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INDEX
Page
Legend .............................................................................................................. 2
1 General information ...................................................................................... 3
1.1 Field of application ................................................................................ 3
1.2 Description of operation ........................................................................ 3
1.3 System features .................................................................................... 4
2 Main system components ............................................................................ 5
2.1 Potentiometers ...................................................................................... 5
2.2 Logic unit ............................................................................................... 6
2.3 Power mosfets....................................................................................... 8
2.4 Diodes ................................................................................................... 8
2.5 Trimmers ............................................................................................... 9
2.6 Fuses .................................................................................................... 9
2.7 Microswtches ........................................................................................ 9
2.8 Contactors ........................................................................................... 10
3 Installation and calibration ................................................................. 11
3.1 Technical information .......................................................................... 11
3.2 Final testing ......................................................................................... 12
4 Diagnosis ..................................................................................................... 13
4.1 Test points ........................................................................................... 13
4.2 Troubleshooting .................................................................................. 15
Fitting plan GA1B 3 cables motor ........................................................................ 16
Power scheme of chopper GA1B with safety with references for test point 3
connections motor ................................................................................................ 17
Fitting area GA1B 4 cables motor ........................................................................ 18
Power scheme of chopper GA1B with safety with references for test point 4
connections motor ................................................................................................ 19
Scheme of chopper GA1B with safety with references for test point ................... 20
Contactor card chopper test-point references ...................................................... 21
Functional plan with test point-contactor card ...................................................... 22
5 Spare part ..................................................................................................... 23

= The informations included into the marked paragraphs by this symbol are
essential for the safety.

APPROVAL SIGNATURES

COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE

TECHNICAL AREA

COMMERCIAL AREA

Pubblication N.: 550176B

Edition: Jannuary 1995
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LEGEND

BTA = Forward contactor coil

BTI = Reverse contactor coil
BTP = Pump contactor coil
CH = Key return
CPOT = Potentiometer switchbox
FA = 10A auxiliary fuse
FP = Main fuse
IR = Quick reversal
MA = Forward micro
MB = Bypass micro
MI = Reverse micro
MP = Pump micro
MS = Safety micro
NPOT = Potentiometer minus
PPOT = Potentiometer plus

COLOURS CODE

A = Orange
B = White
C = Light blue
G = Yellow
GG = Grey
M = Brown
N = Black
R = Pink
RR = Red
V = Green
VV = Violet

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1 GENERAL INFORMATION

1.1 FIELD OF APPLICATION

This new MOSFET equipment is used to control the speed of direct-current motors
operating small and medium-size fork-lift trucks, electrically-operated road vehicles, golf
vehicles, electrically-operated transpallets, industrial sweeping, washing and drying
machinery.
The use of these control devices makes it possible for the operator to easily obtain
smooth and well-controlled vehicle movements. This system also allows continuous
and proportional motor adjustments thanks to electronic system based on the most
sophisticated technology.
The vehicle is moved by simply pressing on the accelerator pedal; the equipment then
automatically calibrates acceleration and braking in order ensure smooth driving.
The most relevant features in this chopper is the use of the MOSFET technology which,
apart from making it very compact, increases its ease-of-use and reliability.

1.2 DESCRIPTION OF OPERATION

The electronic system is used to control the power delivered to the motor. The operator
may control the vehicle speed via a pedal or manual control.
The system feeds the motor checking the supplied voltage from 0 to 100% conduction:
control is achieved by turning a potentiometer connected to a pedal or a steering wheel.
The potentiometer sends a voltage signal which is proportional to the turning angle.
This signal is processed by the logic unit which controls the on and off times of power
mosfets. Power mosfets are connected between motor and battery. When closed, they
connect the battery to the motor letting current throug and suplpying full voltage to the
motor.
When open, they break current supply to the motor and thus provide no power.
By adjusting the on and off times of the mosfets with steplessly-variable frequency and
pulse you can adjust the mean power supply to the motor and thus the speed of the
electrically-operated vehicle.

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1.3 SYSTEM FEATURES

- Very low 0.3V voltage drop at rated current.

