POWERTRONIC SYSTEM Version 1.2.x 2577.010.0006 OPERATOR MANUAL STACKER CS45/50 RS50/60/70 Introduction System configuration Version for electronic engi Version for traditional mechanical engines Powertronic system working. Autom: ransmission management 3.2. Engine and speed control Eco-CAN display functions. E|_key: transmission test - F3 key: safeties test........ F4 key: date and time. 1 | eee ie ae ca /FANTUZZI/ELECTRONIC | Powertronic -V REGGIANE| DEPARTMENT 1. Introduction ‘This manual describes Powertronic System software version 1.2.6. Further versions on the third number (6) do not contain basic modifications to be reported into a manual. ‘This manual is divided into two sections, operator and assistance Itis recommended to keep a copy of the operator manual in the operator cab, in order to allow a quick reference in case of problems or questions. “Assistance manual must never be kept in the operator cab and must be available only for Service, because wrong operations can compromise machine safety. Powertronic System has following features: * Electro hydraulic transmission management like Dana (Clark) or Caterpillar equipped with on/off electro-valves; possibility to set up shifting points according to machine load and stability conditions + Transmission safeties management, like anti-inversion, inching, engine rpm protection, speed sensor check Different machine speed controls according to safties and stability Engine acceleration control during shifting considering also machine stability Starting speed control Management of different engine types, electronic managed (if compatible to CAN standard SAEJ1939) and traditional mechanical © Engine shut off in case of alarms coming from external control devices (like Logicontrol or LMS) ‘© Engine/transmission status monitoring through display Eco-CAN (optional) and/or external laptop. Messages in different languages Then, Powertronic joins all typical functions of engine and transmission controller into a single unit, adding more features thanks to the strong integration with the machine conditions. sw See evs heaisearmers comron FANTUZZI| ELECTRONIC Powertronic - V 1.2.x - 257.010.0006 REGGIANE | DEPARTMENT 2. System configuration 2.1. Version for electronic engines Tosicontro ‘Accolerator } : Pedal esx |}———> Control Speed selector CAN1 ECO-CAN Leman! | oissew From above, it is possible to see that ESX controller is the “heart” of the system: it receives information from the pedal (the same for any engine), from speed sclector and from Logicontrol; then, it supplies all signals for automatic transmission and engine (through secondary CAN line). Primary CAN line is reserved for Eco-CAN display, that receives necessary information for visualization. ‘The engine is accelerated only sending proper data to engine electronic controller, using, CAN network. Only for electronic engines Cummins M11 or N14 with Celect Plus, the system is slightly different: since unit Celect+ does not support standard J1939, Powertronic supplies a voltage signal (0-SV) through a card proportional to engine power required. 3 Bh waeaescegemees. Ly CRN GEIS Se aesFANTUZZ1I| ELECTRONIC Powertronic - V 1.2.x - 2577.010.0006 RAOSI4l| BEPARRVENT 2.2. Version for traditional mechanical engines Logicontrot Accelerator Pedal ESx Controle} Speed oo ry sale an i Sa Controter 5 Conole’ electrical engine Actuator engine CAN In this case, the engine can’t be driven directly through CAN network: it is installed an actuator (electrical engine) on the lever that mechanically accelerates the engine. ‘The actuator is controlled by ESX through an engine bridge controller called TMS. The remaining of the system is like the previous. 