when it is connected to
(continue to hold down the CONT key).
a bench power supply. The following parts are required:
5. The display will scroll through the 16 stored status a. A power source to supply a minimum of 24 DC volts
code registers again, and then will go blank. at 0.5 Amps. Also, a 12-volt battery that can supply
50 milliamperes can be used if a PC is used for
NOTE: Change function 28 to 0 to make sure that the checks and adjustments. A handset requires more
next status code that is stored will be stored in the first power for its operation, and a power supply or two
register. Refer to How to Check and Adjust Registers 12-volt automotive batteries in series must be used.
in this section. Make sure to install connector cover at A DC power supply to a maximum of 84 volts can
motor controller each time handset cable is removed. be used.
RETURNING LIFT TRUCK TO NORMAL NOTE: The bench supply voltage does not need to
OPERATION be the same as the voltage of the lift truck.
CAUTION
Prevent damage to the motor controller. The motor
controller can be damaged if power is not correctly
8
2200 YRM 808 Checks and Adjustments Using a Handset
NOTE: ADJUSTMENT CABLES ARE CONNECTED AT THE SMALL CONNECTOR. REMOVE THE COVER TO
MAKE THE CONNECTION AND MAKE SURE TO INSTALL THE COVER AFTER THE CABLE IS REMOVED. DO
NOT LOSE THE CONNECTOR COVER. THERE ARE JUMPER CONNECTIONS IN THE CONNECTOR COVER
FOR CORRECT OPERATION WHEN THE MOTOR CONTROLLER IS INSTALLED IN THE LIFT TRUCK.
1. SMALL CONNECTOR WITH COVER (12-PIN) 4. 24-VOLT DC POWER SUPPLY OR BATTERIES
2. NEGATIVE CONNECTION OF POWER SUPPLY 5. P-PLUG CONNECTOR (23-PIN)
OR BATTERIES 6. MOTOR CONTROLLER
3. POSITIVE CONNECTION OF POWER SUPPLY 7. NEGATIVE POWER TERMINAL
OR BATTERIES 8. POWER SUPPLY PIN P1 (23-PIN)
CAUTION
Prevent damage to the motor controllers. The
motor controllers can be damaged if power is not
9
Function Parameters Adjustments 2200 YRM 808
WARNING
NEVER attempt to adjust any of the function val-
ues without using the procedures and values given
in this section. Failure to follow these instructions
can cause personal injury or property damage.
CAUTION
The plug cover on the small connector of the motor
controller must be installed for correct operation.
Make sure to disconnect the power and replace the
plug cover each time the handset is disconnected.
10
2200 YRM 808 Function Parameters Adjustments
11
Function Number Descriptions 2200 YRM 808
CAUTION
Make sure the Handset is connected to the correct
motor controller. See Figure 1 or Figure 2. The mo-
tor controller will not operate correctly if the wrong
values are set into the registers.
12
2200 YRM 808 Traction Motor Controller (Label Letter - SR)
13
Traction Motor Controller (Label Letter - SR) 2200 YRM 808
WARNING WARNING
Function Number 06 is not normally adjusted in the Function Number 10 is not normally adjusted in the
field. Adjusting Function Number 06 between the field. Adjusting Function Number 10 between the
minimum and maximum values will not change lift minimum and maximum values will not change lift
truck performance. truck performance.
This function sets the connection between field and ar- This function adjusts the motor field current that can be
mature currents when operating below the Field Weak- used during regen braking. This function does not affect
ening Start Point. The actual FW Ratio is the register stopping distance.
value without the last digit.
Function Number 11
EXAMPLE: Register value of 45 = FW Ratio of 4 NOT USED
Field current equals the FW Ratio times the result of Function Number 12
armature current times 0.024: MAXIMUM ARMATURE % ON TIME (Travel Speed
I FIELD = FW Ratio (I ARMATURE × 0.024). Limit)
(Push 12)
Function Number 07
MINIMUM FIELD CURRENT This function allows for the adjustment of the maximum
(Push 7) lift truck speed (maximum battery volts to the motor).
This function is always active to limit battery volts to the
motor.
WARNING
Function Number 07 is not normally adjusted in the Function Number 13
field. SPEED LIMIT 3
(Push 13)
This function is used to make minor adjustments be-
tween FW Ratio numbers. This function allows for the adjustment of the maximum
lift truck speed (maximum battery volts to the motor)
Function Number 08 available when Speed Limit 3 (SL3) is enabled. SL3
MAXIMUM FIELD CURRENT is activated by status codes 90, 91, or 99.
(Push 8)
Function Number 14
WARNING INTERNAL RESISTANCE COMPENSATION
(Push 14)
Function Number 08 is not normally adjusted in the
field. Adjusting Function Number 08 between the
minimum and maximum values will not change lift CAUTION
truck performance. Adjusting this function setting to the wrong number
can cause battery damage.
This function adjusts the maximum field current that the
motor controller will deliver in normal operation. This function allows improvement in the accuracy of the
BDI. The register value for this function can also be
Function Number 09
changed using the number push buttons on the Pre-
REGENERATIVE BRAKING CURRENT LIMIT (C/L)
mium Display Panel. Refer to the procedure following
(Push 9)
the Caution. The tables for the Parameter Registers
This function adjusts the maximum armature current show the parameters for a battery in average condition.
that can be used during regen braking. The higher the
For the best use of your battery energy, the function can
value and current, the shorter the stopping distance.
be adjusted using the following procedure. However,
setting the value too low for your battery can allow the
14
2200 YRM 808 Traction Motor Controller (Label Letter - SR)
battery to discharge below the minimum specific grav- 4. Find the correct register value using the procedure
ity value. This minimum specific gravity is the specifica- described in previous Steps a through c.
tion given by the battery manufacturer to prevent battery
damage. 5. Use the number push buttons #1 or #4 to increase
or decrease the YY number on the LCD screen to
NOTE: It can be necessary to do this procedure again the new register value. Press push button #5 to
as a battery gets older. store this new number in the register.