- Supply voltage 12/24/36/48.
- Protection against reverse polarity.
- Thermoresistor with gradual reduction of I max.
- 2 regulators for 1st and 2nd ramp acceleration.
- Max. current adjustment.
- Braking adjustment.
- Additional braking for quick safety reversal.
- Electronic zero-setting during reversal.
- Frequency and variable pulses.
- Isolated baseplate.
- 3 speed reducers with trimmer adjustment
- safety devices in compliance with European standards.

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2 MAIN SYSTEM COMPONENTS

The main system components are as follows:

- Potentiometer
- Logic unit
- Power mosfets
- Diodes
- Adjustments trimmers
- Fuses
- Microswitches
- Contactors

2.1 POTENTIOMETERS

The potentiometer has the function of sending a voltage signal which is proportional to
the turning angle of the logic unit. When acting upon a pedal lever or turning a knob you
rotate a potentiometer which sends a voltage signal to the logic unit: the wider the angle
of rotation the stronger the signal.
One of the following procedures can be adopted to check a potentiometer with a tester:

1) Connect the potentiometer to the system and insert key.

Measure voltage between terminal 1 and 2. By turning the potentiometer shaft,
voltage should vary in a steeples fashion from 1 to 2.5V without abrupt changes.

2) Do no connect the potentiometer to the system and follow the above procedure
measuring resistance instead of voltage.
The following potentiometers can be fitted to a system:
- With central zero and angle of rotation from 25 o to 250 o (Fig. 2A)
- Standard version with angle of rotation from 25 o to 270 o approximately
(Fig. 2B)

There is clearly no need for a special potentiometer since trimmers P5 and P3 (Fig. 3)
perform the adjustment between the electric and mechanical angle.

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2.2 LOGIC UNIT

This unit encompasses the most important equipment functions. All signals are sent
and all data processing is performed by the logic unit. The main functions are described
below:

2.2.1 End mosfets operation

End mosfets are operated with ON-OFF voltage to reduce losses. Furthermore, the
ON-OFF time is controlled in such a way as to allow speed adjustment from a
minimum to a maximum.

2.2.2 Peak current control

This control makes it possible to fix a max limit to the motor current supply so that
the preset safety value is never exceeded. The limit value should be such that the
vehicle is allowed to smoothly accelerate and overcome certain slopes.

2.2.3 Acceleration control

Two acceleration ramps are available to ensure the vehicle top performance. One is
also called P4 starting delay while the other one is referred to as traditional
acceleration.

2.2.4 Braking control

To ensure easy manoeuvrability to the vehicle in case of direction reversal during
driving the system comes with smooth automatic braking and P6 adjustable torque.
At the end of braking the vehicle automatically starts moving in the opposite
direction.

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2.2.5 Thermal control

To check that the temperature does not exceed the preset value of 80°C, a
thermoresistor is provided close to the mosfets in order to measure the chopper
temperature.
Having obtained this current reduction the chopper temperature no longer tends to
exceed the preset one. This makes it possible to protect the chopper in case it is
used at current or temperature values which are too high compared to those
considered in the design stage. Current, and thus power supply to the motor, is only
reduced but not brought down to zero because of the following reasons:
a) to avoid a situation in which no power is available to the motor, especially when
driving up a slope;
b) to continue operating the vehicle though at reduced speed.

2.2.6 Safety circuit

The safety circuit ensures that in case of equipment failure the vehicle does not
suddenly receive full power. This circuit complies with the applicable European
standards.
According to these new regulations the vehicle should be stopped in case any
failure occurs.
The safety circuit comes with cyclic selfdiagnostics and makes it possible to stop
the machine as soon as a failure is detected.

2.2.7 Pedal or steering wheel potentiometer stroke adjustment.

Trimmer P5 and P3 are used to check the potentiometer stroke once the pedal or
handle are fitted to the vehicle. If the potentiometer electric zero does not
correspond to the pedal mechanical zero, adjust trimmer P5 without mechanically
adjusting the potentiometer. The end part of the stroke can be corrected by
adjusting trimmer P3. The two trimmers influence each other so that adjustment
should be performed by means of the put and take technique.

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2.3 POWER MOSFETS

All motor current passes through these mosfets causing some degree of heating; for
this reason they are mounted on an aluminium baseplate which acts as a cooling
radiator. These mosfets features an ON-OFF mode of operation to control power
supply to the motor and thus speed.
For inspection purposes mosfets must be unwelded from the cardin order to measure
resistance:
a) between 2 and 3 (fig. 4) resistance should be greater than 10Kohm in one direction
and behave like a diode in the opposite direction;
b) between 3 and 1 the value should be practically infinite in both directions.

