4.1 BR14JW-7 - E.control - SB4394E00

SB4394E00
July. 2012
Electric Control System

Specification
System Operation
Testing & Adjusting
BR14JW-7, BR16JW-7
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have
read and understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, Iubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available
at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations,
and other items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DOOSAN dealers have the most
current information available.
Electric Control System 1

INDEX
Important Safety Information ............................................................................................ 1
SPECIFICATIONS............................................................................................................... 4
Construction ...............................................................................................................................................4
Feature ......................................................................................................................................................5
Main Components ...................................................................................................................................... 7
Controller AS Specification .........................................................................................................................8
Instrument Panel ...................................................................................................................................... 11
Alarm List ......................................................................................................................... 18
SYSTEMS OPERATION ................................................................................................... 33
Glossary ................................................................................................................................................... 38
Installation and Wiring .............................................................................................................................. 40
TECHNICAL INFORMATION of PLUS+1 INVERTER ...................................................... 43
TRACTION INVERTER ..................................................................................................... 94
HYDRAULIC (PUMP) INVERTER ................................................................................... 151
SERVICE TOOL MANUAL for TRACTION INVERTER ................................................. 214
SERVICE TOOL MANUAL for HYDRAULIC INVERTER ............................................... 244
ELECTRIC POWER STEERING SYSTEM ..................................................................... 278
AC MOTOR ..................................................................................................................... 367

SPECIFICATIONS
Construction

Feature
Drive Wheel Auto-Centering

When the Start Key is turn on, the Drive Wheel is Auto-Centered.
The operator doesn’t need to check the direction of Drive Wheel.
Control of Driving Speed

When truck is turning, Driving Speed is reduced.

360°/180° Steering Control
Lifting Speed Control

The lift speed is reduced at the end point.
Reach in/out Speed Control

The reach in/out speed is reduced at the end point.

Main Components
CANbus Communication
1) Traction Inverter 2) Traction Motor 3) Accelerator Pedal

4) Steering Wheel 5) Hydraulic Inverter 6) Hydraulic Motor
7) Hydraulic Pump 8) Main Control Valve 9) Fingertip Lever
10) Instrument Panel 11) Electric Power Steering Inverter 12) EPS Motor

Controller AS Specification
Traction Controller (Inverter)
No Items Specification
1 Nominal Voltage 48 Vdc
2 Input Voltage Range 18~62 Vdc
3 Nominal Current 150 Arms
4 Maximum Current (S2-2min) 300 Arms
5 Peak Current 330 Arms
6 Output Voltage 3 ~ 32V
7 Power Connectors M8
8 Weight 3.0 kg
9 Ambient Temperature Range -40℃ ~ 50℃

10 Signal Line Connectors AMP SEAL 35 Pins
11 IP Protection IP67 with membrane
12 Fuse 80V, 275A
13 Dimension (W x L x H) 200mm x 140mm x 111mm

Pump Controller (Inverter)
1 Nominal Voltage 48 Vdc
2 Input Voltage Range 18~62 Vdc
3 Nominal Current 200 Arms
4 Maximum Current (S2-2min) 400 Arms
5 Peak Current 420 Arms
6 Output Voltage 3 ~ 32V
7 Power Connectors M10
8 Weight 3.7 kg
9 Ambient Temperature Range -40℃ ~ 50℃

10 Signal Line Connectors AMP SEAL 35 Pins
11 IP Protection IP67 with membrane
12 Fuse 80V, 400A
13 Dimension (W x L x H) 200mm x 140mm x 117.5mm

EPS Controller
1 Nominal Input Voltage 48 Vdc
2 PWM operating frequency 16 kHz
3 Maximum encoder frequency 10 kHz
4 Maximum controller output frequency 200 Hz
5 Electrical isolation to heatsink 500V AC (minimum)
6 Storage ambient temperature range -40℃ to + 95℃
7 Operating ambient temperature range -40℃ to + 50℃
8 Internal heatsink operating temperature -40℃ to + 95℃
9 IP Protection IP65 per IEC529
10 Weight 1.3 kg
11 Dimensions (W x L x H) 146mm x 164mm x 60mm

Instrument Panel
Layout
Diagnostic Mode

Calibration Mode

PIN SET at Diagnostic Mode
1. Press the “0” key one more second

- “PINSET MODE” display
- Display saved pin code (Check through up or down key)
2. New save
- To display “0000” use UP or DOWN key
- Press the enter key
- Input pin code and then press the enter key. (four digit number)
- Input drive capacity and then press the enter key. (0-100)
- “Set complete” display and then save.
3. Data revise
- To display pin code which intended to revise use UP or DOWN key
- Press the enter key and then input pin code, drive capacity, pump capacity, name
4. Delete saved pin code

- Display through UP or DOWN key pin code which intended to delete.
- Press enter key and then input “0000” on the pin code.
- “Erase complete” and then complete display.
PIN USE
NOTE
1. Change from disable to enable the pin enable parameter of calibration
2. Pin code will be displayed when power turn on
3. If you input pin code, vehicle should normally operated.
4. When pin is enabled that no saved data, temporary pin code is “2580”

Display Text
Calibration
Description Display Text Unit
Parameters
1 First parameter for calibration enable 1st PASSWORD ASCII
3 Seat switch delay SEAT SW DELAY Sec
4 Foot switch delay FOOW SW DELAY Sec
5 Chat time CHAT TIME Sec
6 Slow speed button enable/disable ENABLE TURTLE Boolean
7 Forward maximum speed FWD MAX SPEED RPM
8 Reverse maximum speed REV MAX SPEED RPM
9 Starting temperature of controller’s fan START CONT. FAN ˚C
10 Accelerator pedal minimum value A output ACCEL MIN VALUE mV
11 Accelerator pedal maximum value A output ACCEL MAX VALUE mV
12 Brake pedal minimum value A output BRAKE MIN VALUE mV
13 Brake pedal maximum value A output BRAKE MAX VALUE mV
14 British unit BRITISH UNIT Boolean
15 Time meter / Odometer on display TIMER-ODOMETER Boolean
16 360degree option 360 DEGREE OPTION Boolean
17 Lift knob minimum value A output LIFT MIN VALUE mV
18 Lift knob maximum value A output LIFT MAX VALUE mV
19 Tilt knob minimum value A output TILT MIN VALUE mV
20 Tilt knob maximum value A output TILT MAX VALUE mV
21 Reach knob minimum value A output REACH MIN VALUE mV
22 Reach knob maximum value A output REACH MAX VALUE mV
23 S/S knob minimum value A output S/S MIN VALUE mV
24 S/S knob maximum value A output S/S MAX VALUE mV
25 Lift max speed LIFT MAX SPEED RPM
26 Tilt speed TILT SPEED RPM
27 Reach speed REACH SPEED RPM
28 S/S speed S/S SPEED RPM
29 Hydro idle speed IDLE SPEED RPM
30 Turtle speed TURTLE SPEED RPM
31 PIN enable PIN ON/OFF Boolean

Diagnostic
Description Display Text Unit
Parameters
1 Drive traction motor speed D MOTOR SPD RPM
2 Drive traction motor speed reference D MOTOR REF SPD RPM
3 Battery voltage BATT VOLTAGE mV
4 Traction Inverter power module temperature D INVERTER TEMP ˚C
5 Traction motor temperature D MOTOR TEMP ˚C
6 Traction motor act current D MOTOR I A
7 Accelerator potentiometer voltage ACCEL 1ST OUT mV
8 Accelerator second Potentiometer voltage ACCEL 2ND OUT mV
9 Brake pedal voltage BRAKE OUT mV
10 Seat switch hour meter SEAT H METER Hr(0.0)
11 Drive motor hour meter DRIVE H METER Hr(0.0)
12 5V out 5V OUT mV
13 Buzzer command BUZZER Boolean
14 Fans command FANS Boolean
15 Foot switch FOOT SW Boolean
16 Drive motor encoder channels D MOTOR ENCODER Boolean or RPM
17 Pump motor speed PUMP MOTOR SPD RPM
18 Pump motor speed reference P MOTOR REF SPD RPM
19 Pump Inverter power module temperature P INVERTER TEMP ˚C
20 Pump motor temperature P MOTOR TEMP ˚C
21 Pump motor act current P-MOTOR I A
22 Pump motor encoder channels P MOTOR ENCODER Boolean or RPM
23 Pump motor hour meter PUMP H METER Hr(0.0)
24 Lift knob output LIFT OUTPUT mV
25 Reach knob output Reach OUTPUT mV
26 S/S knob output S/S OUTPUT mV
27 Tilt knob output TILT OUTPUT mV
28 EPS motor speed E MOTOR SPD RPM
29 EPS motor act angle E MOTOR ACT ANG º
30 EPS motor power module temperature E INVERTER TEMP ˚C
31 EPS motor temperature E MOTOR TEMP ˚C

Alarm List
APPENDIX A, Alarm Standard
Traction
Disable other
Status Error Disable Store in
functions
Priority Level Variable LED LED drive error
(Hydraulic &
(green) (red) (brake) history
Steering)
High 0 ErrLev0 O O O O
1 ErrLev1 O O O O
2 ErrLev2 O O O
3 ErrLev3 O O O
4 ErrLev4 O O O
5 ErrLev5 O O O
Low 6 ErrLev6 O O
High 0 StatLev0 O O O
1 StatLev1 O O
2 StatLev2 O O
Low 3 StatLev3 O
Pump
Status Error Disable Disable Disable Disable Store in

Disable
Priority Level Variable LED LED lower lift reach other error
drive
(green) (red) output output output outputs history
High 0 ErrLev0 O O O O O O O
1 ErrLev1 O O O O O O
2 ErrLev2 O O O O
3 ErrLev3 O O O
4 ErrLev4 O O O
5 ErrLev5 O O O
Low 6 ErrLev6 O O O
High 0 StatLev0 O O O O O O
1 StatLev1 O O O O O
2 StatLev2 O O
Low 3 StatLev3 O
Steering
Status Disable Disable
Store in error
Variable LED other drive
history
(green) functions (brake)
ErrLev0 O O
StatLev0 O O

APPENDIX B, Alarm List for Traction
Device Sub ERROR
no.
No. no.
Name Detection Message LEVEL
Application errors
1 # CAN Timeout
1 # 01 CAN Timeout; Pump inverter; RPDO1 Timeout is active D-CAN FAULT ErrLev4
1 # CAN Timeout
1 # 01 CAN Timeout; Display; RPDO1 Timeout is active DISP CAN FAULT ErrLev4
14 CAN Timeout
1 14 01 CAN Timeout; Steering inverter; Timeout is active STEER CAN FAULT ErrLev0
RPDO1
1 15 01 Sequency Error Input signal Sequency WRONG START ErrLev6

error
Analog accelerator pedal input (line A);

1 # 00 C1p10; Hardware Error PEDAL A FAULT
Analog accelerator pedal input (line Sensor_2Pt_AC;
1 # 01 A); C1p10; Input value is too low Fault = 0x8001 PEDAL A FAULT ErrLev2
1 # 02 Analog accelerator pedal input (line Sensor_2Pt_AC; PEDAL A FAULT ErrLev2

A); C1p10; Input value is too high Fault = 0x8002
1 # 03 Analog accelerator pedal input (line Sensor_2Pt_AC; PEDAL A FAULT ErrLev2
A); C1p10; Value out of range Fault = 0x8010
Analog accelerator pedal input (line

1 # 00 A); C1p10; Input out of range PEDAL A FAULT
1 # 01 Analog accelerator pedal input (line Sensor_2Pt_AC; PEDAL A FAULT StatLev1

A); C1p10; Block is not calibrated Status = 0x8001
1 # 02 A); C1p10; Block is currently in a PEDAL A FAULT StatLev1
Status = 0x8002
calibration cycle
1 # 03 Analog accelerator pedal input (line A); Sensor_2Pt_AC; PEDAL A FAULT StatLev1
C1p10; Parameters are corrupt Status = 0x8004
1 # 04 A); C1p10; Invalid Setup/ Calibration Status = 0x8008 PEDAL A FAULT StatLev1
1 22 00 Analog accelerator pedal input (line PEDAL B FAULT

B); C1p11; Hardware Error
1 22 01 B); C1p11; Input value is too low Fault = 0x8001 PEDAL B FAULT ErrLev2
1 22 02 Analog accelerator pedal input (line Sensor_2Pt_AC;

PEDAL B FAULT ErrLev2
B); C1p11; Input value is too high Fault = 0x8002
1 22 03 Analog accelerator pedal input (line B); Sensor_2Pt_AC; PEDAL B FAULT ErrLev2
C1p11; Value out of range Fault = 0x8010
1 22 05 Analog accelerator pedal input (Compare A PEDAL PHASE FAU ErrLev2
and B)); Accel Error
Analog accelerator pedal input (line

1 23 00 B); C1p11; Input out of range PEDAL B FAULT
1 23 01 Analog accelerator pedal input (line Sensor_2Pt_AC; PEDAL B FAULT StatLev1

B); C1p11; Block is not calibrated Status = 0x8001
1 23 02 B); C1p11; Block is currently in a Status = 0x8002 PEDAL B FAULT StatLev1
calibration cycle

Device
No. Sub
Name Detection Message ERROR
no. no. LEVEL
B); C1p11; Parameters are corrupt Status = 0x8004

B); C1p11; Invalid Setup/ Calibration Status = 0x8008
1 24 00 Analog brake pedal input; C1p22; BRAKE PEDAL FAU

Hardware error
1 24 01 Analog brake pedal input; C1p22; Input Sensor_2Pt_AC; BRAKE PEDAL FAU ErrLev2
value is too low Fault = 0x8001
1 24 02 Analog brake pedal input; C1p22; Input Sensor_2Pt_AC; BRAKE PEDAL FAU ErrLev2
value is too high Fault = 0x8002
1 24 03 Analog brake pedal input; C1p22; Value Sensor_2Pt_AC; BRAKE PEDAL FAU ErrLev2
out of range Fault = 0x8010
1 25 00 Analog brake pedal input; C1p22; Input out BRAKE PEDAL FAU
of range
1 25 01 Analog brake pedal input; C1p22; Sensor_2Pt_AC; BRAKE PEDAL FAU StatLev1
Block is not calibrated Status = 0x8001
1 25 02 Analog brake pedal input; C1p22; Sensor_2Pt_AC; BRAKE PEDAL FAU StatLev1
Block is currently in a calibration cycle Status = 0x8002
Analog brake pedal input; C1p22; Sensor_2Pt_AC;
1 25 03 BRAKE PEDAL FAU StatLev1
Parameters are corrupt Status = 0x8004
Analog brake pedal input; C1p22; Sensor_2Pt_AC;
1 25 04 BRAKE PEDAL FAU StatLev1
Invalid Setup/ Calibration Status = 0x8008
1 40 00 Steering inverter
1 40 01 Fault Steering inverter CP_CANSteerFault = 1 STEER INVER FAU ErrLev2
1 40 02 Position sensor search not completed CP_CANPosiSearEnd = 0 POSITION SEN FAU StatLev1
Standard application errors
Power stage
1 # 00 Warning power stage
1 # 01 Warning power stage; Warn PowerStage.Temp > D-INV OVERTEMP ErrLev6

temperature is reached Warn limit
1 # 00 Error power stage

PowerStage.Temp
1 # 01 Error power stage; Min. Temperature <DeviceInfo.MinTemp ErrLev0
(150℃)
Motor
1 # 00 Error motor
1 # 01 Error motor; Overtemperatur Motor.ActTemp_C > D MOTOROVERTEMP ErrLev2

Max. limit
OS
1 # 00 Error loop time
1 # 02 Error loop time; 3 times in row OS.ExecTime > 2 * LOOP TIME ERROR ErrLev0
OS.ExeceTimeOut

Device
No. Sub
no. no. LEVEL
Monitoring
1 # 00 Error V_DC_Link
1 # 01 Error V_DC_Link; Undervoltage; Level 1 V_DC_Link.Volt < DC LINK FAULT ErrLev2

Min. limit; t = 3s
1 # 00 Error V_DC_Link
1 # 01 Error V_DC_Link; Undervoltage; Level 2 V_DC_Link.Volt <

DeviceInfo.MinVolt t = 3s MIN BATT VOLT ErrLev0
1 57 01 Battery discharge LOW BATT VOLT ErrLev4
1 58 01 Battery miss matching 40Vdc < Battery BATT MISMATCH ErrLev0

voltage >65Vdc
Standard API- errors
General purpose inputs / output

Error general purpose input / output,
1 73 00
C1p13
1 73 01 C1p13; Invalid value at .OutputValue C1p13.PinStatus; Bit2 = 1 PARK BRAKE FAULT ErrLev2

1 73 02 C1p13; Overload / output shorted to C1p13.PinStatus; Bit3 = 1 PARK BRAKE FAULT ErrLev2
+I/O supply / transistor damaged
1 73 03 C1p13; Output disconnected / output C1p13.PinStatus; Bit4 = 1 PARK BRAKE FAULT ErrLev2
shorted to -I/O / transistor shorted
1 73 04 C1p13, switched off because overload C1p13.PinStatus; Bit5 = 1 PARK BRAKE FAULT ErrLev2
1 73 05 C1p13, switch on protection after C1p13.PinStatus; Bit6 = 1 PARK BRAKE FAULT ErrLev2
overload
1 73 06 C1p13.PinStatus; Bit7 = 1 PARK BRAKE FAULT ErrLev2
C1p13, Hardware Watchdog error
1 73 07 Error general purpose input / output, C1p13.SafetyStatus = 1 PARK BRAKE FAULT ErrLev2
C1p13; Safety error

1 # 00 C1p15 WARNING BUZ FAU

1 # 01 C1p15; Overload / output shorted to C1p15.PinStatus; Bit3 = 1 WARNING BUZ FAU ErrLev6
1 # 02 C1p15; Output disconnected / output C1p15.PinStatus; Bit4 = 1 WARNING BUZ FAU ErrLev6
1 # 03 Error general purpose input / output, C1p15.PinStatus; Bit5 = 1 WARNING BUZ FAU ErrLev6
C1p15, switched off because overload
1 # 04 C1p15, switch on protection after C1p15.PinStatus; Bit6 = 1 WARNING BUZ FAU ErrLev6
overload
1 # 05 C1p15, Hardware Watchdog error C1p15.PinStatus; Bit7 = 1 WARNING BUZ FAU ErrLev6

Device
No. Sub
no. no. LEVEL
1 77 00 Error general purpose input / output,

C1p26
1 77 01 C1p26; Overload / output shorted to C1p26.PinStatus; Bit3 = 1 FAN I-O FAULT ErrLev6
1 77 02 C1p26; Output disconnected / output C1p26.PinStatus; Bit4 = 1 FAN I-O FAULT ErrLev6
1 77 03 Error general purpose input / output, C1p26.PinStatus; Bit5 = 1 FAN I-O FAULT ErrLev6
1 77 04 C1p26, switch on protection after C1p26.PinStatus; Bit6 = 1 FAN I-O FAULT ErrLev6
overload
1 77 05 Error general purpose input / output, C1p26.PinStatus; Bit7 = 1 FAN I-O FAULT ErrLev6
Main contactor output
1 # 00 Error main contactor output, C1p24 CONTACTOR FAULT
1 # 01 Error main contactor output, C1p24; C1p24.PinStatus; Bit1 = 1 CONTACTOR FAULT ErrLev0
Invalid value at .OutputValue
Error main contactor output, C1p24;
1 # 02 Overload / output shorted to +I/O C1p24.PinStatus; Bit2 = 1 CONTACTOR FAULT ErrLev0
supply / transistor damaged
Error main contactor output, C1p24;
1 # 03 Output disconnected / output shorted C1p24.PinStatus; Bit3 = 1 CONTACTOR FAULT ErrLev0
to -I/O / transistor shorted
Error main contactor output, switched
1 # 04 C1p24.PinStatus; Bit4 = 1 CONTACTOR FAULT ErrLev0
off because overload
Error main contactor output, switch on
1 # 05 protection after overload C1p24.PinStatus; Bit5 = 1 CONTACTOR FAULT ErrLev0
Error main contactor output, Hardware
1 # 06 Watchdog error C1p24.PinStatus; Bit6 = 1 CONTACTOR FAULT ErrLev0
General purpose proportional inputs /

output
Error general purpose proportional
1 # 0 input / output, C1p16
1 # 01 input / output, C1p16; Invalid value C1p16.PinStatus; Bit2 = 1 F-RH BRKE FAULT ErrLev3
at .OutputValue
1 # 02 input / output, C1p16; Invalid value C1p16.PinStatus; Bit3 = 1 F-RH BRKE FAULT ErrLev3
at .DitherAmp
1 # 03 input / output, C1p16; Output C1p16.PinStatus; Bit4 = 1 F-RH BRKE FAULT ErrLev3
disconnected / output shorted to -I/O /
transistor shorted
1 # 04 input / output, C1p16, Hardware C1p16.PinStatus; Bit5 = 1 F-RH BRKE FAULT ErrLev3
Watchdog error
1 # 0 Error general purpose proportional

input / output, C1p27
1 # 01 input / output, C1p27; Config error C1p27.PinStatus; Bit2 = 1 F-LH BRKE FAULT ErrLev3
at .OutputValue
1 # 02 input / output, C1p27; Config error C1p27.PinStatus; Bit3 = 1 F-LH BRKE FAULT ErrLev3
at .DitherAmp

Device
No. Sub
no. no. LEVEL
1 # 03 input / output, C1p27; Output C1p27.PinStatus; Bit4 = 1 F-LH BRKE FAULT ErrLev3
disconnected / output shorted to -I/O /
transistor shorted
1 # 04 input / output, C1p27, Hardware C1p27.PinStatus; Bit5 = 1 F-LH BRKE FAULT ErrLev3
Watchdog error
1 # 05 Error general purpose proportional C1p27.SafetyStatus = 1 F-LH BRKE FAULT ErrLev3
input / output, C1p27; Safety error
Auxiliary supply voltages

1 # 00 Error sensor supply, C1p23
1 # 01 Error sensor supply, C1p23; C1p23.Volt > + 10%

5V OVERVOLTAGE ErrLev0
Overvoltage of set value for 5s
1 # 02 Error sensor supply, C1p23; C1p23.Volt > + 40% 5V OVERVOLTAGE ErrLev0
Overvoltage of set value
1 # 03 Error sensor supply, C1p23; C1p23.Volt < - 10% of 5V UNDERVOLATGE ErrLev0
Undervoltage set value for 5s
1 # 04 Error sensor supply, C1p23; C1p23.Volt < - 50% of 5V UNDERVOLATGE ErrLev0
Undervoltage set value for 100ms
1 # 05 Error sensor supply, Supply voltage C1p23.PinStatus; Bit1 = 1 5V FAULT ErrLev0
feedback value out of range
1 # 00 Error encoder supply, C1p28

Error encoder supply, C1p28; C1p28.FeedbackValu
1 # 01 12VOVERVOLTAGE ErrLev2
Overcurrent e > Max. limit
Error encoder supply, C1p28; C1p28.FeedbackValu
1 # 02 12V UNDERVOLATGE ErrLev2
Undercurrent e < Min. limit
Power stage
1 # 00 Error power stage
PowerStage.Status;
1 # 01 Error power stage; Overtemperature D-INV OVERTEMP ErrLev2
Bit1 = 1
1 # 02 Error power stage; SensorError PowerStage.Status; D-INV SEN FAU ErrLev2
Bit2 = 1
PowerStage.Status;
1 # 03 Error power stage; Overvoltage Bit3 = 1 MAX BATT VOLT ErrLev2
PowerStage.Status;
1 # 04 Error power stage; Overcurrent Bit4 = 1 D-INV OVERCUR ErrLev2
Error power stage; Power stage PowerStage.Status;
1 # 06 permanently locked because wrong Bit6 = 1 WRONG MOT DATA ErrLev2
motor data
Error power stage; Power Stage PowerStage.Status;
1 # 07 permanently locked because HW Bit7 = 1 WATCHDOG ERROR ErrLev2
watchdog error
1 # 08 permanently locked because current Bit8 = 1 CURRENT SEN FAU ErrLev2
sensor error
1 # 09 permanently locked because Bit9 = 1 UNDERVOLTAGE ErrLev2
undervolt detection
Selftest
1 # 00 Error selftest
1 # 01 Error selftest; Error DC-Link circuit Selftest.Error; Bit0 = 1 DC LINK ERROR ErrLev2
1 # 02 Error selftest; Error in Watchdog Selftest.Error; Bit1 = 1 WATCHDOG FAULT ErrLev0

circuit, operation impossible

Device
No. Sub
no. no. LEVEL
1 # 03 Error selftest; Short circuit to -V DC-

Link Selftest.Error; Bit2 = 1 DC LINK SHORT ErrLev2
1 # 04 Error selftest; Short circuit to +V DC-

Link Selftest.Error; Bit3 = 1 DC LINK SHORT ErrLev2
1 # 05 Error selftest; Error in motor wiring or Selftest.Error; Bit4 = 1 MOTOROUTPUT FAU ErrLev2
power stage
1 # 06 Error selftest; Shorted power output Selftest.Error; Bit5 = 1 FET FAULT ErrLev2
(motor output)
Error selftest; Test not passed,
1 # 07 because of hardware over voltage Selftest.Error; Bit6 = 1 OVERVOLTAGE ErrLev0
protection
1 # 08 Error selftest; Curropted production Selftest.Error; Bit7 = 1 EEPROM FAULT ErrLev2
data in EEPROM detected
1 # 00 Warning selftest
1 # 01 Warning selftest; Error in Watchdog Selftest.Warning; Bit0 = 1 WATCHDOG StatLev0

circuit, limited operation possible FAULT
Warning selftest; Watchdog not
1 # 02 tested, because low voltage at DC- Selftest.Warning; Bit1 = 1 LOW VOTAGE StatLev0
Link
Warning selftest; Curropted user data
1 # 03 Selftest.Warning; Bit2 = 1 EEPROM FAULT StatLev0
in EEPROM detected
Warning selftest; Curropted error
1 # 04 Selftest.Warning; Bit3 = 1 EEPROM FAULT StatLev0
history data in EEPROM detected
1 # 00 Status selftest
1 # 01 Status selftest; DCLink selftest in Selftest.Status = 1 DC-LINK SELF StatLev1

progress
1 # 02 Status selftest; Watchdog selftest in Selftest.Status = 2 WATCHDOG SELF StatLev0
progress
Status selftest; PowerStage selftest in POWERSTAGE
1 # 03 Selftest.Status = 3 StatLev1
progress SELF
Analog input (Rheo)

1 # 00 Error analog input, C1p34
1 # 01 Error analog input, C1p34; Input out C1p34.PinStatus; Bit1 D- THERMAL FAULT ErrLev2
of range =1
1 # 02 Error analog input, C1p34, Hardware C1p34.PinStatus; Bit2 D- THERMAL FAULT ErrLev2
error =1
Motor
1 # 00 Error motor
Motor.Status;
1 # 01 Error motor; Config error Bit0…Bit22 = 1 or CONFIG FAULT ErrLev3
MotorControl.Status;
Bit0….Bit5 = 1
NVMem
1 # 00 Error NVMem
1 # 01 Error NVMem; The NVMem restored NVMem.Status; Bit0 = 1 MEMORY FAULT ErrLev0
to a previouse state
1 # 02 Error NVMem; The NVMem NVMem.Status; Bit1 = 1 MEMORY FAULT ErrLev0
checksumme are not correct
1 # 03 Error NVMem; The reset routine NVMem.Status; Bit2 = 1 MEMORY FAULT ErrLev0
couled not access the NV memory

Device
No. Sub
no. no. LEVEL
CAN
1 # 00 Error CAN
1 # 01 Error CAN; CAN controller error CAN[0].DriverError = 1 CAN FALUT ErrLev0

APPENDIX C, Alarm List for Pump
Device Sub ERROR
no.
No. no.
Name Detection Message LEVEL
Application errors
CAN
2 10 00 CAN Timeout
2 10 01 CAN Timeout; RPDO Timeout is active P-CAN FAULT ErrLev0
2 11 01 Traction Inverter fault Traction Error level 0, 1, T_INVERTER ErrLev1

4, 5, and StatLev0, 1 FAULT
2 15 01 Sequency Error Input signal Sequency WRONG START- StatLev0

error PUMP
CAN Interface
2 20 01 Lift Joystick; Extention(MC012); LIFT LEVER Err ErrLev2

input value is too low
2 20 02 Lift Joystick; Extention(MC012); LIFT LEVER Err ErrLev2
input value is too high
Lift Joystick; Extention(MC012); (MaxIn_mV < In_mV) or
2 20 03 LIFT LEVER Err ErrLev2
input Value out of range (CalCmd> 4)
Lift Joystick; Extention(MC012); (CalLo_pct = 0 and
2 20 05 LIFT LEVER Err StatLev1
Block is not calibrated CalHi_pct = 0)
Lift Joystick; Extention(MC012); (CalLo_pct ≠ 0 and
Block is currently in a calibration cycle CalHi_pct = 0)
Lift Joystick; Extention(MC012);
Parameters are corrupt
Lift Joystick; Extention(MC012);
2 20 08 Invalid Setup/ Calibration LIFT LEVER Err StatLev1
Reach Joystick; Extention(MC012);

2 21 01 REACH LEVER Err ErrLev2
Reach Joystick; Extention(MC012);
2 21 02 input value is too high REACH LEVER Err ErrLev2
Reach Joystick; Extention(MC012); (MaxIn_mV < In_mV) or
2 21 03 input Value out of range (CalCmd> 4) REACH LEVER Err ErrLev2
2 21 05 Reach Joystick; Extention(MC012); (CalLo_pct = 0 and REACH LEVER Err StatLev1

2 21 06 Reach JoystickBlock is currently in a (CalLo_pct ≠ 0 and REACH LEVER Err StatLev1
calibration cycle CalHi_pct = 0)
2 21 07 Reach Joystick; Extention(MC012); REACH LEVER Err StatLev1
2 21 08 Reach Joystick; Extention(MC012); REACH LEVER Err StatLev1
Invalid Setup/ Calibration
2 22 01 Tilt Joystick; Extention(MC012); TILT LEVER Err ErrLev2

2 22 02 Tilt Joystick; Extention(MC012); TILT LEVER Err ErrLev2
2 22 03 Tilt Joystick; Extention(MC012); (MaxIn_mV < In_mV) or TILT LEVER Err ErrLev2
Tilt Joystick; Extention(MC012); (CalLo_pct = 0 and
2 22 05 Block is not calibrated CalHi_pct = 0) TILT LEVER Err StatLev1
Tilt Joystick; Extention(MC012); (CalLo_pct ≠ 0 and
2 22 06 Block is currently in a calibration cycle CalHi_pct = 0) TILT LEVER Err StatLev1
Tilt Joystick; Extention(MC012);
2 22 07 Parameters are corrupt TILT LEVER Err StatLev1
Tilt Joystick; Extention(MC012);
2 22 08 Invalid Setup/ Calibration TILT LEVER Err StatLev1

Device
No. Sub
no. no. LEVEL
2 23 01 SideShift Joystick; Extention(MC012); SS LEVER Err ErrLev2

2 23 02 SideShift Joystick; Extention(MC012); SS LEVER Err ErrLev2
2 23 03 SideShift Joystick; Extention(MC012); (MaxIn_mV < In_mV) or SS LEVER Err ErrLev2
2 23 05 SideShift Joystick; Extention(MC012); (CalLo_pct = 0 and SS LEVER Err StatLev1
2 23 06 SideShift Joystick; Extention(MC012); (CalLo_pct ≠ 0 and SS LEVER Err StatLev1
Block is currently in a calibration cycle CalHi_pct = 0)
2 23 07 SideShift Joystick; Extention(MC012); SS LEVER Err StatLev1
2 23 08 SideShift Joystick; Extention(MC012); SS LEVER Err StatLev1
Invalid Setup/ Calibration
Power stage
2 50 00 Warning power stage
Warning power stage; Warn PowerStage.Temp >
2 50 01 temperature is reached Warn limit P-INV OVERTEMP StatLev3
2 51 00 Error power stage

PowerStage.Temp <
2 51 01 Error power stage; Min. Temperature ErrLev1
DeviceInfo.MinTemp
Motor
2 52 00 Error motor
2 52 01 Error motor; Overtemperatur Motor.ActTemp_C > Max. P-MOTOROVERTEMP ErrLev1

limit
2 53 00 Warning motor
2 53 01 Warning motor; Warn temperature is Motor.ActTemp_C > P-MOTOROVERTEMP StatLev3

reached Warn limit
OS
2 54 00 Error loop time
2 54 02 Error loop time; 3 times in row OS.ExecTime > 2 * LOOP TIME ERROR ErrLev0
OS.ExeceTimeOut
Analog inputs
2 70 01 Analog brake pedal input; C1p10;

Input out of range BRAKE PEDAL FAU StatLev3
2 70 02 Analog brake pedal input; C1p10; BRAKE PEDAL FAU StatLev3

Hardware Error

Device
No. Sub
no. no. LEVEL
2 70 03 Analog brake pedal input; C1p10; Sensor_2Pt_AC; Fault =

Input value is too low 0x8001 BRAKE PEDAL FAU StatLev3
2 70 04 Analog brake pedal input; C1p10; Sensor_2Pt_AC; Fault = BRAKE PEDAL FAU StatLev3
Input value is too high 0x8002
2 70 05 Analog brake pedal input; C1p10; Sensor_2Pt_AC; Fault = BRAKE PEDAL FAU StatLev3
Value out of range 0x8010
2 70 06 Analog brake pedal input; C1p22; Sensor_2Pt_AC; Status = BRAKE PEDAL FAU StatLev3
Block is not calibrated 0x8001
2 70 07 Analog brake pedal input; C1p22; Sensor_2Pt_AC; Status = BRAKE PEDAL FAU StatLev3
Block is currently in a calibration cycle 0x8002
2 70 08 Analog brake pedal input; C1p22; Sensor_2Pt_AC; Status =
BRAKE PEDAL FAU StatLev3
Parameters are corrupt 0x8004
2 70 09 Analog brake pedal input; C1p22; Sensor_2Pt_AC; Status =
BRAKE PEDAL FAU StatLev3
Invalid Setup/ Calibration 0x8008
2 71 00 Error analog input, C1p11
2 71 01 Error analog input, C1p11; Input out C1p11.PinStatus; Bit1 = 1 HEIGHT SIG FAU StatLev3
of range
2 71 02 Error analog input, C1p11, Hardware C1p11.PinStatus; Bit2 = 1 HEIGHT SEN FAULT StatLev3
error
2 71 03 Sensor Input value is too low HEIGHT SEN FAULT StatLev3
2 71 04 Sensor Input value is too high HEIGHT SEN FAULT StatLev3
2 71 05 Sensor Input value is out of range HEIGHT SEN FAULT StatLev3
2 71 06 Height Set error ; Out of range Set value > Mast Height HEIGHT SET ERROR StatLev3
(Height 1 < Height 2 <
2 71 07 Height Set error ; Incorrect setting HEIGHT SET ERROR StatLev3
Height 3)

Error analog input, C1p22; Input out
2 72 01 of range C1p22.PinStatus; Bit1 = 1 WEIGHT SIG FAU StatLev3
2 72 02 Error analog input, C1p22, Hardware C1p22.PinStatus; Bit2 = 1 WEIGHT SEN FAULT StatLev3
error
2 72 03 Sensor Input value is too low WEIGHT SEN FAULT StatLev3
2 72 04 Sensor Input value is too high WEIGHT SEN FAULT StatLev3

C1p14
2 74 01 C1p14; Overload / output shorted to C1p14.PinStatus; Bit3 = 1 REACH OUT SOL FAU ErrLev4
2 74 02 C1p14; Output disconnected / output C1p14.PinStatus; Bit4 = 1 REACH OUT SOL FAU ErrLev4
2 74 03 Error general purpose input / output, C1p14.PinStatus; Bit5 = 1 REACH OUT SOL FAU ErrLev4
2 74 04 C1p14, switch on protection after C1p14.PinStatus; Bit6 = 1 REACH OUT SOL FAU ErrLev4
overload
2 74 05 Error general purpose input / output, C1p14.PinStatus; Bit7 = 1 REACH OUT SOL FAU ErrLev4

C1p15

Device
No. Sub
no. no. LEVEL
2 75 01 C1p15; Overload / output shorted to C1p15.PinStatus; Bit3 = 1 DIVERTER SOL FAU ErrLev3
2 75 02 C1p15; Output disconnected / output C1p15.PinStatus; Bit4 = 1 DIVERTER SOL FAU ErrLev3
2 75 03 Error general purpose input / output, C1p15.PinStatus; Bit5 = 1 DIVERTER SOL FAU ErrLev3
2 75 04 C1p15, switch on protection after C1p15.PinStatus; Bit6 = 1 DIVERTER SOL FAU ErrLev3
overload
2 75 05 Error general purpose input / output, C1p15.PinStatus; Bit7 = 1 DIVERTER SOL FAU ErrLev3

C1p25
2 76 01 C1p25; Overload / output shorted to C1p25.PinStatus; Bit3 = 1 RETRACT SOL FAU ErrLev3
2 76 02 C1p25; Output disconnected / output C1p25.PinStatus; Bit4 = 1 RETRACT SOL FAU ErrLev3
2 76 03 C1p25, switched off because overload C1p25.PinStatus; Bit5 = 1 RETRACT SOL FAU ErrLev3
2 76 04 C1p25, switch on protection after C1p25.PinStatus; Bit6 = 1 RETRACT SOL FAU ErrLev3
overload
2 76 05 C1p25.PinStatus; Bit7 = 1 RETRACT SOL FAU ErrLev3

2 77 00
C1p26
2 77 01 C1p26; Overload / output shorted to C1p26.PinStatus; Bit3 = 1 EXTEND SOL FAU ErrLev3
2 77 02 C1p26; Output disconnected / output C1p26.PinStatus; Bit4 = 1 EXTEND SOL FAU ErrLev3
2 77 03 Error general purpose input / output, C1p26.PinStatus; Bit5 = 1 EXTEND SOL FAU ErrLev3
2 77 04 C1p26, switch on protection after C1p26.PinStatus; Bit6 = 1 EXTEND SOL FAU ErrLev3
overload
2 77 05 Error general purpose input / output, C1p26.PinStatus; Bit7 = 1 EXTEND SOL FAU ErrLev3

C1p13
2 78 01 C1p13; Invalid value at .OutputValue C1p13.PinStatus; Bit2 = 1 REACH IN SOL FAU ErrLev4
2 78 02 C1p13; Overload / output shorted to C1p13.PinStatus; Bit3 = 1 REACH IN SOL FAU ErrLev4
2 78 03 C1p13; Output disconnected / output C1p13.PinStatus; Bit4 = 1 REACH IN SOL FAU ErrLev4
2 78 04 C1p13, switched off because overload C1p13.PinStatus; Bit5 = 1 REACH IN SOL FAU ErrLev4
2 78 05 C1p13, switch on protection after C1p13.PinStatus; Bit6 = 1 REACH IN SOL FAU ErrLev4
overload
2 78 06 C1p13.PinStatus; Bit7 = 1 REACH IN SOL FAU ErrLev4

Device
No. Sub
no. no. LEVEL

C1p13; Safety error C1p13.SafetyStatus = 1 REACH IN SOL FAU ErrLev4
General purpose proportional

inputs / output
2 79 00 Error general purpose proportional
output, Extention (MC012) C1P11
2 79 01 output, Extention (MC012) C1P11; FLOW SOL SOL FAU ErrLev5
Input value too low
Input value too high
Open circuit
Short circuit(Overload)
Input value out of range

2 80 00
output, Extention (MC012) C1P12
2 80 01 output, Extention (MC012) C1P12; LIFT SOL SOL FAU ErrLev5
Input value too low
Input value too high
Open circuit
Short circuit(Overload)
Input value out of range

2 81 00 input / output, C1p27
2 81 01 input / output, C1p27; Config error C1p27.PinStatus; Bit2 = 1 LOWRING SOL FAU ErrLev6
at .OutputValue
2 81 02 input / output, C1p27; Config error C1p27.PinStatus; Bit3 = 1 LOWRING SOL FAU ErrLev6
at .DitherAmp
input / output, C1p27; Output
2 81 03 disconnected / output shorted to -I/O / C1p27.PinStatus; Bit4 = 1 LOWRING SOL FAU ErrLev6
transistor shorted
2 81 04 input / output, C1p27, Hardware C1p27.PinStatus; Bit5 = 1 LOWRING SOL FAU ErrLev6
Watchdog error
2 81 05 Error general purpose proportional C1p27.SafetyStatus = 1 LOWRING SOL FAU ErrLev6
input / output, C1p27; Safety error

2 82 00 Error sensor supply, C1p23
Error sensor supply, C1p23; C1p23.Volt > + 10% of
2 82 01 Overvoltage set value for 5s 5V OVERVOLTAGE StatLev3

Device
No. Sub
no. no. LEVEL
2 82 02 Error sensor supply, C1p23; C1p23.Volt > + 40% of

Overvoltage set value 5V OVERVOLTAGE StatLev3
2 82 03 Error sensor supply, C1p23; C1p23.Volt < - 10% of set 5V UNDERVOLATGE StatLev3
Undervoltage value for 5s
2 82 04 Error sensor supply, C1p23; C1p23.Volt < - 50% of set 5V UNDERVOLATGE StatLev3
Undervoltage value
2 82 05 Error sensor supply, Supply voltage C1p23.PinStatus; Bit1 = 1 5V FAULT StatLev3
2 83 00 Error encoder supply, C1p28
2 83 01 Error encoder supply, C1p28; C1p28.FeedbackValue > 12V OVERVOLTAGE ErrLev1

Overcurrent Max. limit
2 83 02 Error encoder supply, C1p28; C1p28.FeedbackValue < 12V UNDERVOLATGE ErrLev1
Undercurrent Min. limit
Power stage
2 84 00 Error power stage
2 84 01 Error power stage; Overtemperature PowerStage.Status; Bit1 = 1 P-INV OVERTEMP ErrLev1
2 84 02 Error power stage; SensorError PowerStage.Status; Bit2 = 1 P-INV SEN FAU ErrLev1
2 84 03 Error power stage; Overvoltage PowerStage.Status; Bit3 = 1 P-INV OVERVOL ErrLev1
2 84 04 Error power stage; Overcurrent PowerStage.Status; Bit4 = 1 P-INV OVERCUR ErrLev1
Error power stage; Power stage
2 84 06 permanently locked because wrong PowerStage.Status; Bit6 = 1 WRONG MOT DATA ErrLev1
motor data
Error power stage; Power Stage
2 84 07 permanently locked because HW PowerStage.Status; Bit7 = 1 WATCHDOG ERROR ErrLev1
watchdog error
2 84 08 permanently locked because current PowerStage.Status; Bit8 = 1 CURRENT SEN FAU ErrLev1
sensor error
2 84 09 permanently locked because PowerStage.Status; Bit9 = 1 UNDERVOLTAGE ErrLev1
undervolt detection
Selftest
2 85 00 Error selftest
2 85 01 Error selftest; Error DC-Link circuit Selftest.Error; Bit0 = 1 DC LINK ERROR ErrLev1
2 85 02 Error selftest; Error in Watchdog Selftest.Error; Bit1 = 1 WATCHDOG FAULT ErrLev0

circuit, operation impossible
2 85 03 Error selftest; Short circuit to -V DC- Selftest.Error; Bit2 = 1 DC LINK SHORT ErrLev1
Link
Error selftest; Short circuit to +V DC-
2 85 04 Selftest.Error; Bit3 = 1 DC LINK SHORT ErrLev1
Link
2 85 05 Error selftest; Error in motor wiring or Selftest.Error; Bit4 = 1 MOTOR OUTPUT ErrLev1
power stage FAU
Error selftest; Shorted power output
2 85 06 Selftest.Error; Bit5 = 1 FET FAULT ErrLev1
(motor output)
Error selftest; Test not passed,
2 85 07 because of hardware over voltage Selftest.Error; Bit6 = 1 OVERVOLTAGE ErrLev0
protection
2 85 08 Error selftest; Curropted production Selftest.Error; Bit7 = 1 EEPROM FAULT ErrLev0
data in EEPROM detected
2 86 00 Warning selftest

Device
No. Sub
no. no. LEVEL
2 86 01 Warning selftest; Error in Watchdog WATCHDOG

circuit, limited operation possible Selftest.Warning; Bit0 = 1 FAULT StatLev0
Warning selftest; Watchdog not
2 86 02 tested, because low voltage at DC- Selftest.Warning; Bit1 = 1 LOW VOTAGE StatLev0
Link
2 86 03 Warning selftest; Curropted user data Selftest.Warning; Bit2 = 1 EEPROM FAULT StatLev0
in EEPROM detected
2 87 00 Status selftest
2 87 01 Status selftest; DCLink selftest in Selftest.Status; Bit0 = 1 DC-LINK SELF StatLev1

progress
2 87 02 Status selftest; Watchdog selftest in Selftest.Status; Bit1 = 1 WATCHDOG SELF StatLev0
progress
2 87 03 Status selftest; PowerStage selftest in Selftest.Status; Bit2 = 1 POWERSTAGE StatLev1
progress SELF
Analog input (Rheo)

2 88 01 Error analog input, C1p34; Input out C1p34.PinStatus; Bit1 = 1 P- THERMAL FAULT ErrLev1
of range
2 88 02 Error analog input, C1p34, Hardware C1p34.PinStatus; Bit2 = 1 P- THERMAL FAULT ErrLev1
error
Motor
2 90 00 Error motor
2 90 01 Error motor; Config error Motor.Status; Bit0…Bit22 CONFIG FAULT ErrLev1

=1
NVMem
2 91 00 Error NVMem
2 91 01 Error NVMem; The NVMem restored NVMem.Status; Bit0 = 1 MEMORY FAULT ErrLev0
to a previouse state
2 91 02 Error NVMem; The NVMem NVMem.Status; Bit1 = 1 MEMORY FAULT ErrLev0
checksumme are not correct
2 91 03 Error NVMem; The reset routine NVMem.Status; Bit2 = 1 MEMORY FAULT ErrLev0
couled not access the NV memory
CAN
2 92 00 Error CAN
2 92 01 Error CAN; CAN controller error CAN[0].DriverError = 1 CAN FUAL ErrLev0

APPENDIX D, Alarm List for Steering
Device FLASH SUB CLEAR STEER FAULT TRACTION ERROR
NAME POSSIBLE CAUSE SET CONDITION Display Message
No. CODE CODE CONDITION ACTION FAULT ACTION LEVEL
1. An internal hardware error
Hardware has been detected; controller
3 11 01 Fault defective. Hardware error detected. Cycle KSI Shutdown. 1 = Stop. E_HARDWARE ErrLov 0
2. Controller defective.
1. External short of phase U, V,
Controller Controller hardware detected E_OVERCURR
3 12 01 or W motor connection. Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
Overcurrent 1 2. Controller defective. overcurrent condition. NT
1. External short of phase U, V, 1. Phase current > 120% of
or W motor connection. base current limit.
Controller E_OVERCURR
3 12 02 2. Motor parameters are mis- 2. Phase current exceeded Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
Overcurrent 2 tuned. the current measurement NT
3. Controller defective. limit.
1. Leakage to vehicle frame
Current from phase U, V, or W (short in Controller current sensors E_CURRENT_S
3 13 01 Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
Sensor Fault motor stator). have invalid offset reading. ENSOR
1. External load on capacitor
Capacitor bank voltage does
bank (B+ connection terminal)
3 14 01 Precharge that prevents the capacitor bank not complete the charge to Cycle KSI. Shutdown. 1 = Stop. E_PRECHARGE ErrLov 0
minimum of 75% of the
from charging.
2. Controller defective. keyswitch voltage.
Controller Bring heatsink Warning

Controller is operating in an Controller heatsink temperature
3 15 01 Severe temp above - Only. 3 = No action. E_CT_S_UTEMP StatLev0
Undertemp extreme environment. is equal to or below -40°C. 35°C.
1. Improper mounting of
Controller controller. Controller heatsink Warning then E_S_OVERTE
3 16 01 Severe 2. Excessive load on vehicle. temperature is equal to or Cycle KSI. 1 = Stop. ErrLov 0
Shutdown. MP
Overtemp 3. Controller is operating in an above 95°C.
extreme environment.
1. Battery or battery cables or
battery connections defective.
2. Excessive non-controller
Severe system drains on battery. Capacitor bank voltage (B+
3 17 01 terminal) less than 12 V Cycle KSI. Shutdown. 1 = Stop. E_12V_FAULT ErrLov 0
Undervoltage 3. Battery disconnected while
driving. when Interlock = On.
4. Blown B+ fuse or steer
contactor did not close.
1. Battery or battery cable
Severe resistance too high for a given Keyswitch or capacitor
3 18 01 Overvoltage regen current voltage (B+ terminal) greater Cycle KSI. Shutdown. 1 = Stop. E_OVERVOLT ErrLov 0
2. Battery disconnected while than 65 V.
regen braking.

1. Improper mounting or cooling 2 = Reduce

speed. (Max
of controller. Controller heatsink
3 22 01 Controller 2. Excessive load on vehicle. temperature is equal to or Heatsink Warning speed reduced E_CONT_OVE StatLev0
Overtemp temp< 85°C. Only linearly from RTEMP
3. Controller operating in an above 85°C.
extreme environment. 100% at 85°C to
0% at 95°C.)
5V Supply Failure External load impedance on the 5V supply is outside the 5V Hold then
3 25 01 +5V supply is too low. +/- 10% range. Cycle KSI. Shutdown. 1 = Stop. E_5V_FAULT ErrLov 0
3 26 01 10V Supply Failure External load impedance on the 10V supply is outside the Cycle KSI. Warning then 1 = Stop. E_10V_FAULT ErrLov 0
+10V supply is too low. 10V +/- 10% range. Shutdown.
1. Motor is operating in an Sensor Enable = On and

Severe Motor extreme environment. steer motor temperature > Warning then E_MOTOR_O
3 27 01 Overtemp 2. Motor Temperature Control programmed Temperature Cycle KSI. Shutdown. 1 = Stop. VERTEMP ErrLov 0
parameters are mis-tuned. Max.
2 = Reduce
speed. (Max
Steer motor speed reduced
1. Motor is operating in an Sensor Enable = On and temperature
Severe Motor linearly from
3 28 01 extreme environment. steer motor temperature > < Warning 100% at E_S_MT_H_C StatLev0
Hot Cutback 2. Motor Temperature Control programmed Temperature programmed Only. UTBACK
Temperature
parameters are mis-tuned. Hot. Temperature Hot to 0% at
Hot.
Temperature
Max.)
1. Motor thermistor is not
connected properly. Motor temp 2 = Reduce
speed. (Max
Motor Temp 2. If the application does not Motor temperature input is at input within Warning speed reduced E_MT_TEMP_
3 29 01 use a motor thermistor, the the normal StatLev0
Sensor Fault the voltage rail (0 or 5V). Only. to Sensor SENSOR
Motor Temperature Sensor operating
Enable parameter should be range. Fault Traction
Cutback.)
programmed Off.
Steering contactor driver is
1. Open or short on driver load. either open or shorted. This
Contactor Warning then
3 31 01 2. Dirty connector pin fault is set only when Cycle KSI. 1= Stop. ErrLov 0
Open/Short 3. Bad crimps or faulty wiring Contactor Control Type = 1 Shutdown.
and Checks Enable = On
The controller is unable to
1. External load impedance on assert the fault output line. If
Fault Output the Fault Output = On and Warning then
3 35 01 Open/Short the fault output is too low. the fault output voltage is not Cycle KSI. Shutdown. 1= Stop. ErrLov 0
within 5V of the KSI voltage,
the fault is set

The motor has been
commanded to move at more
1. Stalled steer motor. than 25% of the Max Motor
2. Steer motor encoder failure. Speed or at more than 95%
Warning then E_MT_STALL
3 36 01 Motor Stalled 3. Bad crimps or faulty wiring. of the available motor current Cycle KSI. Shutdown. 1 = Stop. ED ErrLov 0
4. Problems with power supply when the motor speed is less
of the steer motor encoder. than the programmed Stall
Speed for the programmed
Stall Time.
1. After the steer contactor
closes but before operation
starts, the motor is checked
for an open phase by running
a DC current out of phase U
and ensuring the current is
1. Motor phase is open. measured back on both
2. Bad crimps or faulty motor phase V and phase W. The Warning then
3 37 01 Motor Open fault is set if the check fails. Cycle KSI. 1 = Stop. E_MT_OPEN ErrLov 0
cable wiring. Shutdown.
3. Controller defective. 2. When the motor is
running, one phase averages
less than 1 A while the other
phases average more than 4
A for 256 msec when the
electrical frequency is greater
than 1 Hz and has not
changed sign.
1. New software loaded into
EEPROM Error in EEPROM CRC
3 46 01 EEPROM memory. Cycle KSI. Shutdown. 1 = Stop. E_EEPROM ErrLov 0
Failure 2. Controller defective. calculation.
1. A parameter was changed
that requires a power cycle.
A parameter value or the 2. A new software
software was changed that application was loaded that
Parameter required a power cycle. This caused the parameter values E_PARA_CHA
3 49 01 to be overwritten, requiring a Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
Change Fault fault is set automatically to force NGE
the vehicle operator to cycle power cycle.
power, for safety purposes. 3. A device using the serial
interface(such as the 1313)
is requesting an out-of-range
parameter change.
1. When the interlock switch
inputs are a crossed Interlock Input 1 = Interlock Interlock
Interlock configuration (N.O. N.C.), the
Input 3. The fault is checked Input1 <> Interlock = E_INTERLOC
3 51 01 Switch two inputs are checked and A only when Interlock Type = 2 Interlock Off. 1 = Stop. K_SW ErrLov 0
Supervision fault is set if Switch 1 (pin 9) (crossed polarity). Input 3.
=Switch 3 (pin 11).2. Interlock
switch defective.

1. Homing Input Type = 1
1. When the wheel position is (crossed polarity) and
not close to home, the redundant Switch2 = Switch4 and the
Home Switch position from home is >5°. Warning then
3 52 01 home switch inputs are checked Cycle KSI. 1 = Stop. E_HOME_SW ErrLov 0
Supervision and a fault is set if they disagree. 2. Homing Input Type = 2 Shutdown.
(same polarity) and Switch2
2. Home switch defective.
<> Switch4 and the position
from home is >5°.
During homing (Steer
Command State = 2), the
3 53 01 Home Position Home switch defective. home position was not found Cycle KSI. Shutdown. 1 = Stop. E_STEER_FA ErrLov 0
Not Found after traveling 180° or within ULT
the programmed Following
Error Time.
During steering (Steer Command
State = 4), the wheel position at
Home which the Home variable
Reference changes is further than the Warning E_HOME_RE
3 54 01 Tolerance Home switch defective. parameter Supervision » Home Cycle KSI. Only. 1 = Stop. FER_Tol ErrLov 0
Fault Reference Tolerance from the
original position found during
homing.
Steer Command differs from
Steer Command2 by more
than the programmed Steer
Steer Command Tolerance. These
3 55 01 Command Command input device command signals are Cycle KSI. Hold then 1 = Stop. E_STEER_CO ErrLov 0
defective. Shutdown. MMAND
Supervision checked by both the main
and supervisor processors if
the Device State = 5
(Operation Enabled).
1. Wheel Position differs from
Wheel Position2 by more than
the Wheel Position Tolerance
for 80 msec. These feedback
signals are checked by both the
main and supervisor
Wheel Position Position feedback device processors if the Device State Hold then E_WHEEL_P
3 56 01 = 5 (Operation Enabled). Cycle KSI 1 = Stop. ErrLov 0
Supervision defective. Shutdown. OSITION
2. Wheel Position differs from
Encoder3 Position by more
than the Encoder Position
Tolerance. These feedback
signals are checked by only the
main processor if the Device
State = 5 (Operation Enabled).