Use the following procedure to adjust the function for Function Number 15
the correct register value: BATTERY VOLTAGE SELECTION
a. Operate lift truck on a normal work cycle. (Push 15)
b. When lift interrupt occurs or the bar graph shows
"empty," stop lift truck and wait for approximately 10 This function permits adjustment for the operating volt-
minutes. age of the lift truck. The adjustment also permits cor-
c. Check specific gravity of several battery cells. If the rect operation of the Battery Discharge Indicator func-
specific gravity is between 1.140 and 1.150, the set- tion. For the controller and BDI to operate correctly, the
ting is correct for that battery. If the specific grav- register value shown in the tables for the Register Pa-
ity reading is high, adjust register value to a lower rameters must be entered.
number. If the specific gravity reading is low, adjust
Battery Volts Parameter
register value to a higher number.
36/48 volts Between 184 and 250
NOTE: It can be necessary to charge the battery and
do Steps a through c again to get an accurate number
NOTE: If the register value is set to a number other than
for your battery.
the number shown for your lift truck in tables for the Reg-
ister Parameters, a status code of 15 or 16 will occur.
CAUTION Make sure the battery is fully charged and battery con-
NEVER discharge a battery below a specific gravity nector has good connections before making this adjust-
of 1.130. The battery can have permanent damage ment. This check is especially important when adjust-
if discharged below 1.130. ing for 36/48 volt operation (numbers 184 to 250).
CHANGE THE REGISTER VALUE USING THE PUSH Function Numbers GREATER THAN 15
BUTTONS OF THE PREMIUM DISPLAY PANEL (If this
The following functions have function numbers larger
function is enabled).
than the numbers on the handset keyboard. To ac-
NOTE: The adjustment can only be made with the key cess these functions, push the CONT key and the num-
in the OFF position. ber shown in () with the function "title". Think of the
CONT key equaling 15. Push and hold the CONT
1. Press the STAR push button. The first item in the key, plus the additional key number 1 through 15,
menu will be shown on the LCD screen. to total the required function number. Example: for
Function Number 18, push the CONT key and key 3
2. Now press the push button #1 as many times (15+3=18). The display will show the selected function.
as necessary for a display of: BATTERY AD- After 1 second, the display will show the setting number
JUSTMENTS NOT ALLOWED or ADJUST BATT. that has been set for that function.
COMPNS DEPRESS 5 NXT 1/4. If ADJUST BATT.
COMPNS DEPRESS 5 NXT 1/4 is shown on the NOTE: The Seat Switch must be OPEN for Function
screen, this feature is enabled. Numbers 16 through 30.
3. Press push button #5 for a display of: CYCLE KEY Function Number 16
OFF/ON BDI NOT RECEIVED or XX % ADJUST STALL TRIP POINT % ON TIME
BDI YY=SETTING <1/4> 5 ST. The XX number is (Push CONT and 1)
the actual bar graph value shown as a number for
better resolution. The YY number is the register This function sets the percent of On Time for the FETs
value stored in the motor controller for Function that the motor controller uses to determine a motor
Number 14. "stall" condition.
15
Traction Motor Controller (Label Letter - SR) 2200 YRM 808
16
2200 YRM 808 Traction Motor Controller (Label Letter - SR)
Setting parameter is 0 to 255. Armature current range Set the register value of Function Number 28 to 0 if the
is 0 to 357 amps. Multiply the register value by 1.4 for stored status codes are cleared (erased) using a hand-
the armature current (90 × 1.4 = 126 Amps). set. If a PC is used to access Function 28, the soft-
ware program will "ask" the technician if the stored sta-
Function Number 25 tus codes will be cleared (erased). Setting the register
MONITOR value of Function Number 28 to 0 will erase the stored
(Push CONT and 10) status codes.
17
Traction Motor Controller (Label Letter - SR) 2200 YRM 808
NOTE: This Controlled Acceleration is in effect when NOTE: This Travel Speed Limit is in effect when mode
mode 1 is selected on the Premium Display Panel. 1 is selected on the Premium Display Panel.
18
2200 YRM 808 Traction Motor Controller (Label Letter - SR)
NOTE: This controlled acceleration is in effect when NOTE: This controlled acceleration is in effect when
mode 3 is selected on the Premium Display Panel. mode 4 is selected on the Premium Display Panel.
WARNING WARNING
Function Number 57 is not normally adjusted in the Function Number 61 is not normally adjusted in the
field. Adjusting Function Number 57 between the field. Adjusting Function Number 61 between the
minimum and maximum values will not change lift minimum and maximum values will not change lift
truck performance. truck performance.
NOTE: This FW start is in effect when mode 3 is se- NOTE: This FW start is in effect when mode 4 is se-
lected on the Premium Display Panel. lected on the Premium Display Panel.
WARNING WARNING
Function Number 58 is not normally adjusted in the Function Number 62 is not normally adjusted in the
field. Adjusting Function Number 58 between the field. Adjusting Function Number 62 between the
minimum and maximum values will not change lift minimum and maximum values will not change lift
truck performance. truck performance.
NOTE: This FW ratio is in effect when mode 3 is se- NOTE: This FW ratio is in effect when mode 4 is se-
lected on the Premium Display Panel. lected on the Premium Display Panel.
Function Number 59 NOTE: For function number 63, push the CONT key and
MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE the ESC key with the seat switch still closed.
3 - TRAVEL SPEED LIMIT)
(Push CONT and 12) Function Number 63
MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE
Same as Function Number 51. 4 - TRAVEL SPEED LIMIT)
(Push CONT and ESC)
NOTE: This travel speed limit is in effect when mode 3
is selected on the Premium Display Panel. Same as Function Number 51.
19
Pump Motor Controller (Label Letter - SP) 2200 YRM 808
This motor controller controls the speed of the motor for Function Number 07
the hydraulic lift pump. See Figure 2. INTERNAL RESISTANCE COMPENSATION RATE
(Push 7)
Function Number 01
STORED STATUS CODE This function allows for the adjustment of the time it
(Push 1) takes for the controller to add the internal resistance
compensation voltage that is applied to the motor. This
This function contains the last status code of a possible function will add 0.375 volts to the motor at the rate
malfunction that caused the pump motor to run contin- of time adjusted until the total internal resistance com-
uously. The battery must be disconnected to stop the pensation voltage has been added. There is 0.0015
motor if it runs continuously. This status code will be sec/unit starting from a 0.0015 second minimum.
replaced with the same status code if another possible
malfunction occurs. The status code can be cleared NOTE: The internal resistance compensation voltage is
from memory by adjusting the setting number to zero. set by Function Number 16, Speed/Torque Compensa-
Any new number (including zero) must be stored by tion.
pushing the STORE key for 1 second. Adjustment of
EXAMPLE: A setting of 20 (20 units) = 0.032 seconds
this function does not change operation of the hydraulic
Voltage added in X time is 0.375 volts. If you had se-
system.
lected 2.08 volts from Function Number 16 to be added
Function Number 02 to the motor, it would take 0.18 seconds to add a total
INTERNAL RESISTANCE COMPENSATION START of 2.08 volts.