4 ( apaeesermeeen. LA3. Powertronic system working 3.1 Automatic transmission management Powertronic can control transmission in automatic or manual mode. Incase of manual mode (Key on dashboard), the driver will have to select the desired speed using the speed selector. All safeties to prevent an incorrect transmission use (anti-inversion or engine high rpm protection) are still valid, In case of automatic mode, the operator has only to select the maximum speed to reach and press the throttle. Powertronic will insert the proper gear according to machine speed, engine rpm and stability. ‘On the display (if installed) it is shown the transmission status according to this logic: (Fi = Fa F stands for forward. In case or reverse, there will be R. First number indicates actual gear inserted, the second is the speed desired by operator If, for example, the operator selects third gear, on the display it will appear: Machine will never teach 4° speed. Functions and automatic transmission safeties * Engine RPM control Starting from neutral, it is not possible to engage first gear (forward or reverse) if engine RPM is over a minimum value (normally 900 RPM). © Anti-inversion control If the operator tries to invert direction when wheels are not still, the transmission is set to neutral unless a minimum speed is reached (normally 2 kna/h) © Inching control Ifthe operator uses parking brake or the button located close to pedal brake with any gear engaged, Powertronic sets transmission to neutral, This to prevent excessive stress on transmission, 5 wi MBSR oS he eenNTUZZI GIANE, LECTRONIC JEPART MENT © Speed sensor check (on drive shafi) If the sensor located on drive shaft does not supply a correct signal, the transmission is set to neutral; to reset the alarm, it is necessary to set the speed selector to neutral. If that was a false warning (sometimes it may happen), the transmission starts working normally again, In case the sensor Was really fault or disconnected, the transmission will keep always first speed. Only switching to manual mode it will be then possible to go to any speed, but, inthis case, all safeties will be not active anymor © Pedal kiek-down control Pressing throttle pedal at maximum, Powertronic moves forward of some percentage (normally 20-30%) shifting points. This means that shift points will be activated at higher machine speed and engine RPM... © Engine torque control (declutch) During shifting (to higher gears) the engine RPM is decreased automatically, in order to avoid a ‘gears engagement with engine at high torque. Engine RPM will be restored as set by pedal with a ramp as soon as the shifting is terminated. © Variable starting speed (first speed start) ‘On some machines itis available an additional button on joystick. Normally, machine starts in second speed. If operator presses the button, machine will start on first speed just for that time. This is to reduce the use of first gear only when necessary. © Load control Logicontrol supplies a signal to Powertronic as regards weight lifted. In case of machine loaded, Powertronic uses a different shift points table, built so that gears are engaged at higher speed and engine RPM, in order to have a sufficient engine power to travel and use the boom. © Stabilizers control In the machines provided with stabilizers, no gear will be selected if stabilizers are not correctly lifted. © Mobile cabin control In the machines provided with mobile cabin, Powertronic control directly cabin proportional electro valves. Cabin forward will be locked if doors are opened. tions, with doors open also transmission is locked to neutral. 6FANTUZZI/ELECTRONIC _ | Powertronic - V 1.2.x -2577.010.0006 R }GIANE | DEPARTMENT 3.2 Engine and speed control Powertronic has pedal information and supplies signals for each engine type, in order to integrate all acceleration, maximum speed and transmission requirements to the engine. ‘These are functions available: © Speed control ‘Logicontrol informs Powertronic about machine stability conditions, using 2 signals (see Logicontrol manual for more details). Following table resumes the speed control according to machine stability conditions: ‘Stability condition [Maximum speed _ [Notes Normal 20 Km/h Machine unloaded Medium 13 Kmih Machine with small load and boom extended Low 8Kmih Machine in overload or with a big load and boom extended * CAN communication control In case of electronic engines, the system checks communication status with the engine, otherwise engine is set to minimum. © Actuator control In case of mechanical engines, the actuator connected to the mechanical lever supplies a feed- back signal to the system, in order to make sure that engine position is exactly as required. If this signal is different, this is an alarm condition and the engine is set to minimum RPM. © Engine on/off control ‘The engine is not started if speed selector is not neutral, ‘When engine is shut off, Powertronic checks if engine RPM is high; in this case, before shutting engine off, it keep engine at minimum RPM for at least 10 seconds, in order to avoid turbo charger overheating. © Engine shut off for alarms Logicontrol can ask an immediate engine shut off in case of alarms from engine itself or external devices. In this case, Powertronic will shut off engine immediately, without any other condition. 