The measured current of the
+5V supply (pins 21 and 34)
The external load on the 5V
3 69 01 5V Current Out supply is drawing either too is less than the parameter Cycle KSI. Hold then 1 = Stop. E_5V_FAULT ErrLov 0
of Range Shutdown. 5V Current Min or
much or too little current.
greater than the parameter
5V Current Max.
1. Software defective. E_SOFTWAR
3 71 01 Software Fault 1 Internal watchdog reset. Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
2. Controller defective. E_FAULT

3 71 02 Software Fault 2 Unexpected software value. Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
1. Value out-of-range.
3 71 03 Software Fault 3 1. Software defective. 2. Parameter CRCs do not Cycle KSI. Shutdown. 1 = Stop. E_SOFTWAR ErrLov 0
match.
3 71 04 Software Fault 4 2. Controller defective. Task overrun. Cycle KSI. Shutdown. 1 = Stop. E_FAULT ErrLov 0
1. Software defective. An internal micro-to-micro E_SOFTWAR

3 71 05 Software Fault 5 2. Controller defective. communication error. Cycle KSI. Shutdown. 1 = Stop. E_FAULT ErrLov 0
Communication between the Time between PDO1

3 72 01 PDO1 Timeout traction controller and the 1222 messages received exceeds Cycle KSI. Warning then 1 = Stop. E_CONT_FAU ErrLov 0
Shutdown. LT
halted. the PDO1 TimeoutTime.
This fault is checked by the
supervisor micro only when the
Steering Command State = 4
1. Position feedback device (Steering). A fault is set if the
3 73 01 Following Error defective. absolute value of the difference Cycle KSI. Warning then 1 = Stop. E_MOTOR_E ErrLov 0
2. Steer motor stalled. between Steer Command2 and Shutdown. NCODER
3. Steer motor encoder failed. Wheel Position2 is greater than
the parameter Following Error
Tolerance for Following Error
Time.
1. The software is not
compatible with the controller
Hardware 1. New software loaded. hardware. E_SW_MISMA
3 74 01 Software 2. Controller hardware cannot Cycle KSI. Shutdown. 1 = Stop. ErrLov 0
2. The software loaded into TCH
Mismatch use the loaded software.
either or both
microprocessors in incorrect.
Device » Command Input
3 75 01 Parameter Parameter settings are in conflict Device = 1 and Vehicle Cycle KSI. Shutdown. 1 = Stop. E_PARA_FAU ErrLov 0
Conflict with each other. Configuration » Traction Speed LT
Input » Input Type = 1.

SYSTEMS OPERATION
Glossary
NAME DESCRIPTION
Accelerator A device that converts mechanical movement into a analog voltage pattern to the logics for
variable drive motor speed.
Ampere (or Amp) The unit of measurement of current flow. The amount of current that one volt can push through
a resistance of one ohm.
Analog to Digital A device that converts an analog voltage into a pattern of digital HIGH and LOW voltage
Converter signals.
Battery Two or more cells connected together for a supply of electric current.
BDI Battery Discharge Indicator - An electrically controlled display showing the operator the state of
batter y charge.
Bus Bar A heavy electrical conductor to which other smaller wires are connected.
Capacitor Device used to store electrical energy for short periods of time.
Circuit A way for current to go from the positive (+) side of an electrical power source to the negative (-
) side of an electrical power source. This can be through wires and electrical components.
Coil A component made from many circles or turns of wire used to concentrate a magnetic field.
Connector Part of a wire assembly or harness that connects with another wire assembly or harness. Used
for ease of assembly and disassembly.
Contactor An electrical component consisting of an electromagnetic coil and a set of heavy contact tips.
Assembly Control current passes through the coil, building a magnetic field which closes or opens the
contact tips.
Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly.
Contact Tips or The portion of a switch, relay or contactor where the circuit can be opened or closed.
Contacts
Current The movement or flow of electricity through a conductor. A circuit must be complete for current
to flow.
Current Limit The maximum allowable armature current of a stalled drive motor during pulsing.
Digital Signal A signal in which the elements may be either of two distinct values.
For example high voltage, low voltage.
Diode A semiconductor device that allows current to flow in one direction, from the anode to the
cathode.
Display An electrical device that converts voltage inputs to a visual output.
Electrical Assist Electrically trying to rotate the drive motor opposite to the direction of truck movement.
Braking
(EAB)
Fuse A component in an electrical circuit that will open the circuit if too much current goes through it.
Harness An assembly made of two or more wires that are held together.
Heat Sink A mounting frame used for semiconductor cooling.
Indicator LCD that gives an indication of some vehicle condition when it turns on or flashes.
LCD Liquid Crystal Display.
Logic Control Unit The main printed circuit board containing a microprocessor and circuits to condition the voltage
signals that go into or come out of the logics. It electronically monitors and controls the truck's
functions.

NAME DESCRIPTION
Microprocessor A small computer chip preprogrammed to control the various electrical functions on a
lift truck.
Normal Condition Words used with a switch or relay. Their normal condition is their condition when they
are not controlled by the application of force, temperature, pressure, or electricity.
MOSFET A semiconductor component used in electric lift trucks as an electronic switch. A
MOSFET most often has three terminals, a GATE(G), a DRAIN(D), a SOURCE(S). A
MOSFET is a voltage-controlled device and required only a small input current. The
switching speed is very high.
Ohm The unit of measurement of resistance. The amount of resistance that will let one volt
push only one ampere of current through it.
ON-Time The amount of time current flows through a transistor.
Open Circuit Wiring or components of a circuit that have no continuity.
Overload The presence of voltage or current which is greater than an electrical circuit or
component is designed to handle.
Plugging A portion of electrical braking where the generated current is directed back through
the armature.
Relay An electrical component consisting of an electromagnetic coil and a set of small
contact tips. Control current passes through the coil, building a magnetic field which
closes or opens the contact tips. When the contact tips are closed, low current can
flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow of current.
Rotor Part that rotate of motor
Schematic A line drawing of an electrical or electronic assembly which uses symbols to show
individual components. It shows how the components, wires and connectors function
electrically.
Short Circuit An electrical connection between two or more components that is not desired.
Socket The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State Reference to semiconductor components or circuits that use semiconductor
components that have no moving parts, such as diodes and transistors.
Stator Fixed part in driving state of motor
Switch A component used to control an electric circuit. It can close or open a circuit.
Systems The electrical components, circuits, and connections that deliver power to perform
specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal Sensor A sensor that activates at a set temperature.
Volt The unit of measurement of electromotive force. One volt is the force needed to
make one ampere of current flow through one ohm of resistance in a circuit.
Watt The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes
(current) multiplied by volts (voltage) is watts (power).
Wire A conductor used to provide a path for current to flow to and from electrical
components.
Wiring Diagram A drawing using visual representation of components the way they actually look. It is
used to show the locations of components and the connections between them.

Installation and Wiring
Controller Installation

Wiring Group Installation

Light Installation

TECHNICAL INFORMATION of PLUS+1 INVERTER
INDEX
Introduction – About this Manual............................................................................................................. 46

PLUS+1 Inverter Family Technical Information ......................................................................................... 46
What Information is in this Manual ............................................................................................................ 46
What Information is in Product Data Sheet................................................................................................ 46
What Information is in the PLUS+1 GUIDE Software User Manual ............................................................ 46
What Information is in the API................................................................................................................... 47
PLUS+1 Library ........................................................................................................................................ 47
PLUS+1 Inverter Family ............................................................................................................................ 48

PLUS+1 Inverter Family............................................................................................................................ 48
Inverter Typical Applications ..................................................................................................................... 49
PLUS+1 Inverters fit with other PLUS+1 Products..................................................................................... 49
PLUS+1 Inverter Naming Convention ...................................................................................................... 50

PLUS+1 Inverter Naming Convention ....................................................................................................... 50
User Liability and Safety Statements ....................................................................................................... 51

OEM Responsibility .................................................................................................................................. 51
PLUS+1 Inverter Power Stage Specification............................................................................................ 52

Ratings ..................................................................................................................................................... 52
Power Data .............................................................................................................................................. 52
Input / Output Types and Specification ................................................................................................... 53

Input / Output Types ................................................................................................................................. 53
Input / Output Wiring Principle .................................................................................................................. 56
Input / Output Supply Voltage. .................................................................................................................. 57
Inputs ....................................................................................................................................................... 57
Digital (DIN) ......................................................................................................................................... 57
Multi Function Input (DIN/DIN PU/Freq)................................................................................................ 58
Analog Input with Unipolar Range (AIN Unipolar) ................................................................................. 58
Analog Inputs with Bipolar Range (AIN bipolar) .................................................................................... 59
Rheo .................................................................................................................................................... 59
Encoder Channel A, Encoder Channel B .............................................................................................. 60
Inputs / Outputs ........................................................................................................................................ 60
General Purpose Input / Output (DOUT/PWMOUT/DIN) ...................................................................... 60
General Purpose Proportional Inputs/Outputs (DOUT/PWMOUT/DIN/POUT)....................................... 62
Main Contactor Output (DOUT MC/PWMOUT MC) .............................................................................. 63
Output with Enhanced Safety (DOUT safety/PWMOUT safety/POUT safety) ....................................... 64
Power Supply ............................................................................................................................................ 65

Control Power Supply ............................................................................................................................... 65
Auxiliary Power Supplies .......................................................................................................................... 65
Sensor Power Supply........................................................................................................................... 65
Encoder Power Supply......................................................................................................................... 66
Power Stage Supply ................................................................................................................................. 66
Precharging of capacitors .................................................................................................................... 68

Protection .................................................................................................................................................. 69
Self Test at Power Up............................................................................................................................... 69
EEPROM CRC Check.......................................................................................................................... 69
DC Link Test ........................................................................................................................................ 70
Hardware Watchdog ............................................................................................................................ 70
Power Stage Test ................................................................................................................................ 71
Runtime Protection Functions ............................................................................................................... 72

Power Stage Protection ....................................................................................................................... 72
Over Voltage........................................................................................................................................ 72
Over Current ........................................................................................................................................ 72
Over Temperature................................................................................................................................ 73
Temperature Sensor Error ................................................................................................................... 73
Unprotected Mode ............................................................................................................................... 73
Power Stage .............................................................................................................................................. 74

Enable / Disable ....................................................................................................................................... 74
PWM Frequency....................................................................................................................................... 75
Diagnostics............................................................................................................................................... 76
Service Function ....................................................................................................................................... 77

Error History ............................................................................................................................................. 77
Hour Counter............................................................................................................................................ 79
Device Info ............................................................................................................................................... 79
NVRam User Data.................................................................................................................................... 79
Motor Control ............................................................................................................................................ 80

Control Structure ...................................................................................................................................... 80
Field Oriented Motor Control................................................................................................................ 80
Speed Controller ................................................................................................................................. 81
Speed Feedback ................................................................................................................................. 81
Torque Feed Forward .......................................................................................................................... 81
Torque Limitation................................................................................................................................. 82
Current Limitation ................................................................................................................................ 82
Speed Control Versus Torque Control ................................................................................................. 82
Motor Definition ........................................................................................................................................ 83
Electric Motor Compliance Blocks ........................................................................................................ 83
Open Electric Motor Data Function Block ............................................................................................. 83
Electric Motor Data Download Block .................................................................................................... 83
Re-Initialization of Motor Data.............................................................................................................. 83
Temperature Compensation ..................................................................................................................... 84
Diagnostics............................................................................................................................................... 84
Encoder Diagnostics............................................................................................................................ 84
Diagnostics of Motor Data.................................................................................................................... 84
Diagnostics of Motor Control................................................................................................................ 85

Controller Area Networks Specifications................................................................................................. 86
CAN (Controller Area Networks) Ports ...................................................................................................... 86
Terminating Resistor ................................................................................................................................ 87
Bus Stubs (Wires form Main Bus to the Unit, also called Drop).................................................................. 87
CAN Wiring Suggestions .......................................................................................................................... 87
CAN Protocols.......................................................................................................................................... 87
Product Ratings ........................................................................................................................................ 88
Product Installation and Start Up ............................................................................................................. 89

Mating Connectors ................................................................................................................................... 89
PLUS+1 Inverter Installation Guidelines .................................................................................................... 90
Mounting the Inverter........................................................................................................................... 90
Wiring the Power Stage ....................................................................................................................... 90
PLUS+1 Inverter Installation Guidelines (continued) ................................................................................. 91
PLUS+1 Recommended Machine Wiring Guidelines ................................................................................. 92
Welding on a Machine Equipped with PLUS+1 Modules ........................................................................... 92
PLUS+1 USB/CAN Gateway .................................................................................................................... 92
Start Up and Recommended Installation Instructions ................................................................................ 93

Introduction – About this Manual
PLUS+1 Inverter Family Technical Information
This manual is designed to be a comprehensive PLUS+1™ inverter family reference tool for vehicle OEM design,
engineering and service personnel. It is one of five primary sources of the PLUS+1 Inverter product technical
information. The other four sources are:
• Individual PLUS+1 Inverter product data sheets

• The PLUS+1 Graphical User Interface Development Environment (GUIDE) Software User Manual
• The application interface document
• The PLUS+1 library
What Information is in this Manual

This manual describes electrical details that are common to all PLUS+1 Inverters hardware, including general
specifications, basic operating system, input and output parameters, environmental ratings and installation details.
What Information is in Product Data Sheet

Parameters and engineering data that are unique to an individual PLUS+1 Inverter are contained in the respective
inverter product data sheet. Data sheets contain the following information:
• Numbers and types of inputs and outputs

• Inverter maximum current and voltage capability
• Power supply current consumption
• Inverter installation drawings
• Inverter weights
• Product ordering information
What Information is in the PLUS+1 GUIDE Software User Manual

Detailed information regarding the PLUS+1 GUIDE software tool set, that is used to build PLUS+1 machine
management solutions is contained in the user manual. This technical information manual covers the following
broad topics:
• How to use the GUIDE graphical application development tool to create machine applications
• How to configure input and output parameters
• How to download GUIDE applications to target PLUS+1 hardware
• How to upload and download tuning parameters
• How to use the diagnostic and service tool

What Information is in the API
Detailed information for the Parameter interface between the internal Inverter control Software and the PLUS+1
Application Software created in PLUS+1 GUIDE. The Application Layer Interface (API) document contains the
following information:
• Variable Name with short description

• Variable Type
• Variable Function & Scaling
PLUS+1 Library
DOOSAN provides a library of defined Software function and applications that can be used in PLUS+ 1 products.
This library contains Compliance Blocks for PLUS+1 products and Function Blocks for defined functions that can
be used to create an individual application Software in PLUS+1 GUIDE. Additionally fully approved application
software for standard applications is available and will be continuously enlarged.
The PLUS+1 Library is part of the PLUS+1 GUIDE software tool and also available on the website.

PLUS+1 Inverter Family
PLUS+1 Inverter Family

Inverter Typical Applications
PLUS+1 Inverters is a unique family of inverters, as well as machine controllers in one enclosure. They are
designed to control AC induction motors used in a variety of battery powered material handling equipment and
machinery, to provide propel, steering and work functionality. The unique requirements of electric vehicle control
necessitate that the specifications and typical use of PLUS+1 Inverter input/output to be different than the
input/output specifications common to other PLUS+1 devices.
Typical applications of PLUS+1 Inverters include, but are not limited to:
• Walkie/rider pallet and various types of low lift warehouse trucks

• Walk behind stacker lift trucks and order pickers
• Reach and 4 way warehouse trucks
• Sweepers/scrubbers
• Side loaders
• Counterbalanced trucks
• Tow tractors and airport ground support vehicles
• Electric, platform and neighborhood vehicles
• Golf cars
• Turf care equipment and machinery
• Aerial (telescopic boom and scissor lift) access equipment
PLUS+1 Inverters fit with other PLUS+1 Products

The PLUS+1 Inverter family represents a major extension to DOOSAN machine management products. In
addition to the PLUS+1 Inverter family, discussed in this manual, these also include: vehicle microcontrollers,
graphical display terminals and operator input devices, such as joysticks and finger tips.
The PLUS+1 products provide flexible, expandable, powerful and cost effective total machine management
systems. Current users of PLUS+1 should note that the PLUS+1 Inverters inputs and outputs are defined
differently from the PLUS+1 microcontrollers.
These devices communicate with each other and with other intelligent systems over a machine Controller Area
Network (CAN) data bus. PLUS+1 hardware products are designed to be equally effective in a distributed CAN
system, with intelligence in every node, or as stand-alone control for smaller machine systems. PLUS+1 systems
are incrementally expandable: additional nodes can be added easily to the machine CAN bus to increase system
capabilities or computational power.

PLUS+1 Inverter Naming Convention
PLUS+1 Inverter Naming Convention

User Liability and Safety Statements
OEM Responsibility
The OEM of a machine or vehicle in which PLUS+1 electronic controls are installed has the full responsibility for
all consequences that might occur. Doosan Inverter has no responsibility for any consequences, direct or indirect,
caused by failures or malfunctions.
• Doosan Inverter has no responsibility for any accidents caused by incorrectly mounted or maintained
equipment.
• Doosan Inverter does not assume any responsibility for PLUS+1 products being incorrectly applied or the
system being programmed in a manner that jeopardizes safety.
• All safety critical systems shall include an emergency stop to switch off the main supply voltage for the
outputs of the electronic control system. All safety critical components shall be installed in such a way that
can be switched off at any time.
Please note the power stage capacitors will maintain a stored energy of over 100Ws and could therefore supply
connected components fore some seconds after emergency stop is switched off. The emergency stop must be
easily seen and must be accessible to the operator.

PLUS+1 Inverter Power Stage Specification
Ratings
The PLUS+1 Inverter Family is designed to operate with a nominal voltage supply of 24V, 36V, 48V and 80V. The inverter
will operate with full functionality if the supply voltage is in the voltage range specified for each of the types.
Power Data
Type: MIxx-S- 24 / 240- 24 / 300- 24 / 400-
Size MI03 MI04 MI06
Nominal voltage [VDC] 24
Input voltage range [VDC] 16...36
Nominal current [3~ Arms]1) 120 150 200
Maximum current [3~ Arms]2) 240 300 400
Boost current [3~ Arms]3) 260 330 420
Output voltage [3~ Vrms]4) 3 x 0...16
Dimensions [mm] W 140 140 140
H 200 200 200
D5) 90/110 91/111 98/118
5)
Weight [kg] 2,5/2,7 2,8/3,0 3,5/3,7
Power connectors M6 M8 M10
Type: MIxx-S- 48 / 180- 48 / 300- 48 / 400-

Size MI03 MI04 MI06
Nominal voltage [VDC] 36-48
Nominal current [3~ Arms]1) 100 150 200
Maximum current [3~ Arms]2) 180 300 400
Boost current [3~ Arms]3) 200 330 420
Output voltage [3~ Vrms]4) 3 x 0...24 or 3 x 0...32
Dimensions [mm] W 140 140 140
H 200 200 200
D5) 90/110 91/111 98/118
5)
Weight [kg] 2,5/2,7 2,8/3,0 3,5/3,7
Power connectors M6 M8 M10
Type: MIxx-S- 80 / 650-

Size MI20
Nominal voltage [VDC] 80
Nominal current [3~ Arms]1) 325
Maximum current [3~ Arms]2) 650
Boost current [3~ Arms]3) 715
Output voltage [3~ Vrms]4) 3 x 0...53
Dimensions [mm] W 280
H 280
D5) 101/143
Weight [kg]5) 9/10,5
Power connectors M10
1)
@ 8kHz switching frequency
2)
S2-2min
3)
for 10 seconds
4)
@ input voltage = nominal voltage
5)
plate version / finned version

Input / Output Types and Specification
Input / Output Types
PLUS+1 Inverters perform two functions:
¾ Motor Control
¾ Application Control
The corresponding hardware sections have separate power supply pins which may be supplied by different
voltages. The Motor Control section is typically powered by the vehicle’s main supply voltage. The application
control section is independent. It may be connected to the vehicle main power supply or to any other power supply
(e.g. DC/DC converter) within the specified voltage range.
The Application Control section of each PLUS+1 Inverter hardware device (MIxx) has interface pins that support
multiple functions as well as pins that support fixed functions. Pins that support multiple input or output functions
are user-configurable via the API variable (.PinConfig) using PLUS+1 GUIDE software. Refer to product data
sheets for the input/output (I/O) content of individual devices.
This portion of the technical information manual provides specifications for each PLUS+1 Inverter I/O type.
AMPSEAL 35 Pin Connector
Power supply – (Ground) C1p01
Power supply + C1p02
CAN High C1p03
CAN Low C1p04
CAN High C1p06
CAN Low C1p07
I / O supply input C1p08
I / O supply output C1p09
AIN unipolar C1p10
AIN bipolar C1p11
DOUT safety / PWMOUT safety / DIN C1p13
DOUT / PWMOUT / DIN C1p14
POUT / DOUT / PWMOUT / DIN C1p16
Encoder channel A C1p17
DIN / DIN PU C1p18
DIN C1p19
DIN C1p20
DIN C1p21
AIN bipolar C1p22
Sensor supply C1p23
DOUT MC / PWMOUT MC C1p24
POUT safety / DOUT safety / PWMOUT safety / DIN C1p27
Encoder supply C1p28
Encoder channel B C1p29
DIN / DIN PU C1p30
DIN C1p31
DIN C1p32
DIN C1p33
Rheo C1p34
Power supply – (Ground) C1p35 C1p35

WARNING
The functionality and the specifications of PLUS+1 Inverter inputs and outputs are different from other
PLUS+1 controllers and I/O expanders.

The following table lists MIxx input and output types and typical usage:
Function Description Typical usage
DIN Digital input, high active Standard digital inputs
DIN PU Digital input with pull-up resistor, low active Interface input from external components
with open-collector outputs such as
encoders (for motor encoder there are
separate inputs available)
AIN unipolar Analog input 0 to 10V Inputs for set value potentiometer, throttle,
minilever,…
AIN bipolar Analog input -10 to +10V Interface input from vehicle master
controller providing set value for speed
and driving direction (-10V to 0V:
backward 0V to +10V: forward)
Rheo Rheostat input. Measurement of an Motor temperature sensor
external resistance between this pin and
minus power supply.
Encoder Paired inputs driven from a quadrature Must be used for motor speed feedback
channel A encoder. encoder.
channel B Encoder with open-collector or push-pull
outputs can be used
DOUT Digital output, low-side-switch with free Driver for external components, like
wheeling diode to I/O supply output electromagnetic brakes, on/off valves,
contactors
PWMOUT Digital output with the same properties as Simple PWM control of external inductive
DOUT but using pulse width modulated loads with on/off functionality
signal with a frequency of 100Hz. (electromagnetic brakes, on/off valves,
Pulse width programmable 0 to 100% with contactors) in order to reduce power
a resolution of 10%. consumption and heat
POUT Current controlled output, superposed with Driver for proportional valves
dither signal, low-side-switch with free
wheeling diode
DOUT MC Same properties as DOUT, but with a free Driver for main contactor.
wheeling diode to main power supply (C1- This output provides a reverse polarity
P2) protection for the inverter in combination
with the main contactor (see further
description at 6.5.3).
PWMOUT MC Same properties as DOUT MC, but in Driver for main contactor.
PWM mode (similar to PWMOUT) This output provides a reverse polarity
protection for the inverter in combination
with the main contactor. (see further
description at 6.5.3).
DOUT safety Same properties as DOUT, but with Driver for safety critical on/off component,
additional safety transistor like electromagnetic brake or lowering
valve
PWMOUT safety Same properties as PWMOUT, but with Driver for safety critical on/off component,
additional safety transistor like electromagnetic brake or lowering
valve in PWM mode
POUT safety Same properties as POUT, but with Driver for safety critical proportional valve
additional safety transistor

The following ratings apply to all input and output types:
Nominal Voltage [V] 24 36 – 48 72 – 80
Inverter Type: MIxx-S- 24/xxx 48/xxx 80/xxx
Protection
Max. input voltage [V] 36 62 105
Max. input voltage spikes 36 72 120
for < 100ms [V]
Input / Output Wiring Principle

The following diagram shows the wiring principle of the inputs and outputs.

Input / Output Supply Voltage.
PLUS+1 Inverters have a separate input pin and output pin for the power supply to external components (such as
relays, valves, vehicle brake, switches). The external I/O component supply voltage is independent of the vehicle’s
main power supply. It can be connected to the vehicle main power supply or to any other power supply (e.g.
DC/DC converter) in the specified voltage range.

IO supply input Power supply input for IOs
Maximum current [ADC] 8.0
Voltage range
Max. input voltage [VDC] 36 62 105
Min. input voltage [VDC] 36 72 120
IO supply output Power supply output for I/Os
Maximum current [ADC] 8.0
Output voltage I/O supply input
WARNING
All output channels contain free-wheeling diodes to make wiring as easy as possible.
Therefore
• it is mandatory that the positive poles of all loads are connected to Pin9 of connector 1.
• be aware that any voltage to the outputs that is higher than the voltage at pin 9 will destroy the free-
wheeling diodes.
• connect Pin8 with the source that has to supply the connected components
Inputs
Digital (DIN)
Digital inputs connected to PLUS+1 Inverter dedicated DIN pins are debounced in system software with a user
configurable time in the range of 0 to 100ms. Digital input debounce is defined as an input being in a given state
for the configured debounce time before a state change is reported. The sample time of digital inputs is 1ms.

DIN Digital input with pull down
Logic High-active
Input resistance [Ω] 18k 18k 47k
Low-level [V] max. 3.75
High-level [V] min. 9.0

Multi Function Input (DIN/DIN PU/Freq)
The characteristics of Multi Function Input pins are GUIDE software controlled. The inputs can be high active with
pull down resistors (DIN) or low active with pull-up resistors to +15V (DIN PU). The inputs can be used as digital
inputs, single counters or paired to one quadrature counter driven from a quadrature encoder. If the inputs are
used in counter mode the status of the digital input signals can be read in parallel. The digital input signals are
debounced in system software with a user configurable time in the range of 0 to 100ms. Digital input debounce is
defined as an input being in a given state for the configured debounce time before a state change is reported. The
sample time of digital inputs is 1ms.

DIN PU Digital input with pull up resistor to +15V
Logic low-active
Input resistance [Ω] 1.1k
Low-level [V] max. 3.75
High-level [V] min. 9.0
Maximum frequency in 100
counter mode [Hz]
Quad counter mode counts 4 pulses per encoder period
Analog Input with Unipolar Range (AIN Unipolar)

The sample time for analog inputs is 1ms. For each analog input a separate first order filter in the system software
is available with a configurable filter time constant in the range of 10ms to 200ms.
The filter can be bypassed by setting the filter time constant to 0.
This analog input provides additional safety functions. The input voltage range of 0 to 10V is converted to the
range of 10% to 90% of the DSP input range and is provided to two separate DSP channels. This allows the
detection of any failure on the hardware input circuit as well as the detection of an input voltage out of the
specified range. A “out of range” or “hardware error” will be reported at the corresponding API variable .PinStatus.

AIN unipolar Analog input unipolar
Resolution 12 bit
Input resistance [Ω] 120k
Voltage range [V] 0...10
Recommended 1k...10k
resistance
range of external
Potentiometer [Ω]

Analog Inputs with Bipolar Range (AIN bipolar)
The sample time for analog inputs is 1ms. In the system software a separate first order filter with configurable filter
time contstant in the range of 10ms to 200ms is available for each analog input. The filter can be bypassed by
setting the filter time constant to 0.

AIN bipolar Analog input bipolar
Resolution 12 bit
Input resistance [Ω] 120k
Voltage range [V] -10...10
Recommended 1k...10k
resistance
range of external
Potentiometer [Ω]
Rheo
This input has a pull up resistor of 10kΩ to +5V. The system software calculates the resistance of the connected
external sensor in the range of 0 to 12kΩ. If the resistance is higher than 12kΩ the results of the calculation shows
12kΩ and an “Input out of range“ status is reported at the API variable .PinStatus
A first order filter in the system software is available with a configurable filter time constant in the range of 10ms to
2000ms. The filter can be bypassed by setting the filter time constant to 0

Rheo Measurement of an external resistance to minus power supply
(e.g. motor temperature sensor)
Range of resistance [Ω] 0...12k

Encoder Channel A, Encoder Channel B
Paired inputs driven from a quadrature encoder. The inputs have pull-up resistors of 1.1kΩ to encoder supply.
Encoders with open-collector or push-pull outputs and 32 to 1024 pulses per revolution can be used.
WARNING
The field oriented motor control requires the speed feedback value, measured with a quadrature encoder.

Encoder channel A / Encoder Square wave signal from encoder with 90° phase shift between channel A and
channel B channel B
Internal structure Internal pull-up-resistors to power supply encoder
Pull-up-resistor [Ω] 1.1k
Maximum frequency
10
[kHz] (open collector)
Maximum frequency
50
[kHz] (push-pull)
Low-level (maximum)
1.77
[V]
High-level (minimum)
7.1
[V]
Inputs / Outputs
WARNING
Single outputs can sink up to 3 Amps. However, the total output current for the application control section
of the device must not exceed 8 amps.
General Purpose Input / Output (DOUT/PWMOUT/DIN)

The characteristics of General Purpose Input/Output pins are GUIDE software controlled. A General Purpose
Input/Output pin can be programmed to work as digital output in binary mode (DOUT), as PWM output (PWMOUT)
or as digital input (DIN).
The output configuration is an open collector sinking output with overload and open circuit detection.
If a General Purpose Input/Output pin is programmed as “PWM output” the output signal is pulse width modulated
with a constant duty cycle. The PWM frequency is constant 100Hz and the duty cycle has a resolution of 10% and
is defined by software.
The purpose of the PWMOUT mode is simple voltage control. For closed loop current control use the POUT mode
on an appropriate pin.

If a General Purpose Input/Output pin is programmed as digital input the signal is debounced in system software
with a user configurable time in the range of 0 to 100ms. Digital input debounce is defined as an input being in a
given state for the configured debounce time before a state change is reported. The sample time of digital inputs
is 1ms.
The status of the pin can be read in GUIDE software in all configuration modes using the API variable “.DigIn”.
The debouncing is only active in DIN mode.

DOUT/PWMOUT Digital output
Internal structure Low-side-switch with free wheeling diode
Cathode of free wheeling
I/O supply output
diode connected to.
Signal condition
Reactions time minimum 1ms, dependent on application SW loop time.
(DOUT)
Signal condition Programmable PWM signal from 0% to 100% with 10% step.
(PWMOUT) PWM frequency = 100Hz.
Nominal current [A] 2.0
Maximum current [A]
(for min. 1 second
3.0
before overload
protection activated)
Over load protection Non-damage, current / thermal limit, status indication at ON state, automatic
latch off/resume
Resistance to minus
power supply [Ω] 136k
in OFF state
Max. load resistance 45k 266k 468k
[Ω] @ 12V I/O-supply
voltage
(A higher resistance
works, but will be
detected as“output
disconnected”)
Open circuit detection Open circuit detection Fault indication provided. If the voltage at the output pin
in OFF state is less than 9V the Pin-status “Output disconnected” will be
reported.
Considering the internal resistance of 136kOhm the load resistance should be
maximum 45kOhm at 12V I/O-supply voltage. For higher I/O-supply voltages
the maximum load
resistance can be calculated with the formula :
With Vio= I/O-supply voltage

Max. resistance, ON state 0.2 0.2 0.25
RDSon [Ω] @25°C

General Purpose Proportional Inputs/Outputs (DOUT/PWMOUT/DIN/POUT)
The characteristics of General Purpose Proportional Input/Output pins are GUIDE software controlled. A General
Purpose Input/Output pin can be programmed to work as digital output in binary mode (DOUT), as PWM output
(PWMOUT), as proportional output, closed loop current controlled (POUT) or as digital input (DIN).
For specification in DOUT, PWMOUT and DIN mode refer to General Purpose Input/Outputs (Section: 6.5.1)
In POUT mode the output is closed loop current controlled by a hardware two-level controller. The frequency of
the output signal varies between 500Hz and 2kHz. The current set-value is defined by software. A set-value of 0
will switch off the output completely. A dither signal with a fixed frequency of 62.5Hz can be added with a software
defined amplitude up to 250mA. The dither amplitude will be limited to the actual current set-value dynamically.

POUT Current controlled output – superposed with dither signal
Cathode of free wheeling
I/O supply output
diode connected to
Current range [A] 0.04...2.0
Dither signal frequency
62,5 Hz / 0… 0,25 A
/ amplitude
Repeat accuracy from < ±10mA (for set values 0 to 330mA)
unit to unit < ±3% (for set values 330mA to 2A)
Switching frequency [Hz] 500...2000
Over load protection Non-damage, current / thermal limit, automatic latch off/resume
Resistance to minus
power supply [Ω] in 136k
OFF state
Max. load resistance 45k 266k 468k
[Ω] @ 12V I/O-supply
voltage
(A higher resistance
works, but will be
detected as“output
disconnected”)
Open circuit detection Fault indication provided. If the voltage at the output pin in OFF state is less
than 9V the Pin-status “Output disconnected” will be reported.
Considering the internal resistance of 136kOhm the load resistance should be
maximum 45kOhm at 12V I/O-supply voltage. For higher I/O-supply voltages
the maximum load resistance can be calculated with the formula :

RDSon [Ω] @25°C

Main Contactor Output (DOUT MC/PWMOUT MC)
The main contactor output is a special output pin designed to drive the vehicle’s main contactor. In difference to
standard output pins the free wheeling diode is connected to the pin “Power supply +” instead of “I/O supply
output”. This is because the main contactor is typically supplied in parallel to “Power supply +” with the vehicle’s
battery voltage via the vehicle’s key switch. Another diode protects this output against reverse polarity. Together
with the main contactor this circuit provides the reverse polarity protection for the inverter, because the main
contactor can only switch the battery to the power stage if the polarity is correct.
The main contactor output can be programmed to work as digital output in binary mode (DOUT MC) or as PWM
output (PWMOUT MC). The output configuration is an open collector sinking output with overload and open circuit
detection. If the output is programmed as “PWM output” the output signal is pulse width modulated with a constant
duty cycle. The PWM frequency is constant 100Hz and the duty cycle has a resolution of 10% and is defined by
software.
The PWMOUT mode is intended to be used only for simple voltage control.
The main contactor output may be locked (C1p24.locked=1) if a failure was detected at the DC-Link test at power
up.
If the main contactor output pin is used for a purpose other than to drive a main contactor, the load has to be
supplied in parallel to “Power supply +”.

DOUT MC / PWMOUT MC Digital output for main contactor
Cathode of free wheeling diode
Power supply +
connected to
Current range [A] 0.04...2.0
Signal condition (DOUT MC) Reactions time minimum 1ms, dependent on application SW loop time.
Signal condition (PWMOUT MC) Programmable PWM signal from 0% to 100% with 10% step.
PWM frequency = 100Hz.
Maximum current [A] 3.0
Over load protection Non-damage, current / thermal limit, status indication at ON state ,
automatic latch off/resume
Max. load resistance [Ω] @ 12V I/O- 45k 266k 468k
supply voltage
(A higher resistance works, but will be
detected as “output disconnected”)
Open circuit detection Fault indication provided. If the voltage at the output pin in OFF state
is less than 9V the Pin-status “Output disconnected” will be reported.
Considering the internal resistance of 136kOhm the load resistance
should be maximum 45kOhm at 12V I/O-supply voltage. For higher
I/O-supply voltages the maximum load resistance can be calculated
with the formula :

RDSon [Ω] @25°C
Damage to the application control section of the inverter may occur. If voltage is applied to the main contactor
output the application control section of the inverter will be powered up. If significant current is driven through the
main contactor output, the module will be demaged.

Output with Enhanced Safety (DOUT safety/PWMOUT safety/POUT safety)
Output pins which are marked with the extension “safety” are equipped with a redundant safety transistor. The
safety transistor is connected in series to the standard output transistor. In case of an unintended activation of the
output caused by a transistor fault the second transistor will switch off the output. At each switching cycle the
functionality of both transistors is checked by system software. If a transistor is damaged and can’t switch off
anymore the second transistor takes over the full functionality of the output and the API variable .SafetyStatus
shows a “Safety Error”. Afterwards the output will work like a standard output.
This feature provides a very high safety on the appropriate outputs. These outputs should be reserved to drive
components related to safety critical functions like electromagnetic brakes or lowering valves.
The technical specification is identical to standard outputs of the type DOUT, PWMOUT and POUT.

DOUT safety / PWMOUT safety Digital output for safety relevant components e.g. magnetic brake.
Internal structure Low-side-switch with (additional safety switch in series and)
I/O supply output
connected to
Signal condition (DOUT safety) Reaction time minimum 1ms, dependent on application SW loop time
Signal condition (PWMOUT safety) Programmable PWM signal from 0% to 100% with 10% step.
PWM frequency = 100Hz
Maximum current [A]
(for min. 1 second before overload 3.0
protection activated)
Resistance to minus power
136k
supply [Ω] in OFF state
Max. load resistance [Ω] @ 45k 266k 468k
12V I/O-supply voltage
(A higher resistance works, but will
be detected as “output disconnected”)
45k 266 k 468 k

POUT safety Current controlled output for safety relevant components e.g. lower
valve – superposed with dither signal
Internal structure Low-side-switch with additional safety switch in series and free
wheeling diode
I/O supply output
connected to
Current range [A] 0...2.0
Dither signal frequency /amplitude 62,5Hz / 0…0,25 A
Repeat accuracy < ±10mA (for set values 0 to 330mA)
< ±3% (for set values 330mA to 2A)
Switching frequency [Hz] 500...2000
Resistance to minus power
136k
supply [Ω] in OFF state
Max. load resistance [Ω] 45k 266k 468k
(A higher resistance works, but will
be detected as “output disconnected”)
45k 266 k 468

Power Supply
Control Power Supply
The main power supply for the application control circuits has to be provided at pin C1p02 (power supply +) and
C1p01 (power supply -). The pre-charge circuit for the power stage capacitors which is supplied by the same pin
causes an inrush current significantly higher than the nominal supply current.

Power supply + Power supply input for internal power supplies of control circuits
Input voltage range [VDC] 16 - 36 18 - 62 40 – 105
Supply current (typ.)
0.24 0.13 0.1
@ nominal voltage [A]
Inrush current [A] 24 10 12
Power supply – (Ground) Power supply and signal ground
Internal structure Connection with minus power supply
Auxiliary Power Supplies

Sensor Power Supply
PLUS+1 inverters provide a sensor power supply pin with a programmable output voltage of 5V, 10V or 12V.
Typically this power supply is used for throttles, foot pedals or mini-levers. A feedback value C1p23.Volt is
available to factor the actual voltage into the calculation of the set value out of the sensor signal. A voltage higher
than 15V will be reported as 15V (C1p23.Volt=15000) and the status “feedback value out of range” will be
reported (C1p23.PinStatus=1)
If the output value of a sensor depends proportionally on its supply voltage (potentiometer) then it is highly
recommended to use the feedback value C1p23.Volt to monitor the actual voltage and to react in application
software if the voltage drops due to a short circuit or overload.

Sensor supply Power supply for external sensors
Programmable output
5 / 10 / 12
voltage[VDC]
Tolerance [%] 5
Max. output current [A] 0.1
Over current, short circuit Current limitation at 0,1A

Encoder Power Supply
PLUS+1 inverters provide another auxiliary power supply with a fixed voltage and a current feedback
(C1p28.FeedbackValue), typically used for encoder supply. A current higher than 100mA will be reported as
100mA (C1p28.FeedbackValue=1000) and the status “value out of range” will be reported (C1p28.PinStatus=1).

Encoder supply Power supply for encoder (e.g. sensor bearing)
Supply voltage[VDC] 13V ± 10%, Ri = 30 Ω
Over current, short circuit Current limitation at 0,1A
Power Stage Supply

The power stage supply is connected using screws, labeled “+” and “-“. An additional screw allows the assembly
of a power fuse on top of the inverter housing.
The inverter is equipped with steel screw assemblies. Don’t use additional washers.
Make sure that the cable shoes lay directly on the brass sleeves of the inverter.
Details for Power Stage wiring see: 14.2.2.
WARNING
As the currents can be in the range of some hundred Amps, a proper electric contact between brass
sleeves and cable shoes is essential to avoid hot spots.

Connection with a fuse
Connection without a fuse

Precharging of capacitors
The power stage capacitors are pre charged by the control power supply (C1p02) via a positive thermal coefficient
(PTC) resistor. The inrush current of the power stage supply is dependent on the voltage level of the power stage
capacitors at the time of connecting voltage to the power stage. The time between switching control power supply
and power stage supply is responsible for the peak value of the inrush current. In practice a compromise between
start-up time and inrush current has to be found. The easiest way is to switch on the main switch immediately after
the start of the application software. The PLUS+1 Inverter function block library provides a function block “main
contactor” which allows a controlled switching of the main contactor at a defined voltage level.
Short delay for main contactor:

Protection
Self Test at Power Up
At power up a self test routine is performed to detect failures in the hardware of the power stage or external wiring.
The system software is processing following steps:
• EEPROM CRC check

• Configuration of the IOs and sensor power supply
• Test of DC link voltage
• Test of hardware watchdog
• Start of PLUS+1 application software
• Test of power stage
The API variable Selftest displays errors, warnings and the status of the self test.
For details please refer to the API description.
During the tests the power stage is locked by system software, means the application software can not enable the
power stage before the tests are passed.
If one of the tests fails with an error the power stage will be locked permanently.
If an over voltage error occurs at any time during the execution of the self test routine, all test will be skipped and
a self test error will be reported: “Test not passed, because of hardware over voltage protection”
EEPROM CRC Check

First a CRC check of the EEPROM data will be performed. The EEPROM is split into three sections:
Production data: Data stored at production of the device in a protected memory area to adjust software scaling to
actual hardware
User data: Memory area accessible by the user Error History data: Memory area where the error history data is
stored
If the CRC check fails for the production data area, an error will be reported
(Selftest.Error Bit7=1) since wrong data may lead to incorrect behavior.
The self test routine will be skipped and the power stage and the main contactor output will be locked.
If the CRC check fails for the user data area only, a warning will be reported.
Appropriated response to this failure should be programmed in the PLUS+1 application software.
If the CRC check fails for the Error History data area only, a warning will be reported.
The device is functional but error history data might be corrupted.

DC Link Test
With the DC link test a short circuit in the DC link circuit (internal hardware, like capacitor board or external wiring)
can be detected. Before the main contactor gets closed, the capacitor bank is pre-charged via a resistor, powered
by the power supply voltage (C1p02).
Test algorithm:
• Wait until V_DC_Link > Threshold voltage ( 1.6V – 3.5V)
• The test is OK as soon as this condition is fulfilled.
• If this condition is not fulfilled before 5s after power-on, the test failed. ->
– Selftest.Error Bit0=1 (Error Link Circuit)
– The main contactor output and the power stage are locked
permanently (C1p24.Locked=1 ; PowerStage.Locked=2)
– all following tests will be skipped
If this error occurs:

¾ Switch off power supply
¾ Disconnect the power cables + and –
¾ Switch on power supply again
If the DC-Link test with the power cables disconnected shows no error, there is either a short circuit in the wiring of
the power cables + and – or the load in that circuit is too high and pulls down the DC-Link voltage.
If the error still occurs with the disconnected power cables, there is a failure in the inverter power stage and the
device must be replaced.
Hardware Watchdog
In addition to the internal DSP watchdog, PLUS+1 Inverters have a separate hardware watchdog. This watchdog
is triggered by a toggle signal, generated by system software. If the trigger signal is not toggling, the hardware
watchdog disables the power stage and all interface outputs. The hardware watchdog will be checked by the self
test routine at power up.
The result can be a warning or an error:
PLUS+1 Inverters are designed and produced to a very high quality standard.
The hardware watchdog is an additional feature which increases the safety of the inverter beyond the DSP
watchdog. If the hardware watchdog test results in a warning, the functionality of the inverter is limited to the DSP
watchdog. If this is the only error, the inverter is still functional.
Appropriated actions should be incorporated in the PLUS+1 Application Software dependent on the safety
requirements of the application.
– Selftest.Warning Bit0=1: Failure in Watchdog circuit, limited operation possible. The Watchdog can’t switch off
the power stage and the outputs.
– Selftest.Warning Bit1=1: Watchdog not tested, because of low DCLink voltage. A minimum DC-Link voltage is
necessary to perform the Watchdog test. If this voltage is not reached 5 seconds after start of Watchdog test
routine the test will be skipped and this warning will be reported.

Minimum DC-Link voltage
5.2 10 11
to perform Watchdog test[V]
Errors:
– Selftest.Error Bit1=1: Watchdog error, operation impossible.
The power stage and the outputs are always disabled. The inverter is not functional. Further self tests are
discontinued.

Power Stage Test
The power stage test will be performed as soon the DC-Link voltage reaches 90% of the power supply voltage
(C1p02). The application software has already started and can close the main contactor to shorten the time of
charging the DC-Link capacitors.
The only criterion to start the power stage test is the level of the DC-Link voltage independent of the status of the
main contactor.
One of the tests requires a correctly connected motor.
An extensive test of the power stage is performed to detect:
• A shorted power transistor

• A damaged power transistor (will not switch on).
This fault can only be detected if a motor is correctly connected.
• A short circuit of a phase output to –V_DC_Link
• A short circuit of a phase output to +V_DC_Link
• A Short circuit between two phase outputs (short circuit in wiring or motor)
Errors:
Error message Meaning Recommended Result afterwards and
recovery action conclusion
Short circuit to Short circuit between a phase Switch off power supply Still the same error:
–V_DC_Link: output and the + or – power stage Disconnect phase outputs Inverter damaged
supply or between the phase Switch on power supply
Short circuit to outputs again Only error “Error in
+V_DC_Link: motor wiring or power
stage”: There is a short
Shorted power circuit in the motor or
output the wiring.
Error in motor Motor not connected. Test motor wiring If the error occurs with a
wiring or power Motor wiring incorrect. Exchange motor correct wired motor the
stage Motor winding broken. power stage is
damaged.
Based on some physical limitations it’s not possible to detect every short circuit!
Dependent on the length of the cable, cable wire size and cable routing, a short circuit at the end of a cable can
exhibit the same electrical behavior as a connected motor.

Runtime Protection Functions
Power Stage Protection
PLUS+1 Inverters provide a number of protection functions with error, warning and status messages. Most of the
messages are reported via the API to the application software which must be programmed to take the necessary
response.
The system software reacts only to those errors which would destroy the power stage hardware.
• Over voltage
• Over current
• Over temperature and temperature sensor error
If one of these errors occurs:
• The power stage will be disabled (PowerStage.EnableStatus=0)

• The API variable PowerStage.Status displays the error in bitwise representation
– Bit1 = 1: Over temperature
– Bit2 = 1: Sensor error
– Bit3 = 1: Over voltage
– Bit4 = 1: Over current
• The error will be displayed in the error history memory
• For each of these errors there is a counter which counts the total number of detected errors over the lifetime
of the inverter
Writing a 1-0 sequence to PowerStage.Enable will clear the errors which are no longer present.
Over Voltage
The DC_Link voltage is compared to the maximum allowed value using a hardware comparator.
If the actual DC_Link voltage exceeds the maximum value:
• The power stage is disabled by hardware

• An interrupt at the highest level is triggered
• The error handling procedure is performed by software
– Disable the power stage: PowerStage.EnableStatus=0
– Display the error: PowerStage.Status Bit3=1
– Increase error counter: ErrorHistory.AbsOVErrors
– Write error history memory
The actual DC_Link voltage is also displayed at V_DC_Link.Volt
Over Current
In normal operation the current is limited by the software current controller. In addition, the current in each phase
is limited by hardware. If the actual current exceeds the maximum value, the corresponding phase output is
switched off for 50 μs and a signal is sent to the DSP.
This signal triggers a software integrator. If the integrator exceeds a limit (over current signal is active for more
than 3 seconds) the error handling procedure is performed:
• Disable the power stage: PowerStage.EnableStatus=0

• Display the error: PowerStage.Status Bit4=1
• Increase error counter: ErrorHistory.AbsOCErrors
• Write error history memory

Over Temperature
The temperature of the power stage (=the transistors) is measured with a PTC resistor and the values are filtered
with a time constant of 500ms. The actual temperature is calculated and displayed at PowerStage.Temp in the
range of -60°C to 170°C. If the actual value exceeds the temperature limit (stored as production data in EEPROM)
an over temperature error occurs:
• Disable the power stage: PowerStage.EnableStatus=0

• Display the error: PowerStage.Status Bit1=1
• Increase error counter: ErrorHistory.AbsOTErrors
In addition to that the inverter types MI03 and MI04 have a second internal measurement which monitors the
temperature of the power pcb. Usually the board temperature is below the temperature of the transistors, so the
previously mentioned over temperature protection switches off in case of a long overload duration.
In some special cases (very effective forced cooling) it can happen, that the pcb temperature
PowerStage.PCBTemp can reach critical values long before the temperature near the transistors is too high. In
such a case a current derating will take place, starting at 115°C with 100%, ending at 135°C with 0% of the
hardware current limit. This derating phase will be indicated at
• MotorControl.Status Bit12 = 1
The very unlikely case of pcb temperature > 135°C will be indicated at
• PowerStage.Status Bit10 = 1
Temperature Sensor Error

If the result of the power stage temperature calculation or the pcb temperature calculation is out of the sensor
range of -60°C to +170°C a temperature sensor error occurs:
• If Unprotected mode is inactive: disable the power stage:

PowerStage.EnableStatus=0
• Display the error: PowerStage.Status Bit2=1 for power stage
PowerStage.Status Bit11=1 for pcb
• Increase error counter: ErrorHistory.AbsTSensErrors for power stage
ErrorHistory.AbsPCBTSensErrors for pcb
With the help of Unprotected mode (see 8.2.2.) a “limp home mode” can be programmed in GUIDE to allow limited
operation in the event of a temperature sensor error.
Unprotected Mode
The unprotected mode allows the power stage to be enabled even if a temperature sensor error would lock it. The
unprotected mode is activated when PowerStage.Unprotected is changed from 0 to 1. To avoid an unintended
usage of the unprotected mode, the APL resets the unprotected mode after 60 seconds. Within these 60 seconds
the unprotected mode can be inactivated by PowerStage.Unprotected=0 but not retriggered.
In order to recognize the usage of unprotected mode when the machine is serviced, usage of unprotected mode is
stored in error history memory.

Power Stage
Enable / Disable
With the variable PowerStage.Enable the power stage can be switched on and off.
• Enabling the power stage is only allowed if:
– PowerStage.Status Bit1=0 ( no Overtemperature

– at power stage )
– PowerStage.Status Bit3=0 ( no Overvoltage )
– PowerStage.Status Bit4=0 ( no Overcurrent )
– PowerStage.Status Bit10=0 (no Overtemperature
– at PCB)
– PowerStage.Locked=0
or
– PowerStage.Status Bit2=1 ( Power stage temperature
– sensor error)
– or
– PowerStage.Status Bit11=1 (PCB temperature sensor error)
– and
– PowerStage.Unprotected=1 ( Unprotected mode activated )
– PowerStage.Status Bit3=0 ( no overvoltage )
– PowerStage.Status Bit4=0 ( no overcurrent )
– PowerStage.Locked=0
• A 1 to 0 sequence at PowerStage.Enable resets the PowerStage status bits
– PowerStage.Status Bit1 (Power stage overtemperature

– PowerStage.Status Bit2 Power stage)
– (temperature sensor error
– PowerStage.Status Bit3 Overvoltage)
– PowerStage.Status Bit4 (Overcurrent)
– PowerStage.Status Bit10 (PCB overtemperature)
– PowerStage.Status Bit11 (PCB temperature sensor error)
The power stage can be disabled because of an error even if PowerStage.Enable is true. Therefore the actual
status of the power stage can be read at PowerStage.EnableStatus.

PWM Frequency
The PWM frequency of the power stage can be varied in 4 steps:
– 4 kHz
– 8 kHz (default value)
– 12 kHz
– 16 kHz
with the API variable PowerStage.PWMFreq

Because a center-aligned modulation method is used which provides the double PWM frequency to the motor in
most of the applications 8 kHz provides a silent behavior.
However, if the motor noise is too high, the PWM frequency can be increased.
A higher PWM frequency leads to:
• higher power losses

• slightly lower maximum motor voltage
(less performance in field weakening area –> reduced maximum speed)

Diagnostics
The API provides a number of data for diagnostic purposes of the power stage:
API variable Description
PowerStage.EnableStatus Displays the actual status of the power stage (The power stage can
be disabled because of an error even if PowerStage.Enable is true)
False: Power Stage disabled
True: Power Stage enabled
PowerStage.Temp Actual temperature at power stage in degree Celsius
PowerStage.TempLimit The temperature limit of the power stage
PowerStage.HWCurrLimit Current capability of the power stage
Remark: The current may be limited by user current limitation
PowerStage. Locked 0: unlocked (okay)
1: the power stage is temporarily locked
(during initialization and self test)
2: the power stage is permanently locked because of an error.
The reason can be found at Seltest.Error or PowerStage.Status
PowerStage.Status Bit0
0 = OK
1 = wrong value at PWMFreq
Bit1
0 = OK
1 = Overtemperature
Bit2
0 = OK
1 = Temperature sensor error
Bit3
0 = OK
1 = Overvoltage
Bit4
0 = OK
1 = Overcurrent
Bit5
0 = Unprotected Mode inactive
1 = Unprotected Mode active
Bit6
0 = OK
1 = Power Stage permanently locked because of wrong motor data
Bit7
0 = OK
1 = Power Stage permanently locked because of HW watchdog error
Bit8
0 = OK
1 = Power Stage permanently locked because of current sensor error
Bit9
0 = OK
1 = Power Stage permanently locked because of undervoltage
Bit10
0 = OK
1 = PCB overtemperature
Bit11
0 = OK
1 = PCB temperature sensor error

Service Function
Error History
PLUS+1 Inverters provide an Error History Memory which tracks all power stage protection errors and self test
errors as integral function of the system software. The application software might provide another error history
memory for application errors.
The first part of the Error History Memory consists of 3 API data arrays
• ErrorHistory.Number[0..7] : Error numbers

• ErrorHistory.Counter[0..7] : Number of the same errors in a row
• ErrorHistory.Hour[0..7] : Value of HourCounter.Inverter when the latest of the same errors in a row occurred
Each data array has 8 elements.

Element 0 shows the latest error.
Element 7 shows the oldest error.
Error numbers:
1 = Overtemperature
2 = Overvoltage
3 = Overcurrent
4 = Temperature sensor error
5 = Unprotected Mode
6 = DC_Link error
7 = Watchdog error (limited operation possible)
8 = Watchdog error (operation impossible)
9 = Power Stage error, short circuit to –V_DC_Link
10 = Power Stage error, short circuit to +V_DC_Link
11 = Error in motor wiring or power stage
12 = Shorted power output
13 = wrong production data in EEPROM detected
14 = current sensor error
15 = Undervoltage
16 = PCB over temperature
17 = PCB temperature sensor error
The second part of the Error History Memory consists of 4 API variables to count the absolute numbers of
detected power stage protection errors during lifetime of the inverter.
• ErrorHistory.AbsOTErrors: Shows absolute number of detected over temperature errors while lifetime of the
inverter.
• ErrorHistory.AbsOVErrors: Shows absolute number of detected over voltage errors while lifetime of the
inverter.
• ErrorHistory.AbsOCErrors: Shows absolute number of detected over current errors while lifetime of the
inverter.
• ErrorHistory.AbsTSensErrors: Shows absolute number of detected temperature sensor errors while lifetime
of the inverter.
• ErrorHistory.AbsPCBOTErrors: Shows absolute number of detected PCB overtemperature errors while
lifetime of the inverter.
• ErrorHistory.AbsPCBTSensErrors: Shows absolute number of detected PCB temperature sensor errors
while lifetime of the inverter.

The listing of errors in the Error History Memory is managed in the following sequence.
• If the current error is the same as the last entry in ErrorHistory.Number[0]
– Copy the value of HourCounter.Inverter to ErrorHistory.Hour[0]

– Increment the value of ErrorHistory.Counter[0]
– Increment the value of the related absolute error counter
• If the current error is different from the last entry in ErrorHistory.Number[0]
– Move all entries of ErrorHistory.Number, ErrorHistory.Hour and

ErrorHistory.Counter to the next element.
– Write the error number to ErrorHistory.Number[0]
– Copy the value of HourCounter.Inverter to ErrorHistory.Hour[0]
– Write 1 to ErrorHistory.Counter[0]
– Increment the value of the related absolute error counter
Example: Errors during live time

Error type Value of HourCounter
Overcurrent 1000
Overtemperature 2050
Overcurrent 3000
Overcurrent 3005
TempSensorError 3100
Unprotected Mode 3300
Content of Error History Memory:

Element. ErrorHistory Number ErrorHistory Hour ErrorHistory Counter
0 4 3409 2
(TempSensorError)
1 5 3316 3
(Unprotected Mode)
2 4 3120 4
(TempSensorError)
3 3 3005 2
(Overcurrent)
4 1 2065 3
(Overtemperature)
5 3 1000 1
(Overcurrent)
6 0 0 0
7 0 0 0
ErrorHistory.AbsOTErrors: 3
ErrorHistory.AbsOVErrors: 0
ErrorHistory.AbsOCErrors: 3
ErrorHistory.AbsTSensErrors: 6

Hour Counter
PLUS+1 Inverters provide a non resettable hour counter as integral function of the system software. The
application software may provide another hour counter for application needs.
API variable Function Remark

HourCounter.Inverter Hourcounter [0.001h], not Counts, when the inverter
resettable is power supplied at
C1p02
HourCounter.Power Hour counter [0.001h], not Counts, when the power
resettable stage is enabled
Device Info
The device info variable structure provides device specific information.
DeviceInfo.DeadTime Dead time of power stage 0…6400 [ns]
DeviceInfo.MinTemp Minimal specified temperature [°C] where the
unit will work properly.
DeviceInfo.MinVolt Minimal specified voltage [mV] where the unit
will work properly.
DeviceInfo.MaxVolt Maximal specified voltage [mV] where the unit
will work properly.
DeviceInfo.SerialNoA First part of the Serial number
DeviceInfo.SerialNoB Second part of the Serial number
DeviceInfo.PartNo0 Defines the hardware assembly with software
loaded.
DeviceInfo.PartNo1 Is a S-D part number and is set when
customer-specific software and / or parameter
settings are loaded from production cell (part
number that the customer is ordering).
DeviceInfo.InverterFrameSize Inverter frame size (6 for MI06, 20 for MI20
and so on)
NVRam User Data

PLUS+1 Inverters provide a non volatile memory area for user data. This memory area consists of a RAM area
with EEPROM backup. In normal operation the memory access for the application software is not different from
other RAM areas. If power down is detected by the control hardware the NVRam area will be copied immediately
to the EEPROM. An energy buffer inside the control hardware is capable to supply the voltage for the needed time.
At power up the data will be restored to the NVRam area before the application software starts.