(Push 2) (20 units X 0.0015 sec) + 0.0015 sec. min. = 0.0315
sec
This function permits adjustment of the current level re- (2.08 V ÷ 0.375 V) X 0.0315 sec = 0.175 or 0.18 sec
quired to start the internal resistance compensation of
Function Number 16. Multiply the register value by 6.5 Function Numbers 08 Through 10 NOT USED
for the current level (72 × 6.5 = 130 Amps).
Function Number 11
Function Number 03 SPEED LIMIT 1 (SL1)
CONTROLLED ACCELERATION (Slow Speed) - Tilt and Slow Auxiliary
(Push 3) (Auxiliary and Slow Rotate for N30XMH2)
(Push 11)
This function permits the adjustment of the maximum
rate of acceleration of the pump motor. The parame- This function permits the adjustment of the speed limit
ter determines the time allowed for the motor controller (maximum battery volts applied to the motor). When
to apply 100% of battery voltage after a switch for a switch SL-1 is closed, the signal to the pump motor
hydraulic function closes. This parameter determines controller causes it to apply the limit on battery volts to
how fast the hydraulic functions will begin to operate. the pump motor. Multiply the register value by 0.375 to
The time can be changed between 0.1 and 5.5 seconds. determine the speed limit voltage (50 x 0.375 = 18.75
volts).
20
2200 YRM 808 Pump Motor Controller (Label Letter - SP)
For functions greater than 15, push and HOLD the 16 1.43 31 0.74
CONT key and the additional key number above 15 to
total the required function number. Example: For Func- Function Number 17
tion Number 18, push CONT key and key 3 (15+3=18). CONTROL TYPE SELECTION
The display will show the selected function. After 1 (Push CONT and 2)
second, the display will show the register value that
has been set in that function. WARNING
NOTE: The Seat Switch must be OPEN for Function Wrong register values entered for Function Number
Numbers 16 through 30. 17 can cause the truck to operate differently than
normal or cause damage to the controller or motor.
Function Number 16 This different operation of the truck can result in
SPEED TORQUE COMPENSATION personal injury. NEVER set Function Number 17
(Push CONT and 1) to a register value outside the register parameters
shown for your lift truck.
This function is used to give the pump speed better
stability by increasing the pump motor voltage during The motor controller for the traction system controls the
heavy loads. This register value adds 0.375 volts to the BDI and Lift Interrupt functions. The BDI signal from the
motor for each 100 amps increase in pump motor cur- traction motor controller must be present at the pump
rent. The voltage is added, starting at the current value motor controller before it can operate. Refer to Func-
set for Function Number 02. For example, a register tion Number 17 of the Traction functions for more in-
value of 10 will add 2.28 volts in six steps of 0.375 volts formation.
each. See Table 1.
Function Numbers 18 through 27
Table 1. Speed/Torque Compensation TEMPORARY DATA REGISTERS
21
Pump Motor Controller (Label Letter - SP) 2200 YRM 808
22
2200 YRM 808 Pump Motor Controller (Label Letter - SP)
Function Number 54 This function will be disabled if the register value in the
MODE 2 - SPEED LIMIT 3 function is set to zero. The maximum number in the
(Push CONT and 7 while the key switch and seat function is 255.
switch are closed)
Function Number 60
This function permits adjustment of the speed limit MODE 4 - CONTROLLED ACCELERATION
(maximum battery volts to the motor). The range is 0% (Push CONT and 13 while the key switch and seat
to 96%. There is no speed limit switch for this function. switch are closed)
This function will be disabled if the register value in
the function is set to zero. Do not set the number in This function permits the adjustment of the maximum
the function to less than the register value for Function rate of acceleration in MODE 4 (Rabbit). The register
Number 58. Do not set the number in the function to value determines the time allowed to reach maximum
greater than the number in the function for Function SCR speed from stop. Do not set the number in the
Number 50. function to less than 8. Do not set the number in the
function to greater than the number in the function for
Function Number 56 Function Number 56.
MODE 3 - CONTROLLED ACCELERATION
(Push CONT and 9 while the key switch and seat Function Number 61
switch are closed) MODE 4 - SPEED LIMIT 2
(Push CONT and 14 while the key switch and seat
This function permits the adjustment of the maximum switch are closed)
rate of acceleration in MODE 3. The register value
determines the time allowed to reach maximum SCR This function permits the adjustment of the speed limit
speed from stop. Do not set the number in the function for the hydraulic pump in MODE 4. Do not set the num-
to less than the register value for Function Number 60. ber in the function to less than the register value for
Do not set the number in the function to greater than Function Number 57. Do not set the number in the func-
the number in the function for Function Number 52. tion greater than 70.
This function permits the adjustment of the speed limit This function permits adjustment of the speed limit
for the hydraulic pump in MODE 3. Do not set the num- (maximum battery volts to the motor). The range is 0%
ber in the function to less than the register value for to 96%. There is no speed limit switch for this function.
Function Number 53. Do not set the number in the func- This function will be disabled if the register value in the
tion to greater than the number in the function for Func- function is set to zero. The maximum number in the
tion Number 61. function is 255.
Function Number 58 The following tables have the location of each Function
MODE 3 - SPEED LIMIT 3 Number in the EEPROM of the motor controllers and
(Push CONT and 11 while the key switch and seat the PC and handset (HS) Function Numbers. The ta-
switch are closed) bles also show which functions can be accessed by the
PC and HS, as well as any restrictions that apply. See
This function permits adjustment of the speed limit Table 2 and Table 3. See the Parameter Tables for the
(maximum battery volts to the motor). The range is 0% register values and register parameters for each Func-
to 96%. There is no speed limit switch for this function. tion Number.