2.4 DIODES

Two power diodes are available:

one is the flywheel diode connected in parallel to the motor ensuring that current still
passes when power mosfets are open.
The other one is the braking diode connected in parallel to the armature (these two
diodes exchange their function depending on whether forward or reverse gear is
engaged). For diode inspection disconnect a terminal and then measure resistance
between A and K. Resistance should be low in one direction and greater than 1 Kohm
in the other direction.

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2.5 TRIMMERS

Trimmers are used to adjusting the vehicle operating features.

The following functions can be adjusted:
- acceleration ramp (2 trimmers)
- peak motor current (1 trimmer)
To inspect a trimmer unweld it from the card and measure resistance between 1 and 2;
when turning the screw, resistance should vary in a stepless fashion from zero to the
peak value. Notches are available to assist the operator during adjustment.

2.6 FUSES

Fuses are protections against short-circuits. Two fuses are available, one for power and
one for auxiliary crcuits.

2.7 MICROSWITCHES

Microswitches are used give the go-ahead to operations such as contactor and safety
device connection or disconnection.
They can be checked measuring resistance between 1 and 2 once they have been
disconnected.
Keeping lever A in a certain position resistance is equal to zero while changing position
resistance becomes infinite.
The same is true for 1 and 3.

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2.8 CONTACTORS

Contactors are used to bear strong currents and to electrically connect or disconnect
system components such as the battery to the chopper. The main contactor
components are as follows: a coil which, once current passes through, moves the mobi-
le contact holder so that the circuit opens or closes; noble metal (silver alloy) contacts
welded onto the mobile or fixed part which, when connected, allow strong currents to
pass through. The arc eliminators, consisting of a resistor and a diode, are used to
reduce the duration of the electric arc generated in the microswitch when the coil is de-
energized. The following procedure should be adopted to inspect a contactor:
- check that the moving part moves smoothly;
- check that contacts are in good state and not stuck;
- disconnect coil and check that resistance shows the correct value with no short
circuiting or erathing effect;
- check that coil arc eliminator components are in good state.

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3 INSTALLATION AND CALIBRATION

3.1 TECHNICAL INFORMATION

The equipment thermal dissipation occurs mainly following contact with its baseplate.
For this reason the plate where the equipment is mounted should feature a thickness of
at least 5mm and be sufficiently flat to ensure good contact. It's advisable to apply
thermoconductive grease on the contact surface. When operating, the equipment
should be adequately kept away from corrosive chemicals, water splashes and battery
acids.
When feeding current to the system for the first time lift the driving wheel for safety
reasons. It's then recommended to fit a resistor of approximately 0.5 ohm 200W in
series with the motor. This resistor should be removed once you feel that the
equipment is working properly showing that all connections have been correctly
performed. When fixing the equipment use all available bores to ensure that weight is
evenly distributed on the aluminium plates and sufficient specific pressure is available
to dissipate heat. Check for proper wiring and wire terminal fixing. Check that
suppressor filters are available on contactors, horn and solenoid valves, if any. Voltage
peaks should not exceed 60V. If the truck is supposed to work in a coldroom fit a 20W
resistor in the steering wheel or pedal to avoid condensate formation.

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3.2 FINAL TESTING

After making all connections and before feeding current to the system, lift the driving
wheels from the ground and fit a 0.5 ohm 200W resistor in series with the motor as
described above. Switch on the equipment by turning the key, then press the
accelerator. Once the chopper pulsates remove the resistor in series with the motor.
Check both forward and reverse. If functioning properly, lower the driving wheels and
continue testing both in load and noload conditions.