Motor Control
PLUS+1 Inverters control three phase AC-induction motors using a field oriented motor control algorithm. This
technology combined with predefined motor data, provided by PLUS+1 Motor Compliance Blocks, guarantees
optimum motor control performance.
PLUS+1 Motor Compliance Blocks eliminate the need for detailed knowledge about AC motors and field oriented
control for successful installation and set-up of the application. Basic knowledge about AC induction motors is
helpful, however, for error diagnostics.
PLUS+1 Motor Compliance Blocks for specific motors can be supported by Doosan Inverter motor
characterization.
A motor data setup for Individual motors can be configured based on IEEE standard values. (see Section: 11.2
Motor Definition)
Control Structure
Field Oriented Motor Control
The main part of the MIxx motor control strategy is the field oriented motor control.
This control requires a set of motor data. If the motor data are well defined (for Doosan Inverter tested motors the
data are available in PLUS+1 Compliance blocks), the torque at the motor shaft follows the torque set value with a
maximum delay of 10ms. This allows optimization of the vehicle drive system to be independent of the motor
torque control and no further tuning of motor data is required to optimize vehicle performance. Only the speed
controller has to be adapted to the application.

Speed Controller
The speed controller has a PI-configuration with anti-windup. The output of the speed controller is the torque set
value. The proportional gain MotorControl.SpeedKP is expressed in Nm/rpm (amount of torque the motor has to
provide per rpm deviation from set-point).
The integral gain MotorControl.SpeedKI is expressed in Nm/rpm/s. (amount the torque set value should increase
in one second per rpm deviation). These control parameters can be optimized at the time of final vehicle
performance testing.
A standard rule for speed control tuning is:
¾ Switch off the integral part by setting MotorControl.SpeedKI=0

¾ Increase the proportional gain until the control starts to oscillate
(consider the complete speed range)
¾ Reduce to proportional gain to 70% of the former value
¾ Keep this proportional gain and follow the same procedure to tune the integral gain
Speed Feedback
The field oriented motor control requires a speed feedback value. The quality of the speed feedback signal is very
important for the performance of the speed control. Inadequate encoder signals or encoder quality may result in
oscillations and insufficient control behavior.
PLUS+1 Inverters require a quadrature encoder with a resolution in the range of 32 to 1024 pulses per revolution
mounted directly to the motor shaft. The output of the encoder can be open collector or push-pull. It is very
important to provide the API variable Motor.EncPulses with the resolution of the encoder used in the application
(PLUS+1 Motor Compliance Blocks provide this data).
The encoder signals have to be aligned with the rotation direction of the motor. If the phase order of the motor
current is U-V-W, the phase of the encoder signal A has to be before B.
WARNING
A wrong value entered in Motor.EncPulses can, in the worst case result in uncontrolled acceleration. If the
encoder signal is missing, the motor will run at low speed but can provide full torque. Bad encoder signal
conditions can result in jerky control behavior.
Torque Feed Forward

A step change in motor load torque will always result in a speed deviation for a short time. The speed deviation
will then change the motor torque to the right level to bring the speed back to the set value. Typically such a
control cycle takes less than 100ms. If a very fast speed control is needed and the motor load can be estimated,
the torque feed forward input (MotorControl.TorqueFF) can be used. The estimated motor load torque has to be
provided to the feed forward input. A load change will directly result in the right motor torque without a speed
deviation. Even if the estimated load is not very accurate the speed deviation can be minimized.

Torque Limitation
The torque limitation for the motor is defined in the motor definition data structure Motor.TorqueMax. Another
torque limitation can be entered at the motor control data structure MotorControl.UserTorqueLimit. This value is
defined as a percentage of MotorTorqueMax. If no torque limitation is needed, MotorControl.UserTorqueLimit
must be set to 10000 (=100%).
With the variable MotorControl.ActTorqueLimit the valid torque limit in Nm can be read.
The current limitation (see 11.1.6.) may prevent achievement of maximum torque.
Current Limitation
There are three different current limitations:
Hardware current limit: This is the maximum current capability of the power stage hardware. Motor current limit:
This is the current limit for the motor, defined at Motor.CurrentMax.
User current limit:
This is the current limit for the application, defined at MotorControl.UserCurrLimit as a percentage of the hardware
current capability.
The valid current limit can be read with the API variable MotorControl.ActCurrLimit.
The torque limitation (see 11.1.5.) may prevent achievement of maximum current.
Speed Control Versus Torque Control

For most applications the preferred control mode is speed control. In some applications torque control may have
advantages.
The speed controller can be used for torque control with following consideration:
• Provide the absolute torque set value to the torque limit value of the speed controller
• Provide a speed limit value to the speed set value of the speed controller
• Since the torque limit value accept only absolute values, the sign of the torque set value has to transferred to
the speed set value.
Example:
Values for torque control Values to the speed controller
Torque set value = 80% MotorControl.UserTorqueLimit = 8000
Speed limit = 2000 rpm MotorControl.RPMSetPoint = 20000
Torque set value = -50% MotorControl.UserTorqueLimit = 5000
Speed limit = 2000 rpm MotorControl.RPMSetPoint = -20000
The PLUS+1 Inverter function block library provides the function block “Torque Control” which contains the related
calculations.

Motor Definition
The field oriented motor control algorithm requires entry of motor data. These are physical data of the motor,
independent of the application. No optimization of motor data at final machine performance testing is required.
The required motor data have to be provided to the API variable structure Motor.xxx. Because the motor typically
comes in a package with encoder and temperature sensor, those data are included in the same structure. There
are three different ways to provide the motor data. With Motor Compliance Blocks and Open Data Blocks the
motor parameters are part of the source code and can only be edited in the PLUS+1 GUIDE. Working with
Download Blocks allows the independent handling of application software and motor parameters by downloading
two lhx files with the PLUS+1 Service tool.
Electric Motor Compliance Blocks

Motors measured by Doosan Inverter are supported with PLUS+1 Compliance Blocks including all required data
for the complete motor package (motor, encoder, temperature sensor) as well as the calculation of the actual
motor temperature, the generation of an error signal at over temperature and the surveillance of the minimum and
maximum encoder supply current. The name of the compliance block is reflecting the part number of the motor
package.
Plug & Perform: All adjustments and calculations related to motor, encoder and temperature sensor are done by
just installing the appropriate Motor Compliance Block.
The following error signals are provided by the Motor Compliance Block:
MotorData.Motor.MaxTempErr: True if actual temperature exceeds maximum motor temperature (specified inside
the compliance block)
MotorData.Enc.MaxCurrErr: True if encoder supply current exceeds maximum (specified inside the compliance
block)
MotorData.Enc.MinCurrErr: True if encoder supply current is lower than minimum (specified inside the compliance
block). Indicates a disconnection of the encoder, a broken encoder wire or any other
encoder failure.
The reaction to these error signals have to be programmed dependent on the application.
Open Electric Motor Data Function Block

For motors not measured by Doosan Inverter, the data for motor, encoder and temperature sensor can be edited
in the GUIDE template. Required motor data are IEEE values supported by the Motor manufacturer.
Electric Motor Data Download Block

This function block allows set-up of motor data (inclusive encoder and temperature sensor data) using the Service
Tool. If the application software allows changing motor data at run time, the Motor Data Download Block has to be
installed. As this block requires default values, a Motor Compliance Block or an Open Motor Data Block has to be
installed additionally.
Re-Initialization of Motor Data

If motor data are changed during runtime (switch between motor data blocks) the data will only become valid after
a reinitialization. This has to be done by writing a 0-1 sequence to Motor.Reinit. The re-initialization will not be
performed until the power stage is disabled and the actual speed is lower than 10 rpm. Motor.Status bit23 is 1
while a reinitialization is pending.

Temperature Compensation
For best performance the field oriented motor control includes an adaptation algorithm to consider the influence of
the actual motor temperature. As the measurement of the motor temperature is dependent on the application, the
PLUS+1 application software must provide the actual motor temperature to the field oriented control via API
variable Motor.ActTemp. If no temperature sensor is available, a constant value of 20°C can be connected to
Motor.ActTemp. In this case a lower control performance could be experienced.
Plug & Perform: The needed calculations for temperature compensation are already included in the Motor
Compliance Blocks and the Open Motor Data Block.
Diagnostics
The motor control system software provides a number of data for diagnostic purposes.
Encoder Diagnostics
Motor.EncA Actual state of the hardware input pin
of encoder line A
High = True
Motor.EncB Actual state of the hardware input pin
of encoder line B
High = True
A simple diagnostic test of the motor encoder can be done by watching the API variables Motor.EncA and
Motor.EncB using the PLUS+1 Service Tool while turning the motor very slowly. Both variables have to change
status while turning the motor.
This test provides information about the wiring of the encoder.
In the event of motor control instability, the quality of the encoder signals should also be checked.
Diagnostics of Motor Data

If the motor data provided to the API are invalid, the variable Motor.Status will show the status in bitwise pattern.

Diagnostics of Motor Control

MotorControl.ActSpeed Actual motor speed
MotorControl.ActStatFreq Actual stator frequency
MotorControl.ActSlipFreq Actual slip frequency
MotorControl.ActTorque Actual torque set value
MotorControl.ActQCurrent Actual Q-axis current. This is the current
vector to provide torque.
MotorControl.ActDCurrent Actual D-axis current. This is the current
vector to provide magnetization
MotorControl.ActCurrent Actual motor current. This is the current that
can be measured at the motor cables.
MotorControl.ActVoltage Actual motor voltage (line to line). Because
the motor voltage is PWM modulated you can
only measure it with a low pass filter.
MotorControl.ActTorqueLimit Actual valid torque limit. This is the minimum
of calculated physical maximum torque
(based on the current limit), user torque limit
and motor torque limit.
MotorControl.ActCurrLimi Actual current limit. This is the minimum of
hardware current limit, user current limit and
motor current limit)
MotorControl.Gen_Mode Motor operation mode:
O = motor mode
Speed and torque are in the same direction.
Energy flows from inverter to the motor.
1 = generator mode
Speed and torque are in opposite direction.
Energy flows from motor to the inverter.

Controller Area Networks Specifications
CAN (Controller Area Networks) Ports
The PLUS+1 Inverters have CAN ports conforming to CAN 2.0B. The 2.0B version of CAN is meant for 29 bit
identifiers. The significance of the 2.0B version is that this is a full CAN, which translates into extensive hardware
filtering of incoming IDs (messages). This in turn leads to a lower load of the CPU, thus allowing for more
calculation capability left for the user (customer) application itself.
The inverters have double CAN ports for easy wiring. The pins related are as follows:
Port Pin name Pin #
1 CAN H C1p03
CAN L C1p04
2 CAN H C1p06
CAN L C1p07
The C1p03 and C1p04 are internally connected in parallel with C1p06 and C1p07.
See:
Figure 7: Double CAN port
The double CAN port also gives the opportunity to use daisy-chain or stub wiring of the bus. The advantage of the
daisy chaining is that it eliminates connectors in the wiring harness, thus providing higher reliability. See Figure 8.
Be aware of stub length, see Figure 9 : Bus stubs
Figure 8: Bus topology

Terminating Resistor
Each end of the CAN bus must be terminated with an appropriate resistance to provide correct termination of the
CAN_H and CAN_L conductors. The terminating resistor must be kept within the following specification:
Description Units Minimum Maximum Nominal Comment
Resistance Ohm 110 130 120 Minimum power
dissipation 400 mW
Bus Stubs (Wires form Main Bus to the Unit, also called Drop)
Be aware of the length of the stubs (drops) when used. Max. length @ 1Mbps is 30 cm
(see Figure 9 : Bus stubs) . Lower baud rates allow longer stubs.
Figure 9 : Bus stubs
WARNING
The programmer of the PLUS+1 application software has to consider a proper reaction on CAN-Bus
malfunction dependent on the application requirements.
CAN Wiring Suggestions

Although the CAN bus is insensitive to electromagnetic interference, it is recommended to use twisted pair with
shield. Shield must be connected to ground.
CAN Protocols
Different protocols will be available through PLUS+1 GUIDE programming, in the form of function blocks. Contact
Doosan Inverter for further information.

Product Ratings
Environmental
Switching frequency 8kHz standard; adjustable 4, 8, 12, 16 kHz
Efficiency about 95% at nominal output
Output frequency 0...300 Hz
Tolerable supply voltage drop Down to 50% of nominal voltage for max.
50ms.
Ambient temperature range -40°C ... 50°C; -40°F … 122°F (104°F)
Maximum heat-sink temperature @ 85°C; 185°F
full current
Heat-sink switch off temperature 85°C; 185°F
Relative humidity 100%, condensation is allowed
Operation signal 2 built-in LEDs (red and green)
Signal line connectors AMP-Seal 35 pins
IP protection IP67 with membrane
EMC / ESD EN 12895 / EN 61000-6-2 / EN 61000-6-3 /
EN 61000-4-2 / ISO 7637 / 1-3
Safety of industrial trucks – electrical EN 1175
requirements
Vibration, broad-band random, EN 60068-2-64 / EN 60068-2-28
resonance
Shock EN 60068-2-27
Bump EN 60068-2-29
Cold EN 60068-2-1
Heat EN 60068-2-2
Change of temperature EN 60068-2-14
Damp heat, cyclic EN 60068-2-30
UL UL583 listing pending
Chemical resistance ISO 16750-5
All PLUS+1 Inverters are CE compliant

Product Installation and Start Up
Mating Connectors
PLUS+1 Inverters use AMPSEAL connectors. Doosan Inverter has assembled a mating connector kit, referred to
as a bag assembly.
Part No information
Part Number Component
10107896 35 pin AMPSEAL Mating Connector Bag
Assembly
1010789 AMPSEAL Connector Crimping Tool 58529-1
AMPSEAL Mating Connector Part Information

Part Number Component
Crimp tool AMP PRO-CRIMPER II
Hand Tool Assembly 58529-1
Connector plug PBT, Black 776164-1
Contacts 770854-1
(0.5 – 1.4 mm²)
(20 – 16 AWG)
Sealing plugs 770678-1
Strip length 4.7 to 5.5 mm
[0.185 to 0.215 in]
Insulation diameter range 1.7 to 2.7 mm
[0.067 to 0.106 in]

PLUS+1 Inverter Installation Guidelines
Mounting the Inverter
While the PLUS+1 Inverters can be mounted in the vehicle in any position, a careful approach should be adopted
when selecting the location in the vehicle for mounting the inverter. In choosing the inverter’s position ensure the
built in two PLUS+1 Inverter LEDs are visible.
In each case, care must be taken to insure that the PLUS+1 Inverter connector is positioned so that moisture
drains away from the inverter. If the inverter is mounted vertically, the connector should be on the bottom. Strain
relief for mating connector wires should be provided.
For the plate-type heat sink version it is recommended that the inverter is assembled to a flat, free of paint surface
preferably lightly coated with a thermal transfer compound using the 4 holes provided. It is a requirement for the
vehicle mounting surface to be a substantial metal part of the truck for the full PLUS+1 Inverter current ratings to
be achieved.
The mounting surface shall meet the requirements:
Planarity = 0,1mm
Surface roughness R2 = 40μm
For the finned-type heat sink version it is recommended to ensure 3m/s air speed through the entire heat sink.
Wiring the Power Stage

The power stage is connected using screws, labeled “+, -” and “U, V, W“. An additional screw (not MI03 type)
allows the assembly of a power fuse on top of the inverter housing.
Power connections should be made with flexible heat resisting cables of suitable cross-sectional area allowing the
current to be carried. These should be terminated in crimped cable shoes.
The inverter is equipped with steel screw assemblies. Don’t use additional washers.
Make sure that the cable shoes lay directly on the brass sleeves of the inverter.
Fixing torque for power connectors:

Screw size Inverter type Fixing torque
M6 MI03 6Nm
M8 MI04 9Nm
M10 MI06….MI20 17Nm

PLUS+1 Inverter Installation Guidelines (continued)
Recommended Main Contactor
A single pole, single throw contactor with silver alloy tips contactor, such as the SW range from Albright
International Ltd. is recommended to be fitted:
For currents up to 250A - SW 80

For currents up to 400A - SW 180
For currents above 400A - SW 200
The contactor coil recommended should be specified for "continuous operation".
When alternative manufacturer’s products are used, the coil currents, pull-in and drop-out times should be
investigated to ensure compatible operation.
If the main contactor coil is not wired to C1p24 (Main Contactor Output) the PLUS+1 Inverter will not be able to
open the main contactor in serious fault conditions and the inverter will not be protected against reverse battery
polarity.
Recommended Main Fuse

The main battery cable should be fused with a suitable air-break fuse. The fuse must
be sized in relation to protect the motor and cabling. For exact determination consider applicable technical
regulations.
For Safety reasons, the use of protected fuses is recommended in order to prevent the spread of fuse particles
should the fuse blow.

PLUS+1 Recommended Machine Wiring Guidelines
• All wires must be protected from mechanical abuse. Wires should be ran in flexible metal or plastic conduits.
• Use 85° C [185° F] wire with abrasion resistant insulation. 105° C [221° F] wire should be considered near
hot surfaces.
• Use a wire size that is appropriate for the inverter connector.
• The cables to the battery should be ran side by side and be as short as possible.
• Separate high current wires from sensor and other noise-sensitive input wires.
• Run wires along the inside of, or close to, metal machine surfaces where possible.
This simulates a shield which will minimize the effects of EMI/RFI radiation.
• Do not run wires near sharp metal corners. Consider running wires through a
grommet when rounding a corner.
• Do not run wires near hot machine members.
• Provide strain relief for all wires.
• Avoid running wires near moving or vibrating components.
• Avoid long, unsupported wire spans.
• All analog sensors should be powered by the sensor supply from the PLUS+1 Inverter and ground returned
to the power supply pin on the PLUS+1 Inverter
• Sensor lines should be twisted about one turn every 10 cm (4 in).
• It is better to use wire harness anchors that will allow wires to float with respect to the machine rather than
rigid anchors.
Welding on a Machine Equipped with PLUS+1 Modules

The following procedures are recommended when welding on a machine equipped with PLUS+1 modules:
• The engine should be off.

• Disconnect the battery cables from the battery.
• Do not use electrical components to ground the welder. Clamp the ground cable for the welder to the
component that will be welded as close a possible to the weld.
PLUS+1 USB/CAN Gateway

Communication (software uploads and downloads and service and diagnostic tool interaction) between PLUS+1
devices and a personal computer (PC) is accomplished using the vehicle’s PLUS+1 CAN network.
The PLUS+1 CG150 USB/CAN gateway provides the communication interface between a PC USB port and the
vehicle CAN bus. When connected to a PC, the gateway acts as a USB slave. In this configuration, all required
electrical power is supplied by the upstream PC host. No other power source is required.
Refer to the PLUS+1 GUIDE Software User Manual 10100824 for gateway set-up information. Refer to the
CG150 USB/CAN Gateway Data Sheet 520L0945 for electrical specifications and connector pin details.

Start Up and Recommended Installation Instructions
Working with electric systems can be potentially dangerous. All testing, fault-finding and adjustment should be
carried out by competent personnel only. The vehicle’s drive wheels should be jacked off the floor and free to
rotate during the ensuing procedures.
The battery must be disconnected before PLUS+1 Inverters are being replaced or repaired.
Before working on the controls it is recommended to disconnect the battery and connect the B+ and B- inverter
terminals via a 10 Ohm, 25 watt resistor to discharge the internal capacitors.
Avoid connecting the inverter to a battery with its vent caps removed as due to the inverter's internal capacitance,
an arc is likely to occur, when it is first connected.
Always wear approved protective equipment.
If the inverter is connected to the battery while charging the voltage must not exceed the specified input voltage of
the inverter.

TRACTION INVERTER
INDEX
Wiring Diagram ......................................................................................................................................... 95

Control Connections ................................................................................................................................. 97
CAN Communication .............................................................................................................................. 107
TPDO1 to pump inverter .................................................................................................................... 107
TPDO2 to pump inverter .................................................................................................................... 107
RPDO1 from pump inverter ................................................................................................................ 108
RPDO2 from pump inverter ................................................................................................................ 108
TPDO1 to steering inverter................................................................................................................. 109
RPDO1 from steering inverter ............................................................................................................ 109
TTPDO1 to display............................................................................................................................. 110
TPDO2 to display ............................................................................................................................... 110
TPDO3 to display ............................................................................................................................... 111
RPDO1 from display .......................................................................................................................... 111
CAN-Bus Timeout .................................................................................................................................. 112
CAN-Bus Identifier.................................................................................................................................. 113
Functions ................................................................................................................................................ 114

Speed set point generation “A” ............................................................................................................... 114
Speed set point generation “B” ............................................................................................................... 115
Braking force calculation......................................................................................................................... 116
FNR functionality .................................................................................................................................... 118
Limitation and direction ........................................................................................................................... 118
Drive characteristic ................................................................................................................................. 119
Braking force calculation for the front wheels .......................................................................................... 120
Brake and power function ....................................................................................................................... 121
Speed Controller .................................................................................................................................... 122
Supervision ............................................................................................................................................ 122
Error and status code ............................................................................................................................. 123
Error and status handling ........................................................................................................................ 123
Error history............................................................................................................................................ 124
Blink code .............................................................................................................................................. 125
Hour counter .......................................................................................................................................... 125
Service counter ...................................................................................................................................... 125
Battery Discharge Indicator..................................................................................................................... 126
De-rating ................................................................................................................................................ 127
Motor data .............................................................................................................................................. 128
General information of the inverter device ............................................................................................... 128
Accessories ............................................................................................................................................ 129

PC-based Software Service Tool ............................................................................................................ 129
Fault Codes ............................................................................................................................................. 130

Error Number Description ....................................................................................................................... 130
Error Conditions ..................................................................................................................................... 130
Table of Errors and System Reactions .................................................................................................... 130
Diagnostic and Troubleshooting............................................................................................................ 135

General Description ................................................................................................................................ 135
Alarm List ............................................................................................................................................... 136

Wiring Diagram

IMPORTANT: The minus-connection always has to be connected first. When disconnecting the system the minus
has to be the last one to be disconnected.
Terminal + and -
The power supply (battery voltage) is connected to these terminals. The diameter of the power cables has to
be determined according to the dimension of the fuse used. To provide for a reverse-connect protection it is
highly recommended to use a main contactor to be controlled by the inverter.
A polarity inversion will damage the inverter.
Variables:
Item Description/Range
Actual DC link voltage
V_DC_Link .Volt (S32)
[mV]
Actual DC link voltage
SupplyPwr_per (U32)
[0.01%]
Parameter:
Item Description/Range Set Value

V_Nominal_mV Nominal voltage of the battery.
48000
(U32) Default: 48000 mV
UnderVolt_mV Threshold for the under voltage detection.
24000
(U16) Default: 24000 [mV]
Terminal U, V, W
The motor is connected to these terminals.
Basically the motor has to be connected to the inverter as U motor to U inverter and so on also for V and W.
Variables:
Enable of the power stage
PowerStage.Enable (Bool)
[False = disabled, True = enabled]
PowerStage.EnableStatus Actual enable status of the power stage
(Bool) [False = disabled, True = enabled]
Actual temperature at power stag Actual temperature
PowerStage.Temp (S16)
at power stage -60…170 [°C]

Control Connections
C1p01 Power Supply – (Ground)
Negative battery-pole connected to the control stage. This connection is used as the return connection for
components powered by the key switch
C1p02 Power Supply +

Battery voltage has to be supplied to this input in order to power-on the inverter. The inverter does not work
without the key-switch being connected to the supply voltage. Without key-switch signal the current
consumption on the main terminals is less than 10mA.
This input provides the supply voltage for other connections like the main contactor or electromechanical brake
and digital inputs. Variables:
Variables:
Power supply.
C1p02.Volt (S32)
(Key switch input)
C1p03 & C1p06 CAN H

C1p04 & C1p07 CAN L
A CAN-bus line must always be terminated in both ends by a termination resistor of 120Ω. This means that every
inverter that is connected at the end of the CAN-bus line must have an external termination resistor connected.
C1p08 IO Supply in
Power supply Input for I/Os.
C1p09 IO Supply out

Output of the supply for the inputs and outputs connection of the internal free wheeling diode of the Outputs

C1p10 Analog input - Accelerator pedal (line A)
The analog accelerator pedal input value is dependent of the displacement of the accelerator pedal and the speed
set point is calculated from the accelerator pedal input value.
Variables:
Analog accelerator pedal input (line A)
C1p10.Volt (S32)
(0…5000) [mV]
C1p11 Analog input - Accelerator pedal (line B)

The analogue accelerator pedal input value is dependent of the displacement of the accelerator pedal and the
speed set point is calculated from the accelerator pedal input value.
Variables:
Analog accelerator pedal input (line B)
C1p11.Volt (S32)
(0…5000) [mV]

C1p13 Negative pin for electromagnetic brake (EM Brake)
The brake output is controlled by the “Brake and Power” functionality and activates the electro mechanical park
brake. The pin is switched to the negative pole via a transistor. A freewheeling diode is implemented to C1p09.
This pin shall also be used for the positive pin of the electromagnetic brake.
The brake output is realized as a PWM output. The output PWM is calculated, after the activation of the output,
according to the parameter “BrkSettlingValue_per“for the time “BrkSettlingTime_ms” and then according to the
parameter “BrkSteadyValue_per “. The PWM value is calculated dependent on the actual supply voltage, in order
to reach a constant voltage at the load.
Variables:
CP_Brk (Bool) Electro magnetic brake output is active.
C1p13.OutputValue Set value electro magnetic brake output.
(C1p13)(U16) (0…10000) [0.01%]
Parameter:
Time while settling value is present at the output.
BrkSettlingTime_ms (U16) 2000
(0… 10000) [1 ms]
Output value during settling time.
BrkSettlingValue_per (U32) 10000
[0.01 %]
Output value when settling time is over and Activate
BrkSteadyValue_per (U32) 7000
is still active. [0.01 %]

C1p15 Negative pin for warning buzzer
The output is connected to the warning buzzer and is controlled by inverter error signal.
The warning buzzer output is digital output.
Variables:
CP_Warning_Buzz (Bool) Error command for output warning buzzer
C1p15.DigOut (Bool) True = Active
C1p16 Negative pin output for the right front brake

The output is connected to the left side front brake. The output is closed loop current controlled by a hardware
two-level controller in the range from 0 to 2,0A. The current set value is controlled by the brake input signal.
Variables:
CP_FBrake_Out (U16) Command for pro. output
C1p16.OutputValue Set current proportional lowering output.
(U16) (0…20000) [0.1mA]
Parameter:
Maximum output current for Front brake
FBrk_MaxCurr (U16) Default 15000 [0.1mA] 15000
(0…20000) [0.1 mA]

C1p17 Encoder signal A (open collector or push-pull)
C1p29 Encoder signal B (open collector or push-pull)
C1p28 +13 V Power supply for encoder
C1p05 0 V connection for encoder
Sequence: A before B, for clockwise rotation of the motor shaft.
The speed of the traction motor is always monitored and controlled through the encoder speed feedback signal.
If the sensor signal is also needed for other equipment (i.e. vehicle controller) it must be connected in the following
way:
Variables:
Actual motor speed
CP_Act Spd (S32)
-100000 … +100000 [0.1 rpm]
Motor encoder pulse counter
CP_Enc Puls (S16)
-32768 … 32767
Number of encoder pulses per revolution.
Motor. Enc Pulses (U16)
32 - 1024 [pulses/rev]
Actual encoder Current
C1p28.FeedbackValue (U16)
0 - 1000 [0.1mA]
Maximum encoder current
Motor Data. Max Enc Cur (U16)
0 - 1000 [0.1mA]
Minimum encoder current
Motor Data. Min Enc Cur (U16)
0 - 1000 [0.1mA]
C1p18 Digital foot switch input

Not used in this Software.

C1p19 Digital input - Seat switch
The seat switch is used to enable the driving and the work functions. This enable signal is de-bounced with a
parametric time-value
(SeatSwDelay_ms) up to 10 seconds.
Variables:
C1p19.DigIn(BOOL) Digital seat switch input
Parameter:
A seat without a driver is detected after this time
SeatSwDelay_ms (U16) 3
(0… 10) [1 s]
C1p20 Digital input

C1p21 Digital input - Foot switch

The foot switch input indicates if the foot switch is closed. The foot switch must be closed to enable the driving and
the work functions. This enable signal is de-bounced with a parametric time-value (FootSwDelay_ms) up to 10
seconds.
Variables:
C1p18.Digin(BOOL) Digital foot switch input
Parameter:
A open foot switch is detected after this time
Foot Sw Delay_ms (U16) 0
(0… 10) [1 s]
C1p22 Analog input - Brake pedal (line A)

The analogue brake pedal input value is dependent on the displacement of the brake pedal and the braking force
is calculated from the brake pedal input value.
Variables:
Analog input value of the sensor supply
C1p23.Volt (S32)
0…5000 [mV],

C1p23 Sensor supply
Sensor supply output to supply additional sensors with +5 V.
Variables:
Analog input value of the sensor supply

C1p23.Volt (S32)
0…5000 [mV],
C1p24 Output - Main contactor

The main contactor output activates the main contactor and is directly switched on, if the V_DC_Link voltage has
reached a percentage level of the key switch input voltage.
The pin is switched to the negative pole via a transistor. A freewheeling diode is implemented to key switch.
The Activation of the output is only possible, if the DC link voltage is above a defined level. This function avoids an
unnecessary high charge current of the DC link capacitors. The output is reset, if the power of the system is shut
down or EPS inverter has some problems.
Variables:
CP_MCOut (Bool) Main contactor output is active.
C1p24.OutputValue Set value main contactor.
(U16) (0…10000) [0.01%]
Parameter:
Define the threshold value of the key switch
voltage to switch on the main contactor. ( 0…
MCThreshold_per (U16) 8000
10.000 ) [0.01%]
MC Coil specification is 36Vdc.
The main contactor output is realized as a PWM output. The output PWM is calculated, after the activation of the
output, according to the parameter “MCSettlingValue_per“ for the time “MCSettlingTime_ms” and then according
to the parameter “MCSteadyValue_per “. The PWM value is calculated dependent on the actual supply voltage, in
order to reach a constant voltage at the load.

Parameter:
MC Settling Time_ms (U16) 5000
(0… 10000) [1 ms]
Output value during settling time.
MC Settling Value_per (U32) 7500
(0… 10000) [0.01 %]
Output value when settling time is over and
MC Steady Value_per (U32) Activate is still active. 5000
(0… 10000) [0.01 %]
C1p25 Negative pin output for back buzzer signal

The output is connected to the back buzzer and is controlled by reverse signal.
The output is digital output.
Variables:
CP_CANOutS9 (Bool) Reverse switch command for output back buzzer
C1p25.OutputValue
Set value backup buzzer output
(Bool)
C1p26 Negative pin for the cooling fan output

The direction extend output is realized as a PWM output. The output PWM is calculated, after the activation of the
output, according to the parameter “CoolingStartTemp“, CoolingStartRpm and then according to the inverter
power stage temp. The PWM value is calculated dependent on the actual power stage temperature.
Variables:
C1p26.OutputValue Set value cooling fan output
(C1p26)(U16) (0…10000) [0.01%]

Parameter:
CoolingStartRpm (U16) 8000
(0… 10.000) [1 ms]
CoolingStartTemp Output value during settling time.
10
(U16) [0.01 %]
Output value when settling time is over and Activate is
CoolingMaxTemp (U16) 50
still active. [0.01 %]
The step size of change in output over DecTm or IncTm
CoolingRange (U16) 1000
(0 … 10000) [1ms]
The time it takes for the output to increase in magnitude
CoolingIncTm (U16) 100
by the Range. (LoopTm … 10000) [1ms]
The time it takes for the output to decrease in
CoolingDecTm (U16) 800
magnitude by the Range. (LoopTm … 10000) [1ms]
RPM
FanMaxRPM
FanMaxRPM
FanstartRPM
Time
IncTm DecTm
FanStartTemp FanMaxTemp
C1p27 Negative pin output for the left front brake

The output is connected to the left side front brake. The output is closed loop current controlled by a hardware
two-level controller in the range from 0 to 2,0A. The current set value is controlled by the brake input signal.
Variables:
CP_F Brake_Out (U16) Command for pro. output
(U16) (0…20000) [0.1mA]
Parameter:
Maximum output current for Front brake
FBrk_Max Curr (U16) Default 15000 [0.1mA] 15000
(0…20000) [0.1 mA]

C1p30 Digital inputse
C1p31 & C1p32 Digital forward and reverse switch input

The forward and reverse switches are used to select the vehicle direction for driving.
Variables:
C1p31.DigIn (BOOL)
Digital forward & reverse switch input
C1p32.DigIn (BOOL)
C1p33 Digital Emergency drive signal

This signal is to use for elimination to the PINCODE function when display is failure.
Variables:
C1p33.DigIn (BOOL) Digital emergency switch input
C1p34 & C1p35 Temperature sensor

A temperature sensor can be connected to this input.
The type of the temperature sensor is defined in the motor data parameters.
Variables:
Actual motor temperature
Motor.Act Temp (S16)
-50…200 [°C]
Type of the temperature sensor
0 = None temperature sensor
Motor Data. Temp Snsr
1 = Switch (NC)
Type (U8)
2 = Switch (NO)
3 = Analog sensor
Motor Data. Max Temp Maximum motor temperature
(S16) 50 - 200 [°C]

CAN Communication
TPDO1 to pump inverter
Byte Bits Data Scale Range/setting Item
Byte 0(low)
Actual Speed TA rpm -32768…32767 CP_CANTAActspd
Byte 1(high)
Byte 2 Pump Set value % 1 ~ 100 CP_DP01_CAN5
0 ~2(P1, P2,
Byte 3 Vehicle Set Value 1 CP_ModeSet_CANValue
P3)
Byte 4 BDI Level 1 0 ~ 10 CP_BDILevel
0 Hyd. Enable signal BOOL CP_CANOutEnable
1 S10 Sol. Output status BOOL CP_CANOutS10Stat

Byte 5
4 Pin Emergency Signal BOOL CP_CANPinEmc
5~7 Not defined
Byte 6 Not defined

Byte 7 Not defined
TPDO2 to pump inverter

0-1 Not defined
2 Display Up switch signal BOOL CP_DPO1_CAN0

3 Display Down switch signal BOOL CP_DPO1_CAN0
Byte 0 4 Not defined
5 Display Enter switch signal BOOL CP_DPO1_CAN0
6 Display ESC switch signal BOOL CP_DPO1_CAN0

7 Parameter write signal BOOL CP_DPO1_CAN0
Byte 1(low)
Calibration Data U16 CP_DPO1_CAN23
Byte 2(high)
0-4 Not defined BOOL
5 Cal. Set enable BOOL

Byte 3
6 Pump Cal. Request BOOL
7 Pump Dig. request BOOL
Byte 4 Pump Calibration number 1
Byte 5 Pump Diagnostic number 1

Byte 6 Not defined
Byte 7 Not defined

RPDO1 from pump inverter
0 Hydraulic function active BOOL 1 : Active
1 Fault BOOL 1 : Fault

2-3 Not defined
Byte 0 4 Warning inverter temp. BOOL 1 : Active CP_CANInvDigit
5 Warning motor temp. BOOL 1 : Active

6 Not defined
7 Not defined
Byte 1(low)
Fault / Warning Code 1 CP_CANPumpFault
Byte 2(high)
Byte 3 Inverter Temperature 1 °C - 60 … 100 CP_CANInvTemp_C
Byte 4(low)
Prop. Output S3 (C1p27) 0,1 mA 0 … 2 0000 CP_CANPropOutS3_mA
Byte 5(high)
Byte 6(low)
Height Scale 1cm 0 … 1500 CP_CANHeight
Byte 7(high)
RPDO2 from pump inverter

0 Cal. Mode set signal BOOL 1 : Active
1 Dig. Mode set signal BOOL 1 : Fault
Byte 0 2 Cal. Set OK signal BOOL 1 : Active CP_CANInvDigit

3 Cal. Set error signal BOOL 1 : Active
4-7 Not defined
Byte 1 Pump Cal./Dig. Act number 1 CP_PPDO01_1

Byte 2(low)
Byte 3
1 CP_PPDO01_2345
Byte 4
Byte 5(high)
Byte 6 Pump inverter set present % 0 ~ 100 CP_PPDO01_6
Byte 7 Not defined

TPDO1 to steering inverter
Byte Bit Data Scale Range/setting Item
0: Enable
0 Steering function 1
1: Disable
0: 360°
Byte 0 1 Steering character 1 CP_CANDPSteerChar
1: 180°
0: Off
2 Digital output 1
1: On
Byte 1 Not defined
Byte 2 Not defined

Byte 3 Not defined
Byte 4 (low)
Act steering speed 1 rpm -32000…32000
Byte 5 (high)
Byte 6 Not defined

Byte 7 Not defined
RPDO1 from steering inverter

0: No warning
0 Warning 1 CP_CANSteerWarning
1: Warning
0: No fault
1 Fault 1 CP_CANSteerFault
1: Fault
2 Position sensor 1 CP_CANSteerPosiSnsr
0: Not active
3 Power stage 1 CP_CANSteerPwrStAct
1: Active
Byte 0 0: Not active
4 Position sensor search 1 CP_CANSteerPosiSearAct
1: Active
Position sensor search 0: Not completed
5 1 CP_CANSteerPosiSearEnd
completed 1: Completed
0: Not active
6 Warning inverter temperature 1 CP_CANSteerWInvTemp
1: Active
0: Not active
7 Warning motor temperature 1 CP_CANSteerWMotTemp
1: Active
Byte 1 (low)
Act steering speed 1 rpm -32000…32000 CP_CANSteerActSpd
Byte 2 (high)
Byte 3 Inverter Temperature 1 °C - 60 … 100 CP_CANSterrInvTemp
Byte 4 Motor Temperature 1 °C 0 … 200 CP_CANSteerMotTemp
Byte 5 Fault / Warning Code 1 CP_CANSteerFltWarn
Byte 6 (low)
Act Angle 0,01° -18000…18000 CP_CANSteerActAng
Byte 7 (high)

TTPDO1 to display
Byte 0(Low) Traction performance % 0 ~ 100 CP_PDO1_0
Byte 1 (High) Pump performance % 0 ~ 100 CP_PDO1_1

-32000 …
Byte 2 Act Speed rpm CP_PDO1_1
32000
Byte 3(Low)
Byte 4 Traction inverter Service hour 0…

0.001h CP_PDO1_3456
Byte 5 count value 4294967295
Byte 6 (High)
Byte 7 Steering Angle 0,01° -18000…18000 CP_PDO1_7
TPDO2 to display
Byte 0 BDI Level 1 0-10 CP_PDO2_0

0 Unit (Km or Mile) T : Mile , F : Km
1 Steer selection signal T : 360 , F : 180
2 Turtle signal T or F
3 EM Brake Signal T or F
Byte 1 CP_PDO2_1
4 Foot SW Signal T or F
5 Seat SW Signal T or F
6 Forward Signal T or F
7 Reverse Signal T or F
01 : Disable
0-1 Pin code enable status
Byte 2 10 : Enable CP_PDO2_2
2-7 Not defined
Byte 3 Not defined
Byte 4 (Low)
Byte 5
Error code 1 0-3 99 99 CP_PDO2_4567
Byte 6
Byte 7 (High)

TPDO3 to display
0 Cal. And Dig. Set enable BOOL T or F
1 Cal. Mode set signal BOOL T or F

Byte 0 2 Dig. Mode set signal BOOL T or F CP_PDO3_0
3 Cal. Set OK signal BOOL T or F
4-7 Not defined

Byte 1 Cal. Or Dig. Act number U8 CP_PDO3_1
Byte 2(low)
Byte 3
Cal. Or Dig. value S32 CP_PDO3_2345
Byte 4
Byte 5(high)
Byte 6 Not defined

Byte 7 Not defined
RPDO1 from display

T: No Main
0 No Main Screen BOOL
Screen
1 Pin Code set status BOOL T : Pin Enable
Pulse signal
2 Up switch signal BOOL
(T)
Pulse signal
`Byte 0 3 Down switch signal BOOL CP_DPO1_CAN0
(T)
4 Parking switch signal BOOL T : Parking ON
Pulse signal
6 Enter switch signal BOOL
(T)
Pulse signal
7 ESC switch signal BOOL
(T)
Pulse signal
Byte 1 Cal. Or Dig. Act number BOOL CP_DPO1_CAN1
(T)
Byte 2
Calibration Data 0000 … 9999 CP_DPO1_CAN23
Byte 3
Byte 4 Traction performance % 0 ~ 100 CP_DPO1_CAN4
Byte 5 Pump performance % 0 ~ 100 CP_DPO1_CAN5
1 : Pin code
Byte 6 Pin Code Status 1 CP_DPO1_CAN6
Enable
Byte 7 Not Define

CAN-Bus Timeout
The maximum time allowed between receiving new RPDO messages from the CAN-bus can be set by parameters.
The timer is initiated by the first RPDO received. The RPDO timeout will set a fault.
If no RPDO message is received within a time after power-on timeout will also be activated. The power-on timeout
will set a fault.
Parameter:
CANTimeoutPump (U16) Timeout of the RPDO CAN bus message from pump. [ms] 150
CANToutPwrPump U16) Timeout of the CAN bus from pump after power on. [ms] 2000
CANTimeoutSteer (U16) Timeout of the RPDO CAN bus message from steering. [ms] 150
CANToutPwrSteer (U16) Timeout of the CAN bus from steering after power on. [ms] 2000
CANTimeoutJoystick (U16) Timeout of the RPDO CAN bus message from Joystick. [ms] 150
CANToutPwrJoystick (U16) Timeout of the CAN bus from Joystick after power on. [ms] 2000
CANTimeoutDisplay (U16) Timeout of the RPDO CAN bus message from Display. [ms] 150
CANToutPwrDisplay (U16) Timeout of the CAN bus from Display after power on. [ms] 2000
CANTimeoutBrakeC (U16) Timeout of the RPDO CAN bus message from brake controller. [ms] 150
CANToutPwrBrakeC (U16) Timeout of the CAN bus from brake controller after power on. [ms] 2000
Variables:
CP_CANToutPump (Bool) Timeout of the RPDO CAN bus message from pump.
CP_CANToutBJM1 (Bool) Timeout of the BJM1 CAN bus message from Joystick.
CP_CANToutEJM1 (Bool) Timeout of the EJM1 CAN bus message from Joystick.
CP_CANToutDP (Bool) Timeout of the RPDO CAN bus message from Display.
CP_CANToutBrakeC (Bool) Timeout of the RPDO CAN bus message from brake controller.
CP_CANToutSteer (Bool) Timeout of the RPDO CAN bus message from steering.

CAN-Bus Identifier
Pump inverter:
TPDO1: 21Dh + Pump inverter CAN node ID (Pump Node ID)
TPDO2: 22Dh + Pump inverter CAN node ID (Pump Node ID)
RPDO1: 30Dh + Pump inverter CAN node ID (Pump Node ID)
RPDO2: 31Dh + Pump inverter CAN node ID (Pump Node ID)
Steering inverter:
TPDO1: 200h + Steering inverter CAN node ID (Steer Node ID)
RPDO1: 180h + Steering inverter CAN node ID (Steer Node ID)
Display inverter:
TPDO1: 23Bh + Display CAN node ID (Display Node ID)
RPDO1: 40Bh + Display CAN node ID (Display Node ID)
Parameter:
Pump Node ID (U8) Node ID for the pump inverter 13
Steer Node ID (U8) Node ID for the steering inverter 30
Display Node ID (U8) Node ID for the display 11
CAN Cycle (U8) Cycle time of the transmitted CAN messages 50
Baudrate of the CAN bus

0= 50 kBaud
1= 100 kBaud
Baudrate (U32) 2= 125 kBaud 3
3= 250 kBaud
4= 500 kBaud
5 = 1000 kBaud
Note: For a change of the node ID, communication with the Plus+1 service tool, is an additional reset needed.

Functions
Speed set point generation “A”
For the speed set point generation “A”, is used a two point curve. The input value is the analog throttle input
(C1p10.Volt) and the output value is the speed set point value. The two point curve is calibrated after the first
complete displacement of the throttle pedal.
Variables:
C1p10.Volt (S32) Analog throttle input (0…10000) [mV]
Analog input, Specified by units of .01% of Snsr Pwr (C1p23.Volt)
CP_SpdStptIn_per (U16)
(0…10000) [0.01%]
Speed set point, Output of the two point curve
CP_SpdStptAn_rpm1 (S32)
(0 … HiOut(see below table) ) [0.1 rpm]
CP_SpdStptAn_per (U16)
(0…10000) [0.01%]
Parameter:
Input value associated with output = 0
CalLo_A (S16) 1000
Specified by units of .01% of Snsr Pwr (C1p23.Volt) (0 – 9999) [0.01%]
CalHi_A (S16) 7000
Input Fault Percent in .01%. A fault is declared when the input is either
AnInFault_A (U16) above Hi Cal or below LoCal by at least (Hi Cal-Lo Cal) * (SnsrPwr) * 500
(Fault %) (0 – 10000) [0.01%]
Is the calibrated minimum value of the speed set point (Spd_rpm1)
LoOut_A (S32) 0
(0…80000) [0.1 rpm]
Is the calibrated maximum value of the speed set point (Spd_rpm1)
HiOut_A (S32) 35000
(0…80000) [0.1 rpm]

Speed set point generation “B”
For the speed set point generation “B”, is used a two point curve. The input value is the analog throttle input
(C1p11.Volt) and the output value is only compare with “A” for checking the accelerator error. The two point curve
is calibrated after the first complete displacement of the throttle pedal.
Variables:
C1p11.Volt (S32) Analog throttle input (0…10000) [mV]
Analog input, Specified by units of .01% of Snsr Pwr (C1p23.Volt)
CP_SpdStptInB_per (U16)
(0…10000) [0.01%]
CP_SpdStptAnB_rpm1 (S32)
(0 … HiOut(see below table) ) [0.1 rpm]
CP_SpdStptAnB_per (U16)
(0…10000) [0.01%]
Parameter:
CalLo_B (S16) 1250
CalHi_B (S16) 7000
Input Fault Percent in .01%. A fault is declared when the input is either above
AnInFault_B
Hi Cal or below LoCal by at least (Hi Cal-Lo Cal) * (SnsrPwr) * (Fault %) (0 – 8
(U16)
10000) [0.01%]
Is the calibrated minimum value of the speed set point (Spd_rpm1) (0…80000)
LoOut_B (S32) 0
[0.1 rpm]
Is the calibrated maximum value of the speed set point (Spd_rpm1)
HiOut_B (S32) 35000
(0…80000) [0.1 rpm]
If CP_SpdStptAn_per minus CP_SpdStptAnB_per value is greater than
AccelErrValue
AccelErrvalue value then accelerator is defect. (CP_SpdStptAn_per) – 5000
(U16)
(CP_SpdStptAnB_per) > (AccelErrValue) (0 … 10000) [0.01%]

Braking force calculation
The analogue brake pedal input (C1p22.Volt), value is dependent on the displacement of the brake pedal. The
braking force is calculated from the brake pedal input value with a two point curve.
The two point curve is calibrated after the first complete displacement of the brake pedal.
Variables:
C1p22.Volt Analog brake input
(C1p22)(S32) (0…10000) [mV]
CP_BrkIn_pct Analogue brake input, output of the two point curve
(U16) (0…10000) [0.01%]
Parameter:
BrkCal_1 (S16) Specified by units of .01% of Snsr Pwr (C1p23.Volt) 1000
(0 – 9999) [0.01%]
BrkCal_2(S16) Specified by units of .01% of Snsr Pwr (C1p23.Volt) 6700
(0 – 9999) [0.01%]

The output of the two point curve, from the analogue brake pedal input is connected to a six point profile function
which shapes the input signal.
Use the Profile 6 Point function block to shape a signal. Input is along the X-axis, output is along the y-axis. For
input greater than X6, the output is based on a linear interpolation of points 5 and 6. For input less that X1, the
output is based on a linear interpolation of points 1 and 2.
Parameter values for X must increase from X1 through X6. Parameter values for Y can increase, decrease, or be
equal from Y1 through Y6.
Variables:
CP_BrkIn_pct Analogue brake input, output of the two point curve
(U16) (0…10000) [0.01%]
CP_BrkInProf_pct Analogue brake input, profiled input value.
(U16) (0…10000) [0,001%]
Parameter:
BrkProfX1 X1 value of the six point profile for the analog brake input
0
(S16) (0 – 10000) [0.01%]
2000
(S16) (0 – 10000) [0.01%]
4000
(S16) (0 – 10000) [0.01%]
6000
(S16) (0 – 10000) [0.01%]
8000
(S16) (0 – 10000) [0.01%]
BrkProfX6 X6 value of the six point profile for the analog brake input 10000
(S16) (0 – 10000) [0.01%]
BrkProfY1 Y1 value of the six point profile for the analog brake input
(S16) (0 – 10000) [0.01%] 0
1000
(S16) (0 – 10000) [0.01%]
2000
(S16) (0 – 10000) [0.01%]
3500
(S16) (0 – 10000) [0.01%]
6000
(S16) (0 – 10000) [0.01%]
BrkProfY6 Y6 value of the six point profile for the analog brake input 10000
(S16) (0 – 10000) [0.01%]

FNR functionality
A forward, neutral and reverse logic is implemented with the forward signal
(CP_SWFwd) and the reverse signal (CP_SWRvs) as input values. A rising edge (0->1) is necessary, on the FWD
or RWD signal, to enable the drive. The precondition of this function is the seat switch (C1p19.DigIn) and the foot
switch (C1p21.DigIn) functionality.
Variables:
CP_CANFwd (BOOL) Digital forward switch input
CP_CANRvs (BOOL) Digital reverse switch input
C1p19.DigIn (BOOL) Digital seat switch input
CP_SeatSwDelay (BOOL) Digital seat switch input, delayed
C1p18.DigIn (BOOL) Digital foot switch input
CP_SBeltSwDelay (BOOL) Digital foot switch input, delayed
CP_Dir (S16) Commanded direction ( -1 = reverse; 0 = neutral; 1 = forward )
CP_DrvEnbl (BOOL) Commanded drive enable
Parameter:
SeatSwDelay_ms Time after which the output follows the negative transition on
3
(U16) the seat switch input. [s] ( 0 ... 10s)
Time after which the output follows the negative transition on
FootSwDelay_ms (U16) 0
the seat belt switch input. [s] ( 0 ... 10s)
Limitation and direction

If the battery charge level value is below a charging threshold (BDILevelRed), then the maximum speed set point
is reduced to a parameter (SpdRed_rpm1). Also the selected direction is combined with the speed set point. The
direction is commanded from the FNR logic. A positive speed set point means drive in forward direction, a
negative speed set point in reverse direction. If the brake pedal is pressed, the speed set point is set to 0 rpm and
the truck is decelerating.
Variables:
CP_SpdStptAn_rpm1 Speed set point, Output of the speed set point generation
(S32) (0…80000) [0.1 rpm]
CP_Dir (S16) Commanded direction

-1 = reverse; 0 = neutral; 1 = forward
Analogue brake input, profiled input value.
CP_BrkInProf_pct (U16) (0…10000) [0,001%]
CP_BDILevel (U8) Current discharge level of the battery.
Speed set point, In consideration of the BDI level, the Brake
CP_SpdStpt_rpm1 (S32) input and the Direction, Input value of the speed curve
(-80000…80000) [0.1 rpm]
Parameter:
The speed set point is limited to the parameter "SpdRed_rpm1",
BDILevelRed (U8) if the BDI Level is below or equal to this threshold. 1
SpdRed_rpm1 (S32) Speed set point limit for the BDI Level reduction.
[0.1 rpm] 6000

Drive characteristic
To obtain a comfortable drive feeling the speed curve is generated with a drive curve generator dependent on the
variation of the set value. Beside the actual speed, it is also considered how far and how fast the set value is
changed. According to the variation of the set value a very sensible and smooth drive feeling can also performed
as well as a dynamic driving.
Variables:
Input value of the speed curve
CP_SpdStpt_rpm1 (S32)
[0.1rpm]
Analogue brake input, profiled input value.
CP_BrkInProf_pct (U16)
(0…10000) [0,001%]
Actual motor speed
CP_ActSpd (S32)
-100000 … +100000 [0.1 rpm]
CP_RPMSetPointOut (S32) Motor speed set value

-80000…+80000 [0.1rpm]
CP_AcelMax (S32) Actual maximum acceleration slope [ 0.1 rpm/s]
CP_DcelMax (S32) Actual maximum deceleration slope [ 0.1 rpm/s]
Parameter:
Specifies the influence of the set value variation to the value of
acceleration or deceleration.
Progression (U8) Progression = 0: Independently of the set value variation always the
0
maximum acceleration or deceleration is active.
Progression = 100: The value of acceleration or deceleration depends on
the variation of the set value on a linear characteristic. (0…100)
Specifies the strange of the roundness (0: no rounding; 90: max.
rounding). The speed curve is always rounded before reaching the final
value. A rounding at the beginning of acceleration or deceleration
Roundness (U8) becomes effective only if the set value changes slowly. With a slowly
90
change of the set value a smoothly drive reaction is performed, as
acceleration is increased continuously. In case of a fast change of the set
value an aggressive drive reaction results, as acceleration achieves it’s
maximum value precipitously. (0…90)
SpdMax_rpm1 (u32) Max. speed value of the application. (1…80000) [0.1 rpm] 38000
AcelMax_rpmps (S32) Maximum acceleration slope [ 0.1 rpm/s] 10000
DcelNeut_rpmps (S32) Maximum deceleration slope for neutral braking [ 0.1 rpm/s] 10000
DcelCoast_rpmps (S32) Maximum deceleration slope for coast braking [ 0.1 rpm/s] 2500
DcelChgDir_rpmps (S32) Maximum deceleration slope for reversal braking [ 0.1 rpm/s] 10000
Maximum deceleration slope for brake pedal displacement of 100 %
DcelBrk_rpmps (S32) 10000
[0.1 rpm/s]

Braking force calculation for the front wheels
The braking force of the front wheels is calculated by the actual deceleration slope of the motor.
Variables:
CP_DcelMax (S32) Actual maximum deceleration slope [ 0.1 rpm/s]
CP_DcelMaxPct (U16) Actual maximum deceleration slope [ 0.01 %]
Indicator for acceleration or deceleration.
CP_AccDec (Bool) 1: Acceleration
2: Deceleration.
CP_CANBrkStpt (U8) Set point for the braking force of the front wheels
0 … 255
CP_CANBrkEnbl (Bool) Enable braking force of the front wheels
Parameter:
X1 value of the six point profile for the braking force of the front wheels
BrkCProfX1
depend on the actual maximum deceleration slope 0
(S16)
(0 – 10000) [0.01%]
BrkCProfX2
(S16)
(0 – 10000) [0.01%]
BrkCProfX3
(S16)
(0 – 10000) [0.01%]
BrkCProfX4
(S16)
(0 – 10000) [0.01%]
BrkCProfX5
(S16) depend on the actual maximum deceleration slope 8000
(0 – 10000) [0.01%]
BrkCProfX6 depend on the actual maximum deceleration slope 10000
(S16)
(0 – 10000) [0.01%]
Y1 value of the six point profile for the braking force of the front wheels
BrkCProfY1
(S16)
(0 – 10000) [0.01%]
BrkCProfY2
(S16)
(0 – 10000) [0.01%]
BrkCProfY3
(S16)
(0 – 10000) [0.01%]
BrkCProfY4
(S16)
(0 – 10000) [0.01%]
BrkCProfY5
(S16)
(0 – 10000) [0.01%]
BrkCProfY6 depend on the actual maximum deceleration slope 10000
(S16)
(0 – 10000) [0.01%]

Brake and power function
The “Brake and Power” function control the electromechanical brake and the power stage, at different driving
conditions.
Drive enable:
If the “DrvEnbl” signal goes active (positive edge) the power stage shall be enabled immediately, but the brake
shall be opened (powered) with a time delay (BrkOpen_ms).
Emergency stop (EMC):

The power stage shall be disabled and the brake shall be closed immediately. Emergency stop has the highest
priority.
If the “DrvEnbl” signal goes inactive and the stop ramp is activated. The function has to wait until the actual speed
is less than a threshold value (BrkThd_rpm1) and then a time (BrkClose_ms) shall be started. After this time the
brake shall be closed immediately and a second time (PwrDsbl_ms) shall be started. During this time the brake
has time to close and at the end of this time the power stage shall be disabled.
Variables:
CP_DrvEnbl (Bool) Commanded drive enable
CP_EMC (Bool) Drive is disabled, because of an error.
CP_ActSpd (S32) Actual motor speed (-100000 … +100000 [0.1 rpm])
CP_Brk (Bool) Electromagnetic brake output is active.
C1p13.OutputValue(U16) Set value electromagnetic brake output. (0…10000) [0.01%]
Power Stage. Enable (Bool) Enable of the power stage [False = disabled, True = enabled]
Parameter:
Brk Open_ms (U16) Brake open delay time (0…1000) [ms] 500
Brk Close_ms (U16) Brake open delay time (0…10000) [ms] 1000
Pwr Dsbl_ms (U16) Power stage off delay time (0…1000) [ms] 100
SafTm_ms (U16) Safety time (0…50000) [ms] 6000
BrkThd_rpm1 (U16) Brake close threshold (0…2500) [0.1 rpm] 500
Mode (U8) Mode 0: ramp ; Mode 1: coast (0…1) 0

Speed Controller
API controller is used to control the speed of the motor. The proportional part has the effect of reducing the rise
time of the motor speed, but it never eliminates the steady-state error. The integral part of the controller has the
effect of eliminating the steady-state error, but it may make the transient response worse.
Parameter:
Proportional gain of speed controller
Speed KP (U32) 10000
1…10000000 [0.00001Nm/rpm]
Integral gain of speed controller
Speed KI (U32) 10000
0…10000000 [0.00001Nm/rpm/s]
Lower limit of rated flux to reduce current at partial load.
Part Load Reduce (U16) 8000
2000…10000 [0.01%]
Supervision
Also some supervision is implemented in the software, like input supervision, output supervision, power stage
supervision, motor control supervision, etc.. See “Fault Codes” for more details.
Parameter:
Warn Temp Motor_C (u16) Warning temperature threshold motor. [°C] 150
Warn Temp MI_C (u16) Warning temperature threshold mobile inverter. [°C] 80
Under Volt_mV (u16) Warning voltage threshold DC- link voltage. [mV] 24000

Error and status code
The error and the status code are composed of a number and a sub number.
The error or status code must be unique.
X XX XX
{ 123 123
notused number sub number
Error and status handling

All errors and status events will be collected and administrated from the error and status handler. The error and
status handler use different error and status variable, with different priorities, to collect the information. If the
variables are equal to zero, no event is triggered. If a variable is set to a code, an error or a status is triggered,
with the attendant error level. See “Fault Codes” for more details.
Variables:
CP_Err (U16) Error variable
CP_Stat (U16) Status variable
Error variable with the error level 0 … 6.
CP_ErrLev0 ... CP_ErrLev6 (U16)
(0 = highest priority; 6 = lowest priority)
Status variable with the status level 0 … 3.
CP_StatLev0 ... CP_StatLev3 (U16)
CP_ErrLev0Act ... CP_ErrLev6Act (Bool) Error level 0 … 6 is active.
CP_StatLev0Act ... CP_StatLev3Act (Bool) Status level 0 … 3 is active.
CP_EMC (Bool) Drive is disabled, because of an error.
Parameter:
A positive edge at the “Clr Err” variable clears all error levels. The
Clr Err (BOOL) 0
error levels can only cleared, if no error is existent in this moment.