23
Pump Motor Controller (Label Letter - SP) 2200 YRM 808
24
2200 YRM 808 Pump Motor Controller (Label Letter - SP)
25
Pump Motor Controller (Label Letter - SP) 2200 YRM 808
26
2200 YRM 808 Pump Motor Controller (Label Letter - SP)
Table 3. Function Map for Motor Controllers SP (Lift Pump Motor) (Continued)
27
Troubleshooting 2200 YRM 808
Troubleshooting
GENERAL NOTE: Due to the interaction of the controller with all
lift truck functions, almost any status code or controller
The SR and SP controllers are sealed units with no ser- fault could be caused by an internal failure of the con-
viceable components. Troubleshooting is usually lim- troller. After all other status code procedures have been
ited to accessing status codes and following the diag- followed and no problem is found, the controller should
nostic procedures listed in the Status Code Charts. then be replaced as the last option to correct the prob-
lem.
Use standard testing procedures to verify inputs and
outputs when necessary. Check resistance on R × 1000 scale from frame to
power and controller terminals. A resistance of less
CAUTION than 20,000 ohms can cause misleading symptoms.
Resistance less than 1000 ohms should be corrected
Never attempt to probe through the back of the
first.
connector plugs of the motor controller or contac-
tor driver module. These plugs are special sealed Before proceeding, visually check for loose wiring, mis-
plugs. Probing through the back of the plugs will aligned linkage to the accelerator switch, signs of over-
destroy the seal and can cause a short circuit. If a heating of components, etc.
circuit must be tested for voltage, check for voltage
at an "amp" type plug, a switch, or a component. If Tools and test equipment required are: clip leads, volt
a circuit is suspect, check the circuit for continuity ohmmeter (20,000 ohms per volt), and basic hand tools.
by disconnecting the P plug and testing continuity
from the front (pin end) of the plug. STATUS CODES
Standard probes are too large to be inserted into the NOTE: Make sure the register values is correct for each
center of the female pins (sockets) of the special Function Number of your lift truck to make sure the
sealed plugs and can expand the pins. Expanded trouble is not just a wrong setting. See the Parame-
pins will not provide good connections once the ter Tables at the end of this section. If there is no status
plug is reconnected. To prevent pin damage, only code display and the lift truck does not operate correctly,
use probes with a diameter of 1.57 mm (0.062 in.) or there can be a fault in the motor controller.
less.
The status codes are code numbers for malfunctions
NOTE: A breakout box tool (Yale part number or lift truck operation that are not correct and that the
580002086) is available to use when troubleshoot- motor controller can sense. The motor controller will
ing the transistor controllers. When the breakout tool indicate this code number on the LCD screen of the
is installed between the controller and the harness, display panel or the display on a handset. The motor
voltage checks can be made. controller will illuminate the numbers of the status code
on the LCD screen. The status codes are twice illumi-
Refer to Table 5 for the SR traction controller connec- nated ("flash") on the LCD screen approximately every
tions. Refer to REPAIRS for the SR lift pump controller 2 seconds. Every third "flash" of the LCD screen will
connections. Also refer to REPAIRS for the transistor indicate the battery charge instead of the status code.
controller plug pin connections.
The control card senses the following types of malfunc-
See the Diagrams manual for your lift truck for addi- tions:
tional wiring details. • Input voltages that are too high or too low
• Input voltages that have the wrong polarity
If the lift truck does not operate correctly, a status code
• Input voltages in the wrong sequence
is displayed on the display panel.
• Correct input voltages that occur at the wrong time
Once the status code number is obtained, follow the
procedures outlined in the Status Code Charts of this
manual to determine the problem.
28
2200 YRM 808 Troubleshooting
NOTE: A status code indication does not always mean Table 4. List of Status Codes (Continued)
that there is a malfunction. A temporary operating con-
dition can cause a status code display.
Code Description
If a status code number is indicated on the LCD screen 23 Motor field current too high on initial start
of the display panel, checks and adjustments cannot - REV.
be done. See Table 4 and the following Status Code
Charts to find and correct the malfunction. There are 24 Motor field current too high on initial start
no checks or adjustments for the status codes. These - FWD.
code numbers are only codes to help identify a possible 27 Voltage to logic circuit less than 10 volts.
malfunction. A short description of the different status
codes is shown in Table 4. 28 Motor field current too high for too long
during operation.
The Status Code Charts in this section have a more
41 Open thermal protector or motor controller
complete description of the status code, the circuit that
temperature too high.
has generated the input for the status code, the symp-
tom, and the possible causes. 42 Motor sensor voltage too high with no
armature current.
Table 4. List of Status Codes
43 Motor sensor voltage too low with no
Code Description armature current.
02 FWD switch closed on initial start. 49 Motor field current too low during
operation.
03 REV switch closed on initial start.
51 C1 voltage too low before line contactor
05 Start switch did not close. closes.
06 Accelerator depressed, no direction 57 Motor current sensor too low during
selected. operation.
07 Accelerator input voltage too high. 64 Line driver voltage input too low.
08 Accelerator input voltage too low. 66 Field current above transistor current limit.
09 Both FWD and REV switches closed at 67 Armature current above transistor current
same time. limit.
11 The START switch is closed before the 69 Contactor coil current of 1A contactor too
key switch is closed. high.
15 Battery volts too low. (Regenerative Braking)
16 Battery volts too high. 76 C1 voltage too high during REGEN.
17 Wrong control type selected. 77 Motor current during REGEN.
*Not used on all models of lift trucks. Status Codes (Motor Stall)
in this group will flash on the LCD screen of display
panel. *Not used on all models of lift trucks. Status Codes
NOTE: Truck speed is decreased when status code 90, in this group will flash on the LCD screen of display
91, or 99 is indicated. panel.
NOTE: Truck speed is decreased when status code 90,
91, or 99 is indicated.