7 cou scape Sor erie te RECENT INCoV 1.2.x - 257.010.0006 4, Eco-CAN display functions Eco-CAN display has 2 lines for 16 characters at high visibility. It is used to show operator automatic transmission status and system alarms. Itis provided with 4 function keys to check in detail system working and 2 keys for contrast adjust. ‘Atstart up this is the main screen page: In the first row there is transmission status (actual and required) and machine speed. In the second row there are the alarms. ‘Multiple messages remain in the screen for one second. This is message list: Message ‘Active when... engine shut off | Engine shut off safety is activated ‘wheel sens. fault | Speed sensor (on drive shaft) is not connected or fault. Go to neutral 10 reset the alarm, anti__iaversion | Attempt to invert direction with machine still moving brake inserted | Machine is set to neutral because parking brake or pedal brake button are inserted. zpn engine safet | First speed forward/reverse has been inserted with high engine RPM. speed Limited [There is a speed limit safety (in case of low/medium machine stability) CEN engine fault [Problems to CAN communication with the engine eng actuator KO | The actuator connected to engine is fault or not connected. pedal fault ‘Accelerator pedal is fault or not connected. doors cab opened [Cabin doors are opened: cabin movements or transmissions is locked stabilizer safet | Stabilizers are not lifted: machine is set to neutral 8FANTUZZI I ELECTRONIC REGGIANE | DEPARTMENT 4.1 FI key: transmission test First row: Jz. transmission selector status: 1 contact selected, 0 not selected; the numbers indicate respectively: forward lever, backward lever, speed 1, speed 2, speed 3, speed 4 ‘M: engine rpm B: brakes inserted: ON/OFF Second row: O: Electro valves output status: 1 output activated (24 V), 0 output not activated: numbers indicate respective forward, backward, speed 1, speed 2, speed 3, speed 4 valves S: speed in meters per hour (the same measurement unit used to set shifting points) ‘W: speed sensor status on drive shaft: Y/N This is how electro valves are activated according to different transmissions: Speed Input from selector ‘Output ‘Output selected electro valves electro valves for for Caterpillar other transmissions F41 104410 101000, 101110 F2 100110, 400100 100110 FS 400010 400010 100010 F4 400000, 100001 100000, Rt (041110 (041000 011110 R2 010110 010100 010110 R3 010010 010010 040010 R4 (070000 010001 010000 Press any of F1-F4 to go back to main screen. 9NTUZZI| ELECTRONIC REGGIANE! DEPARTMENT 4.2 F2 key: pedal/engine test First row: P: Percent of accelerator pedal from potentiometer: 0-100 ‘At Feed-back signal from actuator (only for mechanical engines): 0-100 R: Pereent of power required to the engine according to safeties: 0-100 Second row: Mz engine rpm I: idle switch pedal status, Y/N if present: 1/0 if contact is active or not ¥s actuator alarm status (only for mechanical engines): OK/KO 'S: speed limitations in progress: Y speed limited, N no limit Press any of F1-F4 to go back to main screen. 4.3 F3 key: safeties test First row: E: engine rpm safety: 0/1 B: park brake or inching switch: 0/1 Ws safety for speed sensor on drive shaft: 0/1 N: neutral: 0/1 S: stabilizers lifted: 0/1 D: doors opened: 0/1 Second row: S: engine shut off from Logicontrol T: low stability speed limit from Logicontrol Q: medium stability speed limit from Logicontrol L: general speed limit activated D: engine in declutch mode during shifting All values are at 0 if everything works fine; any 1 value means safeties or transmission interlock activated. Press any of F1-F4 to go back to main sereen. 