Error history
The last eight errors are stored together with a time stamp (hour counter) and a error counter, in the error history
memory. If the same error has appeared, consecutively several times, the error will be shown only once, but with
the latest time stamp and with an increased error counter.
Variables:
CP_ErrStor_0 ... CP_ErrStor_7 (U16) Error storage 0…7.
CP_HCStor_0 ... CP_HCStor_0 (U32) Time stamp storage 0…7.
CP_ErrCStor_0 ... CP_ErrCStor_7 (U16) Counter storage 0…7.
Parameter:
A positive edge at the “Clr Err History ” variable
Clr Err History (BOOL) 0
clears the complete error history memory.

Blink code
The red LED is used to show the error information and the green LED is used to show the status information. Only
the number of the error or the status is shown on the LED’s, the sub number will not be displayed.
Variables:
Error blink code variable.
CP_Err Flash (U16) (Red LED)
Led.Red (Bool) Red LED
Status blink code variable.
CP_Stat Flash (U16)
(Green LED)
Led.Green (Bool) Green LED
Hour counter
An hour counter functionality is implemented in the software. If the power stage is activated the hour counter starts
to count until the power stage is deactivated again.
Variables:
Hour counter.
CP_HCounter_h4 (U32)
[0.001h]
Parameter:
Set value for the hour counter.
HCVal_h4 (U32) 1
[0.001h]
After a rising edge (0->1) on the set value “Set HC” ,
SetHC (BOOL) 1
the hour counter is set to the set value “HCVal_h4”.
Service counter
A service counter functionality is implemented in the software. If the power stage is activated the service counter
starts to count down until the power stage is deactivated again.
Variables:
Service counter.
CP_SHCounter_h4 (U32)
[0.001h]
CP_SHC Zero (Bool) Service counter is equal to zero.
Parameter:
Service interval.
SHCInterval_h4 (U32) 500000
[0.001h]
After a rising edge (0->1) on the set value “Set Interval” , the
Set Interval (BOOL) 1
service counter is set to the service interval “SHCInterval_h4”.

Battery Discharge Indicator
The charge level of the battery is indicated by a Battery Discharge Indicator (BDI) function. The BDI is designed to
cover lead acid battery only. There are 11 discharge and one charge characteristics stored in the function. Each
characteristic consists of 10 internal voltage values. All in all 120 different threshold values are available for the
calculating algorithm. The different battery types can be handled by adjusting the parameter “BDI_Battery Type”
for the discharge characteristics.
A time counter increases if the actual battery voltage is higher than the actual charge threshold and decrease if
the actual battery voltage is lower than the actual discharge threshold value. If the time counter = 0 the Level
decrease one step. If the time counter reaches T max the level increase one step.
The actual threshold values are calculated out of the actual level and battery type.
Discharge Characteristic, Voltage per Cell:

Charge of battery
Type0 Type1 Type2 Type3 Type4 Type5 Type6 Type7 Type8 Type9 Type10
Level %
1,950 1,963 1,974 1,986 1,997 2,006 2,010 2,014 2,021 2,026 2,030 10 100
1,903 1,922 1,938 1,954 1,970 1,982 1,989 1,995 2,005 2,011 2,018 9 90
1,855 1,880 1,901 1,922 1,943 1,959 1,968 1,976 1,988 1,997 2,005 8 80
1,808 1,838 1,864 1,890 1,915 1,936 1,946 1,957 1,972 1,982 1,993 7 70
1,760 1,797 1,827 1,858 1,888 1,913 1,925 1,937 1,956 1,968 1,980 6 60
1,713 1,755 1,790 1,826 1,861 1,890 1,904 1,918 1,939 1,953 1,968 5 50
1,665 1,713 1,754 1,794 1,834 1,866 1,883 1,899 1,923 1,939 1,955 4 40
1,618 1,672 1,717 1,762 1,807 1,843 1,861 1,879 1,906 1,924 1,943 3 30
1,570 1,630 1,680 1,730 1,780 1,820 1,840 1,860 1,890 1,910 1,930 2 20
1,523 1,588 1,643 1,698 1,753 1,797 1,819 1,841 1,874 1,896 1,918 1 10
Variables:
CP_BDILevel (U8) Current discharge level of the battery.
Parameter:
Number of battery cells (^2 Volt/cell)
BDI NmbrCells (U8) 24
Default: 24
Time in Milliseconds between two levels.
BDITmax (U32) 210000
Default: 240000 ms [ms]
Voltage threshold per cell
BDIResetVoltage_mV (U16) 2090
Default: 2090 (0 … 4000)
Selection of the discharge curve
BDIBatteryType (U8) 4
Default: 3 (0 … 10)

De-rating
The reduction of the maximum allowed motor current in relation to the motor temperature and the power stage
temperature is realized with the de-rating function. The minimum of the power stage temperature factor and the
motor temperature factor is transmitted to the user current limit.
Variables:
Actual temperature at power stage
Power Stage.Temp (S16)
-60…170 [°C]
Actual motor temperature
Motor.Act Temp (S16)
-50…200 [°C]
Derating factor of the power stage temperature
CP_Derating Pwr Stage (U16)
0…10000 [0.01%]
Derating factor of the motor temperature
CP_Derating Motor (U16)
0…10000 [0.01%]
User current limit as percentage of
Motor Control. User Curr Limit (U16) hardware current limit.
0…10000 [0.01%]
Parameter:
Motor temperature at which the de-rating curve starts.
MotTemp100perc (S16) 110
[°C]
Motor temperature at which the de-rating curve ends.
MotTempDerate (S16) 150
[°C]
Motor de-rated curve for motor mode.
MotIDerateM (U16) 8000
[0.01%]
Motor de-rated curve for generator mode.
MotIDerateG (U16) 8000
[0.01%]
Inverter temperature at which the de-rating curve starts.
InvTemp100perc (S16) 65
[°C]
Inverter temperature at which the de-rating curve ends.
InvTempDerate (S16) 85
[°C]
Invert de-rated curve for motor mode.
InvIDerateM (U16) 8000
[0.01%]
Invert de-rated curve for generator mode.
InvIDerateG (U16) [0.01%] 8000

Motor data
Variables:
Motor Data. Part No (U32) Part number of the motor package
Motor Data. Cre Data (U32) Creation date of the motor data (YYYYMMDD)
Motor Data. Motor Data ROP Read-only parameters matches the parameters
(Bool) in the motor data block
General information of the inverter device

Variables:
Dead time of power stage
Device Info. Dead Time (U16)
0…6400 [ns]
Specified minimum temperature where the unit will work proper.
Device Info. Min Temp (S16)
-60…200 [°C]
Specified minimum voltage.
Device Info. Min Volt (S32)
[mV]
Specified maximal voltage where the unit will work proper.
Device Info. Max Volt (S32)
[mV]
Device Info. Serial No A (U32) First part of the Serial number.
Device Info. Serial No B (U32) Second part of the Serial number.
Device Info. Part No 0 (U32) Defines the hardware assembly with software loaded.
Is a S-D part number and is set when customer-specific software and/or
Device Info. Part No1 (U32) parameter settings are loaded from production cell (part number that the customer
is ordering).
Inverter frame size of the unit
Device Info. Inv Frame Size (U32)
(i.e. 6 for MI06 unit)

Accessories
PC-based Software Service Tool
Connecting the Computer with the Service Tool
Plug the USB connector of the gateway to a free USB port of the PC. All required drivers are included in the
service tool installation.
Requirements of the Computer to Run the PLUS+1 GUIDE Service Tool
To run the PLUS+1 GUIDE Service Tool a standard personal computer (PC) or laptop/notebook is required with a
free USB port.
System requirements for using the program:
For more information, take a look into the Service Tool help.
USB Gateway
The standard communication interface between the computer and the digital controller is the CG150 gateway.
Pin Function
1 -
2 CAN -
3 Shield/Ground
4 -
5 -
6 -
7 CAN +
8 -
9 -

Fault Codes
Error Number Description
U16 0-65535 → XXXXX
The error is limited from 0 to 99 and each error has 99 sub- errors.
Error Conditions.
Sub-
No. Name Detection Level
no.
Application errors
10 CAN Timeout
10 01 CAN Timeout; Pump inverter; RPDO1 Timeout is active ErrLev4
12 CAN Timeout
12 01 CAN Timeout; Display; RPDO1 Timeout is active ErrLev4
13 CAN Timeout
13 01 CAN Timeout; Brake controller; BCU2 Timeout is active ErrLev0
14 CAN Timeout
14 01 CAN Timeout; Steering inverter; RPDO1 Timeout is active ErrLev0
20 00 Analog accelerator input (line A); C1p10; Hardware error ErrLev2

Sensor_2Pt_AC; Fault =
20 01 Analog accelerator input (line A); C1p10; Input value is too low ErrLev2
0x8001
20 02 Analog accelerator input (line A); C1p10; Input value is too high ErrLev2
0x8002
20 03 Analog accelerator input (line A); C1p10; Value out of range ErrLev2
0x8004
21 00 Analog accelerator input (line A); C1p10; Input out of range StatLev1
Sensor_2Pt_AC; Status =
21 01 Analog accelerator input (line A); C1p10; Block is not calibrated StatLev1
0x8001
Analog accelerator input (line A); C1p10; Block is currently in a Sensor_2Pt_AC; Status =
21 02 StatLev1
calibration cycle 0x8002
21 03 Analog accelerator input (line A); C1p10; Parameters are corrupt StatLev1
0x8004
Analog accelerator input (line A); C1p10; Invalid Setup/ Sensor_2Pt_AC; Status =
21 04 StatLev1
Calibration 0x8008
22 00 Analog accelerator input (line A); C1p11; Hardware Error ErrLev2

22 01 Analog accelerator input (line A); C1p11; Input value is too low ErrLev2
0x8001
22 02 Analog accelerator input (line A); C1p11; Input value is too high ErrLev2
0x8002
22 03 Analog accelerator input (line A); C1p11; Value out of range ErrLev2
0x8004
22 05 Analog accelerator input (Compare A and B)); Accel. Error ErrLev2
23 00 Analog accelerator input (line A); C1p11; Input out of range StatLev1
23 01 Analog accelerator input (line A); C1p11; Block is not calibrated StatLev1
0x8001

Sub-
no.
Analog accelerator input (line A); C1p11; Block is currently in a Sensor_2Pt_AC; Status =
23 02 StatLev1
calibration cycle 0x8002
23 03 Analog accelerator input (line A); C1p11; Parameters are corrupt StatLev1
0x8004
Analog accelerator input (line A); C1p11; Invalid Setup/ Sensor_2Pt_AC; Status =
23 04 StatLev1
Calibration 0x8008
24 00 Analog brake input; C1p22; Hardware error ErrLev2

24 01 Analog brake input; C1p22; Input value is too low ErrLev2
0x8001
24 02 Analog brake input; C1p22; Input value is too high ErrLev2
0x8002
24 03 Analog brake input; C1p22; Open circuit ErrLev2
0x8004
24 04 Analog brake input; C1p22; Short circuit ErrLev2
0x8008
25 00 Analog brake input; C1p22; Input out of range StatLev1

25 01 Analog brake input; C1p22; Block is not calibrated StatLev1
0x8001
Analog brake input; C1p22; Block is currently in a calibration Sensor_2Pt_AC; Status =
25 02 StatLev1
cycle 0x8002
25 03 Analog brake input; C1p22; Parameters are corrupt StatLev1
0x8004
25 04 Analog brake input; C1p22; Invalid Setup/ Calibration StatLev1
0x8008
40 00 Steering inverter
40 01 Fault Steering inverter CP_CANSteerFault = 1 ErrLev1
40 02 Position sensor search not completed CP_CANPosiSearEnd = 0 StatLev1
Power stage
50 00 Warning power stage
PowerStage.Temp > Warn
50 01 Warning power stage; Warn temperature is reached ErrLev6
limit
51 00 Error power stage

PowerStage.Temp
51 01 Error power stage; Min. Temperature <DeviceInfo.MinTemp ErrLev0
(150℃)
Motor
52 00 Error motor
Motor.ActTemp_C > Max.
52 01 Error motor; Over temperature ErrLev2
limit
53 00 Warning motor
Motor.ActTemp_C > Warn
53 01 Warning motor; Warn temperature is reached ErrLev6
limit
OS
54 00 Error loop time
OS.ExecTime > 2 *
54 02 Error loop time; 3 times in row ErrLev0
OS.ExeceTimeOut
Monitoring
55 00 Error V_DC_Link
V_DC_Link.Volt < Min. limit;
55 01 Error V_DC_Link; Under voltage; Level 1 ErrLev2
t = 3s

Sub-
no.
56 00 Error V_DC_Link
V_DC_Link.Volt <
56 01 Error V_DC_Link; Under voltage; Level 2 ErrLev0
DeviceInfo.MinVolt t = 3s
57 01 Battery discharge
40Vdc < Battery voltage
58 01 Battery miss matching
>65Vdc
EM brake Output
73 00 Output, C1p13
73 01 Output, C1p13; Invalid value at .Output Value C1p13.PinStatus; Bit2 = 1 ErrLev2
Output, C1p13; Overload / output shorted to +I/O supply /
73 02 C1p13.PinStatus; Bit3 = 1 ErrLev2
transistor damaged
Output, C1p13; Output disconnected / output shorted to -I/O /
transistor shorted
73 04 Output, C1p13, switched off because overload C1p13.PinStatus; Bit5 = 1 ErrLev2
73 05 Output, C1p13, switch on protection after overload C1p13.PinStatus; Bit6 = 1 ErrLev2
73 06 Output, C1p13, Hardware Watchdog error C1p13.PinStatus; Bit7 = 1 ErrLev2
73 07 Output, C1p13; Safety error C1p13.SafetyStatus = 1 ErrLev2
Warning Buzzer Output
75 00 Output, C1p15
transistor damaged
transistor shorted
Back Buzzer Output
76 00 Output, C1p25
transistor damaged
transistor shorted
Fan output
77 00 Output, C1p26
transistor damaged
transistor shorted
Main contactor output
79 00 Error main contactor output, C1p24
Error main contactor output, C1p24; Invalid value at .Output
Value
Error main contactor output, C1p24; Overload / output shorted to
Error main contactor output, C1p24; Output disconnected / output
79 04 Error main contactor output, switched off because overload C1p24.PinStatus; Bit4 = 1 ErrLev0
79 05 Error main contactor output, switch on protection after overload C1p24.PinStatus; Bit5 = 1 ErrLev0
79 06 Error main contactor output, Hardware Watchdog error C1p24.PinStatus; Bit6 = 1 ErrLev0
Front brake output - Right

Sub-
no.
80 0 Front brake output, C1p16
80 01 Front brake output, C1p16; Config error at .Output Value C1p16.PinStatus; Bit2 = 1 ErrLev3
80 02 Front brake output, C1p16; Config error at .Dither Amp C1p16.PinStatus; Bit3 = 1 ErrLev3
Front brake output, C1p16; Output disconnected / output shorted
80 04 Front brake output, C1p16, Hardware Watchdog error C1p16.PinStatus; Bit5 = 1 ErrLev3
Front brake output - Left
81 0 Front brake output, C1p27
81 01 Front brake output, C1p27; Config error at .Output Value C1p27.PinStatus; Bit2 = 1 ErrLev3
81 02 Front brake output, C1p27; Config error at .Dither Amp C1p27.PinStatus; Bit3 = 1 ErrLev3
Front brake output, C1p27; Output disconnected / output shorted
81 04 Front brake output, C1p27, Hardware Watchdog error C1p27.PinStatus; Bit5 = 1 ErrLev3
81 05 Front brake output, C1p27; Safety error C1p27.SafetyStatus = 1 ErrLev3

82 00 +5V supply, C1p23
C1p23.Volt > + 10% of set
82 01 +5V supply, C1p23; Overvoltage ErrLev0
value for 5s
C1p23.Volt > + 40% of set
82 02 +5V supply, C1p23; Overvoltage ErrLev0
value
C1p23.Volt < - 10% of set
82 03 +5V supply, C1p23; Under voltage ErrLev0
value for 5s
C1p23.Volt < - 50% of set
82 04 +5V supply, C1p23; Under voltage ErrLev0
value for 100ms
82 05 +5V supply, Supply voltage feedback value out of range C1p23.PinStatus; Bit1 = 1 ErrLev0
83 00 Encoder supply, C1p28

C1p28.FeedbackValue >
83 01 Encoder supply, C1p28; Over current ErrLev2
Max. limit
C1p28.FeedbackValue <
83 02 Encoder supply, C1p28; Undercurrent ErrLev2
Min. limit
Power stage
84 00 Power stage
84 01 Power stage; Over temperature Power Stage.Status; Bit1 = 1 ErrLev2
84 02 Power stage; Sensor Error Power Stage.Status; Bit2 = 1 ErrLev2
84 03 Power stage; Overvoltage Power Stage.Status; Bit3 = 1 ErrLev2
84 04 Power stage; Over current Power Stage.Status; Bit4 = 1 ErrLev2
84 05 Power stage; Insecure mode active Power Stage.Status; Bit5 = 1 StatLev3
Power stage; Power stage permanently locked because wrong Power Stage.Status; Bit6 =
84 06 ErrLev2
motor data 1
Power stage; Power Stage permanently locked because HW Power Stage.Status; Bit7 =
84 07 ErrLev2
watchdog error 1
Power stage; Power Stage permanently locked because current Power Stage.Status; Bit8 =
84 08 ErrLev2
sensor error 1
Power stage; Power Stage permanently locked because under Power Stage.Status; Bit9 =
84 09 ErrLev2
volt detection 1
Self test
85 00 Self test
85 01 Self test; Error DC-Link circuit Self test. Error; Bit0 = 1 ErrLev2
85 02 Self test; Error in Watchdog circuit, operation impossible Self test. Error; Bit1 = 1 ErrLev0
85 03 Self test; Short circuit to -V DC-Link Self test. Error; Bit2 = 1 ErrLev2
85 04 Self test; Short circuit to +V DC-Link Self test. Error; Bit3 = 1 ErrLev2
85 05 Self test; Error in motor wiring or power stage Self test. Error; Bit4 = 1 ErrLev2
85 06 Self test; Shorted power output (motor output) Self test. Error; Bit5 = 1 ErrLev2

Sub-
no.
Self test; Test not passed, because of hardware over voltage
85 07 Self test. Error; Bit6 = 1 ErrLev0
protection
85 08 Self test; Curropted production data in EEPROM detected Self test. Error; Bit7 = 1 ErrLev2
86 00 Warning self test

Warning self test; Error in Watchdog circuit, limited operation
86 01 Selftest.Warning; Bit0 = 1 StatLev0
possible
Warning self test; Watchdog not tested, because low voltage at
DC- Link
86 03 Warning self test; Curropted user data in EEPROM detected Selftest.Warning; Bit2 = 1 StatLev0
87 00 Status self test

87 01 Status self test; DC Link self test in progress Selftest.Status = 1 StatLev1
87 02 Status self test; Watchdog self test in progress Selftest.Status = 2 StatLev0
87 03 Status self test; Power Stage self test in progress Selftest.Status = 3 StatLev1
Analog input (Rheo)

88 00 Error analog input, C1p34
88 01 Error analog input, C1p34; Input out of range C1p34.PinStatus; Bit1 = 1 ErrLev2
88 02 Error analog input, C1p34, Hardware error C1p34.PinStatus; Bit2 = 1 ErrLev2
Motor
90 00 Error motor
90 01 Error motor; Configure error Motor.Status; Bit0…Bit22 = 1 ErrLev3
90 02 Error motor; ReInit in progress Motor.Status;Bit23 = 1 StatLev3
NVMem
91 00 Error NVMem
91 01 Error NVMem; The NVMem restored to a previous state NVMem.Status; Bit0 = 1 ErrLev0
91 02 Error NVMem; The NVMem checksum are not correct NVMem.Status; Bit1 = 1 ErrLev0
Error NVMem; The reset routine could not access the NV
91 03 NVMem.Status; Bit2 = 1 ErrLev0
memory
CAN
92 00 Error CAN
92 01 Error CAN; CAN controller error CAN[0].DriverError = 1 ErrLev0
Table of Errors and System Reactions

Disable Disable Store in
Status LED Error LED
Priority Level Variable other drive error
(green) (red)
functions (brake) history
High 0 ErrLev0 X X X X
1 ErrLev1 X X X
2 ErrLev2 X X X
3 ErrLev3 X X
4 ErrLev4 X X X
5 ErrLev5 X X
Low 6 ErrLev6 X
High 0 StatLev0 X X X
1 StatLev1 X X
2 StatLev2 X X
Low 3 StatLev3 X

Diagnostic and Troubleshooting
General Description
Diagnostic information can be obtained in each of three ways: by reading the display, the PC (using PLUS+1
Service Tool) or by observing the fault codes issued by the status LEDs. See below example for a summary of
LED display formats.
Example: Error code 3742
1) The previous two-digit error "42" error blinks method.

Let the red LED as following blinking:
2) The next two-digit error "37" error blinks method.

Let the green LED as following blinking:
3) LED Position
Red LED
Green
This chapter explains how to manage any detected fault and how to return
to a normal working situation; suggestions to be applied in case of each
possible alarm are listed in a growing order, i.e. from the least to the most
serious one.
If an alarm condition is detected by main board, software control inhibits
some lift truck functions, to guarantee operator’s safety. Anomalous

working conditions are indicated by different alarm levels, classified as follows, depending on their effects on
the system:
1. Main breaker is opened and both pump and drive motors are stopped;
buzzer and can you see the error code on the display.
2. Pump or drive motors are stopped.
3. No effects on system performance.
NOTICE If more than one faulty condition is detected, Compact displays shows alarm code referring to the most
serious one (the one characterized by lower alarm level).
Following section gives useful suggestions covering a wide range of possible faults, listing corresponding
alarm cause identified by its alarm code.
Alarm List
CAN Timeout – Pump inverter
1. Alarm code: 11001
2. Display alarm: D-CAN FAULT
3. Error level: 4
4. Alarm cause: Error in CAN communication between traction and pump inverter; DSP present on main board
make a mutual software control, to insure fast diagnosis of such a fault.
In case of alarm follow this procedure:

1. Switch on the system and the turn it on again.
2. Checked the CAN wire
3. Try to the default setting
4. Replace the pump inverter.
CAN Timeout – Display

2. Display alarm: display cannot be seen from
3. Error level: 4
4. Alarm cause: Error in CAN communication between traction inverter and
display; DSP present on main board make a mutual software control, to
insure fast diagnosis of such a fault.

4. Replace the display.
CAN Timeout – Steering Inverter

2. Display alarm: STEER CAN FAULT
3. Error level: 0
4. Alarm cause: Error in CAN communication between traction inverter and steering inverter; DSP present on
main board make a mutual software control, to insure fast diagnosis of such a fault.

4. Replace the steering inverter.
Wrong start
1. Error code: 11501
2. Display Alarm : WRONG START
3. Error level: 6 (warning, main breaker is opened and pump and drive motors are stopped.)
4. Alarm cause: when you start working, you find accelerator pedal pressed or foot switch active.

1. Verify if a switch was active or the pedal pressed, when you turn on the lift truck;
2. Verify if start, foot switches are stuck close;
3. Verify if pedal circuit voltage exceeds 1/3 its maximum range (measured in Volt);
Accelerator Pedal Fault

2. Display alarm: PEDAL A FAULT
3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line A); Hardware error.

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line A); Input value is too low (Open the signal wire).

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line A); Input value is too high (Short the signal wire).

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line A); Open circuit.

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line A); Short circuit.

3. State level: 1
4. Alarm cause: Analog accelerator pedal input (line A); Input out of range.

3. State level: 1
4. Alarm cause: Analog accelerator pedal input (line A); Block is not calibration. And if you replace the accelerator
new on then appears primarily

3. State level: 1
4. Alarm cause: Analog accelerator pedal input (line A); Block is currently in a calibration cycle. And if you replace
the accelerator new on then appears primarily
3. State level: 1
4. Alarm cause: Analog accelerator pedal input (line A); Parameter are corrupt. And if you replace the accelerator

3. State level: 1
4. Alarm cause: Analog accelerator pedal input (line A); Invalid setup/calibration.

2. Display alarm: PEDAL B FAULT
3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Input value is too low (Open the signal wire).

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Input value is too high (Short the signal wire).

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Open circuit.

3. Error level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Short circuit.

3. State level: 2
4. Alarm cause: Analog accelerator pedal input (Compare A and B); Accelerator Error.

3. State level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Block is not calibration. And if you replace the accelerator
3. State level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Block is currently in a calibration cycle. And if you replace
the accelerator new on then appears primarily

3. State level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Parameter are corrupt. And if you replace the accelerator

3. State level: 2
4. Alarm cause: Analog accelerator pedal input (line B); Invalid setup/calibration. And if you replace the
accelerator new on then appears primarily In case of such an alarm, follow these troubleshooting steps:
1. Verify if the accelerator initial set-up is correct; if not, repeat calibration procedure. (You can use PC with CAN
communication software).
2. Verify if the following the 34pin main connector terminals are correctly wired to their correspondent inputs in
accelerator circuit:
T – 23 (5 V)
T – 12 (ground)
T – 10 (pedal output-A)
T – 11 (pedal output-B)
3. In case of correct wiring, replace the accelerator itself.
Brake Pedal Fault

2. Display alarm: BRAKE PEDAL FAU
3. Error level: 2
4. Alarm cause: Analog brake pedal input (line A); Hardware error.

3. Error level: 2
4. Alarm cause: Analog brake pedal input (line A); Input value is too low (Open the signal wire).

3. Error level: 2
4. Alarm cause: Analog brake pedal input (line A); Input value is too high (Short the signal wire).

3. Error level: 2
4. Alarm cause: Analog brake pedal input (line A); Open circuit.

3. Error level: 2
4. Alarm cause: Analog brake pedal input (line A); Short circuit.

3. State level: 1
4. Alarm cause: Analog brake pedal input (line A); Input value out of range.

3. State level: 1
4. Alarm cause: Analog brake pedal input (line A); Block is not calibration. And if you replace the brake new on
then appears primarily

3. State level: 1
4. Alarm cause: Analog brake pedal input (line A); Block is currently in a calibration cycle. And if you replace the
brake new on then appears primarily

3. State level: 1
4. Alarm cause: Analog brake pedal input (line A); Parameter are corrupt. And if you replace the brake new on

3. State level: 1
4. Alarm cause: Analog brake pedal input (line A); Invalid setup/calibration. And if you replace the brake new on
then appears primarily In case of such an alarm, follow these troubleshooting steps:
1. Verify if the accelerator initial set-up is correct; if not, repeat calibration procedure. (You can use PC with CAN
communication software).
2. Verify if the following the 34pin main connector terminals are correctly wired to their correspondent inputs in
accelerator circuit:
T – 23 (5 V)
T – 12 (ground)
T – 22 (pedal output-A)
3. In case of correct wiring, replace the brake pedal itself.
Steering Inverter Fault

2. Display alarm: STEER INVER FAU
3. Error level: 2
4. Alarm cause: If there appears in the Error Steering inverter.
In case of such an alarm, follow these troubleshooting steps:

1. Make sure that the error is on the Steering inverter. (You can use PC with CAN communication software).
2. If you have problems with EPS, replace the EPS Inverter.

2. Display alarm: POSITION SEN FAU
3. State level: 1
4. Alarm cause: When the position sensor for EPS inverter have a problem.

1. Checked the position sensor for EPS system
2. Red LED lighting is operating.
3. If this does not work, replace the sensor.
Traction inverter power stage over temperature

2. Display alarm code: D_INV OVERTEMP
3. Error level: 6
4. Alarm cause: Power module temperatures, measured with a probe, exceed 85 °C.

1. Alarm could be caused by ineffective temperature dissipation; verify thermal coupling between power module
block and aluminum plate. This system is using the fan cooling system.
2. Check the fan status. If the fan does not move then you replace the fan.
Traction motor over temperature

2. Display alarm code: D MOTOR OVERTEMP
3. Error level: 2
4. Alarm cause: The measure of drive motor temperature exceeds 150 °C.

In case of alarm, follow this procedure:
1. Presence of alarm with cold motors:
2. With a handheld multi meter (in resistance operating mode) you have to measure a resistance of about 10
kohm between the two wires of the temperature sensor (execute the measure at ambient temperature of 25°C).
If the measure is not correct it is necessary to replace the temperature sensor.
3. Disconnect the temperature sensor and check the wiring insulation between signal wire and ground wire
(towards logic);
Presence of alarm with hot motors:

1. If temperature value (you can read it from Instrument or via PC) seems correct, verify if fans (if present) work
properly; fault is caused by on inefficient motor refreshing, or by operating out of nominal maximum ranges.
OS Loop time Error

2. Display alarm code: LOOP TIME ERROR
3. Error level: 0
4. Alarm cause: Software error.
Battery under voltage Error

2. Display alarm code: DC LINK FAULT
3. Error level: 2
4. Alarm cause: battery voltage, measured by an internal circuit, is lower than 28V.

2. Display alarm code: MIN BATT VOLT
3. Error level: 0
4. Alarm cause: battery voltage, measured by an internal circuit, is lower than 24V.

2. Display alarm code: LOW BATT VOLT
3. Error level: 4
4. Alarm cause: battery voltage, measured by an internal circuit, This error has occur when battery level 1 is
maintained for 60 seconds
In case of low battery alarm, follow this procedure:

1. Measure battery voltage with a tester and, if different from the value reported on Instrument, replace logic;
2. Otherwise recharge battery.
Battery misses matching

2. Display alarm code: BATT MISMATCH
3. Error level: 0
4. Alarm cause: battery is not suitable voltage to controller
EM brake output fault (Controller pin 13)

2. Display alarm code: PARK BRAKE FAULT
3. Error level: 2
4. Alarm cause: Invalid value at Outputvalue

3. Error level: 2
4. Alarm cause: Overload / output shorted to +I/O supply / transistor damaged

3. Error level: 2
4. Alarm cause: Output disconnected / output shorted to -I/O / transistor shorted

3. Error level: 2
4. Alarm cause: Switched off because overload, the output is switched off because overload of this pin was
detected. This is acknowledged with a switch off/on sequence at Output Value (in PWM output mode).
3. Error level: 2
4. Alarm cause: Switch on protection after overload, the pin is not retriggerable after an overload switch off.

3. Error level: 2
4. Alarm cause: Hardware Watchdog error indicates an error of the ext. HW watchdog of the unit.

3. Error level: 2
4. Alarm cause: Safety error, the output will work in unsafe mode (the PWM signal can be 10 % wider than
commanded)
Warning buzzer output fault (Controller pin 15)

2. Display alarm code: WARNING BUZ FAU
3. Error level: 6

2. Display alarm code: WARN ING BUZ FAU
3. Error level: 6

3. Error level: 6
detected. This is acknowledged with a switch off/on sequence at OutputValue (in PWM output mode).

3. Error level: 6

3. Error level: 6
Backup buzzer output fault (Controller pin 25)

2. Display alarm code: BACK BUZ FAU
3. Error level: 6

3. Error level: 6

3. Error level: 6

3. Error level: 6

3. Error level: 6
Fan output fault (Controller pin 26)

2. Display alarm code: FAN I-O FAULT
3. Error level: 6

3. Error level: 6

3. Error level: 6
3. Error level: 6

3. Error level: 6
MC output fault (Controller pin 24)

2. Display alarm code: CONNECTOR FAULT
3. Error level: 0
4. Alarm cause: Invalid value at Outputvalue

3. Error level: 0

3. Error level: 0

3. Error level: 0

3. Error level: 0

3. Error level: 0
Right front brake output fault (Controller pin 16)

2. Display alarm code: F-RH BRAKE FAULT
3. Error level: 3
4. Alarm cause: Invalid value at Output value

3. Error level: 3
4. Alarm cause: Invalid value at Dither Amp

3. Error level: 3

3. Error level: 3
Left front brake output fault (Controller pin 27)

2. Display alarm code: F-LH BRAKE FAULT
3. Error level: 3
4. Alarm cause: Invalid value at Output value

3. Error level: 3
4. Alarm cause: Invalid value at DitherAmp

3. Error level: 3

3. Error level: 3

3. Error level: 3
4. Alarm cause: Safety error, the output will work in unsafe mode (the PWM signal can be 10 % wider than
commanded)
5V output fault (Controller pin 23)

2. Display alarm code: 5V OVERVOLTAGE
3. Error level: 0
4. Alarm cause: Supply voltage feedback value is 10% higher for 5s.

3. Error level: 0
4. Alarm cause: Supply voltage feedback value is 40% higher.

2. Display alarm code: 5V UNDERVOLTAGE
3. Error level: 0
4. Alarm cause: Supply voltage feedback value is 10% lower for 5s.

3. Error level: 0
4. Alarm cause: Supply voltage feedback value is 50% lower for 100ms.

2. Display alarm code: 5V FAULT
3. Error level: 0
4. Alarm cause: Supply voltage feedback value out of range will be set for voltage values higher than 15000 mV.

1. Verify if 5 V output is grounded, cause an incorrect encoder wiring.
2. Verify if 5 V output is grounded, because any analog sensor (Accelerator, Brake pedal etc.) malfunction. In that
case, replace the defective one.
3. Replace traction inverter.
Encoder supply (12 V) voltage fault (Controller Pin28)

3. Error level: 2
4. Alarm cause: If the current feedback value is greater than the 200mA for longer than a time 100ms the error
output goes to TRUE

3. Error level: 2
4. Alarm cause: If the current feedback value is lower than the 50mA for longer than a time 100ms the error output
goes to TRUE

In case of an alarm follow this procedure:
1. Verify if 12 V output (Pin 28) is grounded, cause an incorrect encoder wiring.
2. Verify if 12 V output is grounded, because any encoder malfunction. In that case, replace the defective one.
Traction inverter power stage fault

2. Display alarm code: D-INV OVERTEMP
3. Error level: 2
4. Alarm cause: The temperature of the power stage is measured with a PTC resistor and the values are filtered
with a time constant of 500ms. The actual temperature is calculated and displayed at Power Stage. Temp in
the range of -60°C – 170°C. If the actual value exceeds the temperature limit (85 °C ) an over temperature
error occurs.

2. Display alarm code: D-INV SEN FAU
3. Error level: 2
4. Alarm cause: The temperature at the power stage is measured with a PTC resistor and the values are filtered
with a time constant of 500ms. If the result of the power stage temperature calculation is out of the sensor
range of -60°C to +200°C a temperature sensor error occurs.

2. Display alarm code: MAX BATT VOLT
3. Error level: 2
4. Alarm cause: The DC_Link voltage is compared with the maximum value by hardware. If the actual DC_Link
voltage exceeds the maximum value error occurs.

2. Display alarm code: D-INV OVERCUR
3. Error level: 0
4. Alarm cause: In normal operation the current is limited by the software of the current controller. In addition, the
current in each phase is limited by hardware. If the actual current exceeds the maximum value the
corresponding phase output is switched off for 50μs and a signal is sent to the DSP. This signal triggers a
software integrator. If the integrator exceeds a limit (over current signal is active for more than 3 seconds) the
error occurs.

2. Display alarm code: WORNG MOT DATA
3. Error level: 2
4. Alarm cause: When the motor data incorrectly defined.

2. Program drive DSP again; maybe software present in flash memory was corrupted.
3. Try to the default setting.
4. Replace the traction inverter.

2. Display alarm code: WATCHDOG ERROR
3. Error level: 2
4. Alarm cause: This watchdog is triggered by a toggle signal, generated by system software. If the trigger signal
is not toggling anymore the watchdog hardware disables the power stage and all interface outputs. The hardware
watchdog will be checked by the self-test routine at power up.

2. If you have a same problem, replace the traction inverter.

2. Display alarm code: CURRENT SEN FAU
3. Error level: 2
4. Alarm cause: Current sensor error in the inverter.


2. Display alarm code: UNDERVOLTAGE
3. Error level: 0
4. Alarm cause: battery voltage, measured by an internal circuit, is lower than 24V

1. Measure battery voltage with a tester and, if different from the value reported on Instrument, replace logic;

2. Display alarm code: DC LINK ERROR
3. Error level: 2
4. Alarm cause: With the DC link test a short circuit in the DC link circuit (internal hardware, like capacitor board or
external wiring) can be detected. Before the main contact will be closed the capacitor bank is pre-charged via a
resistor, powered by the power supply voltage (C1p02). Wait until V_DC_Link > Threshold voltage ( 1.6V – 3.5V)
The test is OK as soon as this condition is fulfilled. If this condition is not fulfilled within 5 seconds after power-on,
the test failed.

1. Switch off power supply
2. Disconnect the power cables + and –
3. Switch on power supply again
4. If the DC-Link test shows no error anymore there is a short circuit in the wiring of the power cables + and – or
the load in that circuit is too high and pushes down the DC-Link voltage.
5. If the error still occurs there is a failure in the inverter.

2. Display alarm code: WATCHDOG FAULT
3. Error level: 0
4. Alarm cause: internal DSP watchdog, or/and defective logic.

1. Using PLUS+1 service tool program interface, try to program control board flash memory.
1. Error code: 18503, 18504

2. Display alarm code: DC LINK SHORT
3. Error level: 2
4. Alarm cause: Short circuit between a phase output and the + or – power stage supply or between the phase
outputs.

1. Switch off power supply Disconnect phase outputs Switch on power supply again.
2. Still the same error: Inverter damaged

2. Display alarm code: MOTOR OUTPUT FAU
3. Error level: 2
4. Alarm cause: Shorted power output (motor output)

1. Motor not connected.
2. Check the traction motor wiring incorrect.
3. Check the motor winding broken.
4. Exchange motor

2. Display alarm code: FET FAULT
3. Error level: 2
4. Alarm cause: Test not passed, because of hardware overvoltageprotection.

2. If the error occurs with a correct wired motor the power stage isdamaged.

2. Display alarm code: OVERVOLTAGE
3. Error level: 0
voltage exceeds the maximum value

1. Error code: 18508, 18603, 18604

2. Display alarm code: EEPROM FAULT
3. Error level: 2
4. Alarm cause: Corrupted production data in EEPROM detected.

1. The EEPROM is split into three sections
a. Production data: Data stored at production of the device in a protected memory area to adjust software
scaling to actual hardware
b. User data: Memory area accessible by the user
c. Error History data: Memory area where the error history data are stored
2. If the CRC check fails for the production data area error will be reported, because wrong data can lead to
incorrect behavior.
3. If the CRC check fails for the user data area only a warning will be reported. Appropriated reaction should be
programmed in the PLUS+1 application software.
4. If the CRC check fails for the Error History data area only a warning will be reported. The functionality of the
device is unlimited but the error history data may be corrupted.

3. State level: 0
4. Alarm cause: Error in watchdog circuit, limited operation possible.

2. Still the same error, Inverter damaged.

2. Display alarm code: LOW VOLTAGE
3. State level: 0
4. Alarm cause: Watchdog not tested, because low voltage at DC-Link or V_Key.

2. Still the same error, recharge battery

2. Display alarm code: DC-LINK SELF
3. State level: 0
4. Alarm cause: DC Link self test in progress.

2. Display alarm code: WATCHDOG SELF
3. State level: 0
4. Alarm cause: Watchdog self test in progress.

2. Display alarm code: POWERSTAGE SELF
3. State level: 0
4. Alarm cause: Power stage self test in progress.
Motor temperature sensor fault

2. Display alarm code: D-THERMAL FAULT
3. Error level: 2
4. Alarm cause: Input out of range shows, that the measured resistance at this input is higher than 12000 Ohm.

2. If you have a same problem, replace the traction motor temperature sensor.

2. Display alarm code: D-THERMAL FAULT
3. Error level: 2
4. Alarm cause: Hardware Error.

Motor configure fault

2. Display alarm code: CONFIG FAULT
3. Error level: 3
4. Alarm cause: Invalid value at .DataStructVersion.

2. Program download again; maybe software present in flash memory was corrupted.
NVMem fault
2. Display alarm code: MEMORY FAULT
3. Error level: 0
4. Alarm cause: The NVMem was restored to a previous state. This may happen when a store operation was
aborted. For example due to power off.


3. Error level: 0
4. Alarm cause: The NV Memory checksums are not correct. This may for instance occur the first boot up after a
new application is downloaded, if the NV Memory usage is changed.


3. Error level: 0
4. Alarm cause: The reset routine could not access the NV memory. For instance due to a hardware problem.

CAN drive fault

2. Display alarm code: CAN FAULT
3. Error level: 0
4. Alarm cause: CAN Controller error


HYDRAULIC (PUMP) INVERTER
INDEX
Wiring Diagram ....................................................................................................................................... 153
Hydraulic Diagram .................................................................................................................................. 154
Power Connections ................................................................................................................................ 155
Inverter Connection ................................................................................................................................ 156
Inverter Control Connection ................................................................................................................... 156
Extension Module Connection ............................................................................................................... 166
CAN Communication .............................................................................................................................. 169

Traction Inverter protocol ........................................................................................................................ 169
TA_PDO1_Tx to traction inverter........................................................................................................ 169
TA_PDO2_Tx to traction inverter........................................................................................................ 169
TA_PDO1_Rx from traction inverter ................................................................................................... 170
TA_PDO2_Rx to traction inverter ....................................................................................................... 170
Display Protocol ..................................................................................................................................... 171
DP_PDO1_Tx to Display .................................................................................................................... 171
DP_PDO1_Rx from Display ............................................................................................................... 171
Extension Module Protocol ..................................................................................................................... 172
MC_RPDO1_Tx to Extension Module ................................................................................................ 172
MC_RPDO2_Tx to Extension Module ................................................................................................ 172
MC_RPDO1_Rx from Extension Module............................................................................................ 173
CAN-Bus Timeout .................................................................................................................................. 174
CAN-Bus Identifier.................................................................................................................................. 174
Functions ................................................................................................................................................ 175

Work functions characteristics ................................................................................................................ 175
Lift Function............................................................................................................................................ 176
Lower Function ....................................................................................................................................... 176
Reach In/Out Function ............................................................................................................................ 177
Tilt Function............................................................................................................................................ 177
Side Shift Function ................................................................................................................................. 177
Determining desired rate of pump speed................................................................................................. 178
Speed characteristic ............................................................................................................................... 179
Speed Controller .................................................................................................................................... 180
De-rating ................................................................................................................................................ 181
Lift height indicator ................................................................................................................................. 182
Load weight indicator .............................................................................................................................. 183
Error System .......................................................................................................................................... 184
Error and status code ............................................................................................................................. 184
Error and status handling ........................................................................................................................ 184
Error history............................................................................................................................................ 185
Blink code .............................................................................................................................................. 185
Hour Counter.......................................................................................................................................... 185

Accessories ............................................................................................................................................ 186
PC-based Software Service Tool ............................................................................................................ 186
Fault Code ............................................................................................................................................... 187

Fault Code ............................................................................................................................................. 187
Table of Errors and System Reactions .................................................................................................... 193
Diagnostic and Troubleshooting............................................................................................................ 194

General Description ................................................................................................................................ 194
Alarm List. .............................................................................................................................................. 196

Wiring Diagram

Hydraulic Diagram

Power Connections
Important: The minus-connection always has to be connected first.
When disconnecting the system the minus has to be the last one to be disconnected.
Terminal + and -
The power supply (battery voltage) is connected to these terminals. The diameter of the power cables has to be
determined according to the dimension of the fuse used. To provide for a reverse-connect protection it is highly
recommended to use a main contactor to be controlled by the inverter.
A polarity inversion will damage the inverter.
Variables:
V_DC_Link .Volt Actual DC link voltage
[mV]
SupplyPwr_per Actual DC link voltage
[0.01%]
Parameter:
Set
Value
V_Nominal_mV Nominal voltage of the battery.
48000
Default: 48000 mV
UnderVolt_mV Threshold for the under voltage detection.
24000
[mV]
Terminal U,V,W
The motor is connected to these terminals.
Basically the motor has to be connected to the inverter as Umotor to Uinverter and so on also for V and W.
Variables:
PowerStage.Enable Enable of the power stage
PowerStage.EnableStatus Actual enable status of the power stage
PowerStage.Temp Actual temperature at power stage
-60…170 [°C]
Parameter:
Set
Value
WarnTempMI_C Warning temperature threshold mobile inverter.
80
[°C]

Inverter Connection
Inverter Control Connection
Negative battery pole connected for the control stage. This connection is used as the return connection for
components powered by the key switch

Battery voltage has to be supplied to this input in order to power-on the inverter. The inverter does not work
without the key-switch being connected to the supply voltage. Without key-switch signal the current consumption
on the main terminals is less than 10mA.
This input provides the supply voltage for other connections like the main contactor or electromechanical brake
and digital inputs.
Variables:
C1p02.Volt Analog input.
(Key switch input)
C1p03 & C1p06 CAN H

C1p04 & C1p07 CAN L
A CAN-bus line must always be terminated in both ends by a termination resistor of 120Ω. This means that every
inverter that is connected at the end of the CAN-bus line must have an external termination resistor connected.
C1p08 IO Supply in
Input supply for the In and Outputs
C1p09 IO Supply out

Output of the supply for the inputs and outputs connection of the internal free wheeling diode of the Outputs
C1p10 Analog pin for brake pedal signal (Line “B”)

The analogue brake pedal input value is dependent on the displacement of the brake pedal and the braking force
is calculated from the brake pedal input value.
Variables:
C1p10.Volt Analog brake pedal input. (0…5000) [mV]
C1p11 Analog pin for height sensor input (Option)
The analogue height sensor input value is dependent of the actual height of the lift mast.

Variables:
C1p11.Volt Analog input
( 0 …5000) [mV]
C1p13 Negative pin for reach-in output (S4)

The output is connected to the solenoid (S4) of the reach function selection valve and controls the reach-in
function. The output should not be activated together with the reach-out output (S5).
The reach-in output is realized as a PWM output. The output PWM is calculated, after the activation of the output,
according to the parameter“S4SettlingValue_per“for the time “S4SettlingTime_ms” and then according to the
parameter “S4SteadyValue_per “. The PWM value is calculated dependant on the actual supply voltage, in order
Variables:
CP_OutS4 (Bool) S4 output is active.
Set value reach-in output (S4)
C1p13.OutputValue
(0…10000) [0.01%]
Parameter:
Set
Value
S4SettlingTime_ms Time while settling value is present at the output.
1000
(0… 10.000) [1 ms]
S4SettlingValue_per Output value during settling time.
4000
[0.01 %]
S4SteadyValue_per Output value when settling time is over and
Activate is still active. 3500
[0.01 %]

C1p14 Negative pin for reach-out output (S5)
The output is connected to the solenoid (S5) of the reach function selection valve and controls the reach-out
function. The output should not be activated together with the reach-in output (S4).
The reach-out output is realized as a PWM output. The output PWM is calculated, after the activation of the output,
according to the parameter“S5SettlingValue_per“ for the time “S5SettlingTime_ms” and then according to the
parameter “S5SteadyValue_per “. The PWM value is calculated dependant on the actual supply voltage, in order
Variables:
CP_OutS5 S5 output is active.
Set value reach-out output (S5)
C1p14.OutputValue
(0…10000) [0.01%]
Parameter:
Set
Value
1000
(0… 10.000) [1 ms]
4000
[0.01 %]
[0.01 %]

C1p15 Negative pin for diverter output (S9)
The output is connected to the diverter solenoid (S9) of the selection valve.
The output should be activated together with the side sift function.
The diverter output is realized as a PWM output. The output PWM is calculated, after the activation of the output,
according to the parameter“S9SettlingValue_per“ for the time “S9SettlingTime_ms” and then according to the
parameter “S9SteadyValue_per “. The PWM value is calculated dependent on the actual supply voltage, in order
Variables:
Set value reach-out output (S9)
C1p15.OutputValue
(0…10000) [0.01%]
Parameter:
Set
Value
1000
(0… 10.000) [1 ms]
4000
[0.01 %]
S9SteadyValue_per Output value when settling time is over and Activ
ate is still active. 3500
[0.01 %]
C1p16 General Purpose Proportional Output


C1p17 Encoder signal A (open collector or push-pull)
C1p29 Encoder signal B (open collector or push-pull)
C1p28 +13 V Power supply for encoder
C1p05 0 V connection for encoder
Sequence: A before B, for clockwise rotation of the motor shaft.
The speed of the traction motor is always monitored and controlled through the encoder speed feedback signal.
If the sensor signal is also needed for other equipment (i.e. vehicle controller) it must be connected in the following
way:
Variables:
CP_ActSpd Actual motor speed
-100000 … +100000 [0.1 rpm]
CP_EncPuls Motor encoder pulse counter
-32 768 … 32 767
Motor.EncPulses Number of encoder pulses per revolution.
32 - 1024 [pulses/rev]
C1p28.FeedbackValue Actual encoder Current
0 - 1000 [0.1mA]
MotorData.MaxEncCur Maximum encoder current
0 - 1000 [0.1mA]
MotorData.MinEncCur Minimum encoder current
0 - 1000 [0.1mA]
C1p18,C1p19 Digital inputs


C1p20 Digital pin for reach in/out sensor input
The reach in input indicates if the reach functions in the in position.
Variables:
C1p20.Digin Digital reach in/out sensor input
(Proximity switch : Normal Open type)
C1p21 Digital inputs

C1p22 Analog pin for pressure sensor input (Option)

The analogue pressure sensor input value is dependent of the actual weight on the fork lift.
Variables:
C1p22.Volt Analog input
( 0 … 5000) [mV]
C1p23 Sensor supply

Variables:
C1p23.Volt Analog input value of the sensor supply
0… 5000 [mV]
C1p24 Main contactor output


C1p25 Negative pin for direction retract output (S7)
The output is connected to the solenoid (S7) of the direction selection valve from the three secondary hydraulic
functions and controls the retract function. The output should not be activated together with the direction extend
output (S8).
The direction retract output is realized as a PWM output. The output PWM is calculated, after the activation of the
output, according to the parameter“S7SettlingValue_per“ for the time “S7SettlingTime_ms” and then according to
the parameter “S7SteadyValue_per “. The PWM value is calculated dependant on the actual supply voltage, in
Variables:
C1p25.OutputValue Set value direction retract output (S7)
(0…10000) [0.01%]
Parameter:
Set
Value
1000
(0… 10.000) [1 ms]
4000
[0.01 %]
[0.01 %]

C1p26 Negative pin for direction extend output (S8)
The output is connected to the solenoid (S8) of the direction selection valve from the three secondary hydraulic
functions and controls the extend function. The output should not be activated together with the direction retract
output (S7).
The direction extend output is realized as a PWM output. The output PWM is calculated, after the activation of the
output, according to the parameter“S8SettlingValue_per“for the time “S8SettlingTime_ms” and then according to
the parameter “S8SteadyValue_per “. The PWM value is calculated dependant on the actual supply voltage, in
Variables:
C1p26.OutputValue Set value direction extend output (S8)
(0…10000) [0.01%]
Parameter:
Set
Value
1000
(0… 10.000) [1 ms]
4000
[0.01 %]
[0.01 %]

C1p27 Negative pins for proportional lower output (S3)
The output is connected to the solenoid (S3) of the proportional lower valve and is current controlled in the range
from 0 to 2,0A.
Variables:
CP_PropOutS3_mA1 Command for prop. output S3
(0…20000) [0.1mA]
Parameter:
Set
Value
S3DitherAmp _mA1 Dither amplitude (proportional valve)
Square wave signal symmetrical to current set
point 500
Default 500 mA
(0…10000) [0.1 mA]
S3DitherFreq Dither frequency (proportional valve)
Default 3
1: 500 Hz
3
2: 250 Hz
3: 167 Hz
4: 125 Hz
5: 100 Hz
S3ThldCrr_mA Threshold current (proportional valve)
Default 1500 mA 1500
(0…10000) [0.1 mA]
C1p30, C1p31 Digital inputs

C1p32 Digital mast height input

The mast height input indicates if the mast in the height position.
Variables:
C1p32.Digin Digital mast height input
(Proximity switch : Normal Open type)
C1p33 Digital inputs


C1p34 & C1p35 Temperature sensor
A temperature sensor can be connected to this input.
The type of the temperature sensor is defined in the motor data parameters.
Variables:
Motor.ActTemp Actual motor temperature
-50…200 [°C]
MotorData.TempSnsrType Type of the temperature sensor
0 = None temperature sensor
1 = Switch (NC)
2 = Switch (NO)
3 = Analog sensor
MotorData.MaxTemp Maximum motor temperature
50 - 200 [°C]
Parameter:
Item Description/Range Set
Value
WarnTempMotor_C Warning temperature threshold motor.
120
[°C]

Extension Module Connection
Make a connection to ground.