29
Troubleshooting 2200 YRM 808
Table 4. List of Status Codes (Continued) Table 4. List of Status Codes (Continued)
30
2200 YRM 808 Status Code Charts
31
Status Code Charts 2200 YRM 808
32
2200 YRM 808 Status Code Charts
33
Status Code Charts 2200 YRM 808
34
2200 YRM 808 Status Code Charts
35
Status Code Charts 2200 YRM 808
36
2200 YRM 808 Status Code Charts
37
Status Code Charts 2200 YRM 808
38
2200 YRM 808 Status Code Charts
39
Status Code Charts 2200 YRM 808
40
2200 YRM 808 Status Code Charts
41
Status Code Charts 2200 YRM 808
42
2200 YRM 808 Status Code Charts
43
Status Code Charts 2200 YRM 808
44
2200 YRM 808 Status Code Charts
45
Status Code Charts 2200 YRM 808
46
2200 YRM 808 Status Code Charts
47
Status Code Charts 2200 YRM 808
48
2200 YRM 808 Status Code Charts
49
Status Code Charts 2200 YRM 808
50
2200 YRM 808 Status Code Charts
CAUTION
If the truck is stalled with partial throttle, this status
code will not appear, and motor damage can occur.
51
Status Code Charts 2200 YRM 808
52
2200 YRM 808 Status Code Charts
53
Status Code Charts 2200 YRM 808
54
2200 YRM 808 Status Code Charts
55
Status Code Charts 2200 YRM 808
56
2200 YRM 808 Status Code Charts
57
Status Code Charts 2200 YRM 808
58
2200 YRM 808 Status Code Charts
59
Status Code Charts 2200 YRM 808
60
2200 YRM 808 Status Code Charts
61
Status Code Charts 2200 YRM 808
62
2200 YRM 808 Status Code Charts
63
Status Code Charts 2200 YRM 808
64
2200 YRM 808 Transistor Motor Controllers Repairs
65
Transistor Motor Controllers Repairs 2200 YRM 808
Figure 9. Traction Motor Controller and Contactor Control for Lift Pump Motor
66
2200 YRM 808 Transistor Motor Controllers Repairs
The transistor motor controllers, like other electronic de- In dusty areas, blow low pressure air over the controller
vices, have temperature limits. These devices can be to remove dust. In oily or greasy areas, a mild solution
damaged if they get too hot. Normal maintenance will of detergent or denatured alcohol can be used to wash
help prevent high temperature conditions. Always make off the controller, and then low-pressure air should be
sure components are installed using the silicon grease used to completely dry the controller.
and insulating sheet (where applicable) and that all heat
For the controller to be most effective, it must be
sink surfaces are clean. Do not block cooling airflow.
mounted against the frame of the lift truck. The metal
Special Precautions frame, acting as an additional heat sink, will give im-
proved lift truck performance by keeping the controller
package cooler. Apply a thin layer of silicone (heat
WARNING transfer) grease Yale P/N 504223239 between the
To avoid injury and prevent electrical shock, per- controller heat sink and the lift truck frame prior to
form the following steps before troubleshooting, controller installation.
adjustments, or repair:
Controller wire plugs and other exposed transistor con-
Turn the key to the OFF position and disconnect the troller parts should be kept free of dirt and paint that
battery connector. might change the effective resistance between points.
Check with the dealer for your lift truck before operating FUSES
in an area with normal temperatures over 40 C (100 F).
The fuses are found on the motor controller assembly
The lift truck motor controllers can be damaged.
or contactor panels. See Figure 8 or Figure 9. The con-
dition of the fuses can normally be checked by looking
CAUTION at them or can be checked with an ohmmeter.
Never add any electrical component to the lift truck
without approval from your dealer for your lift truck.
Other electrical components can prevent operation
and/or damage the motor controller.
67
Transistor Motor Controllers Repairs 2200 YRM 808
CONTACTORS Repair
There can be three contactors on these lift trucks. All
lift trucks have a power steering contactor and a line CAUTION
contactor. See Figure 10 and Figure 12. Lift trucks ALWAYS replace all of the contacts in a contactor
that do NOT have a pump motor controller (SP) also at the same time. Replace the contacts in the con-
have a contactor to energize the lift pump motor. See tactor for the hydraulic pump after 1000 hours of
Figure 10. operation. Replace the contacts in the other con-
tactors when the thickness of any area of a contact
is less than 30% of the thickness of a new contact,
or if there is any transfer of contact material.
68
2200 YRM 808 Transistor Motor Controllers Repairs
69
Transistor Motor Controllers Repairs 2200 YRM 808
70
2200 YRM 808 Transistor Motor Controllers Repairs
Pin Wire Color Traction Motor Motor Controller for Lift Wire Color
No. or =Wire # Controller Pump Motor or =Wire #
P1 BRN=12B Battery Volts From Battery Positive (BAT) BRN=12C
P2 RED/ BLU-LT=10A Battery Volts At Key Switch RED/ BLU-LT=10G
Battery Volts From
P3 GRN/15=6B Status Code 93 Input BLU/YEL =105
Start Switch
Battery Volts From
P4 WHT-5=8B Status Code 93 Input BLU/YEL =106
Forward Switch
Battery Volts From
P5 BLU-LT=7A Status Code 94 Input BLU/PINK =103
Reverse Switch
Battery Volts From
P6 WHT/PINK =7A Status Code 94 Input BLU/PINK =104
Seat Switch
Accel. Potentiometer
P7 YEL/PINK=29 Not Used -
Input Voltage Signal
P8 Not Used Status Code 95 Input BLU/GRY =108
+5 Volt to Accelerator
P9 GRN/WHT=32 Status Code 95 Input BLU/GRY =107
Potentiometer
P10 BLU-LT=5050 BDI Lift Interrupt Output Pump Enable Signal Input BLU-LT=50
+12 Volt Regen Output
P11 YEL/ GRN-DK =75A Status Code 91 Input ORN/YEL =100
Signal
P12 - Not Used Speed Limit #1 Input GRY=53
P13 - Not Used Brush Wear Indicator Output GRN/YEL =110
Brush Wear Indicator Input Over Temperature Indicator
P14 GRN/YEL =110 GRN/PINK =109
Output
P15 - Not Used Not Used -
P16 - Not Used Status Code 90 Input ORN/PINK =102
Traction Line Contactor
P17 BLK=24 Pump Line Contactor Driver BLK = 80
Driver
P18 BLK=41 1A Contactor Driver PM #2 Contactor Driver BLK = 87
+5 Volt Power Supply
P19 GRN/GRY =71 Speed Limit #2 Input BLU/WHT=52
Output
Motor Overtemperature
P20 GRN/PINK =109 Speed Limit #3 Input BLU-DK=51
Indicator Input
P21 - Not Used +5 Volt Input GRN/GRY =71
Serial Receive - Connects Serial Receive - Connects
P22 GRN-1=74 GRN-2=76
To Display Panel To Display Panel
Serial Transmit - Connects Serial Transmit - Connects
P23 WHT-1=73 WHT-2=75
To Display Panel To Display Panel
71
Transistor Motor Controllers Repairs 2200 YRM 808
WARNING
To help prevent damage or injury raise the drive
wheels before doing these checks. Raise the drive
wheels as described in the Operating Manual or the NOTE: CONNECT BATTERY SO MOTOR CAN BE
section Periodic Maintenance of the Service Man- OPERATED. BATTERY MUST BE REMOVED FOR
ual. ACCESS TO MOTOR. USE A JUMPER CABLE TO
CONNECT BATTERY TO LIFT TRUCK. RAISE DRIVE
Use a jumper cable so that the battery can be con- WHEELS. SEE HOW TO RAISE DRIVE TIRES IN THE
nected for operation of the motors. See Figure 13. Dis- PERIODIC MAINTENANCE SECTION OR OPERAT-
connect the sensor wires, one at a time, from outside ING MANUAL.