10ELECTRONIC BEPART MENT 4.4 F4 key: date and time Powertronic - V It is shown date, time and software version installed. First row: Date format: dd/mm/yy ‘Second row: Time format: hh:mm:ss ‘SW: software version installed; format: xxx Press any of F1-F4 to go back to main screen. ul Gl apenas ssenmeemanen, sevoteggianncsn) emai inte cesiulecron etm omFANTUZZI| ELECTRONIC Powertronic - V 1.2.x - 2577.010.0006 REGGIANE | DEPARTMENT ASSISTANCE MANUAL ATTENTION ‘This manual section is reserved to Technical Assistance, and itis useful for all troubleshooting and calibrations of Powertronic System. An incorrect calibration affects seriously machine safety and working. In order to increase the safety, all calibrations procedure are possible only using system internal menus, accessible only by an external PC connected to the serial port or through a removable keyboard connected to Eco-CAN display. The operator is the sole responsible for machine handling. ‘There is a special option to restore default memory values in case of wrong calibrations, protected by acode. This code is 9090 Index Serial Programming Interface: system status and calibration. System status os cones - System inpuis/outputs status... System calibration with PC. Transmission Mat ment Setuy Engine Management Setuy Pedal setup.. Speed setup Machine configuration .. Data transfer . Set date and time. ‘Set language. Restore default System calibrations using Eco-CAN display.. ‘Menu navigation Changing automatic transmission parameters. Pedal calibration. Engine RPM calibration Speed Date and time. 4. — Troubleshooting guide. PPENDIX 1: Nul : APPENDIX 2: Connectors Pin-out ERERER fa Bk ERE RERI ee & 12 a Palate BEANS: SAG RNR CENUA Ne‘UZZI\ ELECTRONIC GIANE | DEPARTMENT 1. Serial Programming Interface: system status and calibration Powertronic system is completely accessible and programmable using Serial Programming Interface (SPI). This is automatically activated with a laptop PC connected to the serial port, using any terminal emulation software (for Windows operating system itis available HyperTerminal). Connection cable between connector available on machine electrical box and the PC has to be null-modem type (see appendix for details). HyperTerminal configuration has to be as follows: Connection: directly to COMI (or to any other COM port available on PC) Baud Rate: 19.200 bps Data Bit: 8 Parity: none Stop bit: 1 Flow Control: none ‘Terminal Emulation: automatic or VT100 Alternatively, itis possible to use an external removable keyboard connected to Eco-CAN display, available on request: With this keyboard it is possible only a basic limited set of calibrations, while all system functions are accessible only through PC. 13 was “ERE Se ee1.1 System status Simply connecting the serial cable between PC and SERIAL connector in the electrical box (battery compartment), following screen appears, with all most important parameters to check engine and transmission: Powertronic software version: 126 STATO MOTORE/PEDALE Engine Type: STANDARD MECHANICAL CONFIGURAZIONE MACCHINA Engine RPM: 0 Stabilizers safety: N Shut Down: N Cabin doors opened Hours meter: H 123 M 45 Pedal: -1% Actuator: 1 @ STATO ECO CAN: ok Power required: 0 % Max speed: 9 kn/h cycle time: 3 ms STATO CAMBIO: AUTO OPZIONI MENU Target speed: RE programming mode Actual speed: Ri soreon refresh First speed start: N 1's system test 1/0 Wheel RPM: 96 Speed: 96 meters/h SICURE2ZE Brakes: N Wheel RPM safety: W Engine RPM safety: N Inversion safety: N ‘Some messages may vary according to engine type installed. Here follows single items description: Powertronic software version: 126 is the actual software version Engine/Transmission Status Engine Type: it specifies engine type installed. It is possible: standard mechanical, Cummins QSM11, Cummins N14 Celect Plus, Volvo 1240 TDE, Caterpillar C Series Engine RPM: actual engine RPM Shut Down: Y if engine has to be shut down for some alarm, N for normal working CAN? 51939: this appears only for electronic engines. It states if CAN packets are correctly received from engine ECU. 14 senretnicigaoaiceen eimai: inte reciahearaggeew comNTUZZI ELECTRONIC ‘GIANE | DEPARTMENT Pedi it shows pedal position in percentage (0-100) or message “fault” in case of pedal not connected or fault Power required: _ percentage of power required to engine. 