Make a connection to the 12V power supply.
C1p03 CAN H
C1p04 CAN L
Connecting to the CAN using twisted wire
C1p05 Analogue signal input - Side shift

The analogue fingertip lever input value is dependent on the displacement of the joystick lever and the side shift
cylinder moving distance is calculated from the fingertip lever input value.
Variables:
C1p05.Volt Analog fingertip lever input.
(0…5000) [mV]
C1p06 Sensor supply

Variables:
C1p06.Volt Analog input value of the sensor supply
0… 5000 [mV]
C1p07 Sensor Supply – (Ground)
C1p08 Analogue signal input - Tilt

The analogue fingertip lever input value is dependent on the displacement of the joystick lever and the tilt cylinder
moving distance is calculated from the fingertip lever input value.
Variables:
(0…5000) [mV]

C1p09 Analogue signal input – Reach
The analogue fingertip lever input value is dependent on the displacement of the joystick lever and the reach
cylinder moving distance is calculated from the fingertip lever input value.
Variables:
(0…5000) [mV]
C1p10 Analogue signal input – Lift and Lower

The analogue fingertip lever input value is dependent on the displacement of the joystick lever and the lift cylinder
moving distance is calculated from the fingertip lever input value.
Variables:
(0…5000) [mV]
C1p11 positive pins for proportional - flow sharing (S2)

The output is connected to the solenoid (S2) of the proportional flow sharing valve and is current controlled in the
range from 0 to 3,0A.
Variables:
Extension Module Set current proportional flow sharing output.
C1p11.OutputValue (0…20000) [0.1mA]
Parameter:
Set
Value
S2DitherAmp(C1p11) Dither amplitude (proportional valve)
500
[0.1mA]
S2DitherFreq (C1p11) Dither frequency (proportional valve)
200
[Hz]
Flow_Thld Threshold current (proportional valve)
1000
Default 1000 [0.1mA] (0…10000) [0.1 mA]
Flow_End_Crnt End current for valve in milliamps
15000
Default 15000 [0.1mA] (0 … 30000) [0.1mA]

C1p12 positive pins for proportional - Lifting (S1)
The output is connected to the solenoid (S1) of the proportional lift valve and is current controlled in the range
from 0 to 3,0A.
Variables:
Extension Module Set current proportional flow sharing output.
C1p12.OutputValue (0…20000) [0.1mA]
Parameter:
Set
Value
S1DitherAmp(C1p11) Dither amplitude (proportional valve)
500
[0.1mA]
S1DitherFreq (C1p11) Dither frequency (proportional valve)
200
[Hz]
Lift_Thld Threshold current (proportional valve)
1500
Default 1000 [0.1mA] (0…10000) [0.1 mA]
Lift_End_Crnt End current for valve in milliamps
Default 15000 [0.1mA] (0 … 30000) 15000
[0.1mA]

CAN Communication
Traction Inverter protocol
TA_PDO1_Tx to traction inverter
Byte 0 Hydraulic function
0 BOOL 1 : Active
active
1 Fault BOOL 1 : Fault
2 - 3 Not defined
4 Warning inverter temp. BOOL 1 : Active CP_CANPumpInv_Act
5 Warning motor temp. BOOL 1 : Active
Service hour active
6 BOOL
signal
7 Brake Pedal B Error BOOL
Byte 1(low)
Fault / Warning Code 1 CP_CANErrStat
Byte 2(high)
Byte 3 Inverter Temperature 1 °C - 60 … 100 CP_CANInvTemp
Byte 4(low)
Brake Pedal Input “B” % 0 … 10000 CP_CANFBrkPct_B
Byte 5(high)
Byte 6(low)
Height Scale 1cm 0 … 1500 CP_CANMastHeight
Byte 7(high)
TA_PDO2_Tx to traction inverter

Byte 0 0 Cal. Mode set signal BOOL 1 : Active CP_CANSetCal
1 Dig. Mode set signal BOOL 1 : Fault CP_CANSetDig
2 Cal. Set OK signal BOOL 1 : Active CP_CANCalSetOK
3 Cal. Set error signal BOOL 1 : Active CP_CANCalSet_Err
4 - 7 Not defined
Byte 1 Pump Cal./Dig. Act
1 CP_CANPumpActNo
number
Byte 2(low)
Byte 3 Calibration and
1 CP_CANCalDigData
Byte 4 Diagnostic Data
Byte 5(high)
Byte 6 Pump inverter set
% 0 ~ 100 CP_CANPump_pct
present
Byte 7 Not defined

TA_PDO1_Rx from traction inverter
Byte 0(low)
Actual Speed TA rpm -32768…32767 CP_CANTAActSpd
Byte 1(high)
Byte 2 CP_CANTAHydSetVa
Pump Set value % 1 ~ 100
lue
Byte 3 Vehicle Set Value 1 0~2(P1, P2, P3) CP_ModeSet
Byte 4 BDI Level 1 0 ~ 10 CP_CANBDILevel
Byte 5 0 Hyd. Enable signal BOOL CP_CANEnblHyd
1 Pin Emergency Signal BOOL CP_CANPinEmc
T inverter error act
2 BOOL
signal
3 Selected mile BOOL
Brake parameter set
4 BOOL
signal
5~7 Not defined
Byte 6(low)
Mast Height mm 3000 ~ 11000 Cp_CANMast_Height
Byte 7(high)
TA_PDO2_Rx to traction inverter

Byte 0 0-1 Not defined
2 Display Up switch signal BOOL CP_Dis_UpSW
3 Display Down switch signal BOOL CP_Dis_DownSW
4 Not defined
5 Display Enter switch signal BOOL CP_Dis_EnterSW
6 Display ESC switch signal BOOL CP_Dis_escSW
7 Parameter write signal BOOL CP_Para_Write
Byte 1(low)
Byte Calibration Data U16 CP_Cal_Data
2(high)
Byte 3 0-4 Not defined BOOL
5 Cal. Set enable BOOL
6 Pump Cal. Request BOOL CP_PCal_Reg
7 Pump Dig. request BOOL CP_PDig_Reg
Byte 4 Pump Calibration number 1 CP_PCal_ReqNo
Byte 5 Pump Diagnostic number 1 CP_PDig_ReqNo
Byte 6 Not defined
Byte 7 Not defined

Display Protocol
DP_PDO1_Tx to Display
Byte 0(Low)
Height 0.01% 0 … 10000 CP_Weight_kg
Byte 1(High)
Byte 2 (Low)
Weight Kpa 0 … 28125 CP_Height_cm
Byte 3 (High)
Byte 4(low)
Byte 5 Pump Inverter 0…
0.001h CP_CANWorkHour
Byte 6 Hour 4294967295
Byte 7(high)
DP_PDO1_Rx from Display

Byte 0 (low) 0…
Height Set 1 1 CP_CANHeightSet1
Byte 1 (high) 11000[mm]
Byte 2 (low) 0…
Byte 4 (low) 0…
Byte 6 Not defined

Byte 7 Not defined

Extension Module Protocol
MC_RPDO1_Tx to Extension Module
Byte 0 (low)
Lift proportion output(S1) 1 0 … 15000
Byte 1 (high)
Byte 2 (low) Flow sharing proportion
1 0 … 15000
Byte 3 (high) output(S2)
Byte 4 0 Lift act signal BOOL

1 Not defined
2 Flow sharing act signal BOOL
3 - 7 Not defined
Byte 5 Not defined
Byte 6 Not defined
Byte 7 Not defined
MC_RPDO2_Tx to Extension Module

Byte 0 0-1 Not defined
2 Display Up switch signal BOOL
3 Display Down switch signal BOOL
4 Not defined
5 Display Enter switch signal BOOL
6 Display ESC switch signal BOOL
7 Parameter write signal BOOL
Byte 1(low)
Calibration Data U16
Byte 2(high)
Byte 3 0 Cal. Set enable BOOL
1 Pump Cal. Request BOOL CP_MCCalReg
2 Pump Dig. request BOOL CP_MCDigReg
3 - 7 Not defined
Byte 4 MC Calibration number 1 CP_MCCalReqNo
Byte 5 MC Diagnostic number 1 CP_MCDigReqNo
Byte 6 Not defined
Byte 7 Not defined

MC_RPDO1_Rx from Extension Module
Byte Data Scale Range/setting Item
Byte 0(low)
Joystick A (Lift/Lower) 1 -10000 … 10000 CP_CANYPosition
Byte 1(high)
Byte 2(low)
Joystick B (Reach) 1 -10000 … 10000 CP_CANReachPosition
Byte 3(high)
Byte 4(low)
Joystick C (Tilt) 1 -10000 … 10000 CP_CANTiltPosition
Byte 5(high)
Byte 6(low)
Joystick D(Side Shift) 1 -10000 … 10000 CP_CANSidePosition
Byte 7(high)

Byte Data Scale Range/setting Item
Byte 0(low)
Joystick error 1 0 … 10000
Byte 1(high)
Byte 2(low)
Joystick status 1 0 … 10000
Byte 3(high)
Byte 4(low)
Valve output error Level2 1 0 … 10000
Byte 5(high)
Byte 6(low)
Valve output error Level5 1 0 … 10000
Byte 7(high)

Byte 0 0 Cal. Mode set signal BOOL 1 : Active
1 Dig. Mode set signal BOOL 1 : Fault
2 Cal. Set OK signal BOOL 1 : Active Cp_MC_CANData0
3 Cal. Set error signal BOOL 1 : Active
4 - 7 Not defined
Byte 1 Pump Cal./Dig. Act number 1 CP_M_ActNo
Byte 2(low)
Byte 3
Calibration and Diagnostic
Byte 4 1 CP_MC_CalDigData
Data
Byte
5(high)
Byte 6 Not defined
Byte 7 Not defined

CAN-Bus Timeout
The maximum time allowed between receiving new command RPDO from the CAN-bus can be set by parameter
“CANTimeout”. The timer is initiated by the first RPDO received. The RPDO timeout will a set fault number 1001,
and disable the drive.
If no RPDO is received within the parameter “CANTimeoutPwr” after poweron timeout will also be activated. The
power-on timeout will a set fault number 9201, and disable the drive.
Parameter:
CANTimeout Timeout of the RPDO CAN bus message.
500
[ms]
CANToutPwr Timeout of the CAN bus after power on.
5000
[ms]
CAN-Bus Identifier
NAME CAN node ID
TA_PDO1_Rx : 21Dh
TA_PDO2_Rx : 22Dh
TA_PDO1_Tx : 30Dh
TA_PDO2_Tx : 31Dh
DP_PDO1_Tx : 35Bh
DP_PDO1_Rx : 46Bh
MC_PDO1_Rx : 506h
MC_PDO2_Rx : 516h
MC_PDO3_Rx : 526h
MC_PDO1_Tx : 546h
MC_PDO2_Tx : 556h
Parameter:
BasicNodeID Basic Node ID 13
Baudrate Baudrate of the CAN bus
0= 50 kBaud
1 = 100 kBaud
2 = 125 kBaud 3
3 = 250 kBaud
4 = 500 kBaud
5 = 1000 kBaud
Note:
For a change of the node ID, communication with the Plus+1 service tool, is an additional reset needed.

Functions
Work functions characteristics
This equipment has been appropriately setting for each hydraulic function.
Each function has been accurate setting the valve open area and the pump motor speed for the minimizing energy
consumption. Also consider the safety of the equipment at the same time; the operation was designed to only a
few.
Lift and Reach In/Out and lower and reach In/Out are move at the same time.
But the rest function are not operate simultaneous.
Each work function has the possibility to adjust the stationary reaction on the defection of the finger lever
command. This function assists the user in precise positioning of the forks. The function is realised by different
parametric look-up tables to generate specific system behaviour for following functions:
- Lift
- Lower
- Reach
- Tilt
- Side shift
Look-up table:
Parameter:
Function 0% 10% 30% 70% 90% 100%
Lift 0% 10% 25% 60% 85% 100%
Lower 0% 20% 40% 60% 85% 100%
Reach 0% 10% 20% 45% 70% 100%
Tilt 0% 10% 30% 70% 90% 100%
Side shift 0% 10% 30% 70% 90% 100%
The parameters are limited from 0% to 100.00% and an unsigned integer variable is used.

Lift Function
This system will increase smooth the mast according to the lever degree.
If there received the high sensor signal then controller will be applied the lower speed operation in order to build
with no impact.
See below Sequence Drawing
Note: If you have a shock at the maximum height of Mast then you should check the” Mast High Switch”.
Figure 1) Lift Sequence
Lower Function
When operator push the Lift/Lower lever then system will go down smooth the mast according to the lever degree.
Pump motor doesn't turn and the mast be go down by the load
If there is received the mast high switch signal then lower speed is very slow for safety.
Figure 2) Lower Sequence

Reach In/Out Function
This system will increase smooth the reach cylinder according to the lever degree.
If there received the reach sensor signal then controller will be applied the lower speed operation in order to build
with no impact.
See below Sequence Drawing
Note: If you have a shock at the inner or outer stop the reach cylinder then you should check the” Reach Sensor
Switch”.
Figure 4) Reach Cylinder Sequence
Tilt Function
This system will increase smooth the tilt cylinder according to the lever degree.
Tilt function is an exclusive operating. In order words, the rest functions are not operating simultaneous.
Side Shift Function

This system will operate smooth the side shift cylinder according to the lever degree.
Side shift function is an exclusive operating. In order words, the rest functions are not operating simultaneous.

Determining desired rate of pump speed
The individual ramped and normalized flow demands of the working functions are multiplied by the maximum
according speed (except of lowering) to adjust the system to the desired functional speeds.
As the gear pumps have got a minimum rate of turn the summation of all individual turning rates is limited to a
minimum speed once a request of speed is active.
Variables:
CP_SpdStptS1_rpm1 Set speed value from S1 valve( lift )
[0.1rpm]
CP_SpdMaxS2_rpm1 Selected maximal speed value from S2Valve(Reach, Tilt, SideShift)
[0.1rpm]
CP_SpdStptS2_rpm1 Set speed value from S2 valve(Reach, Tilt, SideShift)
[0.1rpm]
CP_SpdStpt_rpm1 Input value of the speed curve (Pump motor command rpm)
[0.1rpm]
CP_DrvEnbl Drive enable request
Parameter:
SpdMin_rpm1 Min. speed value of the application.
500
(0…8000) [0.1 rpm]
LiftSpdMax_rpm1 Max. speed value lift.
22500
(1000…40000) [0.1 rpm]
ReSpdMaxOut_rpm1 Max. speed value reach out.
10000
(1000…40000) [0.1 rpm]
ReSpdMaxIn_rpm1 Max. speed value reach in.
6000
(1000…40000) [0.1 rpm]
TiltSpdMaxFwd_rpm1 Max. speed value tilt forward.
4000
(1000…40000) [0.1 rpm]
TiltSpdMaxRvs_rpm1 Max. speed value tilt reverse.
4500
(1000…40000) [0.1 rpm]
SideSpdMaxL_rpm1 Max. speed value side shift left.
3000
(1000…40000) [0.1 rpm]
SideSpdMaxR_rpm1 Max. speed value side shift right.
3000
(1000…40000) [0.1 rpm]

Speed characteristic
To obtain a comfortable drive feeling the speed curve is generated with a drive curve generator dependent on the
variation of the set value. Beside the actual speed, it is also considered how far and how fast the set value is
changed. According to the variation of the set value a very sensible and smooth drive feeling can also performed
as well as a dynamic driving.
Variables:
CP_SpdStpt_rpm1 Input value of the speed curve
[0.1rpm]
CP_RPMSetPointOut Motor speed set value
-80000…+80000 [0.1rpm]
Parameter:
Progression Specifies the influence of the set value variation to the
value of acceleration or deceleration.
Progression = 0: Independently of the set value
variation always the maximum acceleration or
0
deceleration is active.
Progression = 100: The value of acceleration or
deceleration depends on the variation of the set value
on a linear characteristic. Default: 0 (0…100)
Roundness Specifies the strange of the roundness (0: no rounding;
90: max. rounding).
The speed curve is always rounded before reaching
the final value. A rounding at the beginning of
acceleration or deceleration becomes effective only if
the set value changes slowly. With a slowly change of
60
the set value a smoothly drive reaction is performed,
as acceleration is increased continuously. In case of a
fast change of the set value an aggressive drive
reaction results, as acceleration achieves it’s maximum
value precipitously.
Default: 0 (0…90)
SpdMax_rpm1 Max. speed value of the application.
Default 1500 rpm 25500
(1…80000) [0.1 rpm]
AcelMax_rpmps Maximum deceleration slope
50000
Default: 5000 0.1 rpm/s
DcelMax_rpmps Max. speed value tilt forward.
50000
(1000…40000) [0.1 rpm]

Speed Controller
API controller is used to control the speed of the motor. The proportional part has the effect of reducing the rise
time of the motor speed, but it never eliminates the steady-state error. The integral part of the controller has the
effect of eliminating the steady-state error, but it may make the transient response worse.
Parameter:
SpeedKP Proportional gain of speed controller
30000
1…10000000 [0.00001Nm/rpm]
SpeedKI Integral gain of speed controller
100000
0…10000000 [0.00001Nm/rpm/s]
PartLoadReduc Lower limit of rated flux to reduce current at
partial load. 10000
2000…10000 [0.01%]

De-rating
The reduction of the maximum allowed motor current in relation to the motor temperature and the power stage
temperature is realized with the de-rating function. The minimum of the power stage temperature factor and the
motor temperature factor is transmitted to the user current limit.
Variables:
PowerStage.Temp Actual temperature at power stage
-60…170 [°C]
Motor.ActTemp Actual motor temperature
-50…200 [°C]
CP_DeratingPwrStage Derating factor of the power stage temperature
0…10000 [0.01%]
CP_DeratingMotor Derating factor of the motor temperature
0…10000 [0.01%]
MotorControl.UserCurrLimit User current limit as percentage of hardware current limit.
0…10000 [0.01%]
Parameter:
MotTemp100perc Motor temperature at which the derating curve starts.
80
[°C]
MotTempDerate Motor temperature at which the derating curve ends.
120
[°C]
MotIDerateM Motor derated curve for motor mode.
5000
[0.01%]
MotIDerateG Motor derated curve for generator mode.
3500
[0.01%]
InvTemp100perc Inverter temperature at which the derating curve starts.
60
[°C]
InvTempDerate Inverter temperature at which the derating curve ends.
80
[°C]
InvIDerateM Invert derated curve for motor mode.
5000
[0.01%]
InvIDerateG Invert derated curve for generator mode.
3500
[0.01%]

Lift height indicator
The analogue height sensor input (C1p11.Volt) value is dependent of the actual height of the fork lift mast. The
height is calculated from the height sensor input value with a two point curve.
The two point curve is calibrated after the first complete displacement of the mast.
Variables:
C1p11.Volt Analog height sensor input
( 0…10000) [mV]
CP_Height_SnsrPct Analog height sensor input, Specified by units of .01% of HiOut
parameter (0…10000) [0.01%]
CP_Height_cm Mast height
(0…11000) [mm]
Parameter:
H_CalLo_pct Low calibration point as percentage of the sensor
1000
power
H_CalHi_pct High calibration point as percentage of the sensor
9000
power
H_LoOut_pct Calibrated minimum value of the output percentage
10
of HiOut
H_DbndLo_pct Dead band of the low calibration point as percentage
0
of sensor power
H_DbndHi_pct Dead band of the high calibration point as percentage
0
of sensor power
H_HiOut Calibrated maximum value of the output
6900
(Note : This value depends on the type of mast.)
H_FltDetTm_ms Fault detection time 1000
H_FltThd_pct Fault threshold of the low and high calibration point
500
as percentage of the sensor power.
Height_Default Default value of the each mast. 2000

Load weight indicator
The analogue pressure sensor input (C1p22) value is dependent of the actual weight on the fork lift. The weight is
calculated from the pressure sensor input value with a special function block.
Variables:
C1p22.Volt Analog pressure sensor input
( 0 …5250) [mV]
CP_WeightIn_KPa Indicates pressure in kilopascals(kPa)
0 … 28125 kilopascal ( 100 kPa = 1 Bar)
Parameter:
Weight_Zero (S16) It is the Input pressure value when the weight is zero.
1600
(0 – 10000)
Weight_1000 (S16) It is the Input pressure value when the weight is
1000kg. 6050
(0 – 28125)

Error System
Error and status code
The error and the status code are composed of a number and a sub number.
The error or status code must be unique.
X 1
{ XX XX
23 123
controller number sub number
Error and status handling

All errors and status events will be collected and administrated from the error and status handler. The error and
status handler use different error and status variable, with different priorities, to collect the information. If the
variables are equal to zero, no event is triggered. If a variable is set to a code, an error or a status is triggered,
with the attendant error level. See“Fault Codes” for more details.
Variables:
CP_Err Error variable
CP_Stat Status variable
CP_ErrLev0 ... CP_ErrLev6 Error variable with the error level 0 … 6.
CP_StatLev0 ... CP_StatLev3 Status variable with the status level 0 … 3.
CP_ErrLev0Act ... Error level 0 … 6 is active.
CP_ErrLev6Act
CP_StatLev0Act ... Status level 0 … 3 is active.
CP_StatLev3Act
CP_EMCDrive Drive is disabled, because of an error.
CP_EMCLower Lower function is disabled, because of an error.
CP_EMCLift Lift function is disabled, because of an error.
CP_EMCReach Reach function is disabled, because of an error.
CP_EMCOther Tilt, side shift, aux functions are disabled, because of an error.
Parameter:
ClrErr A positive edge at the “ClrErr” variable clears all error
levels.
0
The error levels can only cleared, if no error is existent
in this moment.

Error history
The last eight errors are stored together with a time stamp (hour counter) and a error counter, in the error history
memory. If the same error has appeared, consecutively several times, the error will be shown only once, but with
the latest time stamp and with an increased error counter.
Variables:
CP_ErrStor_0 ... CP_ErrStor_7 Error storage 0…7.
CP_HCStor_0 ... CP_HCStor_0 Time stamp storage 0…7.
CP_ErrCStor_0 ...CP_ErrCStor_7 Counter storage 0…7.
Parameter:
ClrErrHistory A positive edge at the “ClrErrHistory ” variable clears
0
the complete error history memory.
Blink code
The red LED is used to show the error information and the green LED is used to show the status information. Only
the number of the error or the status is shown on the LED’s, the sub number will not be displayed.
Variables:
CP_ErrFlash Error blink code variable (Red LED).
CP_StatFlash Status blink code variable (Green LED).
Hour Counter
An hour counter functionality is implemented in the software. If the power stage is activated the hour counter starts
to count until the power stage is deactivated again.
Variables:
CP_HCounter_h3 Pump inverter hour counter. [0.001h]
Parameter:
HCVal_h3 Set value for the hour counter. [0.001h] 1
SetHC After a rising edge (0->1) on the set value “SetHC” ,
1
the hour counter is set to the set value “HCVal_h4”.

Accessories
PC-based Software Service Tool
free USB port.
USB Gateway
Pin Function
1 -
2 CAN -
3 Shield/Groun
4 -
5 -
6 -
7 CAN +
8 -
9 -

Fault Code
Fault Code
Sub-
no.
CAN
10 00 CAN Timeout
10 01 CAN Timeout; RPDO Timeout is active ErrLev0
11 01 Traction Inverter fault Traction Inverter Error ErrLev1
15 01 Sequence Error Input signal Sequence error StatLev0
CAN Interface
20 01 Lift Joystick input value is too low ErrLev2
20 02 Lift Joystick input value is too high ErrLev2
20 03 Lift Joystick input Value out of range (MaxIn_mV < In_mV) or (CalCmd> 4) ErrLev2
20 05 Lift Joystick Block is not calibrated (CalLo_pct = 0 and CalHi_pct = 0) StatLev1

Lift JoystickBlock is currently in a calibration
20 06 (CalLo_pct ≠ 0 and CalHi_pct = 0) StatLev1
cycle
20 07 Lift Joystick Parameters are corrupt StatLev1
20 08 Lift Joystick Invalid Setup/ Calibration StatLev1
21 01 Reach Joystick input value is too low ErrLev2
21 02 Reach Joystick input value is too high ErrLev2
21 03 Reach Joystick input Value out of range (MaxIn_mV < In_mV) or (CalCmd> 4) ErrLev2
21 05 Reach Joystick Block is not calibrated (CalLo_pct = 0 and CalHi_pct = 0) StatLev1

Reach JoystickBlock is currently in a
calibration cycle
21 07 Reach Joystick Parameters are corrupt StatLev1
21 08 Reach Joystick Invalid Setup/ Calibration StatLev1
22 01 Tilt Joystick input value is too low ErrLev2
22 02 Tilt Joystick input value is too high ErrLev2
22 03 Tilt Joystick input Value out of range (MaxIn_mV < In_mV) or (CalCmd> 4) ErrLev2
22 05 Tilt Joystick Block is not calibrated (CalLo_pct = 0 and CalHi_pct = 0) StatLev1

Tilt JoystickBlock is currently in a calibration
cycle
22 07 Tilt Joystick Parameters are corrupt StatLev1
22 08 Tilt Joystick Invalid Setup/ Calibration StatLev1
23 01 SideShift Joystick input value is too low ErrLev2

23 02 SideShift Joystick input value is too high ErrLev2
23 03 SideShift Joystick input Value out of range (MaxIn_mV < In_mV) or (CalCmd> 4) ErrLev2
23 05 SideShift Joystick Block is not calibrated (CalLo_pct = 0 and CalHi_pct = 0) StatLev1

SideShift JoystickBlock is currently in a
calibration cycle
23 07 SideShift Joystick Parameters are corrupt StatLev1
23 08 SideShift Joystick Invalid Setup/ Calibration StatLev1
Power stage
50 00 Warning power stage

Warning power stage; Warn temperature is
50 01 PowerStage.Temp > Warn limit StatLev3
reached
51 01 Error power stage; Min. Temperature PowerStage.Temp < DeviceInfo.MinTemp ErrLev1
Motor
52 00 Error motor
52 01 Error motor; Overtemperatur Motor.ActTemp_C > Max. limit ErrLev1
53 00 Warning motor
53 01 Warning motor; Warn temperature is reached Motor.ActTemp_C > Warn limit StatLev3
OS
54 00 Error loop time
54 02 Error loop time; 3 times in row OS.ExecTime > 2 * OS.ExeceTimeOut ErrLev0
Analog inputs
70 01 Brake pedal input; C1p10; Input out of range StatLev3
70 02 Brake pedal input; C1p10; Hardware Error StatLev3
70 03 Brake pedal input; C1p10; Input value is too low Sensor_2Pt_AC; Fault = 0x8001 StatLev3
70 04 Brake pedal input; C1p10; Input value is too high Sensor_2Pt_AC; Fault = 0x8002 StatLev3
70 05 Brake pedal input; C1p10; Value out of range Sensor_2Pt_AC; Fault = 0x8010 StatLev3
70 06 Brake pedal input; C1p22; Block is not calibrated Sensor_2Pt_AC; Status = 0x8001 StatLev3
Brake pedal input; C1p22; Block is currently
70 07 Sensor_2Pt_AC; Status = 0x8002 StatLev3
in a calibration cycle

Brake pedal input; C1p22; Parameters are
corrupt
Brake pedal input; C1p22; Invalid Setup/
Calibration
71 01 Error analog input, C1p11; Input out of range C1p11.PinStatus; Bit1 = 1 StatLev3
71 02 Error analog input, C1p11, Hardware error C1p11.PinStatus; Bit2 = 1 StatLev3
71 03 Sensor Input value is too low StatLev3
71 04 Sensor Input value is too high StatLev3
71 06 Height Set error ; Out of range Set value > Mast Height StatLev3
71 07 Height Set error ; Incorrect setting (Height 1 < Height 2 < Height 3) StatLev3
72 01 Error analog input, C1p22; Input out of range C1p22.PinStatus; Bit1 = 1 StatLev3
72 02 Error analog input, C1p22, Hardware error C1p22.PinStatus; Bit2 = 1 StatLev3
72 03 Sensor Input value is too low StatLev3
72 04 Sensor Input value is too high StatLev3
74 00 Error general purpose input / output, C1p14

C1p14; Overload / output shorted to +I/O
C1p14; Output disconnected / output
74 03 C1p14, switched off because overload C1p14.PinStatus; Bit5 = 1 ErrLev4
74 04 C1p14, switch on protection after overload C1p14.PinStatus; Bit6 = 1 ErrLev4
74 05 C1p14, Hardware Watchdog error C1p14.PinStatus; Bit7 = 1 ErrLev4




78 01 C1p13; Invalid value at .Output Value C1p13.PinStatus; Bit2 = 1 ErrLev4

78 07 C1p13; Safety error C1p13.SafetyStatus = 1 ErrLev4
General purpose proportional inputs / output
79 00 Extension Module C1P11
79 01 Extension Module C1P11; Input value too low ErrLev5
79 02 Extension Module C1P11; Input value too high ErrLev5
79 03 Extension Module C1P11; Open circuit ErrLev5

Extension Module C1P11; Short
79 04 ErrLev5
circuit(Overload)
Extension Module C1P11; Input value out of
79 05 ErrLev5
range
80 00 Extension Module C1P12
80 01 Extension Module C1P12; Input value too low ErrLev5
80 02 Extension Module C1P12; Input value too high ErrLev5
80 03 Extension Module C1P12; Open circuit ErrLev5

Extension Module C1P12; Short
80 04 ErrLev5
circuit(Overload)
Extension Module C1P12; Input value out of
80 05 ErrLev5
range

Error general purpose proportional input /
81 00
output, C1p27
81 01 C1p27; Config error at .OutputValue C1p27.PinStatus; Bit2 = 1 ErrLev6
81 02 C1p27; Config error at .DitherAmp C1p27.PinStatus; Bit3 = 1 ErrLev6

81 05 C1p27; Safety error C1p27.SafetyStatus = 1 ErrLev6
82 00 Error sensor supply, C1p23

C1p23.Volt > + 10% of set value for
82 01 Error sensor supply, C1p23; Overvoltage StatLev3
5s
82 02 Error sensor supply, C1p23; Overvoltage C1p23.Volt > + 40% of set value StatLev3
82 03 Error sensor supply, C1p23; Undervoltage C1p23.Volt < - 10% of set value for 5s StatLev3
82 04 Error sensor supply, C1p23; Undervoltage C1p23.Volt < - 50% of set value StatLev3
Error sensor supply, Supply voltage
82 05 C1p23.PinStatus; Bit1 = 1 StatLev3
83 00 Error encoder supply, C1p28
83 01 Error encoder supply, C1p28; Overcurrent C1p28.FeedbackValue > Max. limit ErrLev1
83 02 Error encoder supply, C1p28; Undercurrent C1p28.FeedbackValue < Min. limit ErrLev1
Power stage
84 01 Error power stage; Overtemperature PowerStage.Status; Bit1 = 1 ErrLev1
84 02 Error power stage; SensorError PowerStage.Status; Bit2 = 1 ErrLev1
84 03 Error power stage; Overvoltage PowerStage.Status; Bit3 = 1 ErrLev1
84 04 Error power stage; Overcurrent PowerStage.Status; Bit4 = 1 ErrLev1

Error power stage; Power stage permanently
84 06 PowerStage.Status; Bit6 = 1 ErrLev1
locked because wrong motor data
Error power stage; Power Stage permanently
locked because HW watchdog error
locked because current sensor error
locked because undervolt detection
Selftest
85 00 Error selftest
85 01 Error selftest; Error DC-Link circuit Selftest.Error; Bit0 = 1 ErrLev1

Error selftest; Error in Watchdog circuit,
85 02 Selftest.Error; Bit1 = 1 ErrLev0
operation impossible
85 03 Error selftest; Short circuit to -V DC-Link Selftest.Error; Bit2 = 1 ErrLev1

85 04 Error selftest; Short circuit to +V DC-Link Selftest.Error; Bit3 = 1 ErrLev1
85 05 Error selftest; Error in motor wiring or power stage Selftest.Error; Bit4 = 1 ErrLev1
85 06 Error selftest; Shorted power output (motor output) Selftest.Error; Bit5 = 1 ErrLev1
Error selftest; Test not passed, because of
hardware over voltage protection
Error selftest; Curropted production data in
EEPROM detected
86 00 Warning selftest
Warning selftest; Error in Watchdog circuit,
limited operation possible
Warning selftest; Watchdog not tested,
because low voltage at DC- Link
Warning selftest; Curropted user data in
EEPROM detected
87 00 Status selftest
87 01 Status selftest; DCLink selftest in progress Selftest.Status; Bit0 = 1 StatLev1
87 02 Status selftest; Watchdog selftest in progress Selftest.Status; Bit1 = 1 StatLev0
87 03 Status selftest; PowerStage selftest in progress Selftest.Status; Bit2 = 1 StatLev1
Analog input (Rheo)
88 01 Error analog input, C1p34; Input out of range C1p34.PinStatus; Bit1 = 1 ErrLev1
88 02 Error analog input, C1p34, Hardware error C1p34.PinStatus; Bit2 = 1 ErrLev1
Motor
90 00 Error motor
90 01 Error motor; Config error Motor.Status; Bit0…Bit22 = 1 ErrLev1
NVMem
91 00 Error NVMem
Error NVMem; The NVMem restored to a
previouse state
Error NVMem; The NVMem checksumme
are not correct
Error NVMem; The reset routine couled not
access the NV memory
CAN
92 00 Error CAN
92 01 Error CAN; CAN controller error CAN[0].DriverError = 1 ErrLev0

Table of Errors and System Reactions
Disable Disable Disable Store in
Status LED Error LED lower Disable lift reach other Disable error
Variable (green) (red) output output output outputs drive history
ErrLev0 X X X X X X X
ErrLev1 X X X X X X
ErrLev2 X X X X
ErrLev3 X X X
ErrLev4 X X X
ErrLev5 X X X
ErrLev6 X X X
StatLev0 X X X X X X
StatLev1 X X X X X
StatLev2 X X
StatLev3 X

Diagnostic and Troubleshooting
General Description
Diagnostic information can be obtained in each of three ways: by reading the display, the PC (using PLUS+1
Service Tool) or by observing the fault codes issued by the status LEDs. See below example for a summary of
LED display formats.
Example: Error code 3742
1) The previous two-digit error "42" error blinks method.

Let the red LED as following blinking:
2) The next two-digit error "37" error blinks method.

Let the green LED as following blinking:
3) LED Position
This chapter explains how to manage any detected fault and how to return to a normal working situation;
suggestions to be applied in case of each possible alarm are listed in a growing order, i.e. from the least to the
most serious one.
If an alarm condition is detected by main board, software control inhibits some lift truck functions, to guarantee
operator’s safety. Anomalous working conditions are indicated by different alarm levels, classified as follows,
depending on their effects on the system:

1. Main breaker is opened and both pump and drive motors are stopped;
buzzer and can you see the error code on the display.
2. Pump or drive motors are stopped.
3. No effects on system performance.
NOTICE If more than one faulty condition is detected, Compact displays shows alarm code referring to the most
serious one (the one characterized by lower alarm level).
Following section gives useful suggestions covering a wide range of possible
faults, listing corresponding alarm cause identified by its alarm code.

Alarm List.
CAN Timeout – Pump inverter
2. Display alarm : P-CAN FAULT
3. Error level: 0
4. Alarm cause: Error in CAN communication between traction and pump inverter; DSP present on main board
make a mutual software control, to insure fast diagnosis of such a fault.

Wrong start
2. Display Alarm : WRONG START-PUMP
3. Error level: 6 (warning, pump motors are stopped.)
4. Alarm cause: If you have some fingertip lever activated when you start working then error occurs.

1. Verify if a switch was active or each fingertip lever pressed, when you turn on the lift truck;
2. Verify if each fingertip lever circuit voltage (measured in Volt);
Lift/Lower Fingertip Lever

2. Display alarm: LIFT LEVER Err
3. Error level: 2
4. Alarm cause: Lift/Lower fingertip lever input value is too low or open.

3. Error level: 2
4. Alarm cause: Lift/Lower fingertip lever input value is too high or short.

3. Error level: 2
4. Alarm cause: Lift/Lower fingertip lever input value is out of range.

3. State level: 1
4. Alarm cause : Lift/Lower fingertip lever input value is not calibrated. And if you replace the fingertip lever new on

3. State level: 1
4. Alarm cause : Lift/Lower fingertip lever input value is currently in a calibration cycle. And if you replace the
fingertip lever new on then appears primarily

3. State level: 1
4. Alarm cause : Lift/Lower fingertip parameters are corrupt. And if you replace the fingertip lever new on then
appears primarily

3. State level: 1
4. Alarm cause : Lift/Lower fingertip invalid setup or calibration. And if you replace the fingertip lever new on then
appears primarily

1. Verify if the fingertip lever initial set-up is correct; if not, repeat calibration procedure. (You can use
PC with CAN communication software).
2. Verify if the following the extension module(MC012-010) connector terminals are correctly wired to
their correspondent inputs in fingertip lever circuit:
1) Pin 6 (5 V)
2) Pin 7 (ground)
3) Pin 10 (Lever input, about 2.5V)
3. In case of correct wiring, replace the fingertip lever itself.
Reach Fingertip Lever

2. Display alarm: REACH LEVER Err
3. Error level: 2
4. Alarm cause: REACH fingertip lever input value is too low or open.

3. Error level: 2
4. Alarm cause: REACH fingertip lever input value is too high or short.

3. Error level: 2
4. Alarm cause: REACH fingertip lever input value is out of range.

3. State level: 1
4. Alarm cause : REACH fingertip lever input value is not calibrated. And if you replace the fingertip lever new on

3. State level: 1
4. Alarm cause : REACH fingertip lever input value is currently in a calibration cycle. And if you replace the

3. State level: 1
4. Alarm cause : REACH fingertip parameters are corrupt. And if you replace the fingertip lever new on then
appears primarily

3. State level: 1
4. Alarm cause : REACH fingertip invalid setup or calibration. And if you replace the fingertip lever new on then
appears primarily

1) Pin 6 (5 V)
2) Pin 7 (ground)
Tilt Fingertip Lever

2. Display alarm: TILT LEVER Err
3. Error level: 2
4. Alarm cause: TILT fingertip lever input value is too low or open.

3. Error level: 2
4. Alarm cause: TILT fingertip lever input value is too high or short.

3. Error level: 2
4. Alarm cause: TILT fingertip lever input value is out of range.

3. State level: 1
4. Alarm cause : TILT fingertip lever input value is not calibrated. And if you replace the fingertip lever new on then
appears primarily

3. State level: 1
4. Alarm cause : TILT fingertip lever input value is currently in a calibration cycle. And if you replace the fingertip
lever new on then appears primarily

3. State level: 1
4. Alarm cause : TILT fingertip parameters are corrupt. And if you replace the fingertip lever new on then appears
primarily

3. State level: 1
4. Alarm cause : TILT fingertip invalid setup or calibration. And if you replace the fingertip lever new on then
appears primarily

2. Verify if the following the extension module (MC012-010) connector terminals are correctly wired to
1) Pin 6 (5 V)
2) Pin 7 (ground)

Side Shift Fingertip Lever
2. Display alarm: SS LEVER Err
3. Error level: 2
4. Alarm cause: SIDE SHIFT fingertip lever input value is too low or open.

3. Error level: 2
4. Alarm cause: SIDE SHIFT fingertip lever input value is too high or short.

3. Error level: 2
4. Alarm cause: SIDE SHIFT fingertip lever input value is out of range.

3. State level: 1
4. Alarm cause : SIDE SHIFT fingertip lever input value is not calibrated. And if you replace the fingertip lever new
on then appears primarily

3. State level: 1
4. Alarm cause : SIDE SHIFT fingertip lever input value is currently in a calibration cycle. And if you replace the

3. State level: 1
4. Alarm cause : SIDE SHIFT fingertip parameters are corrupt. And if you replace the fingertip lever new on then
appears primarily

3. State level: 1
4. Alarm cause : SIDE SHIFT fingertip invalid setup or calibration. And if you replace the fingertip lever new on
1) Pin 6 (5 V)
2) Pin 7 (ground)

Pump inverter power stage over temperature
2. Display alarm code: P_INV OVERTEMP
3. State level: 3
4. Alarm cause: Power module temperatures, measured with a probe, exceed 85 °C.

1. Alarm could be caused by ineffective temperature dissipation; verify thermal coupling between
power module block and aluminium plate. This system is using the fan cooling system.
2. Check the fan status. If the fan does not move then you replace the fan.
Pump motor over temperature

2. Display alarm code: P-MOTOR OVERTEMP
3. Error level: 1

2. Display alarm code: P-MOTOR OVERTEMP
3. State level: 3

1. Presence of alarm with cold motors:
2. With a handheld multi-meter (in resistance operating mode) you have to measure a resistance of
about 10 K between the twΩ o wires of the temperature sensor (execute the measure at ambient
temperature of 25°C). If the measure is not correct it is necessary to replace the temperature sensor.
3. Disconnect the temperature sensor and check the wiring insulation between signal wire and ground
wire (towards logic);
Presence of alarm with hot motors:

1. If temperature value (you can read it from Instrument or via PC) seems correct, verify if fans (if present) work
properly; fault is caused by on inefficient motor refreshing, or by operating out of nominal maximum ranges.
OS Loop time Error

2. Display alarm code: LOOP TIME ERROR
3. Error level: 0
4. Alarm cause: Software error.

Brake pedal input “B”

3. State level: 3
4. Alarm cause: Brake pedal input “B” value is out of range.

3. State level: 3
4. Alarm cause: Brake pedal input “B” hardware error.

3. State level: 3
4. Alarm cause: Brake pedal input “B” value is too low or open.

3. State level: 3
4. Alarm cause: Brake pedal input “B” value is too high or short.

3. State level: 3
4. Alarm cause: Brake pedal “B” value is out of range.

3. State level: 3
4. Alarm cause : Brake pedal input “B” value is not calibrated. And if you replace the brake pedal new on then
appears primarily

3. State level: 1
4. Alarm cause : Brake pedal input “B” value is currently in a calibration cycle. And if you replace the brake pedal

3. State level: 3
4. Alarm cause : Brake pedal input “B” parameters are corrupt. And if you replace the brake pedal new on then
appears primarily

3. State level: 3
4. Alarm cause : Brake pedal input “B” invalid setup or calibration. And if you replace the brake pedal new on then
appears primarily

1. Verify if the brake pedal initial set-up is correct; if not, repeat calibration procedure. (You can use
2. Verify if the following the 34pin traction and pump main connector terminals are correctly wired to
their correspondent inputs in accelerator circuit:
T – 23 (5 V)
T – 12 (ground)
P – 10 (pedal output-B)
3. In case of correct wiring, replace the brake pedal itself.

Height Sensor – Option
2. Display alarm: HEIGHT SIG FAU
3. State level: 3
4. Alarm cause: Height sensor input value is out of range.

2. Display alarm: HEIGHT SEN FAULT
3. State level: 3
4. Alarm cause: Height sensor input hardware error.

3. State level: 3
4. Alarm cause: Height sensor input value is too low or open.

3. State level: 3
4. Alarm cause: Height sensor input value is too high or short.

1. This error occurs only if the height sensor is equipped with.
2. Verify if the height sensor initial set-up is correct; if not, repeat calibration procedure. (You can use
3. Verify if the following the 34pin pump main connector terminals are correctly wired to their
correspondent inputs in accelerator circuit:
P – 23 (5 V)
P – 12 (ground)
P – 11 (Signal)
4. In case of correct wiring, replace the height sensor itself.
Weight Sensor – Option

2. Display alarm: WEIGHT SIG FAU
3. State level: 3
4. Alarm cause: Weight sensor input value is out of range.

2. Display alarm: WEIGHT SEN FAULT
3. State level: 3
4. Alarm cause: Weight sensor input hardware error.

3. State level: 3
4. Alarm cause: Weight sensor input value is too low or open.

3. State level: 3
4. Alarm cause: Weight sensor input value is too high or short.

1. This error occurs only if the weight sensor is equipped with.
2. Verify if the weight sensor initial set-up is correct; if not, repeat calibration procedure. (You can use

3. Verify if the following the 34pin pump main connector terminals are correctly wired to their
correspondent inputs in accelerator circuit:
P – 23 (5 V)
P – 12 (ground)
P – 22 (Signal)
4. In case of correct wiring, replace the weight sensor itself.
Reach out Solenoid Error

2. Display alarm: REACH OUT SOL FAU
3. Error level: 4
4. Alarm cause: Output overloads, shorted to +I/O supply or transistor damaged.

3. Error level: 4
4. Alarm cause: Output disconnected, shorted to -I/O supply or transistor shorted.

3. Error level: 4
4. Alarm cause: Output switch off because overload.

3. Error level: 4
4. Alarm cause: Switch on protection after overload.

3. Error level: 4
4. Alarm cause: Hardware watchdog error.

1. Verify the reach out solenoid resistance (About 28.5 ohms), wire (P-14) status.
2. Verify the coil supply power : DC 48V
P–9
P – B- terminal (ground)
3. In case of correct coil, replace the pump inverter.
Diverter Solenoid Error

2. Display alarm: DIVERTER SOL FAU
3. Error level: 3

3. Error level: 3

3. Error level: 3

3. Error level: 3

3. Error level: 3

1. Verify the diverter solenoid resistance (About 28.5 ohms), wire (P-15) status.
P–9
Retract Solenoid Error

2. Display alarm: RETRACT SOL FAU
3. Error level: 3

3. Error level: 3

3. Error level: 3

3. Error level: 3

3. Error level: 3

1. Verify the retract solenoid resistance (About 28.5 ohms), wire (P-25) status.
P–9
Extend Solenoid Error

2. Display alarm: EXTEND SOL FAU
3. Error level: 3

3. Error level: 3

3. Error level: 3

3. Error level: 3

3. Error level: 3

1. Verify the extend solenoid resistance (About 28.5 ohms), wire (P-26) status.
P–9
Reach In Solenoid Error

2. Display alarm: REACH IN SOL FAU
3. Error level: 4
4. Alarm cause: Invalid value at output command.

3. Error level: 4

3. Error level: 4

3. Error level: 4

3. Error level: 4

3. Error level: 4
4. Alarm cause: Safety error.
Note: If the 27806=1, 27802 = 0 and 27803 = 0 the output will work in unsafe mode. (The PWM signal can be 10 %
wider than commanded)

1. Verify the reach in solenoid resistance (About 28.5 ohms), wire (P-13) status.
P–9

Flower sharing Solenoid Error
2. Display alarm: FLOW SOL SOL FAU
3. Error level: 5
4. Alarm cause: Command input value too low

3. Error level: 5
4. Alarm cause: Command input value too high.

3. Error level: 5
4. Alarm cause: Output disconnected.

3. Error level: 5
4. Alarm cause: Output overloads (short).

3. Error level: 5
4. Alarm cause: Input value out or range.

1. Verify the D/D converter output status
2. Verify the fuse (10A)
3. Verify the extension module status. You can see the CAN status by observing the red LED flashes.
The LED built into the extension module.
4. Verify the lowering solenoid resistance (Type: DC12V, About 28.5 ohms), wire (Extension module
pin 11) status.
5. In case of correct coil, replace the extension module.
Lift Solenoid Error.

2. Display alarm: LIFT SOL SOL FAU
3. Error level: 5
4. Alarm cause: Command input value too low

3. Error level: 5
4. Alarm cause: Command input value too high.

3. Error level: 5
4. Alarm cause: Output disconnected.

3. Error level: 5
4. Alarm cause: Output overloads (short).

3. Error level: 5
4. Alarm cause: Input value out or range.

1. Verify the D/D converter output status
2. Verify the fuse (10A)
3. Verify the extension module status. You can see the CAN status by observing the red LED flashes.
The LED built into the extension module.
4. Verify the lowering solenoid resistance (Type: DC12V, About 28.5 ohms), wire (Extension module
pin 12) status.
5. In case of correct coil, replace the extension module.
Lower Solenoid Error

2. Display alarm: LOWRING SOL FAU
3. Error level: 6
4. Alarm cause: Configuration error of the output command.

3. Error level: 6
4. Alarm cause: Configuration error of the output dither amplifier command.

3. Error level: 6

3. Error level: 6

3. Error level: 6
4. Alarm cause: Safety error.
Note: If the 28105=1, 27812 = 0 the output will work in unsafe mode
(The PWM signal can be 10 % wider than commanded)

1. Verify the lowering solenoid resistance (About 28.5 ohms), wire (P-27) status.
P–9
5V output fault (Controller pin 23)

3. State level: 3
4. Alarm cause: Supply voltage feedback value is 10% higher for 5s.

3. State level: 3
4. Alarm cause: Supply voltage feedback value is 40% higher.

3. State level: 3
4. Alarm cause: Supply voltage feedback value is 10% lower for 5s.

3. State level: 3
4. Alarm cause: Supply voltage feedback value is 50% lower for 100ms.

2. Display alarm code: 5V FAULT
3. State level: 3
4. Alarm cause: Supply voltage feedback value out of range will be set for voltage values higher than 15000 mV.

1. Verify if 5 V output is grounded, cause an incorrect encoder wiring.
2. Verify if 5 V output is grounded, because any analog sensor
(Accelerator, Brake pedal etc.) malfunction. In that case, replace the defective one.
Encoder supply (12 V) voltage fault (Controller Pin28)

3. Error level: 1
4. Alarm cause: If the current feedback value is greater than the 200mA for longer than a time 100ms the error
output goes to TRUE

3. Error level: 1
4. Alarm cause: If the current feedback value is lower than the 50mA for longer than a time 100ms the error output
goes to TRUE
In case of an alarm follow this procedure:

1. Verify if 12 V output (Pin 28) is grounded, cause an incorrect encoder wiring.
2. Verify if 12 V output is grounded, because any encoder malfunction. In that case, replace the
defective one.
Pump inverter power stage fault

2. Display alarm code: P-INV OVERTEMP
3. Error level: 1
4. Alarm cause: The temperature of the power stage is measured with a PTC resistor and the values are filtered
with a time constant of 500ms.
The actual temperature is calculated and displayed at PowerStage.Temp in the range of -60°C – 170°C. If the
actual value exceeds the temperature limit (85 °C ) an overtemperature error occurs.

2. Display alarm code: P-INV SEN FAU
3. Error level: 1
4. Alarm cause: The temperature at the power stage is measured with a PTC resistor and the values are filtered
with a time constant of 500ms.
If the result of the power stage temperature calculation is out of the sensor range of -60°C to +200°C a
temperature sensor error occurs.

2. Display alarm code: P-INV OVERVOL
3. Error level: 1
voltage exceeds the maximum value error occurs.

2. Display alarm code: P-INV OVERCUR
3. Error level: 1
4. Alarm cause: In normal operation the current is limited by the software of the current controller. In addition, the
current in each phase is limited by hardware. If the actual current exceeds the maximum value the
corresponding phase output is switched off for 50μs and a signal is sent to the DSP. This signal triggers a
software integrator. If the integrator exceeds a limit (overcurrent signal is active for more than 3 seconds) the
error occurs.

2. Display alarm code: WORNG MOT DATA
3. Error level: 1
4. Alarm cause: When the motor data incorrectly defined.

4. Replace the Pump inverter.

2. Display alarm code: WATCHDOG ERROR
3. Error level: 1
4. Alarm cause: This watchdog is triggered by a toggle signal, generated by system software. If the trigger signal
is not toggling anymore the watchdog hardware disables the power stage and all interface outputs.
The hardware watchdog will be checked by the self-test routine at power up.

2. If you have a same problem, replace the pump inverter.

2. Display alarm code: CURRENT SEN FAU
3. Error level: 1
4. Alarm cause: Current sensor error in the inverter.


2. Display alarm code: UNDERVOLTAGE
3. Error level: 1
4. Alarm cause: battery voltage, measured by an internal circuit, is lower than 24V

1. Measure battery voltage with a tester and, if different from the value reported on Instrument, replace
logic;

2. Display alarm code: DC LINK ERROR
3. Error level: 1
4. Alarm cause: With the DC link test a short circuit in the DC link circuit (internal hardware, like capacitor board or
external wiring) can be detected. Before the main contact will be closed the capacitor bank is pre-charged via a
resistor, powered by the power supply voltage (C1p02). Wait until V_DC_Link > Threshold voltage ( 1.6V – 3.5V)
The test is OK as soon as this condition is fulfilled. If this condition is not fulfilled within 5 seconds after power-
on, the test failed.

1. Switch off power supply
2. Disconnect the power cables + and –
3. Switch on power supply again
4. If the DC-Link test shows no error anymore there is a short circuit in the wiring of the power cables
+ and – or the load in that circuit is too high and pushes down the DC-Link voltage.
5. If the error still occurs there is a failure in the inverter.

3. Error level: 0
4. Alarm cause: internal DSP watchdog, or/and defective logic.

1. Using PLUS+1 service tool program interface, try to program control board flash memory.
1. Error code: 28503, 28504

2. Display alarm code: DC LINK SHORT
3. Error level: 1
4. Alarm cause: Short circuit between a phase output and the + or – power stage supply or between the phase
outputs.

1. Switch off power supply Disconnect phase outputs Switch on power supply again.
2. Still the same error: Inverter damaged

2. Display alarm code: MOTOR OUTPUT FAU
3. Error level: 1
4. Alarm cause: Shorted power output (motor output)

1. Motor not connected.
2. Check the traction motor wiring incorrect.
3. Check the motor winding broken.
4. Exchange motor

2. Display alarm code: FET FAULT
3. Error level: 1
4. Alarm cause: Test not passed, because of hardware overvoltage protection.

2. If the error occurs with a correct wired motor the power stage is damaged.

2. Display alarm code: OVERVOLTAGE
3. Error level: 0
voltage exceeds the maximum value

1. Error code: 28508, 28603

2. Display alarm code: EEPROM FAULT
3. Error level: 0
4. Alarm cause: Corrupted production data in EEPROM detected.

1. The EEPROM is split into three sections
a. Production data: Data stored at production of the device in a protected memory area to adjust
software scaling to actual hardware
b. User data: Memory area accessible by the user
c. Error History data: Memory area where the error history data are stored
2. If the CRC check fails for the production data area error will be reported, because wrong data can
lead to incorrect behavior.
3. If the CRC check fails for the user data area only a warning will be reported. Appropriated reaction
should be programmed in the PLUS+1 application software.
4. If the CRC check fails for the Error History data area only a warning will be reported. The
functionality of the device is unlimited but the error history data may be corrupted.

3. State level: 0
4. Alarm cause: Error in watchdog circuit, limited operation possible.

2. Still the same error, Inverter damaged.

2. Display alarm code: LOW VOLTAGE
3. State level: 0
4. Alarm cause: Watchdog not tested, because low voltage at DC-Link or V_Key.

2. Still the same error, recharge battery

2. Display alarm code: DC-LINK SELF
3. State level: 1
4. Alarm cause: DCLink selftest in progress.

2. Display alarm code: WATCHDOG SELF
3. State level: 0
4. Alarm cause: Watchdog selftest in progress.

2. Display alarm code: POWERSTAGE SELF
3. State level: 0
4. Alarm cause: Powerstage selftest in progress.
Motor temperature sensor fault

2. Display alarm code: P-THERMAL FAULT
3. Error level: 1
4. Alarm cause: Input out of range shows, that the measured resistance at this input is higher than 12000 Ohm.

2. If you have a same problem, replace the traction motor temperature sensor.

2. Display alarm code: P-THERMAL FAULT
3. Error level: 1
4. Alarm cause: Hardware Error.

Motor configure fault

2. Display alarm code: CONFIG FAULT
3. Error level: 1
4. Alarm cause: Invalid value at .DataStructVersion.

NVMem fault
3. Error level: 0
4. Alarm cause: The NVMem was restored to a previous state. This may happen when a store operation was
aborted. For example due to power off.


3. Error level: 0
4. Alarm cause: The NV Memory checksums are not correct. This may for instance occurs the first boot up after a
new application is downloaded, if the NV Memory usage is changed.


3. Error level: 0
4. Alarm cause: The reset routine could not access the NV memory. For instance due to a hardware problem.