3.2.1 Peak current

Stop motor and measure peak current. Adjust with trimmer P8 if current is not as
desidered.
The operator should, if neccesary, perform the following settings:
3.2.2 Acceleration
If acceleration is not as desidered set trimmers P4 (initial ramp or initial delay
adjustment) and P7 (final ramp) until the desidered acceleration is obtained.
3.2.3 Full speed
The equioment has virtually no effect on full speed. If full speed is not as desidered
the potentiometer does not reach its peak value. By means of trimmers P5 and P3
set the electric zero so that it coincides with the mechanical one. Check that the truk
starts operating as the contactor is connected reaching full speed when the throttle
is at the end of stroke, otherwise adjust P5 and P3 again.
3.2.4 Electronic braking
Drive the vehicle at low speed (for safety reasons), then reverse direction. Once the
first adjustment has been made, drive at full speed. At this stage load the truck
completely.
Perform acceleration and braking tests again. Correct if not yet yielding top perfor-
mance.

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4 DIAGNOSIS

4.1 TEST POINTS (REF. PAGE 16, 17, 18, 19, 20, 21, 22)

The number shows as indention corresponds to the reference on the drawing on page
16, 17, 18, 19, 20, 21, 22. All voltage measurements are made with reference to the
battery minus.
1 Available free terminal
2 Relay and electric brake plus. The battery plus should be available when the key is
in and the electric brake microswitch is depressed.
3 Relay and electric brake plus. The battery plus should be available when the key is
in and the electric brake microswitch is depressed.
4 Battery voltage should always be available. It is located upstream of use 35 and
diode 37.
5 Battery voltage should be available when inserting the key.
6 When a microswitch is on, voltage should drop from VBatt to approximately 0V.
7 When the other microswitch is on, voltage should drop from VBatt to 0V.
8 When the pump microswitch is on, voltage should drop from VBatt to 0V.
9 At this point voltage should always be equal to zero since connection is established
with the battery minus.
11 It is the pedal or steering wheel potentiometer minus.
Voltage should be around 1V, adjustable via trimmer P5 (for mechanical
potentiometer stroke adjustment at the beginning of stroke).
11a Drive contactor coil suppressors
11b Drive contactor coil suppressors
11c Pump contactor coil suppressors
12 Supply voltage of the pedal or steering wheel potentiometer. This voltage is
adjustable via trimmer P3 and is used to set potentiometer mechanical end-..of-
stroke.
2-15V for system with VBatt = 24-36-48V.
2-8V for system with VBatt = 12V.
13 It is the pedal or steering wheel variable voltage. By depressing and releasing the
pedal, voltage should vary from 1 to 2.5V. in a stepless fashion. In this case the
chopper performs all its adjustments.
14 Selfretaining relays minus. It should be at the battery plus voltage when the
dead-man microswitch is released and equal to zero when the dead-man
microswitch is depressed.
15 It is the quick reversal signal. It is normally at a zero value. It should rise to top
levels when the dead-man microswitch is depressed.
16 Voltage at this point should always be zero because it is connected with the battery
minus.
17 It is common to all drive microswitch. It is normally at a zero value and shifts to
battery plus voltage when depressing the dead-man microswitch.
18 It is normally closed position of the dead-man microswitch. It It is normally at a zero
value and shifts to battery plus voltage when depressing the dead-man microswitch.
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29 This point should be approximately 0.8V (it is the safety transistor go-ahead which
carries the minus to the drive contactor coils)
30 Electronic card reset. Card reset occurs when both 30 and 31 are high (VBatt) The
minimum requirement to start the electronic card is that either 30 or 31 is low (1V
approximately).
31 Electronic card reset. Card reset occurs when both 30 and 31 are high (VBatt) The
minimum requirement to start the electronic card is that either 30 or 31 is low (1V
approximately).
32 When the key is inserted battery voltage should be available to feed the electronic
card.
34 Battery minus. It is the reference point for all measurements. This point is directly
connected to the battery minus.
35 10A fuse for auxiliary circuits. It feeds the logic unit and contactor coils.
36 Battery voltage should always be available at this point. It is located downstream of
fuse 35 and upstream of diode 37.
37 Diode against reverse polarity. This diode protects the equipment in case of battery
pole exchange.
38 (See 4) Battery voltage should always be available. It is located downstream of fuse
35 and diode 37.
39 Pump contactor warning lamp LED. This LED works in parallel with the contactor
coil. The LED does not turn on when no power is supplied to the coil.
40 Drive motor rotor. This waveform should be obtained when the chopper is
operating.