of the motor case. Touch the end of the sensor wire to
battery positive. The warning light will illuminate if the 1. RAISE DRIVE 2. JUMPER
WHEELS 3. BATTERY
circuit is operating correctly. The motor brushes must
be replaced when they are worn. If equipped with brush Figure 13. Connect Battery So Motor Can Be
wear indicators, the condition of the commutator and Operated
the motor brushes must still be checked during periodic
maintenance.
72
2200 YRM 808 Transistor Motor Controllers Repairs
THERMAL SENSORS to the lift truck frame. Carefully remove the motor
controller.
The thermal sensors indicate to the motor controller that
the motor is too hot. When a motor gets too hot, the
sensor makes an electrical connection to send a signal CAUTION
to the motor controller. Do not remove the small screws that fasten the
cover of the motor controller.
WARNING Make sure there is no dirt between the plate of the
To help prevent damage or injury, raise the drive motor controller and the mount surface of the lift
wheels before doing these checks. Raise the drive truck frame.
wheels as described in the Operating Manual or the
section Periodic Maintenance of the Service Man- 3. Put a thin, even coat of the silicone compound (Yale
ual. Part No. 504223239) or equivalent on the plate of
the motor controller. Make sure there are no air
Use a jumper cable so that the battery can be con- spaces between the plate and mount surface of the
nected for operation of the motors. See Figure 13. Dis- lift truck frame. The plate of the motor controller
connect the sensor wires from the outside of the mo- must make full contact with the lift truck frame. In-
tor case. Touch the ends of the sensor wires together. stall the mount screws that fasten the motor con-
The warning light will illuminate if the circuit is operat- troller to the lift truck frame.
ing correctly. The thermal switch can be replaced if it is
damaged. However, the motor must be disassembled 4. Install the power cables at the power terminals of
to replace the thermal switch. the motor controller as identified during removal.
Install the connector plug for the control wires
MOTOR CONTROLLER, REPLACE on the connector of the motor controller. MAKE
SURE THE PLUG COVER IS INSTALLED ON
Make sure the battery is disconnected and the capacitor THE SMALL CONNECTOR OF THE MOTOR
is discharged using the horn, as previously described. CONTROLLER.
Replace the motor controller as described in the follow-
ing procedure. See Figure 8, Figure 9, Figure 14, and WARNING
Figure 15.
To help prevent damage or injury, raise the drive
1. Make an identification for correct connection of the tires before doing these checks. Raise the drive
power cables on the power terminals of the motor tires as described in the Operating Manual or the
controller. Disconnect the power cables and the section Periodic Maintenance of the Service Man-
connector plug for the control wires. ual.
2. Remove the eight (traction) or six (pump) mounting 5. Before operating lift truck, raise drive tires and
screws that fasten the plate of the motor controller check for correct operation.
73
Transistor Motor Controllers Repairs 2200 YRM 808
74
2200 YRM 808 Transistor Motor Controllers Repairs
75
Parameter Tables 2200 YRM 808
Parameter Tables
GENERAL motor controllers. The personal computer or the hand-
set must be used to adjust the parameters for these
This section must be used with the following sections of motor controllers. There is a description of the code
this motor controller: numbers (functions) in the Parameter Tables. These
• SEM Display Panel 2200 YRM 725 Parameter Tables have the correct register values for
• Troubleshooting and Adjustments With a Com- the functions of each motor controller of the different lift
puter for EV-100ZX, EV-T100, SR (SEM), and SP trucks.
Motor Controllers 2200 YRM 597
There are parameter tables for the different lift truck
These motor controllers have an electronic de- models using the different motors or equipment. Do
vice called an EEPROM (Electrically-Erasable-Pro- NOT adjust a register value to a number that is NOT
grammable-Read-Only-Memory). The EEPROM has a SHOWN in the correct table. MAKE SURE YOU USE
number of memory elements called registers for the THE CORRECT TABLE WHEN YOU MAKE ADJUST-
different functions. These registers can have electronic MENTS. It is a good procedure to check the register
data stored in them to control an operation. The range value for a Function Number and compare this register
of data that can be stored in the registers is called a value to the register value in the Parameter Tables be-
parameter. A register value is a measurement number fore making the adjustment. The factory register value
for a specific function that works with other functions to and the amount (current, time, etc.) for that register
define a system. The EEPROM in a motor controller is value are shown in the columns indicated as Default.
a control system for the operation of the lift truck. The parameter values are shown in the columns indi-
cated as Permitted Range.
The EEPROM used in these motor controllers has 128
registers.