CAN drive fault

2. Display alarm code: CAN FAULT
3. Error level: 0
4. Alarm cause: CAN Controller error


SERVICE TOOL MANUAL for TRACTION INVERTER
INDEX
Introduction............................................................................................................................................. 215
General .................................................................................................................................................. 215
Service Tool Features ............................................................................................................................ 215
Connecting the Computer with the Service Tool ...................................................................................... 215
Requirements of the Computer to Run the PLUS+1 GUIDE Service Tool ................................................ 216
USB Gateway......................................................................................................................................... 216
Starting the Service Tool Software .......................................................................................................... 217
The Windows ......................................................................................................................................... 218
General .................................................................................................................................................. 219
Download of Application Software........................................................................................................... 219
Download of Application Software (continued) ........................................................................................ 220
Overview ................................................................................................................................................. 221

Overview ................................................................................................................................................ 221
Operation ............................................................................................................................................... 221
Functional overview ................................................................................................................................ 222
Parameter Function ................................................................................................................................ 223

Traction Drive Overview ......................................................................................................................... 223
Drive Enable........................................................................................................................................... 224
Seat and Foot switch.......................................................................................................................... 225
EM Brake and Power ......................................................................................................................... 226
EM Brake Coil set .............................................................................................................................. 226
Speed Creation ...................................................................................................................................... 227
Brake Pedal Input “A” ......................................................................................................................... 228
Brake Pedal Input “B” ......................................................................................................................... 229
Throttle Pedal Input “A” ...................................................................................................................... 230
Throttle Pedal Input “B” ...................................................................................................................... 231
Limitation ........................................................................................................................................... 232
Dynamic Drive Curve Generator......................................................................................................... 233
Supervision ............................................................................................................................................ 234
Error Status ............................................................................................................................................ 235
Error History ........................................................................................................................................... 236
Counter .................................................................................................................................................. 237
BDI (Battery Discharge Indicator)............................................................................................................ 238
Derating Parameter............................................................................................................................ 239
Main Contactor ....................................................................................................................................... 240
Main Contactor Parameter ................................................................................................................. 241
Cooling Fan ............................................................................................................................................ 242
System Information................................................................................................................................. 243

Introduction
General
The PLUS+1™ GIUDE Service Tool provides, in conjunction with standard computers a communication software
to handle the control electronic on the production line and in special field service cases.
All screens shown in this document are decided as examples. The actual data may be different.
Service Tool Features

Download the application software
Adjust system parameters
Display run time information
Real time logging function
System data storage on the hard disk

service tool installation

free USB port. System requirements for using the program:
Minimum System Requirements for PLUS+1™ Service Tool

- 1 GHz processor
- Microsoft Windows XP (32-bit) or Windows 7 (32/64-bit)
- Local Administrator Access on used PC.
- 1 GB of system memory
- 125 MB of available hard disk space
- 1024 x 768 or higher resolution graphics card/monitor with 16 bit colors
- USB for use with CAN/USB Gateway
- Access to Email for license registration
- Adobe Acrobat Reader v7.0 or higher
- MSXML 4.0 Service Pack 2 (Microsoft XML Core Services)
USB Gateway
Pin Function
1 -
2 CAN
3 Shield/Ground
4 -
5 -
6 -
7 CAN +
8 -
9 -

Starting the Service Tool Software
1. Connect the gateway to a USB port of the PC. The installation process starts automatically.
2. Connect the computer to the digital controller with the CG150 gateway.
3. Start the service tool.
4. The CG150 appears as standard gateway. If not, go to the communication dialog and set the CG150 as current
gateway.
5. Select and load a Service Application.

Use Menu File Open… or use the button
6. If the system is set to auto scan, the bus is scanned automatically, otherwise scan the bus manually by using
the button
7. The system is ready for diagnosis.

The Windows
The screen of the Service Tool is divided in several windows.
The Diagnostic Navigator

This tab shows a tree view of all hardware and software applications within the Service Tool.
The Work Area

The area where all Service Tool functions are performed.
The Status Line

Controller Connection Status
Displays colored controller connection status:
Green — Controller connected
Light Green — Logging
Yellow — searching for connection
Red — Controller disconnected or Gateway error.
Log Frequency Status
Displays the required and actual log frequency settings in the application.

General
Start and stop the logging with the start and stop buttons in the menu line or F5 and or F6.
For more information about logging, log to disk, log period etc. take a look into the
Service Tool operator manual.
Download of Application Software

It is possible to reprogram the Digital System with the service tool. Use the menu
File | File Download… or the button. Select the controller to whom the software should be downloaded.
Select the application LHX file and press download.
Select controller
Select lhx-File

Download of Application Software (continued)
Start download
If the Fan Drive application ask for an ‘Application Type’ please write the following type
into the window: Fan Drive_Sub System Application
The application type entry is case sensitive
HEX-File Download Screen
After the successful download of the LHX-file the digital system starts operating.

Overview
Overview
This manual describes how to configure the PLUS+1™ inverter software.
It is intended for customer use and is maintained by Doosan.
The PLUS+1 application can be configured with a normal PC using the PLUS+1
Service-Tool. Reference the PLUS+1 Service-Tool Operator Manual for help in downloading, data logging
and performing other tasks with the Service-Tool.
This manual does not contain hardware or electrical specifications.
Operation
The aim of this specification is to provide a basis for forklift AC-driving inverters with a generic software
application for driving the electric traction motor and the appending functions in a typical environment of a
forklift.
One goal of this application software is to show how simple it is to create an inverter application in PLUS+1
guide and to demonstrate the possibilities of the
PLUS+1 service tool as a service and parameterization instrument.

Functional overview
The pump drive software is grouped in different sub functions:
The conversion from the input values to internal and physical values is located in the sub function “Input
Converting”.
The “Supervision” block contains the biggest part of the malfunction monitoring and the status selection.
All functions which are not part of the drive functionality from the truck are placed in the “Secondary
Functions” area.
The estimation of the detected errors and the selected status is realized in the “Error Status” function.
The “Drive Control” area contains the set point creation and the enable of the traction.
The state of the digital outputs is generated in the “Output Driver” block.

Parameter Function
Traction Drive Overview
Select the ‘Traction Drive’ Screen.
This screen gives an overview about the traction drive system.
The “System Overview” is the most important page of the traction drive diagnostic screens. Here an
overview of the system is given. The inputs are displayed on the left side, the traction inverter control logic is
seen in the middle and the outputs are on the right side.
The headlines (Enable Drive, Speed Creation etc.) are linked to subpages, which allow the operator to get
more information on the specific part of the system and to adjust it through parameters.
Also, you can check the status of the various sensors, solenoid output state, traction motor, etc.

Drive Enable
Push the ‘Enable Drive’ screen.

This screen gives a drive enable statue.
You can check the seat and direction switch status and EM brake status.
You want to check the each function status then you are pushing the each “Parameter” button.
Also, if you push the “Traction Drive” button then you can go to the “Traction Drive” view.

Seat and Foot switch
This screen gives the seat and foot switch status.
This function block is an on/off switch with delayed off-switching. The delay function is active on the negative
transition. On a positive transition at the input signal Seat Switch (or Foot Switch) the output is activated
immediately. On a negative transition at the input signal Seat Switch (or Foot Switch) the output is
deactivated after an adjustable delay time.
You push the “Log Page” button then you can go to the “Enable Drive” view.
You push the “Traction Drive” button then you can go to the “Traction Drive” view.

EM Brake and Power
This screen gives the EM brake parameter set status.
And you can change the parameter.
EM Brake Coil set

This screen gives the EM brake coil parameter status.
And you can change the parameter.

Speed Creation
Push the “Speed Creation” screen.

This screen gives the pump motor speed statue.
You can check the front brake and throttle pedal status and other parameter status.
You want to check the each function status then you are pushing the each “Parameter” button.
Also, if you push the “Traction Drive” button then you can go to the “Traction Drive” view.

Brake Pedal Input “A”
This screen gives the brake pedal input “A” parameter status.
And you can change the each parameter.
You push the “Log Page” button then you can go to the “Speed Creation” view.
You push the “Parameter” button then you can go to the “Parameter B” view.

Brake Pedal Input “B”
This screen gives the brake pedal input “B” parameter status.

Throttle Pedal Input “A”
This screen gives the throttle pedal input “A” parameter status.

Throttle Pedal Input “B”
This screen gives the throttle pedal input “B” parameter status.

Limitation
This screen gives the limitation parameter status according to the BDI.

Dynamic Drive Curve Generator
This screen gives the each maximum speed parameter status.

Supervision
Push the “Supervision” screen.

This screen gives the system temperature parameter statue.

Error Status
Push the “Error Status” screen.

This screen gives the current error statue.
A description of the error codes, please refer to the error list.
You push the “Error History” button then you can go to the “Error History” view.

Error History
Push the “Error History” screen.

This screen shows stored error status in the memory.
You push the “Error Status Handler” button then you can go to the “Error Status” view.

Counter

This screen shows the each hour counter status.
You push the “Parameter” button then you can go to the “Parameter” view.
You push the “Log Page” button then you can go to the “Inverter Counter” view.

BDI (Battery Discharge Indicator)
Push the “BDI” in the screen.

This screen shows the current BDI status.
You push the each “Parameter” button then you can go to each “Parameter” view.
You push the “Log Page” button then you can go to the “BDI Status” view.

Derating Parameter
You push the “Log Page” button then you can go to the “Derating Status” view.

Main Contactor
Push the “Main Contactor” screen.

This screen shows the “Main Contactor” status.
You push the each “Parameter” button then you can go to the “Parameter” view.

Main Contactor Parameter
You push the each “Log Page” button then you can go to the “Main Contactor” view.

Cooling Fan
Push the “Main Contactor” screen.

This screen shows the “Main Contactor” status.
You push the each “Parameter” button then you can go to the “Parameter” view.
You push the each “Log Page” button then you can go to the “Cooling Fan Status” view.

System Information
Push the “Info” screen.

This screen shows the inverter system status.

SERVICE TOOL MANUAL for HYDRAULIC INVERTER
INDEX
Introduction............................................................................................................................................. 245
General .................................................................................................................................................. 245
Service Tool Features ............................................................................................................................ 245
Connecting the Computer with the Service Tool ...................................................................................... 245
Requirements of the Computer to Run the PLUS+1 GUIDE Service Tool ................................................ 246
Minimum System Requirements for PLUS+1™ Service Tool................................................................... 246
USB Gateway......................................................................................................................................... 246
Starting the Service Tool Software .......................................................................................................... 247
The Windows ..................................................................................................................................... 248
The Diagnostic Navigator ................................................................................................................... 248
The Work Area................................................................................................................................... 248
The Status Line.................................................................................................................................. 248
General .................................................................................................................................................. 249
Download of Application Software .......................................................................................................... 249
Download of Application Software (continued) ........................................................................................ 250
Overview ................................................................................................................................................. 251

Overview ................................................................................................................................................ 251
Operation ............................................................................................................................................... 251
Functional overview ................................................................................................................................ 252
Parameter Function ................................................................................................................................ 253

Hydraulic Drive Overview ....................................................................................................................... 253
Drive Enable........................................................................................................................................... 254
Fingertip Lever input status .................................................................................................................... 255
Drive Enable........................................................................................................................................... 257
Acceleration/Deceleration ....................................................................................................................... 258
Dynamic Drive Curve Generator ............................................................................................................. 259
Error Status ............................................................................................................................................ 260
Error History ........................................................................................................................................... 261
Counter.............................................................................................................................................. 262
Option (Mast Height & Weight function) .................................................................................................. 263
Weight Sensor........................................................................................................................................ 264
Height Sensor ........................................................................................................................................ 265
Preference Reducing .............................................................................................................................. 266
Derating Parameter ................................................................................................................................ 267
Proportion Output ................................................................................................................................... 268
Flow Sharing Parameter ......................................................................................................................... 269
Proportional Sol. Setting (Flow Sharing) ................................................................................................. 270
Lift Function Parameter .......................................................................................................................... 271
Proportion Sol. Setting (Lift) .................................................................................................................... 272
Lower Function Parameter...................................................................................................................... 273
Proportion Sol. Setting (Lower) ............................................................................................................... 274
Solenoid Output Status ........................................................................................................................... 275
Solenoid Status.................................................................................................................................. 276
System Information................................................................................................................................. 277

Introduction
General
The PLUS+1™ GIUDE Service Tool provides, in conjunction with standard computers a communication
software to handle the control electronic on the production line and in special field service cases.
All screens shown in this document are decided as examples. The actual data may be different.
Service Tool Features

Download the application software
Adjust system parameters
Display run time information
Real time logging function
System data storage on the hard disk


To run PLUS+1 GUIDE Service Tool a standard personal computer (PC) or laptop/notebook is required with
a free USB port.
Minimum System Requirements for PLUS+1™ Service Tool

- 1 GHz processor
- Microsoft Windows XP (32-bit) or Windows 7 (32/64-bit)
- Local Administrator Access on used PC.
- 1 GB of system memory
- 125 MB of available hard disk space
- 1024 x 768 or higher resolution graphics card/monitor with 16 bit colors
- USB for use with CAN/USB Gateway
- Access to Email for license registration
- Adobe Acrobat Reader v7.0 or higher
- MSXML 4.0 Service Pack 2 (Microsoft XML Core Services)
USB Gateway
Pin Function
1 -
2 CAN -
3 Shield/Ground
4 -
5 -
6 -
7 CAN +
8 -
9 -

Starting the Service Tool Software
1. Connect the gateway to a USB port of the PC. The installation process starts automatically.
2. Connect the computer to the digital controller with the CG150 gateway.
3. Start the service tool.
4. The CG150 appears as standard gateway. If not, go to the communication dialog and set the CG150 as
current gateway.
5. Select and load a Service Application.

Use Menu File Open… or use the button
6. If the system is set to auto scan, the bus is scanned automatically, otherwise scan the bus manually by
using the button
7. The system is ready for diagnosis.

The Windows
The screen of the Service Tool is divided in several windows.
The Diagnostic Navigator

This tab shows a tree view of all hardware and software applications within the Service Tool.
The Work Area

The area where all Service Tool functions are performed.
The Status Line

Controller Connection Status
Displays colored controller connection status:
Green — Controller connected
Light Green — Logging
Yellow — searching for connection
Red — Controller disconnected or Gateway error.
Log Frequency Status
Displays the required and actual log frequency settings in the application.

General
Start and stop the logging with the start and stop buttons in the menu line or F5 and or F6.
For more information about logging, log to disk, log period etc. take a look into the Service Tool operator
manual.
For more information about logging, log to disk, log period etc. take a look into the Service Tool operator
manual.
Download of Application Software

It is possible to reprogram the Digital System with the service tool. Use the menu
File | File Download… or the button. Select the controller to whom the software should be downloaded.
Select the application LHX file and press
Select controller
Select lhx-File

Download of Application Software (continued)
Start download
If the Fan Drive application ask for an ‘Application Type’ please write the following type into the window: Fan
Drive_Sub System Application
The application type entry is case sensitive.
HEX-File Download Screen
After the successful download of the LHX-file the digital system starts operating.

Overview
Overview
This manual describes how to configure the PLUS+1™ inverter software.
It is intended for customer use and is maintained by Doosan.
The PLUS+1 application can be configured with a normal PC using the PLUS+1
Service-Tool. Reference the PLUS+1 Service-Tool Operator Manual for help in downloading, data logging
and performing other tasks with the Service-Tool.
This manual does not contain hardware or electrical specifications.
Operation
The aim of this specification is to provide a basis for forklift AC-driving inverters with a generic software
application for driving the electric traction motor and the appending functions in a typical environment of a
forklift.
One goal of this application software is to show how simple it is to create an inverter application in PLUS+1
guide and to demonstrate the possibilities of the PLUS+1 service tool as a service and parameterization
instrument.

Functional overview
The pump drive software is grouped in different sub functions:
The conversion from the input values to internal and physical values is located in the sub function “Input
Converting”.
The “Supervision” block contains the biggest part of the malfunction monitoring and the status selection.
All functions which are not part of the drive functionality from the truck are placed in the “Secondary
Functions” area.
The estimation of the detected errors and the selected status is realized in the “Error Status” function.
The “Drive Control” area contains the set point creation and the enable of the traction.
The state of the digital outputs is generated in the “Output Driver” block.

Parameter Function
Hydraulic Drive Overview
Select the ‘Hydraulic Drive’ Screen.
This screen gives an overview about the Hydraulic Drive system.
The “System Overview” is the most important page of the hydraulic drive diagnostic screens. Here an
overview of the system is given. The inputs are displayed on the left side, the pump inverter control logic is
seen in the middle
and the outputs are on the right side.
The headlines (Enable Drive, Speed Creation etc.) are linked to subpages, which allow the operator to get
more information on the specific part of the system and to adjust it through parameters.
Also, you can check the status of the various sensors, Solenoid output state, pump motor, etc.

Drive Enable
Push the ‘Enable Drive’ screen.

This screen gives a drive enable statue.
You can check the motor speed, CAN communication status and power stage status.
You want to check the joystick status then you are pushing the Joystick picture( ) button.
Also, if you push the “Log Page” button then you can go to the “Speed Creation” view.

Fingertip Lever input status
Push the “Joystick picture” in the “Enable drive” screen.

This screen gives each fingertip lever status.
You want to check the fingertip lever setting status then you are pushing the each parameter button.
You push the “Hydraulic Drive” button then you can go to the “Hydraulic Drive” view.
You want to know more detail setting method then you are pushing the “Go to Detail” button.
You push the “Log Page” button then you can go to the “Fingertip Lever input status” view.

The description below will help you to change the fingertip lever parameter.
Item/Range Description
CalLoPos_pct : (0 – 10000[0.01% of Low calibration point for the positive part as percentage of
MaxIn_mV]; default value: 5500) MaxIn_mV.
CalHiPos_pct : (0 – 10000 [0,01% of High calibration point for the positive part as percentage of
LoOutPos_pct : (0-1000 [0,01% of HiOut]; Is the calibrated minimum value of the output for the positive
default value: 0) part as percentage of HiOut.
HiOutPos : Is the calibrated maximum value of the output for the positive
(0-10000; default value: 10000) part, 10000 is the maximum input for the valve function block
DbndLoPos_pct : (0 – 1000 [0,01% of Dead band of the low calibration point for the positive part as
MaxIn_mV], default value: 0) percentage of MaxIn_mV.
DbndHiPos_pct : (0 – 1000 [0,01% of Dead band of the high calibration point for the positive part as
CalLoNeg_pct : (0 – 10000 [0.01% of Low calibration point for the negative part as percentage of
CalHiNeg_pct : (0 – 10000 [0,01% of High calibration point for the negative part as percentage of
LoOutNeg_pct : (0-1000 [0,01% of Is the calibrated minimum value of the output for the negative
HiOut]; default value: 0) part as percentage of HiOut.
HiOutNeg : Is the calibrated maximum value of the output for the negative
(0-10000; default value: 10000) part, 10000 is the maximum input for the valve function block
DbndLoNeg_pct : (0 – 1000 [0,01% of Dead band of the low calibration point for the negative part as
DbndHiNeg_pct : (0 – 1000 [0,01% of Dead band of the high calibration point for the negative part as
FltThd_pct : (0 to 5000 [0,01% of Fault threshold of the lower and upper calibration points as
MaxIn_mV]; default value: 500) percentage of MaxIn_mV.
FltDetTm_ms : (0 – 10000 [ms]; default Fault detection time in ms. The time that a fault needs to be
value: 1000) present before it is declared
You push the “Each Para” button then you can go to the “Loge Page ” view.

Drive Enable
Push the “Speed Creation” screen.

This screen gives the pump motor speed statue.
If you change the motor Acceleration/Deceleration status then you are pushing the parameter button.

Acceleration/Deceleration
Acceleration:
Specifies the maximum acceleration, without rounding and without progression (Roundn.=0, Progr.=0).
The maximum acceleration is achieved, if the set value escalates from zero to maximum speed.
Deceleration:
Specifies the maximum deceleration, without rounding and without progression(R=0, P=0).
The maximum deceleration is achieved, if the set value jumps down from maximum speed to zero.

Dynamic Drive Curve Generator
Progression (U8) (0…100%; default value: 0)

Specifies the influence of the set value variation to the value of acceleration or deceleration.
Progression = 0: Independently from set value variation always the maximum acceleration or deceleration is
active. (Graph DDCG_3)
Progression = 100: The value of acceleration or deceleration depends on the variation of the set value on a
linear characteristic. (Graph DDCG_4)
Roundness (U8) (0…90; default value: 0)

Specifies the strength of the roundness (0: no rounding; 90: maximum rounding).
The speed curve is always rounded before reaching the final value. A rounding at the beginning of
acceleration or deceleration becomes effective only if the set value changes slowly. With a slow change of
the set value a smooth drive reaction is performed, as acceleration is increased continuously. In case of a
fast change of
the set value an aggressive drive reaction results, as acceleration achieves its maximum value precipitously.
(Graph DDCG_5)

Error Status
Push the “Error Status” screen.

This screen gives the current error statue.
You push the “Error History” button then you can go to the “Error History” view.

Error History

This screen shows stored error status in the memory.
You push the “Error Status Handler” button then you can go to the “Error Status” view.

Counter

This screen shows the each hour counter status.
You push the “Parameter” button then you can go to the “Counter Parameter” view.
The Service Hour Counter block can be used to determine service intervals for vehicles (Default value:
500h).
You push the “Log Page” button then you can go to the “Inverter and Service Counter” view.

Option (Mast Height & Weight function)
Push the “Option” in the screen.

This screen shows the option (Mast Height & Weight function) status.

Weight Sensor
You push the “Log Page” button then you can go to the “Option (Mast Height & Weight function)” view.

Height Sensor

Preference Reducing
Push the “Derating” screen.

This screen shows the motor derating status.
Function:
This function can be used for derating the max motor current dependent on the inverter temperature as well
as for a derating dependent on the motor temperature.
There are two separate derating curves, one for motor mode (acceleration) and one for generator mode
(deceleration).
If ActTemp is lower than Temp100perc, the output is at 10000 (100%).
If ActTemp is higher than TempDerate the output is IDerateG (GenMode=1) or IDerateM (GenMode=0).
If ActTemp is between Temp100perc and TempDerate the output is reduced by a linear curve between 100%
and IDerateM (GenMode=0) or IDerateG (GenMode=1)

Derating Parameter

Proportion Output
Push the “Proportion Valve” screen.

This screen shows each proportion valve status.
You can see the each proportion valve statues.

Flow Sharing Parameter
You can be the setting the “flow sharing valve” depending on the features.
- Input fingertip lever profile.
- Ramp time
- Valve output profile.
You push the each “Log Page” button then you can go to each “Proportion Output” view.
You push the “Valve Set” button then you can go to the “Proportion Sol. Setting (Flow Sharing)” view.

Proportional Sol. Setting (Flow Sharing)
You can set the flow sharing valve preference and each function flow and motor maximum speed.
You push the “Valve Set” button then you can go to the “Flow Sharing Parameter” view.

Lift Function Parameter
You can be the setting the “Lift valve” depending on the features.
- Ramp time
You push the “Valve Set” button then you can go to the “Proportion Sol. Setting (Lift)” view.

Proportion Sol. Setting (Lift)
You can set the lift valve preference, flow and motor maximum speed.
You push the “Valve Set” button then you can go to the “Lift Function Parameter” view.

Lower Function Parameter
You can be the setting the “Lower valve” depending on the features.
- Ramp time
You push the “Valve Set” button then you can go to the “Proportion Sol. Setting (Lower)” view.

Proportion Sol. Setting (Lower)
You can set the lower valve preference, flow and motor maximum speed.
You push the “Valve Set” button then you can go to the “Lower Function Parameter” view.

Solenoid Output Status
Push the “Solenoid Valve” screen.

This screen shows each solenoid valve status.
You can see the each solenoid valve statues.
You push the “Hydraulic Drive” button then you can go to the “Hydraulic Drive”view.

Solenoid Status
You can set each solenoid valve preference.

You push the each “Log Page” button then you can go to each “Solenoid Output Status” view.

System Information
Push the “Info” screen.

This screen shows the inverter system status.

ELECTRIC POWER STEERING SYSTEM
INDEX
Overview ................................................................................................................................................. 279
Installation and Wiring............................................................................................................................ 281

Mounting the Controller .......................................................................................................................... 281
High Current Connections....................................................................................................................... 283
Low Current Connections ....................................................................................................................... 284
Input/Output Signal Specifications .......................................................................................................... 288
Programmable Parameters ..................................................................................................................... 292

Programming Menus .............................................................................................................................. 292
Monitor Menu .......................................................................................................................................... 322
Controller Information Menu .................................................................................................................. 334
Commissioning ....................................................................................................................................... 335
Interface with Master Controller ............................................................................................................. 345

CAN MESSAGES................................................................................................................................... 345
GENERIC AC TRACTION CONTROLLER SOFTWARE ......................................................................... 347
Diagnostics & Troubleshooting ............................................................................................................. 351

Diagnostics............................................................................................................................................. 351
Summary of LED display formats............................................................................................................ 352
Troubleshooting...................................................................................................................................... 352
Maintenance ............................................................................................................................................ 362

Cleaning ................................................................................................................................................. 362
Fault History ........................................................................................................................................... 362
APPENDIX A. Vehicle Design Considerations ....................................................................................... 363

APPENDIX B. Programming Devices ..................................................................................................... 365
APPENDIX C. Specifications .................................................................................................................. 366

Overview
The Doosan Model 1222 is an AC induction motor controller for electric power steering (EPS) systems. In
these “steer by wire” systems, the AC steering gearmotor functions as an actuator to change the angle of
the vehicle’s steered wheel(s) and thus change the direction of travel. The 1222 performs as the steering
system controller, interpreting the steering command input and wheel position feedback, then driving the
steering motor to move the steered wheel(s) to the desired position.
The Doosan 1222 controller is designed for use as an electric power steering controller for 300–1400W AC
induction gearmotors with overall gear reductions between 50:1 and 800:1 on vehicles using Doosan VCL
AC motor controllers. Intended applications are materal handling vehicles such as reach trucks, order
pickers, stackers, “man up” warehouse trucks, and other similar industrial vehicles.
Fig. 1 Doosan 1222 electric steering controller
Advanced Motor Control
✓ Absolute Position (pedestrian stacker) or Relative Position (reach truck) control modes.
✓ Indirect Field Orientation (IFO) vector control algorithm provides maximum possible torque while
ensuring maximum efficiency and accurate current control.
✓ 16kHz PWM switching frequency ensures silent operation across the 0–200Hz stator frequency range.
✓ Advanced PWM techniques produce low motor harmonics, low torque ripple, and minimized heating
losses, resulting in high efficiency.
✓ 70 amp RMS 2-minute current output.
✓ 24–48V nominal supply voltage.
Versatile Steering Input and Feedback Options
✓ Dual redundant quadrature encoder, sine/cosine sensor, or analog voltage steering command inputs.
✓ Steered angle feedback via dual redundant homing switch, quadrature encoder, sine/cosine sensor, or
analog voltage inputs.
✓ Fully programmable input/output ratio mapping.
✓ Configurable homing methods, center offset, auto-center, and end-stop protection.

Maximum Safety
✓ Dual redundant configuration of all safety-related parts.

✓ Two microprocessors, each with its own EEPROM memory.
✓ Separate input paths to each micro for all input and feedback signals.
✓ 5 amp high-side fault output driver, consisting of two switches connected in series; each switch is
controlled by one micro with independent supervision.
✓ Meets EN 954-1 Category 3 safety requirements when used in a properly configured system.
Unmatched Flexibility
✓ CANopen system communications.

✓ 35-pin AMPSEAL logic connector.
✓ Software includes a library of pre-defined AC steering motor types from various manufacturers.
✓ Programmable motor temperature input prevents thermal damage to motor and supports all commonly
used thermistors.
✓ Integrated hourmeter and diagnostic log functions.
✓ +5V and +10V low-power supplies for input sensors, etc.
✓ Doosan 1313 handheld programmer and 1314 PC Programming Station provide easy programming and
powerful system diagnostic and monitoring capabilities.
✓ Integrated Status LED gives instant diagnostic indication.
✓ Field upgradeable software.
Robust Reliability
✓ Insulated Metal Substrate (IMS) powerbase ensures superior heat transfer.

✓ Intelligent thermal cutback and overvoltage/undervoltage protection functions maintain steering while
reducing traction speed until severe over/under limits are reached.
✓ Rugged sealed housing and AMPSEAL connector meet IP65 environmental standards for use in harsh
environments.
✓ Reverse polarity protection on battery connections and short circuit protection on all output drivers.
Meets or complies with relevant US and International Regulations
✓ EMC: Designed to the requirements of EN12895

✓ Safety: Designed to the requirements of EN1175–1:1998 and EN954–1 category 3
✓ ISO 20898:2008 and EN ISO 13849-1 pending.
✓ IP65 rated per IEC529.
✓ UL583 recognized component status pending.
✓ Regulatory compliance of the complete vehicle system with the controller installed is the responsibility of
the vehicle OEM.
MODELCHART
2 Minute RMS 1 Hour RMS

Model No. Battery Voltage
Current Rating (Arms) Current Rating (Arms)
1222-51XX 24-48 70 30

Installation and Wiring
Mounting the Controller
The outline and mounting hole dimensions for the 1222 controller are shown in Figure 2. The controller
meets the IP65 requirements for environmental protection against dust and water. Nevertheless, in order to
prevent external corrosion and leakage paths from developing, the mounting location should be carefully
chosen to keep the controller as clean and dry as possible.
It is recommended that the controller be fastened to a clean, flat metal surface with four 6mm (1/4") diameter
bolts, using the holes provided. A thermal joint compound can be used to improve heat conduction from the
controller heatsink to the mounting surface. Additional heatsinking or fan cooling may be necessary to meet
the desired continuous ratings.
Fig. 2 Mounting dimensions, Doosan 1222 motor controller.

You will need to take steps during the design and development of your end product to
ensure that its EMC performance complies with applicable regulations; suggestions are
presented in Appendix A.
The 1222 controller contains ESD-sensitive components. Use appropriate precautions in
connecting, disconnecting, and handling the controller.
See installation suggestions in Appendix B for protecting the controller from ESD damage.
CATION: Working on electrical systems is potentially dangerous. Protect yourself against

uncontrolled operation, high current arcs, and outgassing from lead acid batteries:
UNCONTROLLED OPERATION — Some conditions could cause the motor to run out
of control. Disconnect the motor or jack up the vehicle and get the drive wheels off
the ground before attempting any work on the motor control circuitry.
HIGH CURRENT ARCS — Batteries can supply very high power, and arcing can occur
if they are short circuited. Always open the battery circuit before working on the
motor control circuit. Wear safety glasses, and use properly insulated tools to
prevent shorts.
LEAD ACID BATTERIES — Charging or discharging generates hydrogen gas, which

can build up in and around the batteries. Follow the battery manufacturer’s safety
recommendations. Wear safety glasses.

High Current Connections
There are five high-current terminals, identified on the controller housing as B+, B-, U, V, and W.
Table 1 High Current Connections

TERMINAL FUNCTION
B+ Positive battery to controller.
B- Negative battery to controller.
U AC steer motor phase U.
V AC steer motor phase V.
W AC steer motor phase W.
Lug assembly
Five aluminum M6 terminals are provided. Lugs should be installed as follows, using M6 bolts sized to
provide proper engagement (see diagram):
• Place the lug on top of the aluminum terminal, followed by a high-load safety washer with its convex side
on top. The washer should be a SCHNORR 416320, or equivalent.
• If two lugs are used on the same terminal, stack them so the lug carrying the least current is on top.
• Tighten the assembly to 10.2 ±1.1 N·m (90 ±10 in-lbs).
High current wiring recommendations
Battery cables (B+, B-)

These two cables should be run close to each other between the controller and the battery. Use high quality
copper lugs and observe the recommended torque ratings. For best noise immunity the cables should not run
across the center section of the controller. With multiple high current controllers, use a star ground from the
battery B- terminal.
Motor wiring (U, V, W)

The three phase wires should be close to the same length and bundled together as they run between the
controller and the motor. The cable lengths should be kept as short as possible. Use high quality copper lugs and
observe the recommended torque ratings. For best noise immunity the motor cables should not run across the
center section of the controller. In applications that seek the lowest possible emissions, a shield can be placed
around the bundled motor cables and connected to the B- terminal at the controller. Typical installations will
readily pass the emissions standards without a shield. Low current signal wires should not be run next to the
motor cables. When necessary they should cross the motor cables at a right angle to minimize noise coupling.

Low Current Connections
All low power connections are made through a single 35-pin AMPSEAL connector. The mating plug housing
is AMP p/n 776164-1 and the contact pins are AMP p/n 770520-3. The connector will accept 20 to 16 AWG
wire with a 1.7 to 2.7mm diameter thin-wall insulation.
The 35 individual pins are characterized in Table 2.
Low current wiring recommendations
Command input encoder and Steer motor encoder

The encoder wires should be bundled together as they run between the motor and controller logic connector.
These can often be run with the rest of the low current wiring harness. The encoder cables should not be run
near the motor cables. In applications where this is necessary, shielded cable should be used with the
ground shield connected to the I/O ground (pin 18 or pin 30) at only the controller side. In extreme
applications, common mode filters (e.g. ferrite beads) could be used.
CAN connection
The two CAN wires should be connected directly to the CAN pins on the traction controller; running from pin
23 on the steering controller to pin 23 on the traction controller, and from pin 35 on the steering controller to
pin 35 on the traction controller.
Note: The 1222 controller has no internal 120Ω CAN terminating resistor. Typically the wiring of the CAN
bus nodes is a daisy chain topology with 120Ω CAN terminating resistors at each end. If the vehicle
wiring is done such that the 1222 is the last node in the chain, then an external 120Ω terminating
resistor should be provided by the OEM in the wiring harness.
CAN wiring should be kept away from the high current cables and cross it at right angles when
necessary.
All other low current wiring

The remaining low current wiring should be run according to standard practices.
Running low current wiring next to the high current wiring should always be avoided.

Table 2 Low Current Connections
PIN NAME DESCRIPTION
1 Keyswitch Provides logic power for the controller and power for the coil drivers.
2 Contactor Driver Driver for steer contactor.
3 [reserved] Not used.
7 Ground Ground.
8 Command Analog 1 Primary steer command pot.
9 Interlock Input 1 Primary interlock switch input.
10 Home Input 2 Primary home switch input.
11 Interlock Input 3 Redundant interlock switch input.
12 Home Input 4 Redundant home switch input.
13 Coil Return This is the coil return pin for all the contactor coils.
14 Command Encoder 1A Steer Command Encoder 1 input phase A.
15 +10V Regulated low power +10V output.
16 Position Analog 5 Primary position feedback pot.
17 Position Analog 6 Redundant position feedback pot.
18 Ground Ground.
19 Command Analog 3 Redundant steer command pot.
20 Command Encoder 2B Steer Command Encoder 2 input phase B.
22 Motor Temperature Sensor Motor temperature sensor.
23 CAN High CAN bus high.
24 Fault Output Steer fault output.
25 Command Encoder 1B Steer Command Encoder 1 input phase B.
26 Steer Motor Encoder 4A Steer Motor Encoder 4 input phase A.
27 Steer Motor Encoder 4B Steer Motor Encoder 4 input phase B.
28 TX Serial transmit line.
29 RX Serial receive line.
30 Ground Ground.
31 Steer Motor Encoder 3A Steer Motor Encoder 3 input phase A.
32 Steer Motor Encoder 3B Steer Motor Encoder 3 input phase B.
33 Command Encoder 2A Steer Command Encoder 2 input phase A.
35 CAN Low CAN bus low.

Controller Wiring: Safety Requirements
As shown in the wiring diagram (Figure 3a), the 1222’s key switch power must go through the traction
controller so that when the key switch is turned off both controllers turn off. The fault output (Pin 24) should
be able to shut down the traction system in the case of a serious fault; otherwise the system may not meet
the international safety requirements listed in Table D-1.
As shown in the wiring diagram, two steer command devices and two position feedback devices are used.

The 1222 supervises and matches each device input to its counterpart (steering to steering, feedback to
feedback). If any of these input pairs do not match, the 1222 begins its fault sequence to bring the vehicle to
a stop.
As shown in the software control diagram (Figure 3b), the safety critical parts are included twice to provide
redundancy:
• two microprocessors
• separate paths to each micro for the command and feedback signals
• cross checks on the normalized steer command
• cross checks on the normalized wheel position.
A following error check ensures that the wheel position tracks the steer command.
Although not shown in the wiring diagram, the analog inputs can be used for single sine/cosine sensors
instead of for redundant pairs of pots. Each single sensor has two levels of fault detection, which provide
redundancy. (See description of Tolerance parameter in Sin/Cos Sensor menus, pages 25 and 32.)
The wiring diagram (Figure 3a) is designed for generic applications and may not fully meet the requirements
of your system. You may wish to contact your local Doosan representative to discuss your particular
application. In cases where the wiring deviates from the wiring shown in Figure 3a, it is up to the OEM to
evaluate the overall system safety.

Input/Output Signal Specifications
The input/output signals wired to the 35-pin connector can be grouped by type as follows; their electrical
characteristics are discussed below.
— digital inputs
— driver outputs
— analog inputs
— power supply outputs
— keyswitch and coil return inputs
— communications port inputs/outputs
— encoder inputs.
Digital inputs
The digital inputs must be wired to switch to B+ (not to ground). All digital inputs are protected against shorts
to B+ or B-.
A home switch is required if encoder position feedback is used (Position Feedback Device = 1).
DIGITAL INPUT SPECIFICATIONS

LOGIC INPUT VOLTAGE ESD
SIGNAL NAME PIN
THRESHOLDS IMPEDANCE RANGE TOLERANCE
Interlock Input 1 9 Rising edge= 10.7 kΩ 10–65 V ± 8 kV (air
Home Input 2 10 5 V max
Interlock Input 3 11 Falling edge= discharge)
Home Input 4 12 1.5 V min
Driver outputs
The fault output shuts down the traction system if the 1222 has a fault. This output switches B+ to the high
side of the traction main contactor and EM
brake; without this signal, the system shuts down.
Both driver outputs are protected against shorts to B+ or B-.
DRIVER OUTPUT SPECIFICATIONS

SIGNAL NAME OUTPUT FREQUENCY OUTPUT PROTECTED ESD
PIN
TYPE CURRENT VOLTAGE TOLERANCE
Contactor Driver 2 Low Side 16 kHz 2 A max 65 V ± 8 kV (air
High discharge
Fault Output 24 n/a 5 A max 65 V
Side

Analog inputs
The command and position analog inputs are used when the steer command and
position feedback devices are pots or sine/cosine sensors.
The motor temperature sensor input provides a constant current appropriate for a
thermistor sensor. Some standard predefined motor temperature sensors are supported
in software (see Sensor Type parameter, page 39).
Note: The industry standard KTY temperature sensors are silicon temperature sensors with a
polarity band; the polarity band of a KTY sensor must be the end connected to I/O
Ground (pin 7).
All analog inputs are protected against shorts to B+ or B-.
ANALOG INPUT SPECIFICATIONS

LOGIC INPUT
VOLTAGE ESD
SIGNAL NAME PIN THRESHOLD IMPEDANC
RANGE TOLERANCE
S E
Command Analog 1 8
Command Analog 3 19 ± 8 kV (air
Position Analog 5 16 0 to 10 V 100 kΩ 65 V
Position Analog 6 17 discharge)
Motor Temp Sensor 22
Power supply outputs
The +5V supply is used for all steer command and position feedback devices.
The +10V supply is provided for the handheld programmer; it should not be used for
steer command or position feedback devices because voltage could change when the
programmer is plugged in. Both power supply outputs are protected against shorts to B+
or B-.
OUTPUT OUTPUT PROTECTED ESD

SIGNALNAME PIN
VOLTAGE CURRENT VOLTAGE TOLERANCE
+5V 21, 34 5 V ±10% 100 mA max * ± 8 kV (air
+10V 15 10 V ±10% 100 mA max * discharge) ± 8 kV (air
7, 18, discharge)
Ground n/a n/a ± 8 kV (air
30
* The total combined current from +5V and +10V outputs should not exceed 150 mA.

Key switch input and coil return
Key switch power to the 1222 is provided through the coil return of the traction controller. This ensures that
the steer controller is not turned Off unless the traction controller is Off. Both controllers shut down in the
event of a fault.
Coil suppression for the traction controller is provided when the traction main contactor and EM brake are
wired to the fault output (pin 24). However, you may wish to use coil suppression diodes to reduce EMI
emissions.
Coil Return should be wired to the positive battery side of the steer contactor so that switching noise
associated with PWM operation of the contactor is localized to the contactor wiring only.
Reverse polarity protection is ensured only when the key switch input and coil return are wired as shown in
Figure 3a (page 11).
KEYSWITCH AND COIL RETURN INPUT SPECIFICATIONS

OPERATING MAXINPUT PROTECTED ESD
SIGNAL NAME PIN
VOLTAGE CURRENT VOLTAGE TOLERANCE
Between under- 50–500mA
Keyswitch 1 65 V ± 8 kV (air
and overvoltage + coil return current
Coil Return 13 cutbacks 10 A 65 V discharge)
Communications ports
Separate CAN and serial ports provide complete communications and programming capability for all user
available controller information.
Note: The 1222 controller has no internal 120Ω CAN terminating resistor. Typically the wiring of the CAN
bus nodes is a daisy chain topology with 120Ω CAN terminating resistors at each end. If the vehicle
wiring is done such that the 1222 is the last node in the chain, then an external 120Ω terminating
resistor should be provided by the OEM in the wiring harness.
The Doosan programmer plugs into a connector wired to pins 28 and 29, along with ground (pin 7) and the
+10V power supply (pin 15); see wiring diagram, Figure 3a.
COMMUNICATIONS PORT SPECIFICATIONS

SIGNAL NAME SUPPORTED PROTECTED ESD
PIN DATA RATE
PROTOCOL/DEVICES VOLTAGE TOLERANCE
CAN High 23 -5 V to
(MaxV +
10 V) ± 8 kV (air
CANopen up to 1 Mbps
CAN Low 35 with < 30 V discharge)
differentiall
y
Tx 28 1313 Handheld
Programmer, as required, -0.3 to 12 ± 8 kV (air
Rx 29 1314 PC Programming 9.6 to 56 kbps V discharge)
Station

Encoder inputs.
Pairs (A, B) of control lines are internally configured to read quadrature type encoders. The encoders are
typically powered from the 5V supply (pin 21), but can be powered from any external supply (from 5V up to
B+) as long as the logic threshold requirements are met.
For the steer commands, you can use Command Encoders 1 and 2, or steer command pots, or sine/cosine
sensors.
For position feedback, you can use Steer Motor Encoders 3 and 4, or position feedback pots, or sine/cosine
sensors. Steer Motor Encoder 3 is always required, even when redundant feedback pots or sine/cosine
sensors are used.
Encoder 3 must be directly connected to the motor shaft as it is used for motor control; it must have a
minimum of 32 ppr. Encoder 4, if it is used, can be connected to either the motor shaft or the steered wheel;
if it is connected to the steered wheel, it should have a minimum of 1024 ppr.
ENCODER INPUT SPECIFICATIONS

SIGNAL NAME INPUT
LOGIC MAX PROTECTED ESD
PIN IMPEDANC
THRESHOLDS FREQ VOLTAGE TOLERANCE
E
Command Encoder 1A 14
Command Encoder 1B 25
Rising edge= 2 kHz
Command Encoder 2A 33
4 V max
Command Encoder 2B 20 ± 8 kV (air
Falling edge= 1 kΩ 65 V
Steer Motor Encoder 3A 31 discharge)
1 V min
Steer Motor Encoder 3B 32 10
Steer Motor Encoder 4A 26 kHz
Steer Motor Encoder 4B 27

Programmable Parameters
The 1222 controller has a number of parameters that can be programmed using a Doosan 1313 handheld
programmer or 1314 Programming Station. The programmable parameters allow the steering performance
to be customized to fit the needs of specific applications.
Programming Menus
The programmable parameters are grouped into nested hierarchical menus, as shown in Table 3.
We strongly urge you to read Section 5, Initial Setup, before adjusting any of the parameters.
Caution: Even if you opt to leave most of the parameters at their default settings, it is imperative that
you perform the procedures outlined in Section 5, which set up the basic system
characteristics for your application.

Table 3 Programmable Parameter Menus
COMMAND DEVICE FEEDBACK DEVICE VEHICLE

CONFIGURATION ......... p. 33
Command Input Device ..... p. 20 Position Feedback Device ........ p. 27 Nominal Voltage
Interlock Type
0 - Analog1 and 3 ............... p. 22 0 – Analog5 and 6 ............... p. 29 Fault Steering Timeout
Analog1 Left Analog5 Left Stop Steer Contactor Driver ......... p. 34
Analog1 Center Analog5 Center Contactor Control Type
Analog1 Right Analog5 Right Stop Pull-In Voltage
Analog1 Center Deadband Analog5 Fault Min Holding Voltage
Analog1 Fault Min Analog5 Fault Max Open Delay
Analog1 Fault Max Analog6 Left Stop Checks Enable
Analog3 Left Analog6 Center Sequencing Delay
Analog3 Center Analog6 Right Stop Traction Speed Input ......... p. 35
Analog3 Right Analog6 Fault Min Traction Speed Input Type
Analog3 Center Deadband Analog6 Fault Max Type 1 – Encoder 1
Analog3 Fault Min Encoder1 Steps
Analog3 Fault Max 1 – Encoder3 and 4 ............ p. 30 Swap Encoder1 Direction
Encoder3 Counts/Degree Interlock Enabled Speed
1 - Encoder1 and 2 ............. p. 24 Encoder4 Counts/Degree
Left Stop to Center Swap Encoder3 Direction
Right Stop to Center Swap Encoder4 Direction
Swap Encoder1 Direction Auto Center Type
Swap Encoder2 Direction SUPERVISION ..................... p. 36
Center Offset (deg) 5V Current Min
Homing ...................... p. 31 5V Current Max
2 – Sin/Cos Sensor ............ p. 25 Input Type
Left Angle (deg) Steer Command Tolerance (deg)
Home on Interlock Wheel Position Tolerance (deg)
Center Angle (deg) Homing Direction Method
Right Angle (deg) Home Reference Tolerance (deg)
Homing Speed Encoder Position Tolerance (deg)
Offset
Amplitude Following Error Tolerance (deg)
2 – Sin/Cos Sensor ............. p. 32 Following Error Time
Swap Direction Offset
Fault Min Stall Steering Speed
Amplitude Stall Timeout
Fault Max Swap Direction
Tolerance Center Position (deg)
Command Map ................... p. 26 Fault Min
Left Stop (deg) Fault Max
P1 Input Tolerance
P1 Output (deg)
P2 Input
P2 Output (deg)
P3 Input
P3 Output (deg)
P4 Input
P4 Output (deg)
P5 Input
P5 Output (deg)
P6 Input
P6 Output (deg)
Right Stop (deg)

Table 3 Programmable Parameter Menus, cont’d
MOTOR .......................... p. 38 CANopen ....................... p. 41 MOTORCONTROLTUNING........ p. 42.

Max Speed Node ID Position Kp
Max Current Node ID Supervisor Velocity Kp
Encoder3 Steps Baud Rate Velocity Ki
Swap Encoder3 Direction Producer Heartbeat Time Steering Sensitivity ...... p. 44
Swap Two Phases PDO1 Timeout Time LS Sensitivity
Temperature Control ......... p. 39 HS Sensitivity
Sensor Enable Low Speed
Sensor Type Mid Speed
Sensor Temp Offset High Speed
Temperature Hot Field Weakening Control ..... p. 45
Temperature Max FW Base Speed
Sensor Fault Traction Cutback Field Weakening
User-DefinedTempSensor...p. 40 Weakening Rate
Sensor 1 Min Field Current
Temp 1 Motor Type ....................... p. 46
.....
Sensor 7
Temp 7
Individual parameters are presented as follows in the menu charts:
Parameter name as it
appears in the Allowable range in the Description of the parameter’s function and,
programmer display programmer’s units where applicable, suggestions for setting it
Analog1 Center 0 – 10.00 V Defines the Analog 1 wiper voltage required to produce a steer position
0x400A 0x00 0 – 1023 command of center (Steer Command = 0°).
CAN Object index Allowable range

and sub-index in CAN units

COMMAND DEVICE MENU
ALLOWABLE
PARAMETER DESCRIPTION
RANGE
Command Input 0–2 This parameter determines which input will be used as the steer command:
Device 0–2 0 = Pot input, where Analog 1 and Analog 3 inputs are connected to two
0x4003 0x00 potentiometers as redundant inputs.
When an analog steering command is used, two channels
are required.
NAME PIN FUNCTION

Analog 1 8 Primary analog input command
Analog 3 19 Redundant analog input command
It is best practice to wire the primary and redundant input

signals in an “X” configuration (0–5V and 5V–0). However, the
1222 has independent maps and will support redundant signals
that move in the same direction.
1 = Encoder input, where Encoder 1 and Encoder 2 inputs are connected to two
quadrature encoders as redundant inputs. When an encoder steering
command is used, two quadrature encoders are required. In the table below,
“+” and “-” indicate encoder phase differences (“-” being some amount of
phase shift from “+”). This means that the primary and redundant encoders
do not have to have the same alignment.
NAME PIN FUNCTION

Encoder 1A 14 Primary quadrature encoder command A+
Encoder 1B 25 Primary quadrature encoder command AEncoder
AEncoder 2A 33 Redundant quadrature encoder command B+x
Encoder 2B 20 Redundant quadrature encoder command B
2 = Sin/Cos Sensor command, where Analog 1 and Analog 3 inputs are

COMMAND DEVICE MENU
connected to a sine-cosine transducer. The transducer could be mounted
to a steering wheel or a tiller arm; it senses the absolute position.
When this steering command is used, sine and cosine channels are both
required.
NAME PIN FUNCTION

Analog 1 8 Sine input (Command Analog 1)
Analog 3 19 Cosine input (Command Analog 3)

COMMAND INPUT DEVICE 0 – ANALOG1 and 3
ALLOWABLE
RANGE
Analog1 Left 0 – 10.00 V Defines the Analog 1 wiper voltage required to produce a steer position
0x4008 0x00 0 – 1023 command of full left (Steer Command = -100% = Left Stop).
0x400A 0x00 0 – 1023 command of center (Steer Command = 0% = 0°).
Analog1 Right 0 – 10.00 V Defines the Analog 1 wiper voltage required to produce a steer position
0x4009 0x00 0 – 1023 command of full right (Steer Command = 100% = Right Stop).
Analog1 Center Defines the voltage around the Analog1 Center voltage that acts as a
0 – 10.00 V
Deadband deadband to produce a steer position command of center
0 – 1023
0x4010 0x00 (Steer Command = 0% = 0°).
Sets the minimum threshold for the Analog 1 steer command pot input. If
Analog1 Fault Min 0 – 10.00 V
the Analog 1 steer command pot voltage goes below this threshhold for
0x400E 0x00 0 – 1023
60 msec, a fault is issued.
Sets the maximum threshold for the Analog 1 steer command pot input.
Analog1 Fault Max 0 – 10.00 V
If the Analog 1 steer command pot voltage rises above this threshhold
0x400F 0x00 0 – 1023
for 60 msec, a fault is issued.
Analog3 Left 0 – 10.00 V Defines the Analog 3 wiper voltage required to produce a steer position
0x409F 0x00 0 – 1023 command of full left (Steer Command = -100% = Left Stop).
0x40A1 0x00 0 – 1023 command of center (Steer Command = 0% = 0°).
Analog3 Right 0 – 10.00 V Defines the Analog 3 wiper voltage required to produce a steer position
0x40A0 0x00 0 – 1023 command of full right (Steer Command = 100% = Right Stop).
Analog3 Center Defines the voltage around the Analog3 Center voltage that acts as a
0 – 10.00 V
Deadband deadband to produce a steer position command of center (Steer
0 – 1023
0x400D 0x00 Command = 0% = 0°).
Sets the minimum threshold for the Analog 3 steer command pot input.
If the Analog 3 steer command pot voltage falls below this threshhold for
0x400B 0x00 0 – 1023
60 msec, a fault is issued.
Sets the maximum threshold for the Analog 3 steer command pot input.
If the Analog 3 steer command pot voltage rises above this threshhold
0x400C 0x00 0 – 1023
for 60 msec, a fault is issued.

Fig. 4 Command Input Device “0” signal flow (Analog 1 shown; Analog 3 is similar)

ALLOWABLE
RANGE
Defines the total steer command encoder counts to produce a steer
Left Stop to Center -32768 – 0 command from the center position (Steer Command = 0% = 0°) to the
0x4094 0x00 -32768 – 0 full left position (Steer Command = -100% = Left Stop).
Left Stop to Center is always a negative number.
Defines the total steer command encoder counts to produce a steer

Right Stop to Center 0 – 32767 command from the center position (Steer Command = 0% = 0°) to the
0x406D 0x00 0 – 32767 full right position (Steer Command = 100% = Right Stop).
Right Stop to Center is always a positive number.
Swap Encoder1 Direction On / Off Changes the direction (left or right) of the Encoder 1 steer command
0x406C 0x00 On / Off input.
Swap Encoder2 Direction On / Off Changes the direction (left or right) of the Encoder 2 steer command
0x4069 0x00 On / Off input.
Fig. 5 Command Input Device “1” signal flow (Encoder 1 shown; Encoder 2 is similar)

ALLOWABLE
RANGE
Left Angle (deg) -180.0° – 180.0° Defines the position (in degrees) required to produce a steer command
0x40CC 0x00 -32768–32767 of full left (Steer Command = -100% = Left Stop).
Center Angle
-180.0° – 180.0° Defines the position (in degrees) required to produce a steer command
(deg)
-32768–32767 of center position (Steer Command = 0% = 0°).
0x40D2 0x00
Right Angle (deg) -180.0° – 180.0° Defines the position (in degrees) required to produce a steer command
0x40CD 0x00 -32768–32767 of full right (Steer Command = 100% = Right Stop).
Set this parameter to the midpoint voltage of the sine wave output
Offset 0 – 10.00 V
of the sin/cos sensor. This value is usually available in the sensor
0x40CE 0x00 0 – 1023
specifications, and is typically half the voltage supply to the sensor.
Amplitude 0 – 10.00 V Set this parameter to one half of the expected peak-to-peak voltage
0x40DE 0x00 0 – 1023 for the sin/cos sensor input signals.
Swap Direction On / Off Use this parameter to invert the signal to avoid physically swapping
0x406A 0x00 On / Off the wires to pins 8 and 19.
Sets the minimum threshold for the Analog 1 and Analog 3 inputs
Fault Min 0 – 10.00 V
of the sin/cos sensor. If either the Analog 1 or Analog 3 voltage falls
0x400B 0x00 0 – 1023
below this threshold for 60 msec, a fault is issued.
Sets the maximum threshold for the Analog 1 and Analog 3 inputs
Fault Max 0 – 10.00 V
of the sin/cos sensor. If either the Analog 1 or Analog 3 voltage rises
0x400C 0x00 0 – 1023
above this threshold for 60 msec, a fault is issued.
Tolerance 0 – 10.00 V The sine and cosine signals are used together to calculate the absolute
0x40DF 0x00 0 – 1023 position, i.e. arctan (Analog 1 / Analog 3). This calculated position is
then used to back-calculate the expected sine and cosine inputs, based
on the Amplitude parameter. If the difference between these expected
inputs (Command Sin/Cos Sensor Angle 2) and the actual inputs
(Command Sin/Cos Sensor Angle) is greater than the set Tolerance
voltage for 60 msec, a fault is issued. This provides a second level of
fault detection and triggers a separate SinCos Command fault.
Fig. 6 Command Input Device “2” signal flow.

A command map is used in the input command signal flow to compensate for steering geometry differences between
vehicles.
The command map menu contains 14 parameters defining an 8-point map that modifies the steer command input.
The first point (Left Stop) always defines the steer command input of -100% and the last point (Right Stop) always
defines the steer command input of 100%.

ALLOWABLE
RANGE
These six parameters define the steer command input (in %)
to the steer command map.
P1 Input = 0x401C 0x00

-100.0 – 100.0 % P2 Input = 0x401E 0x00
P1–P6 Input
-32768 – 32767 P3 Input = 0x4020 0x00
P4 Input = 0x4022 0x00
P5 Input = 0x4024 0x00
P6 Input = 0x4026 0x00
These eight parameters define the steer command output (in

-120.0° – 0.0°
Left Stop (deg), degrees) of the steer command map.
-21845 – 0
Left Stop = 0x401B 0x00
-120.0° – 120.0°
P1–P6 Output (deg), P1 Output = 0x401D 0x00
-21845 – 21845
P2 Output = 0x401F 0x00
P3 Output = 0x4021 0x00
P4 Output = 0x4023 0x00
0.0° – 120.0° P5 Output = 0x4025 0x00
Right Stop (deg)
0 – 21845 P6 Output = 0x4027 0x00
Right Stop = 0x4028 0x00
The steer command map is shaped by points A – H
X Y
A -100% Left Stop
B P1 input P1 Output
C P2 input P2 Output
D P3 input P3 Output
E P4 input P4 Output
F P5 input P5 Output
G P6 input P6 Output
H 100% Right Stop
The map in this example is set up to provide a

deadband in the center (points D and E) and less
sensitivity at the ends (between A and B, and
between G and H).
Fig. 7 Steer Command Map.