41 Drive motor stator.

42 Warning lamp LED for forward contactor.
43 Drive motor stator.
44 Battery plus. The range should be between +10% and -30% under any load condition.
45 Key-in warning lamp LED: this LED is connected to the key plus.
46 Warning lamp LED for reverse contactor.
47 Drive motor rotor.

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4.2 TROUBLESHOOTING (REF. PAGE 16, 17, 18, 19, 20, 21, 22)

1 The vehicle is completely dead. Check the following test points:

36 If no battery voltage is available, fuse 35 is burnt or there is a brake in the circuit
which, from the battery plus, supplies current to the fuse.
38 If battery voltage is available at 36 but not a 38, diode 37 is to be replaced. A wire
bridge could possibly be created losing the battery function as protection against
reverse polarity.
29 B4: it is the safety transistor collector. If this voltage is high, the chopper is in safe
condition. This problem could also be due to short-circuited power mosfets, pedal or
steering wheel potentiometer voltage exceeding 1.3V or interrupted potentiometer
minus. Check the above conditions and replace electronic card if not yet properly
operating.
2 Drive contactors do not close. Check following test points. With drive microswitch
on, check that LED 42 or 46 (depending on the gear) is on. If they do not turn on, no
voltage is applied to the drive coils.
5 It is the voltage which feeds the drive contactor coils. If not available, check voltage
at point 38, fuse 35 and test point 44 which derives voltage directly from the battery.
30 It is the voltage upstream of the drive coil which, at the time the microswitch closes,
should reach approximately 1V via the safety transistor.
31 It is the voltage upstream of the drive coil which, at the time the microswitch closes,
should reach approximately 1V via the safety transistor.
29 = B4: Voltage at this point should be approximately 0.8V. If, at the time the drive
microswitch is closed, this voltage rises up to the battery value, the safety system is
engaged. This problem can be due to short-circuited power mosfets, pedal or
steering wheel potentiometer voltage exceeding 1.3V or interrupted potentiometer
minus.
3 The pump contactor does not close and the pump motor does not turn.
Check whether LED 39 is on. If this is not the case, the contactor coil is not live.
Check test point 8 because if voltage at this point does not drop to zero when the
pump microswitch is engaged, the microswitch is faulty.
If the contactor closes, contacts are possibly oxidized or dirty so that they do not let
current through.
4 Fuse 35 burns repeatedly.
Disconnect fastons from all contactor coils and check that they are as shown in the
table: if not short-circuit occurs and resistance values are not extremely low, check
arc eliminator filters 11a - 11b - 11c. They can be inspected with a tester once the
coil wires have been disconnected. They should not be shorted.
5 The vehicle moves at low speed and does not receive any power. Check test point
13 where the potentiometer peak voltage with fully depressed pedal should reach at
least 2.5V. If this test is correct fit an ammeter along one motor cable and check
that peak current is as required. Otherwise set via trimmer P8.
6 The vehicle shows a starting delay.
Adjust trimmer P4.
7 The power supply resistor inside card R16 has burnt with light smoke generation. In
this case green and orange wires of the pedal or steering wheel potentiometer heve
most probably been inverted. Replace R16 with an equivalent one.
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5 SPARE PART

Article code Description

E42020 IRFZ44 mosfet transistor

E07047 2K5 1G HM potentiometer for 24V
E07008 5K 1G plast. potentiometer for 12V
C22000 10A 250V AC 1 scam. microswitch
E08200 NTC 33K
E02256 470R 0.5W R15 power supply res. for 24V
E04040 22R 1W R16 power supply res.for 24V
E02224 220R 0.5W R15 power supply res. for 12V
E04030 3R3 1W R16 power supply res. for 12V
C16511 80A protected power fuse, centre dist.60
C16502 160A protected power fuse, centre dist. 60
C16500 10A 5X20 glass fuse
C16508 5X20 fuse holder
C16510 5X20 plastic fuse cover
C29500 150D 12V SW80 contactor
C29501 150R 12V SW84 contactor
C29502 150D 24V SW80 contactor
C29503 150R 24V SW84 contactor
C12302 6 pin female connector
C12303 8 pin female connector
C12755 0.32-0.9 mm² female pin
C23511 M8X20 081057 female brass stud

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COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI

42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259

ELECTRONIC CONTROLLER
MODEL GA1B
USER'S MAUAL