MOTOR CONTROLLER CHECKS AND
ADJUSTMENTS
WARNING
Each register in each motor controller has a range A personal computer (PC) is used by Authorized Per-
of numbers so that the control card can be used sonnel to make checks and adjustments. A handset
on different models of lift trucks. This variation is can also be used.
needed for lift trucks of different sizes, motors, and
NOTE: The PC can be connected to each separate mo-
operating voltages. Adjustment of the register to
tor controller. The PC can also be connected to the
the wrong number for your lift truck and compo-
SEM Display Panel for computer access to the memory
nents can cause the lift truck to operate differently
of the SEM Display Panel AND the motor controllers. If
than normal. This different operation of the truck
the PC is connected to the SEM Display Panel, the SEM
can cause component damage or an injury.
Display Panel must FIRST be programmed by the PC as
NOTE: These Parameter Tables show the permitted described in the section SEM Display Panel 2200 YRM
ranges and the default register value for each control 725. The motor controller functions can be checked and
function. The Factory-Set Parameters are the recom- adjusted as described in the section Troubleshooting
mended register values for new units. These values and Adjustment With a Computer 2200 YRM 597.
will give satisfactory performance for most applications.
The following checks and adjustments can be made:
Some functions register values can be adjusted within • Check system status codes history for both traction
the permitted range to change the lift truck operation and hydraulic pump systems
for a specific application. Adjustment of a register num- • Check state of charge of battery
ber value to a number that is different than the factory • Check hourmeter readings on traction circuit and hy-
setting is allowed. Make sure to follow the instructions draulic pump controllers
carefully and stay within the minimum and maximum • Monitor or adjust register values for each function as
limits. shown in the Parameter Tables.
76
2200 YRM 808 Parameter Tables
the motor controllers. See Table 7, Table 8, Table 9, and Make sure to read the WARNINGS and CAUTIONS at
Table 10. See the information at the beginning of this each function description in this section. These WARN-
to identify the TYPE of motor controller so that you can INGS and CAUTIONS must be read before entering a
use the correct table for your lift truck. register value other than the factory value.
Table 7. Traction Control - SR Transistor Control Settings, 11-Inch Motor (36/48 Volts)
77
Parameter Tables 2200 YRM 808
Table 7. Traction Control - SR Transistor Control Settings, 11-Inch Motor (36/48 Volts) (Continued)
Table 8. Traction Control - SR Transistor Control Settings, 13-Inch Motors, Standard Speed (36/48 Volts)
78
2200 YRM 808 Parameter Tables
79
Parameter Tables 2200 YRM 808
Table 9. Traction Control - SR Transistor Control Settings, 13-nch Motors, High Speed (36/48 Volts)
80
2200 YRM 808 Parameter Tables
81
Parameter Tables 2200 YRM 808
82
2200 YRM 808 Theory of Operation
Table 10. Hydraulic Pump - SR Transistor Control Settings (36/48 Volts) (Continued)
Theory of Operation
GENERAL use Field Effect Transistors (FET) as power transistors
to control motor armature and field voltages and cur-
This section is for lift trucks that have the Separately Ex- rents. The speed of DC motors is primarily controlled
cited Motor (SEM) system. This SEM system controls by the average applied voltage. Generally, the higher
a single traction motor. The SEM system has a tran- the average applied voltage to the armature, the faster
sistor motor controller (SR) that controls the shunt trac- the motor will rotate. If a switch is put in the armature
tion motor. Units with this system can have a transistor and field circuits, the average voltage of each circuit can
motor controller (SP) or a contactor motor controller to be changed. The switches are changed to OFF and ON
control the lift pump motor. The lift pump motor is a se- quickly to change the average voltages. See Figure 16.
ries motor. By controlling the average voltage, the current can also
be controlled. The average voltage increases as the
A display panel operates with these motor controllers.
time the switch is ON increases. The average voltage
For more information on this display panel. See the
decreases if the switch is OFF for a longer time than it is
section SEM Display Panel 2200 YRM 725.
ON. The speed and characteristics of the motor can be
NOTE: The description of the current flow in the electri- controlled by separately changing the average voltages
cal circuits in this section uses the "Conventional The- of both the armature and the field of a shunt motor.
ory of Current Flow." This theory describes the current
as flowing from positive to negative. An electric lift truck SEM SYSTEM DESCRIPTION
uses a two-wire electrical system. There is no common
Most electric lift trucks have used series motor designs
ground through the frame. Both the positive supply and
because of their ability to produce very high levels of
the negative return current flow through wires and ca-
torque at low speeds. Higher efficiency shunt motors
bles. There must be a minimum resistance of 50,000
are now often being considered over series motors. By
ohms between the electrical circuits and the frame of
separately controlling the field and armature currents
the lift truck.
the SEM system, the best attributes of both the series
These motor controllers have solid-state electronic cir- and the shunt wound motors can be combined.
cuits that control the operation of a DC motor. They
83
Theory of Operation 2200 YRM 808
84
2200 YRM 808 Theory of Operation
Field Weakening
Field weakening of a series wound motor uses a re-
sistor in parallel with the field windings of the motor.
Current through the resistor makes less current through
the field. Less field current makes the field weaker so
motor speed increases. To change the speed during
field weakening, the resistor value must change. A con-
tactor and resistor are usually used to change speed
during field weakening with a series motor. In a sep-
arately excited motor, independent control of the field
current provides for an infinite adjustment of field weak-
ened speeds, between motor base speed and maxi-
mum weak field. The contactor and resistor required
for field weakening with a series motor is not needed
with the transistorized controller.
85
Theory of Operation 2200 YRM 808
86
2200 YRM 808 Theory of Operation
Controlled Acceleration
This feature allows for adjustment of the time it takes
for the controller to accelerate to 100% applied battery
voltage to the motor on hard acceleration. Controlled
acceleration is adjustable from 0.1 to 22 seconds.
Current Limit
This circuit monitors motor current by utilizing sensors
in series with the armature and field windings. The infor-
mation is used to maintain maximum currents at a pre-
set value. If heavy load currents are detected, this cir-
cuit overrides the oscillator and limits the average cur-
rent to a value set by Function 4 and Function 8. The
C/L setting is based on the maximum thermal rating of
the controller. Because of the flyback current, the motor
current is usually greater than battery current, except at
100% ON time.