100% means maximum RPM Actuator: percentage (0-100) of actuator internal potentiometer position, used to move the mechanical lever on engine to accelerate it. In case of fault, the message “fault” appears. Information available only with mechanical engines Max speed: maximum current speed allowed Transmission Status: Automatic/Manual Target: this is gear (speed) selected by operator with speed selector Actual: this is actual gear engaged First speed start: if starting on first speed has been requested, N for standard start (second speed) ‘Wheel RPM: frequency of sensor’s signal located on drive shaft, that indicates real wheels RPM Speed: machine real speed in meters per hour, calculated from wheels RPM; this is the measurement unit to set shifting points Safeties If machine is locked into neutral or does not accelerate, it is necessary to check if any of following values has its field to “Y” (safety activated) instead of “N” (safety not activated): Brakes: Y if machine has brakes on, N if itis free ‘Wheel RPM safety: if the speed sensor is fault or not connected. N otherwise Engine RPM safety: _Y if first speed is requested with high engine RPM Inversion safety: Y if machine speed is too high to invert direction Feed-Back: 'Y if actuator is fault or not connected, ¥ otherwise (available only for mechanical engines) Machine Configuration Stabilizers safety: __N if stabilizers are lifted, Y otherwise Cabin doors open/close: __actual doors status (only for mobile cabin machines) ECO-CAN Status: OK/Fault: it indicates if Eeo-CAN communication is working Menu Options Spacebar: it switches to input/output status screen (see next paragraph) P: ‘access to main menu for programming and calibration (available only with engine off) R: screen printing refresh 15 wpa eramensuen. LE /FANTUZZI ‘TRONIC REGGIANE |BEBSRE MENT 1.2 System inputs/outputs status From main screen, pressing spacebar, you get this window: 162 He 6.AINI Pedal: -1 @ (816 mV) 382 Re 29.AIN2 Actuator: 1% (422 mv) 0 46.0UT1 cab forward: 0/0 mA 35.DIN3 speed 13.DIN4 speed 2: 0 47.00T2 cab backward: 100/0 mA 36.DINS speed 3: 0 48.0093 TMS PyM: 0 14.DIN6 low speed start: 0 49,0UT4 IMS direction: 0 37,DIN7 engine start: 1 64.0UTS forward: 0 15.DINS pedal brake: 1 61.0076 backward: 1 38. DIN park.brake: 0 62.007 speed 1: 1 16.DINI0 idle switch: 1 63.0098 speed 2: 1 39.DINiL stabilizers up: 1 24.0UT9 speed 3: 27.DIN12 auto/manual: 0 2.00710 speed 4: 0 40.01N13 max.speed mid-stab: 0 25.0UT11 engine stop: 1 18.DIN14 max.speed low stab: 1 41,DINIS forward: 0 OPZIONT MENU 19.DIN16 reverse: 1 programming mode 42.DINL? cab forward: 0 tr't refresh screen 20.DINL8 cab backward: 1 ‘+2 system status 43.DIN19 reset ECU: 0 21.DIN20 empty/load: 0 44.DIN21 eng.stop Logicontrol: 0 22.DIN22 cabin open doors: 1 Each message indicates the ESX unit pin, signal type, signal description and its value in the correct ‘measurement units. Possible signals types: 1) RPM: frequency signals, measured in hertz, 2) DIN: digital signal: 1 when contact is closed, 0 contact open 3) AIN: analog signal, in millivolts or milliampere 4) OUT digital output signal: 1 output on (24V), 0 output off (OV) 5) OUT PWM: PWM output signal: measured in percentage of duty cycle and the real current used by the actuator in mA. Notes: ‘¢ Engine RPM are detected from W+ altemator signal only for mechanical engines, otherwise it comes from engine ECU through CAN line. © Actuator output control (OUTS) is a PWM signal at 350 Hz. * All PWM signals frequency for electro valves is 100 Hz. «The output that controls engine stop (QUT) works in negative logic (for safety reason): when active engine is on, when not active engine has to shut down. This output can be connected to some relay that kills the engine power or directly to engine ECU (according to engine types) ae LES577.010.0006 FANTUZZI| ELECTRONIC REGGIANE | DEPARTMENT 2. System calibration with PC Pressing ‘p’ from main screen it is possible to go to the main menu for Powertronic full calibrations. This mode is accepted only with engine off. To navigate into menus, simply press the number for each option. To modify values, select the option and insert the new value in the proper range. 