COMMAND DEVICE MENU
ALLOWABLE
RANGE
Position Feedback Device 0–2 This parameter defines which inputs will be used to determine steer position:
0x4005 0x00 0–2 0 = Steer pot position feedback, where Analog 5 and Analog 6 inputs are
connected to two potentiometers as redundant feedback pots.
When analog position feedback is used, two channels are required.
NAME PIN FUNCTION

Analog 5 16 Primary analog feedback
Analog 6 17 Redundant analog feedback
It is best practice to wire the primary and redundant input signals in an “X”
configuration (0–5V and 5V–0). However, the 1222 has independent maps
and will support redundant signals that move in the same direction.
1 = Encoder position feedback, where Encoder 3 and Encoder 4 are

connected to two quadrature encoders as redundant inputs.
When encoder position feedback is used, two quadrature encoders are
required. In the table below, “+” and “-” indicate encoder phase
differences (“-” being some amount of phase shift from “+”). This means
that the primary and redundant encoders do not have to have the same
alignment.
NAME PIN FUNCTION

Encoder 3A 31 Primary quadrature encoder feedback A+
Encoder 3B 32 Primary quadrature encoder feedback AEncoder
AEncoder 4A 26 Redundant quadrature encoder feedback B+X
Encoder 4B 27 Redundant quadrature encoder feedback B

COMMAND DEVICE MENU
2 = Sin/Cos Sensor feedback, where Analog 5 and Analog 6 inputs are
connected to a sine-cosine transducer. This transducer is mounted in a
location where it can sense the actual wheel position.
When this position feedback is used, sine and cosine channels are both
required.
NAME PIN FUNCTION

Analog 5 6 Sine input (Feedback Analog 5)
Analog 6 17 Cosine input (Feedback Analog 6)

POSITION FEEDBACK DEVICE 0 – ANALOG5 and 6
ALLOWABLE
RANGE
Analog5 Left Stop 0 – 10.00 V Defines the Analog 5 wiper voltage when the steer position feedback is
0x407F 0x00 0 – 1023 at the Left Stop (Wheel Position = Left Stop).
Analog5 Center 0 – 10.00 V Defines the Analog 5 wiper voltage when the steer position feedback is
0x4081 0x00 0 – 1023 at the center position (Wheel Position = 0°).
Analog5 Right Stop 0 – 10.00 V Defines the Analog 5 wiper voltage when the steer position feedback is
0x4080 0x00 0 – 1023 at the Right Stop (Wheel Position = Right Stop).
Sets the minimum threshold for the Analog 5 steer position feedback
pot. If the Analog 5 steer position feedback pot voltage falls below this
0x40AE 0x00 0 – 1023
threshold for 60 msec, a fault is issued.
Sets the maximum threshold for the Analog 5 steer position feedback
pot. If the Analog 5 steer position feedback pot voltage rises above this
0x40AF 0x00 0 – 1023
threshold for 60 msec, a fault is issued
Analog6 Left Stop 0 – 10.00 V Defines the Analog 6 wiper voltage when the steer position feedback is
0x40A3 0x00 0 – 1023 at the Left Stop (Wheel Position = Left Stop).
Analog6 Center 0 – 10.00 V Defines the Analog 6 wiper voltage when the steer position feedback is
0x4082 0x00 0 – 1023 at the center position (Wheel Position = 0°).
Analog6 Right Stop 0 – 10.00 V Defines the Analog 6 wiper voltage when the steer position feedback is
0x40A4 0x00 0 – 1023 at the Right Stop (Wheel Position = Right Stop).
Analog6 Fault Min Sets the minimum threshold for the Analog 6 steer position feedback
0 – 10.00 V
0x4011 0x00 pot. If the Analog 6 steer position feedback pot voltage falls below this
0 – 1023
Analog6 Fault Max Sets the maximum threshold for the Analog 6 steer position feedback
0 – 10.00 V
0x4012 0x00 pot. If the Analog 6 steer position feedback pot voltage rises above this
0 – 1023
Fig. 8 Position Feedback Device “0” signal flow (Analog 5 shown; Analog 6 is similar).

POSITION FEEDBACK DEVICE 1 – ENCODER3 and 4
ALLOWABLE
RANGE
Encoder3 10.0 – 1000.0 counts/degree Defines the number of Encoder 3 pulses (counts) per degree of
Counts/Degree 100 – 10000 wheel position.
0x40C7 0x00 Encoder3 Counts/Degree is always a positive number.
Encoder4 10.0 – 1000.0 counts/degree Defines the number of Encoder 4 pulses (counts) per degree of
Counts/Degree 100 – 10000 wheel position.
0x40C8 0x00 Encoder4 Counts/Degree is always a positive number.
Swap Encoder3 On / Off
Direction On / Off Changes the direction of the Encoder 3 steer position feedback.
0x4014 0x00
Swap Encoder4 On / Off
Direction On / Off Changes the direction of the Encoder 4 steer position feedback.
0x4068 0x00
Auto Center Type 0–1 Defines which event will trigger the controller to center the
0x407D 0x00 0–1 steered wheel.
0 = Auto Center after homing.
1 = Auto Center after homing and every interlock.
Center Offset -180.0° – 180.0° The Center Offset is the difference between the zero position
0x4018 0x00 -32768 – 32767 (center) for the application and the home reference position
(found during homing). During homing, the home position is
found and once the coming is completed the zero position is
offset from the home position by adding the Center Offset to the
home position. All subsequent absolute moves shall be taken
relative to this new zero position, including Auto Center.
If the home switch is at the same position as center, set Center
Offset to zero.
Fig. 9 Position Feedback Device “1” signal flow (Encoder 3 shown; Encoder 4 is similar)

POSITION FEEDBACK DEVICE 1 – ENCODER3 and 4: HOMING
ALLOWABLE
RANGE
Input Type 0–2 Defines which inputs will be used to determine Home position.
0x407E 0x00 0–2 0 = Single NO switch (switch 2 input).
1 = Single switch with NO and NC contacts (same as two
switches with crossed polarity: switch 2 is NO and switch 4 is
NC).
2 = Two switches with the same NO polarity (switch 2 is NO and
switch 4 is NO).
Home on Interlock 0–1 Defines when the homing function is activated.
0x4075 0x00 0–1 0 = Home when keyswitch is turned On.
1 = Homing on first Interlock = On. If the interlock signal is
turned off during the homing, the homing procedure is
paused (PWM off) and will resume when the interlock
becomes active again.
Homing Direction 0–3 Defines which method is used to find Home position. The method
Method 0–3 determines the initial direction the homing function takes and on
0x407C 0x00 which edge the homing function is complete.
0 = Left of positive Home switch.
1 = Right of positive Home switch.
2 = Right of negative Home switch.
3 = Left of negative Home switch.
Methods 0 and 1 use a Home switch that is On if the wheel is to
the right of it and Off if the wheel is to the left of it. At the start of
homing the wheel will move to the left if the Home switch is On and
to the right if it is Off. The home position is just to the left of the
switch transition in method 0 and just to the right of the switch
transition in method 1.
Methods 2 and 3 use a Home switch that is On if the wheel is to the

left of it and Off if the wheel is to the right of it. At the start of homing
the wheel will move to the right if the Home switch is On and to the
left if it is Off. The home position is just to the right of the switch
transition in method 2 and just to the left of the switch transition in
method 3.
Homing Speed 0 – 100.0 %

Defines the speed of the steering motor during the homing function,
0x407B 0x00 0 – 32767
as a percentage of the steer motor Max Speed.

POSITION FEEDBACK DEVICE 2 – SIN/COS SENSOR
ALLOWABLE
RANGE
Offset 0 – 10.00 V Set this parameter to the midpoint voltage of the sine wave output of
0x40D1 0x00 0 – 1023 the sin/cos sensor. This value is usually available in the sensor
specifications, and is typically half the voltage supply to the sensor.
Amplitude 0 – 10.00 V Set this parameter to one half of the expected peak-to-peak voltage
0x40E0 0x00 0 – 1023 for the sin/cos sensor input signals.
Swap Direction On / Off Use this parameter to invert the signal to avoid physically swapping
0x4015 0x00 On / Off the wires to pins 16 and 17.
Center Position (deg) -180.0° – 180.0° Defines the sin/cos position (in degrees) that corresponds to a steer
0x40D3 0x0 -32768 – 32767 position feedback at the center (straight) position (Wheel Position =
0%).
This setting allows the service technician to re-calibrate the center
straight) without having to physically adjust the sin/cos sensor.
Fault Min 0 – 10.00 V Sets the minimum threshold for the Analog 5 and Analog 6 inputs of
0x4011 0x00 0 – 1023 the sin/cos sensor. If either the Analog 1 or Analog 3 voltage falls
below this threshold for 60 msec, a fault is issued.
Fault Max 0 – 10.00 V Sets the maximum threshold for the Analog 5 and Analog 6 inputs of
0x4012 0x00 0 – 1023 the sin/cos sensor. If either the Analog 5 or Analog 6 voltage rises
above this threshold for 60 msec, a fault is issued.
Tolerance 0 – 10.00 V The sine and cosine signals are used together to calculate the
0x40E1 0x00 0 – 1023 absolute position, i.e. arctan (Analog 5 / Analog 6). This calculated
position is then used to back-calculate the expected sine and cosine
inputs, based on the Amplitude parameter. If the difference between
these expected inputs and the actual inputs is greater than the set
Tolerance voltage for 60 msec, a fault is issued. This provides a
second level of fault detection and triggers a separate SinCos
feedback fault.
Fig. 10 Position Feedback Input Device “2” signal flow.

VEHICLE CONFIGURATION MENU
ALLOWABLE
RANGE
Nominal Voltage 24.0 – 48.0 V This parameter must be set to the vehicle’s nominal battery pack
0x405E 0x00 307 – 614 voltage.
Interlock Type 0–3 Defines which inputs will be used to determine an interlock:
0x4001 0x00 0–3 0 = KSI (interlock turns on with keyswitch).
1 = Single NO switch (Switch 1 Input).
2 = Single switch with NO and NC contacts
(same as two switches with crossed polarity, such as Switch
1 is NO and Switch 3 is NC).
3 = CAN bus PDO message from the traction controller.
Fault Steering Timeout 0.0 – 8.0 sec. This parameter applies only when a steer fault action of either
0x40DD 0x00 0 – 80 “Warning then Shutdown” or “Hold then Shutdown” is triggered (see
Table 6, troubleshooting chart).
This parameter sets a delay from when either of these fault
actions is set to when the fault output high side driver (pin 24) turns
off. Turning off the fault output will cause the traction contactor to
open and EM brake to release, thus causing traction to stop.
Typically this parameter is set to zero. When set to zero, there is
no “warning” and there is no “hold” before the shutdown. Setting this
parameter to a value greater than zero can allow time for the
traction system to start interlock braking to come to a smoother,
gentler stop before the fault output forces the traction contactor to
open and EM brake to release.
Note: Setting this parameter to a value greater than zero
requires changes in the traction controller’s software (VCL and
parameters) to permit interlock braking. Please review your traction
software before setting this parameter to a non-zero value.

VEHICLE CONFIGURATION: STEER CONTACTOR
ALLOWABLE
RANGE
Contactor Control Type 0–2 This parameter determines how the steer contactor is controlled.
0x4095 0x00 0–2 0 = No steer contactor (Contactor Driver = Off).
This setting is used when the 1222 B+ stud is wired to a battery
with no steer contactor. This setting is not recommended and
may not meet the required vehicle safety standards.
1 = Steer contactor controlled by contactor driver.
This is the recommended setting, and is used when the 1222 B+
stud is wired to a steer contactor. Type 1 requires programming
the Pull-in Voltage, Holding Voltage, Open Delay, and Checks
Enable parameters.
2 = Steer contactor controlled by traction controller (Cont. Driver =
Off).This setting is used in systems that have only one main
contactor to supply both the traction controller and the 1222. In
these systems, the traction controller must tell the 1222 that the
contactor is open or closed in the CAN PD01 message.
Pull-in Voltage 0 – 80.0 V The contactor pull-in voltage parameter allows a high initial voltage
0x4061 0x00 0 – 800 when the contactor driver first turns on, to ensure contactor closure.
After 1 second, the pull-in voltage drops to the steer contactor
holding voltage.
Note: The pull-in voltage is always battery voltage compensated.
Holding Voltage 0 – 80.0 V The contactor holding voltage parameter allows a reduced average
0x4062 0x00 0 – 800 voltage to be applied to the contactor coil once it has closed.
This parameter must be set high enough to hold the contactor
closed under all shock and vibration conditions the vehicle will be
subjected to.
Note: The holding voltage is always battery voltage
compensated.
Open Delay 0 – 40 sec. The open delay can be set to allow the steer contactor to remain
0x4060 0x00 0 – 40 closed for a period of time (the open delay) after the interlock is
turned off.
The delay is useful for preventing unnecessary cycling of the
contactor and for maintaining power to auxiliary functions that may
still be used for a short time after the interlock has turned off.
Checks Enable 0n / Off When programmed On, the controller performs ongoing checks to
0x4067 0x00 On / Off ensure that the steer contactor has closed properly each time it was
commanded to do so, and that it has not welded closed.
These checks (Contactor Welded and Contactor Did Not Close)
are not performed if the parameter is programmed Off.The contactor
driver, however, is always protected from short circuits.
Sequencing Delay 0 – 5.0 sec. The sequencing delay feature allows the interlock switch to be
0x4063 0x00 0 – 50 cycled within a set time (the sequencing delay), thus preventing
inadvertent deactivation of the steering control. This feature is useful
in applications
where the interlock switch may bounce or be momentarily cycled
during operation.

VEHICLE CONFIGURATION: TRACTION SPEED INPUT
ALLOWABLE
RANGE
Traction SpeedInput Type 0–2 This parameter defines how the traction speed is determined by the
0x40B5 0x00 0–2 1222.
0 = Traction speed input disabled.
1 = Encoder1 input (not allowed if Command Input Device = 1)
2 = CAN bus PDO message from the traction controller.
Encoder1 Steps 32 – 1024 Sets the number of traction motor encoder pulses per revolution.
0x4007 0x00 32 – 1024 This must be set to match the traction motor encoder; see info on
the traction motor nameplate.
This parameter is valid only for Traction Speed Input Type 1.
Swap Encoder1 Direction On / Off Changes the traction motor encoder’s effective direction of rotation.
0x406C 0x00 On / Off The traction encoder provides data used to determine traction
speed.
This parameter must be set such that when the traction motor is
turning forward, the traction speed is positive.
This parameter is valid only for Traction Speed Input Type 1.
Interlock Enabled Speed 0 – 500 rpm This parameter sets the traction speed above which interlock will
0x40B7 0x00 0 – 500 automatically be enabled, thus enabling steering.
A setting of zero disables this function.

SUPERVISION MENU
ALLOWABLE
RANGE
5V Current Min 0 – 100 mA Defines the lower threshold of the output current of the +5V supply
0x4096 0x00 0 – 1000 (pins 21 and 34). At or below this threshold, a fault is issued.
5V Current Max 0 – 100 mA Defines the upper threshold of the output current of the +5V supply
0x4097 0x00 0 – 1000 (pins 21 and 34). At or above this threshold, a fault is issued.
Steer Command 2.0° – 90.0° Defines the maximum difference allowed between the two steer
Tolerance (deg) 364 – 16380 command inputs (Steer Command and Steer Command 2).
0x40AA 0x00 If the programmed tolerance is exceeded, a fault is issued.
The difference between the two steer command inputs can be
seen in the monitor variable Steer Command Error.
A setting of 90.0° turns off this fault check.
Wheel Position 2.0° – 90.0° Defines the maximum difference allowed between the two position
Tolerance (deg) 364 – 16380 feedback outputs (Wheel Position and Wheel Position 2).
0x40AB 0x00 If the programmed tolerance is exceeded, a fault is issued. The
difference between the two wheel position outputs can be seen in
the monitor variable Wheel Position Error.
Home Reference 2.0° – 90.0° Defines the maximum difference allowed between the two home
Tolerance (deg) 364 – 16380 reference inputs (Home Reference and Home Reference 2).
0x40B6 0x00 If the programmed tolerance is exceeded, a fault is issued.
The difference between the two home reference inputs can be
seen in the monitor variable Home Reference Error.
Encoder Position 2.0° – 90.0° Defines the maximum difference allowed between the Wheel
Tolerance (deg) 364 – 16380 Position and the Encoder 3 Position.
0x40DC 0x00 This parameter should be used only for configurations where the
programmed Position Feedback Device = 0 (Analog 5 and 6) or = 2
(Sin/Cos Sensor).
If Position Feedback Device = 1 (Encoders 3 and 4) the Wheel
Position and Encoder 3 Position are the same. Therefore this check
should not be used when Position Feedback Device = 1.
If the programmed tolerance is exceeded, a fault is issued.
The difference between the Wheel Position and the Encoder 3
Position can be seen in the monitor variable Encoder Position Error.
Following Error 2.0° – 90.0° Defines the maximum difference allowed between the two home
Tolerance (deg) 364 – 16380 reference inputs (Home Reference and Home Reference 2).
0x40BE 0x00 If the programmed tolerance is exceeded for the programmed
Following Error Time, a fault is issued.
The difference between the two inputs can be seen in the
monitor variable Following Error.

SUPERVISION MENU, cont’d
ALLOWABLE
RANGE
Following Error Time 0.1 – 10.0 sec. Defines how long the Following Error Tolerance can be exceeded
0x40BF 0x00 1 – 100 before a fault is issued.
Stall Steering Speed 0 – 10000 rpm Defines the speed below which the steer motor will be considered
0x40DB 0x00 0 – 10000 stalled if it remains below this speed for the length of time defined
by the Stall Timeout parameter. When this condition is detected, a
fault is issued (code 36, Motor Stalled).
A setting of Stall Speed = 0 turns off this fault check.
Stall Timeout 0 – 2000 msec. Defines the timeout time for the motor stalled fault check.
0x40DA 0x00 0 – 2000

SUPERVISION MENU, cont’d
ALLOWABLE
RANGE
Max Speed 0 – 8000 rpm Defines the maximum allowed steer motor rpm.
0x401A 0x00 0 – 8000
Max Current 5 – 100 % Defines the maximum rms current the controller will supply to the
0x4126 0x00 1638 – 32767 steer motor during steering operation, as a percentage of the
controller’s full rated current. Reducing this value will reduce the
maximum steer torque.
Encoder3 Steps 32 – 1024 Sets the number of of steer motor encoder pulses per revolution.
0x40D6 0x00 32 – 1024 This must be set to match the steer motor encoder; see
specifications on the steer motor nameplate.
Adjusting this parameter can be hazardous; setting it improperly
may cause vehicle malfunction, including uncommanded steer
motor drive.
Swap Encoder3 Direction On / Off Changes the steer motor encoder’s effective direction of rotation.
0x4014 0x00 On / Off The steer encoder provides data used to determine steer speed.

MOTOR: TEMPERATURE CONTROL
ALLOWABLE
RANGE
Sensor Enable On / Off The Sensor Enable parameter can be used only if a temperature
0x403C 0x00 On / Off sensor has been properly configured in the steering motor. When
Sensor Enable is programmed On, the motor temperature cutback
feature and the motor temperature compensation feature are enabled.
The motor temperature cutback feature will reduce traction speed
between the Temperature Hot and Temperature Max setpoints, but it
will not inhibit the 1222 steering.
The motor temperature compensation feature will adapt the motor
control algorithms to varying motor temperatures, for improved
efficiency and more consistent performance.
Sensor Type 0–5 The following sensor types are predefined in the software.
0x4085 0x00 0–5
Type 0 User-defined sensor
Type 1 KTY83–122
Type 2 2 × Type 1 in series
Type 3 KTY84-130 or KTY84-150
Type 4 2 × Type 3 in series
Type 5 PT1000
Custom sensor types can be set up if none of the predefined types is

appropriate for your application. Sensor Type 0 is for a user-defined
motor temperature sensor; see menu on the next page for the user-
defined parameters that must be configured for Type 0 sensors.
Caution Note: The industry standard KTY temperature sensors are silicon
temperature sensors with a polarity band; the polarity band
of a KTY sensor must be connected to I/O ground (pin 7).
Sensor Temp Offset -20.0 – Often the sensor is placed in the motor at a location with a known
0x4064 0x00 20.0 °C offset to the critical temperature; the offset can be corrected with this
-200 – 200 parameter. The parameter can also be used to correct a known offset
in the sensor itself.
Temperature Hot 0 – 250.0 °C Defines the temperature at which traction speed cutback begins. The
0x40AC 0x00 0 – 2500 cutback is linear between the Temperature Hot and Temperature Max
setpoints.
Temperature Max 0 – 250.0 °C Defines the temperature at which traction speed is cut back to the
0x40AD 0x00 0 – 2500 speed defined by the Sensor Fault Traction Cutback parameter.
Sensor Fault Traction 0 – 100 %

Defines the amount of traction speed cutback that will result from a
Cutback 0 – 100
sensor fault.
0x40BD 0x00

MOTOR: USER-DEFINED TEMPERATURE SENSOR
This menu contains 14 parameters (7 sensor-temperature pairs) which
define a 7-point map that is used to map the voltage input to a sensor
temperature profile.
This menu is used only when Motor Temperature Sensor Type = 0
(User-defined).
It is best to select one point near the Temperature Hot value so the
controller will accurately regulate motor temperature.
ALLOWABLE
RANGE
Sensor 1–7 0.0 – 10.0 V The seven Sensor parameters define inputs to the user-defined
see list 0 – 1023 temperature sensor map.
The units are in volts.
Sensor 1 = 0x4086 0x00
Sensor 2 = 0x4088 0x00
Sensor 3 = 0x408A 0x00
Sensor 4 = 0x408C 0x00
Sensor 5 = 0x408E 0x00
Sensor 6 = 0x4090 0x00
Sensor 7 = 0x4092 0x00
Temp 1–7 -60.0 – 250.0 °C The seven Temp parameters define outputs to the user-defined
see list -600 – 2500 temperature sensor map.
The units are in °C.
Temp 1 = 0x4087 0x00
Temp 2 = 0x4089 0x00
Temp 3 = 0x408B 0x00
Temp 4 = 0x408D 0x00
Temp 5 = 0x408F 0x00
Temp 6 = 0x4091 0x00
Temp 7 = 0x4093 0x00

CANopen MENU
ALLOWABLE
RANGE
Node ID 1 – 127 Sets the Node ID of the CANopen Slave system. This is the first
0x5001 0x01 1 – 127 of the two node IDs that need to be set up for the 1222 controller.
Node ID Supervisor 1 – 127 Sets the supervisor Node ID of the CANopen Slave system. This is
0x40B2 0x00 1 – 127 the second of the two node IDs that need to be set up for the 1222
controller. The Node ID Supervisor should always be different from
the Node ID.
Baud Rate 0–4 Sets the CAN baud rate for the CANopen Slave system:
0x5001 0x02 0–4 0 = 125 Kbps
1 = 250 Kbps
2 = 500 Kbps
3 = 800 Kbps
4 = 1 Mbps
Producer Heartbeat 16 – 200 msec Sets the rate at which the CAN heartbeat messages are sent from
Rate 16 – 200 the 1222 controller.
0x1017 0x00
PDO1 Timeout Time 20 – 80 msec Sets the PDO1 timeout period for receiving the PDO1 CAN
0x40CB 0x00 20 – 80 message. The steering controller will set a fault if this timer expires
between receiving
PDO1 messages.

MOTOR CONTROL TUNING MENU
ALLOWABLE
RANGE
Position Kp 0 – 100.0 % Determines how aggressively the steer controller attempts to match
0x4047 0x00 1 – 32767 the steer position to the commanded steer position. Larger values
provide tighter control.
If the gain is set too high, you may experience oscillations as the
controller tries to control position. If it is set too low, the motor may
behave sluggishly and be difficult to control.
See Figure 11.
Position Kp can be fine-tuned using the Steering Sensitivity
parameters (page 44).
Velocity Kp 0 – 100.0 % Determines how aggressively the steer controller attempts to match
0x4065 0x00 0 – 32767 the steer velocity to the determined velocity to reach the desired
position.
Larger values provide tighter control.
controller tries to control velocity. If it is set too low, the motor may
behave sluggishly and be difficult to control.
See Figure 12.
Velocity Ki 0 – 100.0 % The integral term (Ki) forces zero steady state error in the
0x4066 0x00 0 – 32767 determined
velocity, so the motor will run at exactly the determined velocity.
Larger values provide tighter control.
controller tries to control velocity. If it is set too low, the motor may
takea long time to approach the exact commanded velocity.
See Figure 12.

Fig. 11 Position Control signal flow.
Fig. 12 Velocity Control signal flow.

ALLOWABLE
RANGE
LS Sensitivity 0 – 100 % Defines the steering sensitivity at very low speeds (i.e., at near zero traction
0x4132 0x00 0 – 32767 rpm),as a percentage of the programmed Position Kp.
Sensitivity is typically reduced at low speeds to prevent excessive hunting for
the commanded position.
HS Sensitivity 0 – 100 % Defines the steering sensitivity at high speeds, as a percentage of the
0x4133 0x00 0 – 32767 programmed Position Kp.
Sensitivity is typically reduced at high speeds to make the vehicle easier to
drive.
Low Speed 0 – 32767 rpm Defines the speed at which 100% sensitivity will be applied, as the vehicle
0x4134 0x00 0 – 32767 accelerates.
Mid Speed 0 – 32767 rpm Defines the speed at which 100% sensitivity will start to decrease to the
0x4135 0x00 0 – 32767 programmed HS Sensitivity value as the vehicle accelerates.
High Speed 0 – 32767 rpm Sets the speed at and above which the programmed HS Sensitivity value will
0x4136 0x00 0 – 32767 be applied.
Fig. 13 Steering Sensitivity Map.

ALLOWABLE
RANGE
FW Base Speed 200 – 6000 rpm This parameter needs to be reset each time the Motor Type is
0x410A 0x00 200 – 6000 changed. See Motor Type table on page 46.
Field Weakening 0 – 100 % Determines the amount of high speed power the controller will allow,
0x4108 0x00 0 – 1024 while still maintaining maximum effficiency at the allowed power.
Reducing this parameter effectively reduces controller current at
high speeds, which can reduce energy consumption and motor
heating, but at the expense of reduced available torque from the
motor.
Weakening Rate 0 – 100 % Determines the control loop gains for field weakening. Setting the
0x412B 0x00 0 – 500 rate too low may create surging in the vehicle as it accelerates at
mid to high speeds. Setting the rate too high may create high
frequency oscillations (usually audible) when the vehicle accelerates
at mid to high speeds.
Min Field Current 0 – 800 A Min Field Current sets the amount of current used to pre-flux the
0x4112 0x00 0 – 8000 steer motor field. This current will run in the steer motor whenever
the bridge is enabled (Interlock = On). Pre-fluxing the steer motor
improves steering response, but because it also reduces efficiency
and causes controller and steer motor heating, this parameter is
typically set to zero.

ALLOWABLE
RANGE
Motor Type 0 – 11 This parameter references a predefined set of motor parameters
0x40B0 0x00 0 – 11 for many AC motors. The table also provides appropriate settings
for the
FW Base Speed parameter.
If your motor is not included here, consult your local Doosan
customer support engineer for information on how to set these
three parameters based on your application and motor.
Motor Type STEER MOTOR STEER MOTOR WATTAGE (W) FW Base Speed (rpm)
0 [User defined] n/a n/a n/a

1 ABM 4DG63D_4 24 670 TBD
2 CFR AM106.0026 24 1000 TBD

3 Kordel KM A 63/4-80/3 24 700 450
4 Iskra ASG 7101 24 300 1525
5 [Reserved] n/a n/a n/a
6 Metalrota ARD114 24 700 2020
7 CFR AM106.0124 36 TBD TBD

8 CFR AM106.0059.01 48 600 TBD
9 Schabmuller 50060170 24 580 500
10 Superec SY09-0.6Q 24 600 2300

11 Kordel KM A 80/4-60/3 24 400 2300

Monitor Menu
Through its Monitor menu, the handheld programmer provides access to realtime data during vehicle operation.
This information is helpful during diagnostics and troubleshooting, and also while adjusting programmable
parameters.
Table 3 Monitor Menu
COMMAND INPUT ......................... p. 48 INTERLOCK ................................... p. 54

Target Speed Interlock
Target Position (deg) Switch1
Steer Command (deg) Switch3
Steer Command 2 (deg)
HOME REFERENCE ...................... p. 54
Steer Command
Steer Command 2 Home
Analog Input .............................. p. 49 Switch2
Analog 1 Switch4.
Analog 3 OUTPUTS ....................................... p. 54
Sin/Cos Angle (deg) Fault Output Voltage
Sin/Cos Angle 2 (deg) Contactor Driver PWM
Sin/Cos Angle Raw (deg) BATTERY AND SUPPLY ............... p. 55
Sin/Cos Angle Raw 2 (deg) Capacitor Voltage
Encoder Input ........................... p. 50 Keyswitch Voltage
Encoder 1 Counts 10v Out
Encoder 2 Counts
5v Out
Encoder 1A
Encoder 1B 5v Out Current
Encoder 2A STEER MOTOR .............................. p. 55
Encoder 2B Motor RPM
POSITION FEEDBACK .................. p. 50 Temperature
Wheel Position (deg) Temperature Sensor Voltage
Wheel Position 2 (deg) CONTROLLER ............................... p. 56
Left Stop Reached Current (RMS)
Right Stop Reached Modulation Depth
Analog Input .................................... p. 51 Frequency
Analog 5 Temperature
Analog 6
Contactor State
Sin/Cos Position (deg)
Sin/Cos Position 2 (deg) Steer Command State
Encoder Input .................................. p. 52 Device State
Encoder 3 Degrees from Home Keyswitch Hour Meter
Encoder 4 Degrees from Home Interlock Hour Meter
Encoder 3 Counts from Home Motor Tuning ............................. p. 57
Encoder 4 Counts from Home Base Speed Captured
Encoder 3 Position (deg) CAN STATUS ................................. p. 57
Encoder 3A CAN NMT State
Encoder 3B From Traction Controller ......... p. 58
Encoder 4A Traction Motor RPM
Encoder 4B
Traction Is Ready
SUPERVISION ............................... p. 53
Following Error (deg) CAN Interlock
Steer Command Error (deg) To Traction Controller .............. p. 58
Wheel Position Error (deg) Enable Traction
Encoder Position Error (deg) Traction Cutback
Home Reference Error (deg) Traction Fault Action

DISPLAY
VARIABLE DESCRIPTION
RANGE
Target Speed -32768 – 32767 rpm Steer motor speed target for the velocity control loop.
0x442E 0x00 -32768 – 32767
Target Position (deg) -180.0° – 180.0°

0x4427 0x00 -32768 – 32767 Wheel position target for the position control loop.
Steer Command (deg) -180.0° – 180.0° The operator’s final Steer Command (in degrees).
0x44BA 0x00 -32768 – 32767
Steer Command 2 (deg) -180.0° – 180.0° The operator’s redundant final Steer Command (in degrees).
0x44BB 0x00 -32768 – 3276
Steer Command -100.0 – 100.0% The operator’s Steer Command (in percent) that is the input into the
0x4423 0x00 -32768 – 32767 command map.
The output of the command map is the Steer Command (in
degrees).
Steer Command 2 -100.0 – 100.0% The operator’s redundant Steer Command in percent) that is the
0x446A 0x00 -32768 – 32767 input into the command map.
The output of the command map is the Steer Command 2 (in
degrees).

Monitor Menu: COMMAND INPUT → Analog Input
DISPLAY
RANGE
Analog 1 0 – 10.00 V The voltage measured at the Command Analog 1 input (pin 8).
0x4413 0x00 0 – 1023
Analog 3 0 – 10.00 V
The voltage measured at the Command Analog 3 input (pin 19).
0x4414 0x00 0 – 1023
Sin/Cos Angle (deg) -180.0° – 180.0° Sin/Cos Angle = Sin/Cos Angle Raw minus the Center Offset parameter.
0x44BC 0x00 -32768 – 32767
Sin/Cos Angle 2(deg) -180.0° – 180.0° Sin/Cos Angle 2 = Sin/Cos Angle Raw 2 minus the Center Offset
0x44BD 0x00 -32768 – 32767 parameter.
Sin/Cos Angle 2 is compared to Sin/Cos Angle, and if the difference
exceeds the programmed Tolerance, a fault is issued (code 47: Sin/Cos
Command Sensor).
Sin/Cos Angle Raw (deg) -180.0° – 180.0° The angle calculated from the
0x44BE 0x00 -32768 – 32767 Sin/Cos Sensor input voltages
(pins 8 and 19).
Sin/Cos Angle Raw 2 -180.0° – 180.0° The expected angle back-calculated from the Sin/Cos Sensor Angle Raw
(deg) -32768 – 32767 and the Amplitude parameter.
0x44BF 0x00

Monitor Menu: COMMAND INPUT → Encoder Input
DISPLAY
RANGE
Encoder 1 Counts -2147483648 – 2147483647 Encoder 1 counts from a command to the center position. Moving the
0x4420 0x00 -2147483648 – 2147483647 command encoder should increase the counts (positive or negative,
depending on the direction moved).
A command left of center will be negative counts.
A command right of center will be positive counts.
Encoder 2 Counts -2147483648 – 2147483647 Encoder 2 counts from a command to the center position. Moving the
0x4474 0x00 -2147483648 – 2147483647 command encoder should increase the counts (positive or negative,
depending on the direction moved).
A command left of center will be negative counts.
A command right of center will be positive counts.
Encoder 1A On / Off Command Encoder 1A switch input On or Off (pin 14). This can be used to
0x4478 0x00 On / Off verify that phase A of Command Encoder 1 is operating correctly.
Encoder 1B On / Off Command Encoder 1B switch input On or Off (pin 25). This can be used to
0x4479 0x00 On / Off verify that phase B of Command Encoder 1 is operating correctly.
Encoder 2A On / Off Command Encoder 2A switch input On or Off (pin 33). This can be used to
0x447A 0x00 On / Off verify that phase A of Command Encoder 2 is operating correctly.
Encoder 2B On / Off Command Encoder 2B switch input On or Off (pin 20). This can be used to
0x447B 0x00 On / Off verify that phase B of Command Encoder 2 is operating correctly.

Monitor Menu: POSITION FEEDBACK
DISPLAY
RANGE
Wheel Position (deg) -180.0° – 180.0° The final wheel position.
0x2000 0x00 -32768 – 32767
Wheel Position 2 (deg) -180.0° – 180.0° The operator’s redundant final wheel position.
0x4458 0x00 -32768 – 32767 Wheel Position 2 is compared to Wheel Position, and if the difference
exceeds the programmed Wheel Position Tolerance, a fault is issued (code
56: Wheel Position Supervision).
Left Stop Reached On / Off Flag indicating the left stop has been reached.
0x4421 0x00 On / Off
Right Stop Reached On / Off Flag indicating the right stop has been reached.
0x4422 0x00 On / Off
Monitor Menu: POSITION FEEDBACK → Analog Input

DISPLAY
RANGE
Analog 5 0 – 10.00 V The voltage measured at the Position
0x4411 0x00 0 – 1023 Analog 5 input (pin 16).
Analog 6 0 – 10.00 V The voltage measured at the Position

0x4480 0x00 0 – 1023 Analog 6 input (pin 17).
Sin/Cos Position (deg) -180.0° – 180.0° The angle calculated from the Sin/Cos
0x44C0 0x00 -32768 – 32767 Sensor input voltages (pins 16 and 17)
Sin/Cos Position 2 (deg) -180.0° – 180.0° The expected angle back-calculated from the Sin/Cos Position variable and
0x44C1 0x00 -32768 – 32767 the Amplitude parameter.
Sin/Cos Position 2 is compared to Sin/Cos Position, and if the difference
exceeds the programmed Tolerance (Position Feedback Device 2 »
Sin/Cos Sensor » Tolerance), a fault is issued
(code 48: Sin/Cos Feedback Sensor).

Monitor Menu: POSITION FEEDBACK → Encoder Input
DISPLAY
RANGE
Encoder 3 Degrees -180.0° – 180.0° Encoder 3 degrees from home position.

from Home -32768 – 32767 The steer motor rotating should change the degrees; a move left of home
0x44C3 0x00 position will be in negative degrees and a move right of home will be in
positive degrees.
Encoder 4 -180.0° – 180.0° Encoder 4 degrees from home position.

Degrees -32768 – 32767 The steer motor rotating should change the degrees; a move left of home
from Home position will be in negative degrees and a move right of home will be in
0x44C4 0x00 positive degrees.
Encoder 3 Counts -2147483648 – 2147483647 Encoder 3 counts from the home position. The steer motor rotating
from Home -2147483648 – 2147483647 should change the counts; a move left of home position will be
0x441F 0x00 negative counts, and a move right of home will be positive counts.
Encoder 4 Counts -2147483648 – 2147483647 Encoder 3 counts from the home position. The steer motor rotating
from Home -2147483648 – 2147483647 should change the counts; a move left of home position will be
0x4473 0x00 negative counts, and a move right of home will be positive counts.
Encoder 3 -180.0° – 180.0° Wheel position based on Encoder 3 counts.

Position (deg) -32768 – 32767 Accuracy depends on the parameters Encoder 3 Counts from Home and
0x44D0 0x00 Center Offset being configured correctly. This variable is used in a
supervision check (see code 56: Wheel Position Supervision).
Encoder 3A On / Off Steer Motor Encoder 3A switch input On or Off (pin 31). This can be used to
0x4434 0x00 On / Off verify that phase A of Steer Motor Encoder 3 is operating correctly.
Encoder 3B On / Off Steer Motor Encoder 3B switch input On or Off (pin 32). This can be used to
0x4435 0x00 On / Off verify that phase B of Steer Motor Encoder 3 is operating correctly.
Encoder 4A On / Off Steer Motor Encoder 4A switch input On or Off (pin 26). This can be used to
0x447C 0x00 On / Off verify that phase A of Steer Motor Encoder 4 is operating correctly.
Encoder 4B On / Off Steer Motor Encoder 4B switch input On or Off (pin 27). This can be used to
0x447D 0x00 On / Off verify that phase B of Steer Motor Encoder 4 is operating correctly.

Monitor Menu: POSITION FEEDBACK
DISPLAY
RANGE
Following Error (deg) -180.0° – 180.0° Following Error = Steer Command 2 minus Wheel Position 2. If the
0x44C9 0x00 -32768 – 32767 difference exceeds the programmed Following Tolerance, a fault is issued
(code 73: Following Error).
Steer Command Error -180.0° – 180.0° Steer Command Error = Steer Command minus Steer Command 2. If the
(deg) -32768 – 32767 difference exceeds the programmed Steer Command Tolerance, a fault is
0x44CA 0x00 issued (code 55: Steer Command Supervision).
Wheel Position -180.0° – 180.0° Wheel Position Error = Wheel Position minus Wheel Position 2. If the
Error (deg) -32768 – 32767 difference exceeds the programmed Wheel Position Tolerance, a fault is
0x44CB 0x00 issued (code 56: Wheel Position Supervision).
Encoder Position -180.0° – 180.0° Encoder Position Error = Wheel Position minus Encoder 3 Position. If the
Error (deg) -32768 – 32767 difference exceeds the programmed Encoder Position Tolerance, a fault is
0x44D2 0x00 issued (code 56: Wheel Position Supervision).
Home Reference -180.0° – 180.0° Home Reference Error = Home Reference minus Home Reference 2. If the
Error (deg) -32768 – 32767 difference exceeds the programmed Home Reference Tolerance, a fault is
0x44CC 0x00 issued (code 54: Home Reference Tolerance Fault).

Monitor Menu: INTERLOCK
DISPLAY
RANGE
Interlock On / Off The interlock is used to enable/disable the the electric steering. The source
0x440C 0x00 On / Off of the interlock state is determined by the Interlock Type parameter.
Switch1 On / Off Switch 1 input On or Off (pin 9). This input is used as an input for the NO
0x440A 0x00 On / Off contact of the Interlock switch.
Switch3 On / Off Switch 3 input On or Off (pin 11). This input is used as an input for the NC
0x444F 0x00 On / Off contact of the Interlock switch.
Monitor Menu: HOME REFERENCE

DISPLAY
RANGE
Home On / Off Home is used to recalibrate the position,
0x440D 0x00 On / Off when the position feedback devices are encoders (Position Feedback
Device = 1).
Switch2 On / Off Switch 2 input On or Off (pin 10). This input is used as an input for the NO
0x440B 0x00 On / Off contact of the Home switch.
Switch4 On / Off Switch 4 input On or Off (pin 12). This input is used as an input for the NC
0x4450 0x00 On / Off contact of the Home switch.
Monitor Menu: OUTPUTS

DISPLAY
RANGE
Fault Output Voltage 0.0 – 80.0 V Voltage measured at the Fault Output
0x440F 0x00 0 – 1023 (pin 24).
Contactor Driver PWM 0 – 100 %

Steer contactor driver PWM output (pin 2).
0x44A4 0x00 0 – 32767

DISPLAY
RANGE
Capacitor Voltage 0.0 – 80.0 V Voltage of steer controller’s internal capacitor
0x4417 0x00 0 – 1023 bank at the B+ terminal.
Keyswitch Voltage 0.0 – 80.0 V Voltage measured at the keyswitch input

0x4416 0x00 0 – 1023 (pin 1).
10v Out 0.0 – 20.0 V Voltage measured at the +10V output (pin 15).
0x445E 0x00 0 – 1023
5v Out 0.00 – 10.00 V Voltage measured at the +5V output

0x44A9 0x00 0 – 1023 (pins 21 and 34).
5v Out Current 0.00 – 10.00 V Measured current of the +5V output supply
0x4415 0x00 0 – 1023 (pins 21 and 34).

DISPLAY
RANGE
Motor RPM -32768 – 32767 rpm Steer motor speed in revolutions per minute.
0x4433 0x00 -32768 – 32767
Temperature -3276.8 – 3276.7 °C Steer motor temperature measured as

0x441B 0x00 -32768 – 32767 measured by the motor temperature sensor
input (pin 22).
Temperature 0.00 – 10.00 V Voltage measured at the motor

Sensor Voltage 0 – 1023 temperature sensor input (pin 22).
0x4410 0x00

DISPLAY
RANGE
Current (RMS) 0 – 6553.5 A RMS current of the steer controller, taking all three phases into account.
0x44B1 0x00 0 – 65535
Modulation Depth 0.0 – 100.0 %

Percentage of available voltage being used.
0x4520 0x00 0 – 1024
Frequency -300 – 300 Hz Steer controller electrical frequency.

0x452F 0x00 -18000 – 18000
Temperature -3276.8 – 3276.7 °C Steer controller internal temperature.

0x441A 0x00 -32768 – 32767
Contactor State 0–4 Steer contactor state:

0x44AA 0x00 0–4 0 = open
1 = closing
2 = closed
3 = opening
4 = fault.
Steer Command 0 – 255 Steer command state:
State 0 – 255 0 = init
0x4432 0x00 1 = open phase check
2 = homing
3 = auto center
4= steering
5 = idle
6 = steering faulted.
Device State 0 – 255 Device state:
0x444C 0x00 0 – 255 0 = “Not Ready To Switch On”:
controller initialization state
2 = “Switch On Disabled”:
software upload state
3 = “Ready To Switch On”:
controller enabled, motor bridge disabled, Interlock = Off
4 = “Switched On”:
controller enabled, processing the Interlock = On command
5 = “Operation Enabled”:
controller enabled, motor bridge
enabled, Interlock = On
13 = “Fault Reaction State”:
controller processing a shutdown
fault action
14 = “Fault”:
controller shut down by shutdown
fault action, Fault Output = Off.

Monitor Menu: CAN STATUS → FROM TRACTION CONTROLLER
DISPLAY
RANGE
Keyswitch Hour 0 – 429496729.5 hour Displays the total time the steer
Meter 0 – 4294967295 controller has been powered On.
0x4499 0x00
Interlock Hour Meter 0 – 429496729.5 hour Displays the total time the steer
0x4498 0x00 0 – 4294967295 controller has had the interlock On.

DISPLAY
RANGE
Base Speed 0 – 8000 rpm Displays the value of the steering motor base speed captured in the most
Captured 0 – 8000 recent acceleration.
0x44C2 0x00 This value can be used to set the FW Base Speed parameter (Motor
Control Tuning »
Field Weakening Control » FW Base Speed).

DISPLAY
RANGE
CAN NMT State 0 – 255 Controller CAN NMT state:
0x1C00 0x00 0 – 255 0 = initialization
4 = stopped
5 = operational
127 = pre-operational.

DISPLAY
RANGE
Traction Motor RPM -32768 – 32767 rpm Traction motor speed in revolutions per minute.
0x441E 0x00 -32768 – 32767 This variable is based on the input selected with the Traction Speed
Input Type parameter.
Traction Is Ready On / Off Flag sent by the traction controller over the CAN bus (PDO1_MOSI
0x2081 0x00 On / Off Byte 3) to indicate whether the traction motor is
ready. Typically implemented in the traction controller VCL to indicate
that the traction main contactor is closed.
CAN Interlock On / Off Flag sent by the traction controller over the CAN bus (PDO1_MOSI
0x4447 0x00 On / Off Byte 4) to indicate whether the interlock is enabled.
This flag is used by the 1222 only when Interlock Type = 3.
Monitor Menu: CAN STATUS → TO TRACTION CONTROLLER

DISPLAY
RANGE
Enable Traction On / Off Flag sent from the steer controller
0x2001 0x00 On / Off to enable the traction controller.
Traction Cutback 0 – 100 % Variable sent from the steer controller

0x2003 0x00 0 – 100 to cut back the speed of the traction motor.
Traction Fault Action 0 – 10 Variable sent from the steer controller to trigger a fault action in the traction
0x2005 0x00 0 – 10 controller.
0 = no fault
1 = stop traction
2 = reduce traction speed
3 = no action.

Controller Information Menu
This menu provides ID and version numbers for your controller hardware and software.

DISPLAY
RANGE
Model Number 0 – 4294967295 Model number. For example, if you have a 1222 controller with the model
0x5000 0x08 0 – 4294967295 number 1222-5101, the Model Number variable will have a value of
12225101.
Serial Number 0 – 4294967295 Serial number. For example, if the serial number printed on your controller
0x1018 0x04 0 – 4294967295 is 11125L.11493, the Serial Number variable will have the value of 11493.
Protocol Version 0 – 32767 Version of the serial communications protocol.

0 – 32767
Param Block 0 – 32767 Version of the parameter block.

Version 0 – 32767
Mfg Date Code 0 – 65535 Controller date of manufacture, with the first two digits indicating the year
0x4801 0x00 0 – 65535 and the last three indicating the day. For example, if the serial number
printed on your controller is 11125L.11493, the Mfg Date Code variable will
have the value of 11125 (125th day of 2011).
Hardware Version 0 – 65.535 The hardware version number uniquely describes the combination of power
0x4802 0x00 0 – 65535 base assembly and the logic, cap, and IMS board assemblies used in the
controller.
OS Version 0 – 65535 Version number of the operating system software that is loaded into the
0x4804 0x00 0 – 65535 controller. This variable specifies the major version number of the
controller’s operating system.
Build Number 0 – 65535 Build number of the operating system software that is loaded into the
0x4803 0x00 0 – 65535 controller. This variable specifies the minor version number of the
controller’s operating system.
SM Version 0 – 655.35 Version number of the Start Manager

0x4800 0x00 0 – 65535 software that is loaded into the controller.

Commissioning
The 1222 steer controller can be used in a variety of vehicles, which differ widely in characteristics and in their
input and feedback devices. Before driving the vehicle, it is imperative that the commissioning procedures be
carefully followed to ensure that the controller is set up to be compatible with your application.
The 1222 controller must be used in conjunction with a Doosan AC traction controller with VCL (1232, 1234, 1236,
1238, or 1298). The Doosan traction controller must implement special software (VCL) to communicate with the
1222 controller, via the CAN bus, and to support safe vehicle operation.
A single main contactor can be used to support both traction and steer controllers. All vehicles must use the Fault
Output connection (J1-24) to allow the 1222 to disable the traction main contactor during certain fault conditions.
BEFORE YOU START
The correct value for the Motor Type and FW Base Speed parameters
must be determined individually for each AC motor. You can determine
these values in one of the following ways:
➡ Check the motor types that are already supported by comparing your
motor model number to the list of characterized motors listed in the
parameter description for Motor Type (page 46). If there is a match,
consult the table for the correct FW Base Speed based on the Motor
Type and Nominal Voltage.
➡ Contact Doosan with the manufacturer’s part number for your motor.
We have a database of many AC motors for which we have already
determined the correct motor parameter settings.
If no testing has been done, it may be possible for Doosan to dyno
test your motor. Contact Doosan before shipping your motor.
After obtaining this information, set the Motor Type and FW Base Speed
parameters to their correct values.
Caution: Before starting the commissioning procedures, jack the vehicle drive wheels up off the ground so
that they spin freely and steer freely from stop to stop.
Manually disable the Interlock (traction and steer) so that the 1222 will not begin steering and the
traction wheel will not turn. Double-check all wiring to ensure it is consistent with the wiring
guidelines presented in Section 2. Make sure all connections are tight. Turn on the controller and
plug in the handheld programmer.

Preparation for commissioning.
Caution: Lower these five parameter values to force low steering performance and stable response (with
the wheel off the ground) while the setup procedures are performed:
Motor
Max Speed = 1000 rpm or lower
Max Current = 5%
Motor Control Tuning
Position Kp = 5%
Velocity Kp = 5%
Velocity Ki = 5%.
Verify that the 1222 interlock = Off (Monitor » Interlock » Interlock) and the traction controller interlock = Off. If
either interlock is On, either change the interlock input to the controllers or adjust the Interlock Type parameter
until the interlock variables are both Off. If the interlock is accidentally set to On during commissioning, the steered
wheel may turn without warning.
Set these parameters based on the vehicle configuration:
Motor Control Tuning

Motor Type (see above)
Field Weakening Control
FW Base Speed (see above)
Vehicle Configuration
Interlock Type (see above)
Nominal Voltage
Contactor Driver
Contactor Control Type
Pull-In Voltage
Holding Voltage
Open Delay
Checks Enable
Sequencing Delay.
Motor
Encoder3 Steps
Temperature Control
Sensor Enable
Sensor Type
Temperature Hot
Temperature Max
Sensor Fault Traction Cutback
CANopen
Baud Rate

Temporarily set these six parameters to disable the supervision; this will allow for easier setup of the primary and
redundant signals:
Supervision
Steer Command Tolerance = 90°
Wheel Position Tolerance = 90°
Home Reference Tolerance = 90°
Encoder Position Tolerance = 90°
Following Error Tolerance = 90°
Stall Steering Speed = 0
Steer Direction
Parameter and monitor values for wheel position and steer motor speed are signed
(i.e., they are positive and negative values).
Right wheel positions (positive values) are such that when traveling in the forward
vehicle direction in a vehicle with the steered wheel in the front the steer direction is to
the driver’s right.
Left wheel positions (negative values) are such that when traveling in the forward
vehicle direction in a vehicle with the steered wheel in the front the steer direction is to
the driver’s left.
In vehicles where the steered wheel is in the back, these directions are reversed.
If your application has a motor temperature sensor, check the temperature (Monitor » Steer Motor » Temperature)
and verify that the reading is correct or resolve the problem.
Verify that the correct VCL software is loaded into the Doosan AC traction controller to support the 1222. Verify
that the CAN communications between the AC traction controller and the 1222 are operating correctly. Resolve
any problems with the traction software or CAN communications before continuing on to the commissioning
procedures.

Command Input Device Setup
Your steering command input device will be a dual potentiometer or a sine/ cosine sensor (both using pins J1-
8and J1-19) or a dual encoder (using pins J1-14, J1-25, J1-33, and J1-20).
Set the Command Input Device parameter (see pages 20–21):
0 = Pot input
1 = Encoder input
2 = Sin/Cos Sensor input
Use the appropriate setup menu for the input you have chosen.
“0” — Setup for Pot input (see page 22)
Note: The steer motor should not respond to this command input because the Interlock is Off. If the steer motor
shows any movement (or if the Interlock is On), stop and resolve the issue; see Preparation for
commissioning, page 61.
a. Move the steer command pots to the Left position (not to the actual physical stop, but a small amount
away, to allow for pot tolerance variation) and observe the two voltages shown in the Monitor »
Command Input » Analog Input » Analog1 and Analog3 variables. Set the parameters Analog1 Left and
Analog3 Left to the observed voltages.
b. Move the steer command pots to the Center position and observe the two voltages shown in the Analog1
and Analog3 variables. Set the parameters Analog1 Center and Analog3 Center to the observed voltages.
c. Move the steer command pots to the Right position (not to the actual physical stop, but a small amount
away, to allow for pot tolerance variation) and observe the two voltages shown in the Analog1 and
Analog3 variables. Set the parameters Analog1 Right and Analog3 Right to the observed voltages.
d. Move the steer command pots to the Center position and decide how wide the deadband should be,
observing the Analog1 and Analog3 variables. Set the parameters Analog1 Center Deadband and
Analog3 Center Deadband to the observed voltages.
e. Set the four fault parameters (Analog1 Fault Min, Analog1 Fault Max, Analog3 Fault Min, and Analog3
Fault Max). Set these to voltages that will not be reached during normal operation, but will be reached
when the steer command inputs become faulty (e.g., should there be an open or short circuit).
The Fault Min settings must be below the minimum voltage seen on Analog1 or Analog3 when steered to
the maximum left and right positions.
The Fault Max settings must be above the maximum voltage seen on Analog1 or Analog3 when steered
to the maximum left and right positions.
“1” — Setup for Encoder input (see page 24)
a. Both command encoders must move in the same direction and the values must be positive for the Right
direction and negative for the Left direction, as defined on page 62. Observe the Monitor » Command
Input » Encoder Input » Encoder1 Counts and Encoder2 Counts variables. While moving the command
encoders, verify that these values are both positive (for movements to command Right steer direction) or
negative (for movements to command Left steer direction). If so, go on to Step b.
If one or both of the Encoder Counts is incorrect, use the parameters Swap Encoder1 Direction and/or
Swap Encoder2 Direction. Recheck the Encoder1 Counts and Encoder2 Counts variables and verify that
they both move in the same direction with the correct sign. If problems persist, contact your Doosan
customer support engineer before continuing.

b. Set the parameters Left Stop to Center and Right Stop to Center. These parameters determine how
many revolutions of the command encoders are required to steer between the Left and Right stops.
These values can be calculated based on the encoders’ pulses per revolution (ppr) and the desired
number of revolutions of the steering wheel. Both encoders must have the same ppr.
Another way to set up these parameters is by observing the Encoder1 Counts and Encoder2 Counts
values and steering while observing the change in the encoder counts during one complete revolution of
the steering wheel.
“2” — Setup for Sin/Cos Sensor input (see page 25)
a. Set the parameters Amplitude and Offset according to the sensor manufacturer’s specifications.
Amplitude is usually referred to as Gain in the specs. Amplitude is half the peak-to-peak voltage, and
Offset is the center of the peak-to-peakfrom ground.
If sensor specs are not available, use the voltages shown in the Monitor » Command Input » Analog
Input » Analog1 and Analog3 variables as follows. To calculate the Offset, find the highest and lowest
values of Analog1 and Analog3 while slowly sweeping the command device. Add these two values
together and divide by two. Input this number in the Offset parameter. Next, subtract the lowest value of
Analog1 and Analog3 from the Offset parameter value. Input this number in the Amplitude parameter.
Example: While the command device is moved slowly, Analog1 and Analog3 are shown to have a
maximum voltage of 4.1V and a minimum voltage of 1.9V; therefore,
Offset = 3.0V and Amplitude = 1.1V.
b. Move the Sin/Cos Sensor to the center position and observe the angle shown in the Monitor » Command
Input » Analog Input » Sin/Cos Angle Raw variable. Set the Center Angle to the observed angle. This
parameter must be set before the Left and Right angle parameters are set, because the center angle is
based on the raw reading and normalizes the sin/cos angle for setting up the Left and Right angles.
c. Move the Sin/Cos Sensor to the Left position (not to the actual physical stop, but a small amount away,
to allow for sensor tolerance variation) and observe the angle shown in the Monitor » Command Input »
Analog Input » Sin/Cos Angle variable. If the observed angle was negative, set the Left Angle parameter
to the observed angle.
If the observed angle was positive, change the parameter Swap Direction. Verify that the steer direction
sign is correct (-), and then return to step b to reset the Center Angle parameter. Finally, set the Left
Angle parameter to the observed angle.
d. Move the Sin/Cos Sensor to the Right position (not to the actual physical stop, but a small amount away,
to allow for sensor tolerance variation) and observe the angle shown in the Sin/Cos Angle variable. Set
the Right Angle parameter to the observed angle.
e. Set the two fault parameters (Fault Min and Fault Max) to voltages that will not be reached during normal
operation, but will be reached when the steer command inputs become faulty (e.g., should there be an
open or short circuit).
f. The Tolerance parameter can be set in either of two ways.
1. Obtain the tolerance of the Offset, Gain, and Phase from the manufacturer’s specs, and then calculate
the worst case difference in voltage between the calculated voltages and the measured Analog1 and
Analog3 voltages over the range of the sensor. Set the Tolerance to a comfortable margin above the
maximum calculated difference.
2. Manually lower the Tolerance value while adjusting the Sin/Cos Sensor over the entire output range
until the fault Sin/Cos Command Sensor (Fault Code 47) is generated. Repeat this until you find the
minimum Tolerance value that will not cause the fault (over the entire sensor range). Set the Tolerance
to a comfortable margin above the minimum tolerance found.