BRAKING
Figure 19. Regenerative Braking Circuit
Regenerative Braking to Zero Speed
Pedal Position Braking
Slow down is accomplished when reversing direction by
providing a small amount of retarding torque for deceler- This feature allows control of the reversing distance
ation. If the lift truck is moving, and the directional lever based on pedal position when there has been a "direc-
or Foot Directional Control pedal is moved from one tional switch" change. Pedal position will reduce the
direction to the other, the regenerative braking signal regenerative braking current to the "value set by this
is initiated. Once the regenerative braking signal has function" as the accelerator is returned to the creep
been initiated, the field current is increased. Armature speed position. Maximum current is obtained with the
current is regulated to the regenerative braking current accelerator in the top speed position. This feature is
limit as set by Function 9. As the lift truck slows down, adjustable by using Function 16 on the handset.
the field current continues to increase, and transistor
Q5 begins to turn on and off. See Figure 19. The field Auto Braking
current will increase until it reaches a preset value set
by Function 10, and transistor Q5 on time will increase This feature is enabled by initiating a "neutral position"
until it reaches 100% on time. Once both of the above using either the directional switch or the accelerator
conditions have been met, and the regenerative braking switch. Once activated, Auto Braking operates similar
current limit can no longer be maintained, the braking to Pedal Position Braking and is adjusted by using Func-
function is canceled. The fields will then reverse, and tion 21.
the controller reverts back to normal operation.
AUXILIARY SPEED CONTROL
Part of the energy produced by the motor during regen-
erative braking is returned to the battery, and part is Field Weakening
converted to heat in the drive motor.
The Field Weakening (FW) ratio (Function 6) adjusts the
Function 9, Regen Current Limit is adjustable and will field weakening level in order to set the top speed of the
change the distance the lift truck requires to reach zero motor. The FW ratio is enabled when the armature cur-
speed. Function 10, Regen Field Current is not nor- rent is less than the FW Start Current (Function 24) and
mally adjusted in the field. the accelerator input voltage is less than 1 volt. Func-
tion 24 is used to optimize motor and controller perfor-
mance.
87
Theory of Operation 2200 YRM 808
NOTE: The FW ratio has been determined by the fac- Coil Drivers and Internal Coil Suppression
tory. Function 6 is not normally adjusted in the field.
The coil drivers for the line contactor and 1A contactors
NOTE: FW Start, Functions 24, 49, 53, 57, and 61, is are internal to the controller. The contactors must have
not normally adjusted in the field. coils rated for the lift truck battery volts.
NOTE: Top speed can be reduced by increasing the The coil driver for the lift pump contactors are internal
value of Maximum Armature % On Time. Maximum Ar- to the contactor driver module. The lift pump contactors
mature % On Time is set using Function 12 (standard must also have coils rated for the lift truck battery volts.
instrument panel) or Functions 41, 55, 59, and 63 (pre-
mium instrument panel). Suppressors for contactor coils are internal to the motor
controller or contactor driver module.
Speed Limits
SYSTEM PROTECTIVE OVERRIDE
This feature provides a means to control speed by limit-
ing motor volts utilizing two adjustable speed limits. The SRO (Static Return to Off)
lower motor volt limit always takes priority when more
than one speed limit is activated. This motor volts limit If the seat switch or key switch is opened, the controller
regulates "on time" of the transistor controller, but ac- shuts off and cannot be restarted until the directional
tual truck speed will vary at any set point depending on lever is returned to neutral. A time delay of approxi-
the loading of the lift truck. Each speed limit can be ad- mately 2 seconds is built into the seat switch input to
justed with the handset. allow momentary opening of the seat switch.
88
2200 YRM 808 Theory of Operation
limits. As the controller cools, the thermal protector The second speed (Speed Limit 2) is activated by con-
will automatically reset, returning the controller to full necting P19 to battery negative. SL2 is set by Function
power. 12. Operation of SL2 is similar to SL1.
89
Theory of Operation 2200 YRM 808
Standard Status Codes or the section SEM Display Panel 2200 YRM 725. A
handset or PC must be used to clear the stored status
The traction motor controller (SR) has over 30 status codes.
codes and the pump motor controller has over 20 status
codes to assist the service technician and operator in Hourmeter Readings
troubleshooting the lift truck. If a controller or circuit
malfunction occurs, a status code is displayed on the This feature will display the recorded hours of use of
display panel. the traction and pump motor controllers. The hours are
shown on the display panel each time the key is turned
Stored status codes can be retrieved on lift trucks with- to the OFF position.
out a Premium Display Panel by using a standard GE
handset or a PC connected through the small plug of the Maintenance Management Capability
controller. The handset can only connect to one motor
controller at a time. A PC can connect to the display The traction motor controller (SR) has the capability of
panel for access to checks and adjustments of each monitoring some maintenance items. The hourmeter
motor controller. To obtain a complete list of all status reading is monitored and can be used to provide a main-
codes present, EACH controller (traction and pump) on tenance status code 99 when a set hourmeter reading
the lift truck must be checked, one at a time, using the is reached. Brush wear and motor temperature are also
handset, or with a PC through the display panel. monitored. Temperature sensors can be present on the
traction and lift pump motors. Brush wear sensors can
NOTE: The STATUS CODES tables of this manual do be present on the traction, lift pump, and steer pump
not cover all possible causes of a display of a "status motors.
code." They provide instructions for checking the most
direct inputs that can cause status codes to appear. The traction controller will set a status code and re-
duce maximum lift truck speed if the maintenance alert
Stored Status Codes hourmeter reading is reached or if an optional temper-
ature sensor determines that a motor is overheated.
This feature records the last 16 "Stored Status Codes"
that have caused a controller PMT shutdown and/or dis- The traction controller will set a status code if an op-
rupted normal lift truck operation. PMT-type faults are tional brush wear indicator detects a worn brush.
reset by moving the key to the OFF and ON positions.
These stored status codes, along with the correspond- The maintenance alert hourmeter reading is pro-
ing BDI and hourmeter readings, can be accessed with grammed into the traction controller using Function
the handset, or by using the RS 232 communications Number 19 and Function Number 20.
port and downloading the information to a PC.
NOTE: The brush wear and motor temperature inputs to
Stored status codes can also be displayed on the Pre- the traction controller are received from the pump motor
mium Display Panel. Refer to the Operating Manual controller or contactor driver module.
90
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011