2.1 Transmission Management Setup 1. Engine minimum RPM: 1000 : minimum number of engine RPM to allow first gear engagement 2. Anti inversion speed (m/h): 500: ‘maximum speed in meters/hour allowed to invert direction 3. Kick down (empty): 20%: % of speed increase of shifting table (with machine unloaded) when pedal is at maximum 4, Kick down (load): 10%: % of speed increase of shifting table (with machine loaded) when pedal is at maximum 5. Declutch: 30%: engine RPM decrease (in %) during shifting from lower to higher gear 6. Set up shift table (empty): shifting table for unloaded machine: 1. Shift 1-2: 5000 m/h: meters per hour to shift from first to second gear 2. Shift 2-3: 10000 m/h; meters per hour to shift from second to third gear 3. Shift 3-4: 13000 m/h: meters per hour to shift from third to fourth gear 4, Hysteresis 2-1: 3000 m/h: meters per hour less than shift 1-2 to shift back from second to first gear 5. ‘Hysteresis 3-2: 3000 m/h: meters per hour less than shift 2-3 to shift back from third to second gear 6. Hysteresis 4-3: 3000 m/h: meters per hour less than shift 3-4 to shift back from fourth to third gear "7 swwettecipare: sor wma: na rectaiecr eye CO7. Set up shift table (laod): shifting table for unloaded machine: the meaning is the same as above, but in this case it will be necessary to insert higher speeds, in order to allow a shifting at higher engine rpm and torque. 8, Set up shift timing: timing in milliseconds for declutch function, that is the forced reduction of engine RPM during ‘gear shifting: L.Time 1-2 in: 250 ms: time interval between engine in idle and second gear engaged (declutch active) 2:Time 2-3 in: 380 ms: time interval between engine in idle and third gear engaged (declutch active) 3.Fime 3-4 in: 250 ms: time interval between engine i (declutch active) 4,Time 1-2 out: 250 ms: time interval between second gear engaged and engine restored (declutch not active) 5.Time 2-3 out: 350 ms: time interval between third gear engaged and engine restored (declutch not active) 6-Time 3-4 out: 250 ms: time interval between fourth gear engaged and engine restored (declutch not active) idle and fourth gear engaged 9, Acceleration ramp: 1000 ms time interval between end of declutch phase and maximum engine RPM restore 2.2 Engine Management Setup 1. Engine Type: Cummins QSM11: this shows actual engine selected. Pressing “1” the engine list is scrolled: © Cummins QSM11 * Volvo 1240 TD VE © Caterpillar €9/10 © Cummins NI4/M11 Celect Plus Standard Mechanical 2, Max engine RPM: 2300: real engine maximum RPM, used to calibrate engine RPM for mechanical and some electronic engines. 18 a SAE ar'TUZZI | ELEC OGLE BEPARRVENT EB R 3. Engine RPM calibration this option is used to calibrate mechanical engines or Celect+ engines. For electronic engines, it isnot necessary any calibration: Sengor frequency: 154 Hz 2. Store max.freq: 17655 2. Store calibration Usually the sensor used is W+ from alternator. Any frequency signal (0-5V minimum amplitude) proportional to engine RPM is allowed. Calibration procedure: ‘Press accelerator pedal (with engine on): frequency value must increase ‘© Press 1: frequency value must be copied in the line “store freq max” ‘© Press 2to store calibration It will be necessary to repeat calibration in case of alternator replacement. 4, Hour meter It shows engine hours, Pressing the key, it is possible to set a new hour meter value (useful in case of Powertronic replacement to restart hour meter from previous value) 5. Min PWM: 22 Option available only for Cummins Celect+. It indicates the percentage of power required to engine with pedal at minimum. This percentage is converted into a voltage, that can’t be below a threshold to avoid an error condition from engine ECU. 6, Max PWM: 77 Option available only for Cummins Celect*. It indicates the percentage of power required to engine with pedal at maximum. ‘This percentage is converted into a voltage, that can’t be over a threshold to avoid an error condition from engine ECU.2.3 Pedal setup 4. Pedal Type: potentiometer it shows actual pedal type: pressing “1” the pedal list is scrolled: © Potentiometer, pedal with standard potentiometer at SK or 10K ‘© Potentiometer with “idle switch”: potentiometer with additional switch for pedal at minimum position 3. Pedal calibration This option is used to calibrate pedals, and it is necessary for all engines: Minimum and maximum value from sensor in mV stored in the last calibration 1.Set Pedal Mii Signal lied in real 2 Soeareaat tinal] Signal, supe lin 3Store calibratiol| '™® "om Pedel nm oO. Exit Actual Pedal: 5% (1050 mv) Calibration procedure: ‘¢ With pedal at minimum (value around 1000 mV), press “1” key: the mV value is copied in the line “pedal minimum” ‘« Press completely throttle pedal (value goes to about 6000-7000 mV) and press key “2”: the value in mV is copied in the line “pedale maximum” + Press “3” to store calibration, or “0” to get out without calibration It will be necessary to repeat this calibration in case of pedal replacement. 