Command Map Setup (see page 26)
The fourteen parameters in the Command Map menu define an 8-point map, as described on page 26.
The input to the Command Map (in units of %) can be observed in Monitor » Command Input » Steer Command.
The output to the Command Map (in units of degrees) can be observed in Monitor » Command Input » Steer
Command (deg).
The Left Stop parameter is paired with a value of -100%, and the Right Stop parameter is paired with a value of
100%. The P1-P6 Output values fill in the continuum between the two stops; these values should get positive
when center is crossed. Similarly, the P1-P6 Input parameters should start with negative percent values and
increase to positive percent values. The settings of the point pairs can be customized to shape the map according
to the needs of the application. In general, starting with a linear command map without any deadband is
recommended for vehicles that have the steered wheel in the center.
IMPORTANT: Setting the Left Stop and Right Stop to the correct angle is critical to the setup of the vehicle as
these two parameters set the maximum steering angle.
They must be set before continuing on to set up the position feedback.
Verification of the Command Input Setup

To verify the setup thus far, observe Monitor » Command Input » Steer Command (deg) and Steer Command 2
(deg). If either signal gives an undesired output, you must go back and resolve this problem before continuing.
Observe the variable Monitor » Supervision » Steer Command Error while changing the steer command input; this
will show the difference between Steer Command (deg) and Steer Command 2 (deg). Find the maximum Steer
Command Error, and set the Supervision » Steer Command Tolerance to a comfortable margin above the
maximum Steer Command Error found.
Verification of Steer Motor Encoder 3 Direction

Note: The steer motor should move freely as there should be no power applied to the steer motor. If the steered
wheel cannot move freely and be safely moved (or if the Interlock is On), please stop and resolve the issue.
Use the Monitor » Steer Motor » Motor RPM menu to check the Encoder 3 direction. Rotate the steer motor by
hand and observe the sign of Motor RPM. Positive is Right and negative is Left. If you get a positive Motor RPM
when you rotate the motor in the Right direction and a negative Motor RPM when you rotate the motor in the Left
direction, the Motor » Swap Encoder3 Direction parameter is set correctly and should not be changed.
If you get negative Motor RPM when you rotate the motor in the Right direction, Swap Encoder3 Direction must be
changed. Cycle KSI power and repeat until you are satisfied that Swap Encoder3 Direction is correctly set.
Contact your Doosan customer support engineer to resolve any issues about encoder direction before continuing.
Caution: Continuing with the commissioning procedures will require the steer motor to turn, so you will
have to enable the steer interlock (interlock = On). The vehicle drive wheels should continue to
be jacked up off the ground so they can spin freely and steer freely from stop to stop. Enabling
the steer interlock can result in erratic movement of the steer motor.

Position Feedback Device Setup
Manually enable the steer interlock, so that the 1222 will begin steering; the traction interlock can remain Off.
Verify that the 1222 interlock is now On (Monitor » Interlock » Interlock). If Interlock = Off, resolve the fault
condition that is causing this, change the interlock input to the steer controller, or adjust the Interlock Type
parameter (Vehicle Configuration » Interlock Type) until the Interlock variable = On.
Your steering position feedback device will be a dual potentiometer or a sine/ cosine sensor (both using pins J1-
16and J1-17) or a dual motor encoder with a Home switch (using pins J1-31, J1-32, J1-26, and J1-27 for the
motor encoders and J1-12 for the Home switch).
Set the Position Feedback Device parameter (see pages 27–28):
0 = Pot input
1 = Encoder and Home switch input
2 = Sin/Cos Sensor input
Use the appropriate setup menu for the input you have chosen.
“0” — Setup for Pot input (see page 29)
a. Use the steer command input to move the steered wheel to the Left stop. If the steer motor turns to the
Right when the command is to turn to the Left, shut down the vehicle and disconnect the battery. Swap
any two of the steer motor phase cables (U, V, or W) at the 1222; this will reverse the direction of the
steer motor. Reconnect the battery and retest to confirm that the steer motor now turns to the Left when
commanded to turn Left.
Once the steered wheel has moved to the Left stop, observe the two voltages shown in the Monitor »
Position Feedback » Analog Input » Analog5 and Analog6 variables. Set the parameters Analog5 Left
Stop and Analog6 Left Stop to the observed voltages.
If the steered wheel fails to reach the Left stop because it reaches the Analog5 Left Stop voltage before it
reaches the stop, adjust the Analog5 Left Stop to a value that will allow the Left stop to be reached.
Adjust Analog6 Left Stop similarly, if necessary.
b. Similarly, move the steered wheel to the Center and observe the two voltages shown in the Analog5 and
Analog6 variables. Set the parameters Analog5 Center and Analog6 Center to the observed voltages.
c. Finally, move the steered wheel to the Right stop and observe the two voltages shown in the Analog5
and Analog6 variables. Set the parameters Analog5 Right Stop and Analog6 Right Stop to the observed
voltages.
d. Set the four fault parameters (Analog5 Fault Min, Analog5 Fault Max, Analog6 Fault Min, and Analog6
Fault Max). Set these to voltages that will not be reached during normal operation, but will be reached if
the steer position feedback becomes faulty (e.g., should there be an open or short circuit).
“1” — Setup for Encoder input and Home Switch (see pages 30–31)
a. Set the Input Type, Home on Interlock, and Homing Speed parameters. Homing Speed should be set low
to start.
b. Review the diagrams in the Homing Direction Method parameter description on page 31. Then determine
the correct Homing Direction Method by observing the Monitor » Home Reference » Home variable while
also observing the position of the steered wheel and the Home switch.
If Home = On and the steered wheel is to the right of the Home switch (or Home = Off and steered wheel
is to the leftt), setting Homing Direction Method to either 0 or 1 will result in the correct direction toward
the Home
switch during homing. Choose 0 or 1 depending on which side of the Home switch you prefer the steered
wheel to be on when homing is complete.

If Home = On and the steered wheel is to the left of the Home switch (or Home = Off and steered wheel
is to the right), setting Homing Direction Method to either 2 or 3 will result in the correct direction toward
the Home switch during homing. Choose 2 or 3 depending on which side of the Home switch you prefer
the steered wheel to be on when homing is complete.
After setting the Homing Direction Method, verify that the homing function works correctly starting from
either side of the Home switch.
c. The correct settings for Encoder3 Counts/Degree and Encoder4 Counts/Degree can be either calculated
or determined by testing.
Calculation method:
Encoder Counts/Degree = Gear Ratio * Encoder PPR * 4/360
Note: The factor of 4 in the equation accounts for the number of edges in one encoder pulse (rising
phase A, falling phase A, rising phase B, falling phase B).
Example: Steer motor gearbox ratio = 45:1
Big gear around steer motor = 80 teeth
Small gear around steer motor shaft = 20 teeth
Encoder 3 steps (pulses per revolution) = 32.
The overall Gear Ratio = 45 * 80/20 = 180:1.
Encoder3 Counts/Degree = Gear Ratio * Encoder PPR * 4/360 = 180 * 32 * 4/360 = 64.
Testing method:
Use the steer command input to move the wheel position to a known angle. For best accuracy, choose
a known angle as far as possible from the Home switch; this will usually be either the Left stop or the
Right stop. If you cannot reach the “known angle,” most likely the present setting of Encoder#
Counts/Degree is too high; you can check whether Monitor » Position Feedback » Left Stop Reached
or Right Stop Reached = On. Decreasing the Encoder# Counts/Degree values will move the Left and
Right stops out, allowing more movement of the steered wheel.
When the wheel position reaches the “known angle” (usually either the Left or Right stop), observe the
two variables Monitor » Position Feedback » Encoder Input » Encoder3 Counts from Home and
Encoder4 Counts from Home. Divide these values by the number of degrees between the known angle
and the Home switch to get the Encoder Counts/Degree for both encoders.
Example: Home Switch is at -4°

Left Stop set to 90°
Right Stop set to 90°.
Use the steer command input to steer the wheel to a 90° position. (This is the confirmed physical steer
angle and may not agree with the monitored wheel position variable.) Observe the variables Monitor »
Position Feedback » Encoder Input » Encoder3 Counts from
Home and Encoder4 Counts from Home.
Encoder3 Counts from Home = 6016
Encoder4 Counts from Home = 3008.
6016/90 - (-4) = 6016/94 = 64
So set Encoder3 Counts/Degree = 64.
3008/90 - (-4) = 3008/94 = 32
So set Encoder4 Counts/Degree = 32.
Note: Encoders 3 and 4 can have different counts/degree, either because they have different PPRs or
because Encoder 4 is not a steer motor encoder (e.g., it may be counting teeth of the steering
gear).

“2” — Setup for Sin/Cos Sensor input (see page 32)
a. Set the parameters Amplitude and Offset according to the sensor manufacturer’s specifications.
Amplitude is usually referred to as Gain in the specs. Amplitude is half the peak-to-peak voltage, and
Offset is the center of the peak-to-peak from ground.
If sensor specs are not available, use the voltages shown in the Monitor » Position Feedback » Analog
Input » Analog5 and Analog6 variables as follows. To calculate the Offset, find the highest and lowest
values of Analog5 and Analog6 while slowly sweeping the position feedback device. Add these two
values together and divide by two. Input this number in the Offset parameter. Next, subtract the lowest
value of Analog5 and Analog6 from the Offset parameter value. Input this number in the Amplitude
parameter. Example: While the position feedback device is moved slowly, Analog5 and Analog6 are
shown to have a maximum voltage of 4.1V and a minimum voltage of 1.9V; therefore, Offset = 3.0V and
Amplitude = 1.1V.
b. Use the steer command input to move the steered wheel (and the position feedback Sin/Cos Sensor) to
the center position and observe the angle shown in the Monitor » Position Feedback » Analog Input »
Sin/Cos Position variable. Set the Center Position to the observed angle.
c. Use the steer command input to move the steered wheel (and the position feedback Sin/Cos Sensor) to
the Left position and observe the angle shown in the Monitor » Position Feedback » Wheel Position
variable. The Left steer direction must be set up as negative. If the observed angle is positive, change the
Swap Direction parameter and verify that the wheel position sign is now correct.
d. Set the two fault parameters (Fault Min and Fault Max) to voltages that will not be reached during normal
operation, but will be reached if the steer command inputs become faulty (e.g., should there be an open
or short circuit).
The Fault Min settings must be below the minimum voltage seen on Analog5 or Analog6 when steering
between the maximum left and right positions.
The Fault Max settings must be above the maximum voltage seen on Analog5 or Analog6 when steering
between the maximum left and right positions.
e. The Tolerance parameter can be set in either of two ways.
1. Obtain the tolerance of the Offset, Gain, and Phase from the manufacturer’s specs, and then calculate
the worst case difference in voltage between the calculated voltages and the measured Analog5 and
Analog6 voltages over the range of the sensor. Set the Tolerance to a comfortable margin above the
maximum calculated difference.
2. Manually lower the Tolerance value while adjusting the Sin/Cos Sensor over the entire output range
until the fault Sin/Cos Feedback Sensor (Fault Code 48) is generated. Repeat this until you find the
minimum Tolerance value that will not cause the fault (over the entire sensor range). Set the Tolerance
to a comfortable margin above the minimum tolerance found.
Verification of the Position Feedback Setup

To verify the setup thus far, observe Monitor » Position Feedback » Wheel Position (deg) and Wheel Position 2
(deg) while exercising the steer command input device over the entire operational steer range. If either signal
gives an undesired output, go back and resolve this problem before continuing.
Next, observe the variable Monitor » Supervision » Wheel Position Error while changing the position; this will show
the difference between Wheel Position (deg) and Wheel Position 2 (deg). Find the maximum Wheel Position Error,
and set the Supervision » Wheel Position Tolerance to a comfortable margin above the maximum
Wheel Position Error found.

Set remaining performance and supervision parameters
a. Restore these two parameter values to their desired performance settings:
Motor » Max Speed
Motor » Max Current.
b. Observe Monitor » Battery and Supply » 5v Out and set the following parameter values to a comfortable
margin above and below the observed value:
Supervision » 5V Current Max
Supervision » 5V Current Min.
The 5V Current Min setting should be such that it will detect a disconnected
sensor (pot, encoder, or sine/cosine sensor) in either the steer command or
position feedback circuit. Check the settings by disconnecting a steer command
sensor and verify that a 5v Current Out of Range fault (code 69) is
triggered. Similarly, disconnect a position feedback sensor and verify that a
code 69 fault is triggered.
c. If a Home switch is present, steer across the Home switch while observing Monitor » Supervision » Home
Reference Error. Set Supervision » Home Reference Tolerance to a comfortable margin above the
maximum Home Reference Error found.
d. Temporarily set Steering Sensitivity » LS Sensitivity and HS Sensitivity = 100%.
With this setting, and the drive wheels still jacked up off the ground, set the three parameters in the Motor
Control Tuning menu (see page 42) to get correct responsiveness to the steer command input.
Note: Setting these values too high will result in unstable responsiveness.
Increase these values as high as possible without becoming unstable.
Motor Control Tuning » Position Kp
Motor Control Tuning » Velocity Kp
Motor Control Tuning » Velocity Ki.
After setting these three parameters, return LS Sensitivity and HS Sensitivity to their proper values.
Resolve any existing faults

Cycle the Keyswitch input to reset the vehicle controllers. Check the active faults in the controller and resolve any
faults until all faults have been cleared. All faults must be cleared before lowering the vehicle drive wheels to the
ground. Use Section 6 for help in troubleshooting. Contact your Doosan customer support engineer to resolve any
remaining issues about faults before continuing.
Caution: Do not take the vehicle down off the blocks until both the steer and traction motors are
responding properly. Once the motors are responding properly, lower the vehicle to put the drive
wheels on the ground.
Set the remaining Supervision parameters

Measure the time to steer from the Right stop to the Left stop. Set Supervision » Following Error Time to the time
to steer from stop to stop.
While steering, observe Monitor » Supervision » Following Error. Set Supervision » Following Error Tolerance to a
comfortable margin above the maximum Following Error found. Or, if you prefer, you can lower the Following Error
Tolerance value until a Following Error fault is triggered, and then set the Following Error Tolerance to a
comfortable margin above the setting that began to trigger the fault.
If Position Feedback Device = 1, leave the setting Supervision » Encoder Position Tolerance = 90°. This fault
check is not used when the position feedback devices are encoders, so the setting of 90° disables this fault check.
For all other settings of Position Feedback Device (= 0 or = 2), observe the variable Monitor » Supervision »
Encoder Position Error (deg) while changing the position; this will show the difference between Wheel Position
and Encoder 3 Position. Find the maximum Encoder Position Error (deg), and set Supervision » Encoder Position
Tolerance to provide a comfortable margin above the maximum Encoder Position Error (deg) found.
Set Supervision » Stall Steering Speed and Stall Timeout to appropriate values that will not cause a fault during
normal operation, but will trigger a fault during a real stall condition.

Interface with Master Controller
The 1222 controller is a slave controller. The master controller is a Doosan AC traction controller. The controllers
communicate with each other through the CAN bus.
CAN MESSAGES
The 1222 and the traction controller communicate with each other through
the CAN bus, using PDO messages. The 1222 sends an emergency message
to the traction controller any time a fault is set or cleared.
PDO Message Configuration

The traction controller sends PDO1_MOSI every 20 ms and the steering controller sends both PDO1_MISO and
PDO2_MISO every 20 ms.
PDO1_MOSI — Received from traction controller every 20 ms

Byte 1 — Traction Motor RPMCAN (CAN Index 0x2080, Low Byte)
Byte 2 — Traction Motor RPMCAN (CAN Index 0x2080, High Byte)
Byte 3 — Traction Is Ready (CAN Index 0x2081, Bit 0)
Byte 4 — CAN Interlock (CAN Index 0x4447, Bit 0)
Byte 5 — Unused
Byte 6 — Unused
Byte 7 — Unused
Byte 8 — Unused
PDO1_MISO — Sent by the 1222 every 20 ms when in operational state

Byte 1 — Wheel Position (CAN Index 0x2000, Low Byte)
Byte 2 — Wheel Position (CAN Index 0x2000, High Byte)
Byte 3 — 0 (Reserved)
Byte 4 — Traction Cutback (CAN Index 0x2003)
Byte 5 — Traction Fault Action (CAN Index 0x2005)
Byte 6 — Enable Traction (CAN Index 0x2001)
Byte 7 — 0
Byte 8 — 0
PDO2_MISO — Sent by the 1222 every 20 ms when in operational state

Byte 1 — Enable Traction Inverted (CAN Index 0x2002)
Byte 2 — Traction Cutback Inverted (CAN Index 0x2004)
Byte 3 — Switches (CAN Index 0x4475)
Byte 4 — 0
Byte 5 — 0
Byte 6 — 0
Byte 7 — 0
Byte 8 — 0

Traction Motor RPMCAN is the rpm of the traction motor and can be used to determine when to steer (see
Interlock Enabled Speed, page 35).
Traction Is Ready is used if programmed Contactor Type = 2; it has bit 0 = contactor is open, and bit 1 =
contactor is closed.
CAN Interlock is the interlock from the traction system that is used if programmed Interlock Type = 3; it has bit 0
= interlock is open, and bit 1 = interlock is closed.
Wheel Position is the position of the steered wheel, in degrees. This is used by the traction system to determine
the maximum allowed speed.
Traction Cutback is the percentage of its Max Speed that the traction controller is allowed to run.
Traction Fault Action has bit 0 = no fault, bit 1 = stop traction, bit 2 = reduce traction speed, and bit 3 = no action.
See right-hand column in the troubleshooting chart (Table 6).
Enable Traction has bit 0 = stop and bit 1 = traction enabled.
Enable Traction Inverted is the inverse of Enable Traction.
Traction Cut back Inverted is the inverse of Traction Cutback.
Switches has bit 0 = Interlock Input 1, bit 1 = Home Input 2, bit 2 = Interlock
Input 3, and bit 3 = Home Input 4.
Emergency Message Configuration
The 1222 sends an emergency message any time a fault is set or cleared. For a description of the variables see
the troubleshooting chart (Table 6) and the generic Doosan CAN open specification.
Byte 1 — Error Code (Low Byte)

Byte 2 — Error Code (High Byte)
Byte 3 — Error Register (CAN Object 0x1001)
0x01 if any fault is present or 0x00 is no faults
Byte 4 — Sub Code See the troubleshooting chart
Byte 5 — Flash Code See the troubleshooting chart
Byte 6 — Traction Fault Action See the troubleshooting chart
Byte 7 — Reserved
Byte 8 — Reserved

GENERIC AC TRACTION CONTROLLER SOFTWARE
IMPORTANT: Review your application’s needs carefully to ensure they are met by the conditions described below
and the signal flow diagram presented in Figure 14. If they are not, contact your local Doosan
representative for assistance in reconfiguring the software.
The bulleted items below are based on AC_Traction_with_1222.vcl software features description for VCL App
Version = 2.00.
• The 1222 software is limited to traction applications that use Speed Mode or Speed Mode Express. If your AC
controller uses Torque Mode, you will need to make changes in the software. Contact your local Doosan
representative.
• You must use 1222 software version OS 12.0 or later; earlier versions will not work.
• Steering CAN Comm Failure (AC controller fault code 51) is set when:
– AC controller is unable to receive a CAN heartbeat from the 1222 on startup
– neither PDO1_MISO nor PDO2_MISO arrives within 50 msec (PDO Timeout)
– redundant 1222 CAN data (from PDO1_MISO and PDO2_MISO) mismatches for more than 100 ms.
• Severe Steering Fault (code 52) is set when the traction fault action sent from the 1222 to the AC controller (in
either a PDO1_MISO or an emergency message) indicates Stop Traction (=1).
• Steering Fault (code 53) is set when the traction fault action sent from the 1222 to the AC controller (in either a
PDO1_MISO or an emergency message) indicates Reduce Traction Speed (=2) or No Action (=3).
• The generic AC traction controller software contains a traction speed reduction map with the wheel position
angle at different forward and reverse maximum speeds.
• PDO1_MOSI messages are sent every 20 msec; if you want a different frequency, you will need to change the
AC traction controller software.
• The 1222 Traction Cutback (from PDO1_MISO) will reduce the traction speed by reducing the throttle
command. This method of traction speed reduction means that the traction Emergency Reverse function will
not be speed-reduced by the 1222 Traction Cutback data.
Note: The AC controller’s Analog Output (pin 30) can be connected to the Doosan 1165 wheel position indicator
to display the 1222 wheel position from PDO1_MISO.

Diagnostics & Troubleshooting
The 1222 controller detects a wide variety of fault conditions. Faults with the steering controller typically affect the
traction controller as well, as shown in the troubleshooting chart.
Diagnostics
Diagnostics information can be obtained in either of two ways: (1) by reading the display on a handheld
programmer or (2) by observing the fault codes issued by the Status LEDs. See Table 4 for a summary of LED
display formats.
The handheld programmer will display all faults that are currently set as well as a history of the faults that have
been set since the history log was last cleared. The programmer displays the faults by name.
The pair of LEDs built into the controller (one red, one yellow) produce flash codes displaying all the currently set
faults in a repeating cycle. Each code consists of two digits. The red LED flashes once to indicate that the first
digit of the code will follow; the yellow LED then flashes the appropriate number of times for the first digit. The red
LED flashes twice to indicate that the second digit of the code will follow; the yellow LED flashes the appropriate
number of times for the second digit.
Example: Command Analog3 Out of Range (code 42).
In the Fault menu of the handheld programmer, the words Command

Analog3 Out of Range will be displayed; the actual voltage is
displayed in the Monitor menu (Command Input » Analog Input »
Analog 3).
The controller’s two LEDs will display this repeating pattern:
The numerical codes used by the yellow LED are listed in the troubleshooting chart (Table 6), which also lists
possible fault causes and describes the conditions that set and clear each fault.

Summary of LED display formats
The two LEDs have four different display modes, indicating the type of information they are providing.
Table 5 TYPES OF LED DISPLAY
DISPLAY STATUS
Neither LED illuminated Controller is not powered on; or vehicle has

dead battery; or severe damage.
Yellow LED flashing Controller is operating normally.
Both LEDs on solid Controller is in Flash program mode.
Red LED and yellow LED Controller has detected a fault. 2-digit code
flashing alternately flashed by yellow LED identifies the specific
fault; one or two flashes by red LED indicate
whether first or second code digit will follow.
Troubleshooting
The troubleshooting chart, Table 6, provides the following information about each controller fault:
• fault code and sub-code
• fault name as displayed on the programmer’s LCD
• possible causes of the fault
• fault set conditions and fault clear conditions
• steer fault action (effect of fault on steering)
• traction fault action (effect of fault on traction)
For each fault, the chart shows one of these four Steer Fault actions:
Warning Only — The 1222 still operates normally.
Shutdown — Immediate shutdown of the 1222 and turn-off of the fault output (pin 23).
Warning then Shutdown — The 1222 continues to operate until the traction motor comes to a stop or the timer
(set by Fault Steering Timeout) expires. After this occurs, the Shutdown action takes
place.
Hold then Shutdown — The 1222 tries to hold the existing wheel position regardless of operator input until the
traction motor comes to a stop or the timer (set by Fault Steering Timeout) expires. After
this occurs, the Shutdown action takes place.
Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off KSI and turn it back on to
see if the fault clears. If it does not, shut off KSI and remove the 35-pin connector. Check the connector for
corrosion or damage, clean it if necessary, and re-insert it.

Table 6 TROUBLESHOOTING CHART
STEER TRACTION
FLASH SUB SET CLEAR
NAME POSSIBLE CAUSE FAULT FAULT
CODE CODE CONDITION CONDITION
ACTION ACTION
11 1 Hardware An internal hardware error Hardware error Cycle KSI. Shutdown. 1 = Stop.
Fault has been detected; detected.
controller defective.
12 1 Controller 1. External short of Controller Cycle KSI. Shutdown. 1 = Stop.
Overcurre phase U, V, or W hardware
nt 1 motor connection. detected
2. Controller defective. overcurrent
condition.
12 2 Controller 1. External short of 1. Phase current > Cycle KSI. Shutdown. 1 = Stop.
Overcurre phase U, V, or 120% of base
nt 2 Wmotor connection. current limit.
2. Motor parameters 2. Phase current
are mis-tuned. exceeded the
3. Controller defective. current
measurement
limit.
13 1 Current 1. Leakage to vehicle Controller Cycle KSI. Shutdown. 1 = Stop.
Sensor frame from phase U, current
Fault V, or W (short in sensors have
motor stator). invalid offset
2. Controller defective. reading.
14 1 Precharge 1. External load on Capacitor bank Cycle KSI. Shutdown. 1 = Stop.
capacitor bank (B+ voltage does
connection terminal) not complete
that prevents the the charge to
capacitor bank from minimum of
charging. 75% of the
2. Controller defective. keyswitch
voltage.
15 1 Controller Controller is operating Controller heatsink Bring Warning 3 = No action.
Severe in an extreme temperature is heatsink Only.
Undertemp environment. equal temp above
to or below - -35°C.
40°C.
16 1 Controller 1. Improper mounting Controller Cycle KSI. Warning 1 = Stop.
Severe of controller. heatsink then
Overtemp 2. Excessive load on temperature is Shutdown.
vehicle. equal
3. Controller is operating in an to or above
extreme environment. 95°C.
17 1 Severe 1. Battery or battery Capacitor bank Cycle KSI. Shutdown. 1 = Stop.
Undervoltage cables or battery voltage (B+
connections terminal)
defective. less than 12 V
2. Excessive non- when Interlock
controller system = On.
drain on battery.
3. Battery disconnected
while driving.
4. Blown B+ fuse or
steer contactor did
not close.

STEER TRACTION
FLASH SUB SET CLEAR
ACTION ACTION
18 1 Severe 1. Battery or battery Keyswitch or Cycle KSI. Shutdown. 1 = Stop.

Overvoltage cable resistance too capacitor
high for a given voltage (B+
regen current. terminal)
2. Battery disconnected greater than
while regen braking. 65 V.
22 1 Controller 1. Improper mounting Controller Heatsink Warning 2 = Reduce
Overtemp or cooling of heatsink temp< 85°C. Only. speed.
controller. temperature is (Max speed
2. Excessive load on equal to or reduced
vehicle. above 85°C. linearly from
3. Controller operating 100% at
in an extreme 85°C to 0%
environment. at 95°C.)
25 1 5V Supply External load 5V supply is Cycle KSI. Hold then 1 = Stop.
Failure impedance on the +5V outside the 5V Shutdown.
supply is too low. +/- 10% range.
26 1 10V External load 10V supply is Cycle KSI. Warning 1 = Stop.
Supply impedance on the +10V outside the then
Failure supply is too low. 10V +/- 10% Shutdown.
range.
27 1 Severe External load Sensor Enable Cycle KSI. Warning 1 = Stop.
Motor impedance on the +10V = On and steer then
Overtemp supply is too low. motor Shutdown.
temperature >
programmed
Temperature
Max.
28 1 Severe 1. Motor is operating in Sensor Enable Steer motor Warning 2=Reduce
Motor an extreme = On and steer temperature Only. speed.(Max
Hot environment. motor <programme speedreduced
Cutback 2. Motor Temperature temperature > d linearlyfrom100%
Control parameters programmed Temperature at Temperature
are mis-tuned. Temperature Hot. Hotto0%at
Hot. Temperature
Max.)
29 1 Motor 1. Motor thermistor is Motor Motor temp Warning 2 = Reduce
Temp not connected temperature input within Only. speed. (Max
Sensor properly. input is at the the normal speed
Fault 2. If the application voltage operating reduced to
does not use a motor rail (0 or 5V). range. Sensor Fault
thermistor, the Motor Traction
Temperature Cutback.)
Sensor Enable
parameter should be
programmed Off.
31 1 Contactor 1. Open or short on Steer contactor Cycle KSI. Warning 1 = Stop.
Open/Short driver load. driver is either open then
2. Dirty connector pins. or shorted. Thisfault Shutdown.
3. Bad crimps or faulty is set only when
wiring. Contactor
Control Type =
1 and Checks
STEER TRACTION
FLASH SUB SET CLEAR
ACTION ACTION
Enable = On.
35 1 Fault 1. External load The controller Cycle KSI. Warning 1 = Stop
Output impedance on the is unable to then
Open/Short fault output is too assert the fault Shutdown.
low. output line. If
2. Controller defective. the Fault
Output = On
and the fault
output voltage
is not within 5
V of the KSI
voltage, the
fault is set.
36 1 Motor 1. Stalled steer motor. The motor has Cycle KSI. Warning 1 = Stop.
Stalled 2. Steer motor encoder been then
failure. commanded to Shutdown.
3. Bad crimps or faulty move at more
wiring. than 25% of
4. Problems with power the Max Motor
supply of the steer Speed or at
motor encoder. more than
95% of the
available
motor current
when the
motor speed is
less than
the
programmed
Stall Speed for
the
programmed
Stall Time.

STEER TRACTION
FLASH SUB POSSIBLE CLEAR
NAME SET CONDITION FAULT FAULT
CODE CODE CAUSE CONDITION
ACTION ACTION
37 1 Motor 1. Motor phase 1. After the steer Cycle KSI. Warning 1 = Stop.
Open is open. contactor closes but then
2. Bad crimps before operation starts, Shutdown.
or faulty the motor is checked
motor cable for an open phase by
wiring. running a DC current
3. Controller out of phase U and
defective. ensuring the current is
measured back on
both phase V and
phase W. The fault is
set if the check fails.
2. When the motor is
running, one phase
averages less than 1 A
while the other phases
average more than 4 A
for 256 msec when the
electrical frequency is
greater than 1 Hz and
has not changed sign.
38 1 Contactor 1. Steer The steer contactor tips Cycle KSI. Shutdown 1 = Stop.
Welded contactor are shorted when the
tips are contactor is supposed to
welded be open. This fault is set
closed. only when Contactor
2. An Control Type = 1 and
alternative Checks Enable = On.
voltage path The weld check is done
(such as an in Steer Contactor State
external = 3 (Opening) when DC
precharge current is applied to the
resistor) is motor. The fault will be
providing a set if the difference
current to between the capacitor
the bank and keyswitch
capacitor voltages does not exceed
bank (B+ 2 V.
terminal).
39 1 Contactor 1. Steer The steer contactor was Cycle KSI. Warning 1 = Stop.
Opened contactor closed, but detected then
was closed open. This fault is set Shutdown.
temporarily, only when Contactor
but then
Control Type = 1 and
opened.
Checks Enable = On. In
2. Steer
contactor Contactor State = 2
tips are (Closed), the fault will be
oxidized. set if the capacitor bank
3. An external and keyswitch voltages
load on the differ by more than 5 V.
capacitorba
nk (B+
terminal)
that

STEER TRACTION
ACTION ACTION
prevents the
bank from
charging.
39 2 Contactor 1. Steer The steer contactor did Cycle KSI. Shutdown. 1 = Stop.
Did Not contactor not close when
Close did not commanded. This fault is
close. set only when Contactor
2. Steer Control Type = 1 and
contactor Checks Enable = On. In
tips are Contactor State = 1
oxidized. (Closing), the fault will be
3. An external set if the capacitor bank
load on the and keyswitch voltages
capacitor differ by more than 2 V.
bank (B+
terminal)
that
prevents the
bank from
charging.
41 1 Command Command Analog1 voltage > Cycle KSI. Shutdown. 1 = Stop.
Analog1 input device’s Analog1 Fault Max or
Out of Analog 3 input Analog1 voltage <
Range (pin 8) is out of Analog1 Fault Min. The
range. fault is checked only if
Command Input Device =
0 or 2.
42 1 Command Command Analog1 voltage > Cycle KSI. Shutdown. 1 = Stop.
Analog3 input device’s Analog1 Fault Max or
Out of Analog 3 input Analog1 voltage <
Range (pin 19) is out Analog1 Fault Min. The
of range. fault is checked only if
Command Input Device =
0 or 2.
43 1 Feedback Position Analog5 voltage > Cycle KSI Shutdown. 1 = Stop.
Analog5 feedback Analog5 Fault Max or
Out of device’s Analog5 voltage <
Range Analog 5 input Analog5 Fault Min. The
(pin 16) is out fault is checked only if
of range. Position Feedback
Device = 0 or 2.
44 1 Feedback Position Analog6 voltage > Cycle KSI. Shutdown. 1 = Stop.
Analog6 feedback Analog6 Fault Max or
Out of device’s Analog6 voltage <
Range Analog 6 input Analog6 Fault Min. The
(pin 17) is out fault is checked only if
of range. Position Feedback
Device = 0 or 2.
46 1 EEPROM 1. New Error in EEPROM CRC Cycle KSI. Shutdown. 1 = Stop.
Failure software calculation.
loaded into
EEPROM
memory.
2. Controller

STEER TRACTION
ACTION ACTION
defective.
47 1 Sin/Cos 1. Sin/Cos The Analog 1 and Analog Cycle KSI. Shutdown. 1 = Stop.
Command Sensor 3 inputs do not match the
Sensor defective. expected sine and cosine
2. Sin/Cos signals.
Sensor They must be within the
parameters parameter Fault Volts of
are mis- the ideal waveform as
tuned. defined by the Gain and
Offset parameters.
48 1 Sin/Cos 1. Sin/Cos The Analog 5 and Analog Cycle KSI. Shutdown 1 = Stop.
Feedback Sensor 6 inputs do not match the
Sensor defective. expected sine and cosine
2. Sin/Cos signals.
Sensor They must be within the
parameters parameter Fault Volts of
are mis- the ideal waveform as
tuned. defined by the Gain and
Offset parameters.
49 1 Parameter A parameter 1. A parameter was Cycle KSI. Shutdown. 1 = Stop.
Change value or the changed that requires
Fault software was a power cycle.
changed that 2. A new software
required a application was loaded
power cycle. that caused the
This fault is set parameter values to be
automatically overwritten, requiring a
to force the power cycle.
vehicle 3. A device using the
operator to serial interface
cycle power, (such as the 1313) is
for safety requesting an
purposes. out-of-range parameter
change.
51 1 Interlock 1. When the Interlock Input 1 = Interlock Interlock = 1 = Stop.
Switch interlock Interlock Input 3. Input Off.
Supervision switch The fault is checked only 1 <>
inputs are a when Interlock Interlock
Type = 2 (crossed Input 3.
crossed
polarity).
configuratio
n (N.O. and
N.C.), the
two inputs
are
checked.
A fault is set
if Switch 1
(pin 9) =
Switch 3
(pin 11).
2. Interlock
switch

STEER TRACTION
ACTION ACTION
defective.
52 1 Home 1. When the 1. Homing Input Type = 1 Cycle KSI. Warning 1 = Stop.
Switch wheel (crossed polarity) and then
Supervisio position is Switch2 = Switch4 and Shutdown.
n not close to the position from home
home, the is >5°.
redundant 2. Homing Input Type = 2
home switch (same polarity) and
inputs are Switch2 <> Switch4
checked and and the position from
a fault is set home is >5°.
if they
disagree.
2. Home
switch
defective.
53 1 Home Home switch During homing (Steer Cycle KSI. Shutdown. 1 = Stop.
Position defective. Command State = 2), the
Not Found home position was not
found after traveling 180°
or within the programmed
Following Error Time.
54 1 Home Home switch During steering (Steer Cycle KSI. Warning 1 = Stop.
Reference defective. Command State = 4), the Only.
Tolerance wheel position at which
Fault the Home variable
changes is further than
the parameter
Supervision » Home
Reference Tolerance
from the original position
found during homing.
55 1 Steer Command Steer Command differs Cycle KSI. Hold then 1 = Stop.
Command input device from Steer Command2 Shutdown.
Supervision defective. by more than the
programmed Steer
Command Tolerance.
These command signals
are checked by both the
main and supervisor
processors if the Device
State = 5 (Operation
Enabled).
56 1 Wheel Position 1. Wheel Position differs Cycle KSI. Hold then 1 = Stop.
Position feedback from Wheel Position2 Shutdown.
Supervision device by more than the
defective. Wheel Position
Tolerance for 80 msec.
These feedback
signals are checked by
both the main and
supervisor processors
if the Device State = 5

STEER TRACTION
ACTION ACTION
2. Wheel Position differs
from Encoder3 Position
by more than the
Encoder Position
Tolerance. These
feedback signals are
checked by only the
main processor if the
Device State = 5
69 1 5V Current The external The measured current of Cycle KSI. Hold then 1 = Stop.
Out of load on the 5V the +5V supply (pins 21 Shutdown.
Range supply and 34) is less than the
is drawing parameter 5V Current
either too Min or greater than the
much or too parameter 5V Current
little Max.
current.
71 1 Software 1. Software Internal watchdog reset. Cycle KSI. Shutdown. 1 = Stop.
Fault 1 defective.
2. Controller
defective.
71 2 Software 1. Software Unexpected software Cycle KSI. Shutdown. 1 = Stop.
Fault 2 defective. value.
2. Controller
defective.
71 3 Software 1. Software 1. Value out-of-range. Cycle KSI. Shutdown. 1 = Stop.
Fault 3 defective. 2. Parameter CRCs do
2. Controller not match.
defective.
71 4 Software 1. Software Task overrun. Cycle KSI. Shutdown. 1 = Stop.
Fault 4 defective.
2. Controller
defective.
71 5 Software 1. Software An internal micro-to- Cycle KSI. Shutdown. 1 = Stop.
Fault 5 defective. micro communication
2. Controller error.
defective.
72 1 PDO1 Communicatio Time between PDO1 Cycle KSI. Warning 1 = Stop.
Timeout n between the messages received then
traction exceeds the PDO1 Shutdown.
controller and TimeoutTime.
the 1222
halted.
73 1 Following 1. Position This fault is checked by Cycle KSI. Warning 1 = Stop.
Error feedback the supervisor then
device micro only when the Shutdown.
defective. Steering Command State
2. Steer motor = 4 (Steering). A fault is
stalled. set if the absolute value
3. Steer motor of the difference between
encoder Steer Command2 and

STEER TRACTION
ACTION ACTION
failed. Wheel Position2 is
greater than the
parameter Following
Error Tolerance for
Following Error Time.
74 1 Hardware 1. New 1. The software is not Cycle KSI. Shutdown. 1 = Stop.
Software software compatible with the
Mismatch loaded. controller hardware.
2. Controller 2. The software loaded
hardware into either or both
cannot use microprocessors in
the loaded incorrect.
software.
75 1 Parameter Parameter Device » Command Input Cycle KSI. Shutdown. 1 = Stop.
Conflict settings are in Device = 1 and Vehicle
conflict with Configuration » Traction
each other. Speed Input » Input Type
= 1.

Maintenance
There are no user serviceable parts in Doosan 1222 controllers. No attempt should be made to open, repair, or
otherwise modify the controller. Doing so may damage the controller and will void the warranty.
It is recommended that the controller and connections be kept clean and dry and that the controller’s fault history
file be checked and cleared periodically.
Cleaning
Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control
problems created by dirt, grime, and chemicals that are part of the operating environment and that normally exist
in battery powered systems.
CAUTION: When working around any battery powered system, proper safety precautions should be taken. These
include, but are not limited to: proper training, wearing eye protection, and avoiding loose clothing and
jewelry.
Use the following cleaning procedure for routine maintenance. Never use a high pressure washer to clean the
controller.
1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil) across the
controller’s B+ and Bterminals.
3. Remove any dirt or corrosion from the power and signal connector areas. The controller should be wiped
clean with a moist rag. Dry it before reconnecting the battery.
4. Make sure the connections are tight. Refer to Section 2, page 6, for maximum tightening torque specifications
for the battery and motor connections.
Fault History
The handheld programmer can be used to access the controller’s fault history file. The programmer will read out
all the faults the controller has experienced since the last time the fault history file was cleared. Faults such as
contactor faults may be the result of loose wires; contactor wiring should be carefully checked. Faults such as
overtemperature may be caused by operator habits or by overloading.
After a problem has been diagnosed and corrected, it is a good idea to clear the fault history file. This allows the
controller to accumulate a new file of faults. By checking the new fault history file at a later date, you can readily
determine whether the problem was indeed fixed.

APPENDIX A. Vehicle Design Considerations
Regarding Electromagnetic Compatibility (EMC) and Electrostatic Discharge (ESD)
Electromagnetic Compatibility (EMC)

Electromagnetic compatibility (EMC) encompasses two areas: emissions and immunity. Emissions are radio
frequency (RF) energy generated by a product. This energy has the potential to interfere with communications
systems such as radio, television, cellular phones, dispatching, aircraft, etc. Immunity is the ability of a product to
operate normally in the presence of RF energy.
EMC is ultimately a system design issue. Part of the EMC performance is designed into or inherent in each
component; another part is designed into or inherent in end product characteristics such as shielding, wiring, and
layout; and, finally, a portion is a function of the interactions between all these parts. The design techniques
presented below can enhance EMC performance in products that use Doosan motor controllers.
Emissions
Signals with high frequency content can produce significant emissions if connected to a large enough radiating
area (created by long wires spaced far apart). Contactor drivers and the motor drive output from Doosan
controllers can contribute to RF emissions. Both types of output are pulse width modulated square waves with fast
rise and fall times that are rich in harmonics. (Note: contactor drivers that are not modulated will not contribute to
emissions.) The impact of these switching waveforms can be minimized by making the wires from the controller to
the contactor or motor as short as possible and by placing the wires near each other (bundle contactor wires with
Coil Return; bundle motor wires separately).
For applications requiring very low emissions, the solution may involve enclosing the controller, interconnect wires,
contactors, and motor together in one shielded box. Emissions can also couple to battery supply leads and throttle
circuit wires outside the box, so ferrite beads near the controller may also be required on these unshielded wires
in some applications. It is best to keep the noisy signals as far as possible from sensitive wires.
Immunity
Immunity to radiated electric fields can be improved either by reducing overall circuit sensitivity or by keeping
undesired signals away from this circuitry. The controller circuitry itself cannot be made less sensitive, since it
must accurately detect and process low level signals from sensors such as the throttle potentiometer. Thus
immunity is generally achieved by preventing the external RF energy from coupling into sensitive circuitry. This RF
energy can get into the controller circuitry via conducted paths and radiated paths.
Conducted paths are created by the wires connected to the controller. These wires act as antennas and the
amount of RF energy coupled into them is generally proportional to their length. The RF voltages and currents
induced in each wire are applied to the controller pin to which the wire is connected. Doosan controllers include
bypass capacitors on the printed circuit board’s throttle wires to reduce the impact of this RF energy on the
internal circuitry. In some applications, additional filtering in the form of ferrite beads may also be required on
various wires to achieve desired performance levels.
Radiated paths are created when the controller circuitry is immersed in an external field. This coupling can be
reduced by placing the controller as far as possible from the noise source or by enclosing the controller in a metal
box. Some Doosan controllers are enclosed by a heatsink that also provides shielding around the controller
circuitry, while others are partially shielded or unshielded. In some applications, the vehicle designer will need to
mount the controller within a shielded box on the end product. The box can be constructed of just about any metal,
although steel and aluminum are most commonly used.
Most coated plastics do not provide good shielding because the coatings are not true metals, but rather a mixture
of small metal particles in a non-conductive binder. These relatively isolated particles may appear to be good
based on a dc resistance measurement but do not provide adequate electron mobility to yield good shielding
effectiveness. Electroless plating of plastic will yield a true metal and can thus be effective as an RF shield, but it
is usually more expensive than the coatings.
A contiguous metal enclosure without any holes or seams, known as a Faraday cage, provides the best shielding
for the given material and frequency. When a hole or holes are added, RF currents flowing on the outside surface
of the shield must take a longer path to get around the hole than if the surface was contiguous. As more “bending”
is required of these currents, more energy is coupled to the inside surface, and thus the shielding effectiveness is
reduced. The reduction in shielding is a function of the longest linear dimension of a hole rather than the area.
This concept is often applied where ventilation is necessary, in which case many small holes are preferable to a
few larger ones.
Applying this same concept to seams or joints between adjacent pieces or segments of a shielded enclosure, it is

important to minimize the open length of these seams. Seam length is the distance between points where good
ohmic contact is made. This contact can be provided by solder, welds, or pressure contact. If pressure contact is
used, attention must be paid to the corrosion characteristics of the shield material and any corrosion-resistant
processes applied to the base material. If the ohmic contact itself is not continuous, the shielding
effectiveness can be maximized by making the joints between adjacent pieces
overlapping rather than abutted.
The shielding effectiveness of an enclosure is further reduced when a wire passes through a hole in the enclosure;
RF energy on the wire from an external field is re-radiated into the interior of the enclosure. This coupling
mechanism can be reduced by filtering the wire where it passes through the shield boundary.
Given the safety considerations involved in connecting electrical components to the chassis or frame in battery
powered vehicles, such filtering will usually consist of a series inductor (or ferrite bead) rather than a shunt
capacitor. If a capacitor is used, it must have a voltage rating and leakage characteristics that will allow the end
product to meet applicable safety regulations.
The B+ (and B-, if applicable) wires that supply power to a control panel should be bundled with the other control
wires to the panel so that all these wires are routed together. If the wires to the control panel are routed separately,
a larger loop area is formed. Larger loop areas produce more efficient antennas which will result in decreased
immunity performance.
Keep all low power I/O separate from the motor and battery leads. When this is not possible, cross them at right
angles.
Electrostatic Discharge (ESD)

Doosan motor controllers contain ESD-sensitive components, and it is therefore necessary to protect them from
ESD (electrostatic discharge) damage. Most of these control lines have protection for moderate ESD events, but
must be protected from damage if higher levels exist in a particular application.
ESD immunity is achieved either by providing sufficient distance between conductors and the ESD source so that
a discharge will not occur, or by providing an intentional path for the discharge current such that the circuit
is isolated from the electric and magnetic fields produced by the discharge. In general the guidelines presented
above for increasing radiated immunity will also provide increased ESD immunity.
It is usually easier to prevent the discharge from occurring than to divert the current path. A fundamental
technique for ESD prevention is to provide adequately thick insulation between all metal conductors and the
outside environment so that the voltage gradient does not exceed the threshold required for
a discharge to occur. If the current diversion approach is used, all exposed metal components must be grounded.
The shielded enclosure, if properly grounded, can be used to divert the discharge current; it should be noted that
the location of holes and seams can have a significant impact on ESD suppression. If the enclosure is not
grounded, the path of the discharge current becomes more complex and less predictable, especially if holes and
seams are involved. Some experimentation may be required to optimize the selection and placement of
holes, wires, and grounding paths. Careful attention must be paid to the control panel design so that it can tolerate
a static discharge.
MOV, transorbs, or other devices can be placed between B- and offending wires, plates, and touch points if ESD
shock cannot be otherwise avoided

APPENDIX B. Programming Devices
Doosan programmers provide programming, diagnostic, and test capabilities for the 1222 controller. The power for
operating the programmer is supplied by the host controller via a 4-pin connector. When the programmer powers
up, it gathers information from the controller.
Two types of programming devices are available: the 1314 PC Programming Station and the 1313 handheld
programmer. The Programming Station has the advantage of a large, easily read screen; on the other hand, the
handheld programmer (with its 45×60mm screen) has the advantage of being more portable and hence
convenient for making adjustments in the field.
Both programmers are available in User, Service, Dealer, and OEM versions. Each programmer can perform the
actions available at its own level and the levels below that—a User-access programmer can operate at only the
User level, whereas an OEM programmer has full access.
PC Programming Station (1314)

The Programming Station is an MS-Windows 32-bit application that runs on a standard Windows PC. Instructions
for using the Programming Station are included with the software.
Handheld Programmer (1313)

The 1313 handheld programmer is functionally equivalent to the PC Programming Station; operating instructions
are provided in the 1313 manual.
This programmer replaces the 1307 and 1311, earlier models with fewer functions.
Programmer Functions
Programmer functions include:
Parameter adjustment — provides access to the individual programmable parameters.

Monitoring — presents real-time values during vehicle operation; these include all inputs and outputs.
Diagnostics and troubleshooting — presents diagnostic information, and also a means to clear the fault history file.
Programming — allows you to save/restore custom parameter settings files and also to update the system
software (not available on the 1307 or 1311).
Favorites — allows you to create shortcuts to your frequently-used adjustable parameters and monitor variables
(not available on the 1307 or 1311).

APPENDIX C. Specifications
Table D-1 SPECIFICATIONS: 1222 CONTROLLERS
Nominal input voltage 24 – 48 V

PWM operating frequency 16 kHz
Maximum encoder frequency 10 kHz
Maximum controller output frequency 200 Hz
Electrical isolation to heatsink 500 V (minimum)
Storage ambient temperature range -40°C to 95°C (-40°F to 203°F)

Operating ambient temperature range -40°C to 50°C (-40°F to 122°F)
Internal heatsink operating temp. range -40°C to 95°C (-40°F to 203°F)
Package environmental rating IP65 per IEC 529

(Note: Compliance requires AMPSEAL 35-pin connector header)
Weight 1.3 kg (3.0 lbs)
Dimensions, W× L×H 146 × 164 × 60 mm (5.7" × 6.5" × 2.3")
EMC Designed to the requirements of EN 12895.
Safety Designed to the requirements of EN 1175-1:1998, EN 954-1

category 3.
ISO 20898:2008 and EN ISO 13849-1 pending.
UL UL583 recognized component (pending).

Note: Regulatory compliance of the complete vehicle system with the controller installed is the responsibility
of the OEM.
NOMINAL
2 MIN RATING CONTINUOUS LIFETIME RATING
MODEL NUMBER BATTERY VOLTAGE
(amps) RATING (amps) (hours)
(volts)
1222-51XX 24-48 70 40 20,000
Notes: All current ratings are rms values per motor phase. Internal algorithms automatically reduce maximum
current limit when heatsink temperature is >85°C or battery voltage is outside the allowed limits. Heatsink
temperature is measured internally near the power MOSFETs.
The 2-minute rating is based on an initial controller heatsink temperature of 25°C and a maximum heatsink
temperature of 85°C. No additional external heatsink is used for the 2-minute rating test.
Operation at or below the continuous rating is required to achieve the lifetime rating.
Ratings are based on the more conservative result of an airflow test and a power capacitor lifetime
calculation. For the airflow test, the controller is mounted on a 6mm thick square steel plate (0.25m2) in a
6km/hr airflow at 25°C temperature. Rated current is when the controller baseplate temperature reaches
85°C (thermal cutback). The capacitor lifetime calculation assumes internal controller
temperature = 70°C (same as baseplate temperature), modulation index = 60%, and power factor = 0.866.

AC MOTOR
Main Service Parts
NO. Description Qt'y
1. Rotor Ass’y 1
2. Stator Ass’y 1
3. Endbell de. 1
4. Endbell 1
5. Block, Terminal-A 1
6. Speed Sensor Kit 1
7. Bolt, Stud 4
8. Protector, Terminal 1
9 Bearing 1
10 Key, Woodruff 1

Inspection
Rotor
- Rotor should always be cleaned with compressed air.
If the dirt will not come off lightly wipe off with piece of
cotton or soft cloth wetted with gasoline
- Rotor Out Diameter : ø 123.1 ± 0.05(Drive / Pump)
- Tool : Vernier Calipers and Standard Tool
Stator
- Stator should always be cleaned with compressed air.
If the dirt will not come off lightly wipe off with piece of
cotton or soft cloth wetted with gasoline, using care
not to damage the coil insulation.
- Use mmΩ tester and check for two power line of
Stator repeatedly (U-V, V-W, W-U)
At that time Resistance is around
=> Drive Motor : 7.10 mmΩ
=> Pump Motor : 3.50 mmΩ
- Insulation Test
Use Insulation tester (1000Vac, Min. 10MΩ) and
measure as a picture. If the insulation is defective,
replace with new parts

Disassembly
- Before disassembling motor, remove Terminal Protector from the motor and separate Thermistor and
Speed Sensor connectors from hanger.
- Remove 3-Nuts from terminal block of the motor to

disassemble terminal block from the Motor.
- Remove 4 screw fixing Speed Sensor on the Enbell

side and then disassemble Speed sensor, fixed Nut
and toothed wheel of the motor.
- Remove 4 flange nuts with available General tool

on the Endbell Drive side.

- Remove Endbell de and wave washer.
- Remove Stator Assembly by hand or suitable tool.
(Removing Endbell)
(Removing Stator)
- Remove Endbell from Rotor Assembly by Hand-puller as a above picture.
- The motor are composed of 5-parts (Rotor Assembly, Stator Assembly, Enbell de, Endbell, ETC)

Assembly and Installation
- Perform assembly in the reverse order of disassembling
- After assembling, check for Speed Sensor. Normal signal is as below.

Drive Motor Specification.
Power 5.3 kW
Voltage 30 V
Current 135 A
Rated Speed 2324 RPM
Maximum Speed 4500 RPM
Frequency 80 Hz
Cos Ø 0.909
Service S2 60
Insulation Class F
Protection Degree IP20
Weight 66.3 kg
Hydraulic (Pump) Motor Specification

Power 13.2 kW
Voltage 30 V
Current 345 A
Rated Speed 1614 RPM
Maximum Speed 4500 RPM
Frequency 56 Hz
Cos Ø 0.8430
Service S3-15%
Insulation Class F
Protection Degree IP20
Weight 42 kg

4.1 BR14JW-7 - E.control - SB4394E00

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4.1 BR14JW-7 - E.control - SB4394E00

Uploaded by

Copyright:

Available Formats

SB4394E00

Electric Control System

The meaning of this safety alert symbol is as follows :

Attention! Become Alert! Your Safety is Involved.

Electric Control System 1

Electric Control System 3

Electric Control System 4

Drive Wheel Auto-Centering

Control of Driving Speed

Electric Control System 5

Lifting Speed Control

Reach in/out Speed Control

Electric Control System 6

1) Traction Inverter 2) Traction Motor 3) Accelerator Pedal

Electric Control System 7

9 Ambient Temperature Range -40℃ ~ 50℃

Electric Control System 8

9 Ambient Temperature Range -40℃ ~ 50℃

Electric Control System 9

Electric Control System 10

Electric Control System 11

Electric Control System 13

1. Press the “0” key one more second

4. Delete saved pin code

Electric Control System 15

1 First parameter for calibration enable 1st PASSWORD ASCII

3 Seat switch delay SEAT SW DELAY Sec

4 Foot switch delay FOOW SW DELAY Sec

5 Chat time CHAT TIME Sec

6 Slow speed button enable/disable ENABLE TURTLE Boolean

7 Forward maximum speed FWD MAX SPEED RPM

8 Reverse maximum speed REV MAX SPEED RPM

9 Starting temperature of controller’s fan START CONT. FAN ˚C

10 Accelerator pedal minimum value A output ACCEL MIN VALUE mV

11 Accelerator pedal maximum value A output ACCEL MAX VALUE mV

12 Brake pedal minimum value A output BRAKE MIN VALUE mV

13 Brake pedal maximum value A output BRAKE MAX VALUE mV

14 British unit BRITISH UNIT Boolean

15 Time meter / Odometer on display TIMER-ODOMETER Boolean

16 360degree option 360 DEGREE OPTION Boolean

17 Lift knob minimum value A output LIFT MIN VALUE mV

18 Lift knob maximum value A output LIFT MAX VALUE mV

19 Tilt knob minimum value A output TILT MIN VALUE mV

20 Tilt knob maximum value A output TILT MAX VALUE mV

21 Reach knob minimum value A output REACH MIN VALUE mV

22 Reach knob maximum value A output REACH MAX VALUE mV

23 S/S knob minimum value A output S/S MIN VALUE mV

24 S/S knob maximum value A output S/S MAX VALUE mV

25 Lift max speed LIFT MAX SPEED RPM

26 Tilt speed TILT SPEED RPM

27 Reach speed REACH SPEED RPM

28 S/S speed S/S SPEED RPM

29 Hydro idle speed IDLE SPEED RPM

30 Turtle speed TURTLE SPEED RPM

31 PIN enable PIN ON/OFF Boolean

Electric Control System 16

1 Drive traction motor speed D MOTOR SPD RPM

2 Drive traction motor speed reference D MOTOR REF SPD RPM

3 Battery voltage BATT VOLTAGE mV

4 Traction Inverter power module temperature D INVERTER TEMP ˚C

5 Traction motor temperature D MOTOR TEMP ˚C

6 Traction motor act current D MOTOR I A

7 Accelerator potentiometer voltage ACCEL 1ST OUT mV