4, Kick down threshold: 80% % of pedal to be considered in kick-down conditions (see automatic transmission management) 20 TS wrageeans saeripeaet2.4 Speed setup Machine speed is regulated through a standard control PID algorithm (with parameters not adaptive). For more details on PID controls, please refer to proper bibliography. it is possible that according to terrain or load conditions the control can be more or less effective maintaining a constant speed. ‘An optimal calibration for some conditions could create control instability in other conditions: this behavior can be considered normal. 1, Maximum Speed: 25 km/h this is maximum speed allowed in normal conditions (no alarms, machine with good stability) 2. Maximum speed low stab.: 8 Kni/h: this is maximum speed allowed when machine is in low stability conditions (digital input DIN14) 3. Maximum speed medium stab.: 12 Km/h: this is maximum speed allowed when machine is in medium stability conditions (digital input DINI3) 4, Speed factor: 16 factor to convert frequency signal from wheels rpm (hertz) into meters per hour (machine real speed) 5. PID Kp: 20 Proportional factor in the PID control system: change this value in presence of strong speed oscillations during control 6. PID Ki: 0 Integral factor in the PID control system: change this value in presence of low speed control stability 7. PID Kd: 40 Derivative factor in the PID control system: change this value in presence of delays on reaching target speed 2 Th capes perenneFANTUZZI| ELECTR IC RONGEAG | BEBSRE MENT 2.5 Machine configuration 1. Stabilizers: YES/NO this is to inform system if stabilizers are installed. Press the key to switch YES/NO. 2. Mobile Cabin: YES/NO this is to inform system if mobile cabin is installed. Press the key to switch YES/NO. 3. First speed start: ENABLED/DISABLED this is to inform system if the button to allow machine start on first gear only on request is installed. Press the key to switch ENABLED/DISABLED. 2.6 Data transfer Following options allow to create a file on PC with all Powertronic calibrations. This file can be used to set up very easily a new unit with the same calibrations of the previous (in case of replacement) or to prepare units for similar machines. ‘The file format is text (-txt extension). 1, Sending calibrations to PC: Inside HyperTerminal program, follow these instructions: Select capture text option in the menu Transfer Insert file name where all calibrations will be stored Click on button Start Press any key on PC: many data will be shown on the screen When data flow is finished, select Terminate from menu capture text. The file has been saved and it is available for future use sees 2. Receiving calibrations from PC: Inside HyperTerminal program, follow these instructions: «Select send text file in the menu Tranfer + Insert the existing file name that contains correct calibations * Click on OK button: Powertronic will update its internal memory with new data With this operation, all previous stored data will be losta ‘UZZI ;CTRONIC Tl |BEE ;GIANE | DEPARTMENT. 2.7 Set date and time This option allows to modify date and time on the Eco-CAN display 1. day: 7 2. month: 1 3. year: 3 4. hour: 17 5. minutes:0 y: OK n: NO ‘After having set the right values, press “y” to update date and time or “n” not to make any change. 2.8 Set language This option allows to change the language for all PC and Eco-CAN messages. ‘Standard languages installed are Italian and English. 2.9 Restore defaults ‘This option allows to reset Powertronic internal memory and to reinsert standard calibrazion parameters (defaults). This can be used only by maintenance for software or memory configuration problems. This option is protected by a safety code (9090). This option erases permanently all present memory calibrations, and it replaces them with others. Use this option only if strictly necessary. 233. System calibrations using Eco-CAN display G8? Connecting the removable keyboard to DBIS connector available in the rear of Eco-CAN box, itis possible to modify only the most important parameters. This option has been inserted to allow anyone who can’t use an external PC the possibility to maintain the system. ‘When external keyboard is connected, calibrations with PC is disabled. 3.1 Menu navigation Main menu is accessible pressing key “MENU”. Programming mode is accepted only with engine off. Here it is the menu tree: 0. autom transm. 0. table load 0) shift 1-2 i) shitt 2-3 2) shift 3-4 3) Hysteresi 2-1 4) Hysteresi 3-2 5) Hysteresi 4-3 1. table empty 0) Shift 1-2 1) Shift 2-3 2) shift 3-4 3) Hysteresi 2-1 ay Hysteresi 3-2 _....5)___ Hysteresi 4-3 ( Eepedadncabitoms, “2. engine calib 0) maximum RPM 1) calibrat. RPM 3. speed limits 0) maximum speed 1) low stability 2) med.stability 4. date and time 0) day 1) month 2) year 3) hour 4) minutes 24 Go wang ecenme mete. wna tegpiana sen ernalk sia receresrogger. oa”PANTUZZI| ELECTRONIC _ | Powertronic - V 1.2.x - 2577010006 RI GGIANE | D) [PARTMENT To access to menu items it is necessary to press the proper item number (for example, to access the function "maximum speed” press the keys: MENU - 3- 0). "DEL" key allows to switch to previous menu, F4 goes back to main screen except during changing, parameters options: in this case the control goes back one level. On the display there are only two lines; with the arrows, itis possible to scroll all options. “DEL? key is used also to exit from programming mode. ‘To change parameters and insert new values, do as follows: ‘* Insert number using numerical keys; DEL deletes last number, F3 deletes all numbers, ENTER saves the value inserted and goes back one level. «Ifthe value inserted is out of range, for two seconds the following screen appears: ‘The correct range is specified on second line ‘After 2 seconds, the last menu is shown again. 3.2 Changing automatic transmission parameters ‘To change automatic transmission parameters, select first the shifting table tyoe (empty/loaded) and the parameter to be modified. On display it will appear: The cursor stays close to number 5.000. It is possible to insert the new number or get out without any modification, For further details regarding terms description, see section dedicated to calibrations using PC. 25 a a| ELECTRONIC DEPARTMENT 3.3 Pedal calibration gBRE/ It is displayed actual calibrations values and the value read from pedal. Procedure: © Press FI with pedal at minimum. ‘* Press F2 with pedal at maximum. ‘¢ Press F3 or ENTER to store calibration, F4 to exit without calibrating After confirmation, following screen appears: ieee aan eee eee eee cere cece eee Press F4 to go back to oné menu level, 3.4 Engine RPM calibration Its possible to change maximum real engine RPM (for all engines): Besides, to calibrate engine RPM from alternator signal (only for mechanical engines and ‘Cummins Celectt, see PC section for more details): It is displayed sensor frequency and previous calibration value. Procedure: © With engine at maximum RPM (throttle full down), press F1; the read value is copied # To store the value, press F3. If calibration has been successful you have: 26 iF] ed Ramat BSR NGS aS OR SenN NL ae COE CeV 1.2.x - 257.010.0006 ELECTRONI Powertroni DEPARTME! 3.5 Speed limits Option “0” modifies maximum speed allowed: Option “1” modifies maximum speed in case of low stability Option “2” modifies maximum speed in case of medium stability 3.6 Date and time Press ‘0° to access day modification screen; Press ‘1? to access month modification screen; Press ‘2’ to access year modification screen; Press ‘3° to access hour modification screen; Press ‘4’ to access minutes modification screen; 27 Pic TSS Ec eeC Powertronic - V 1. FANTUZZI | ELECTRONIC REGGIANE | DEPARTMENT 4, Troubleshooting guide Pressing throttle pedal, engine does not rev up ‘Check if some speed limit is active (system status or display) Check if pedal is connected correctly (test inputs/outputs) Check if pedal is correctly calibrated (system status, pedal calibration) Check if CAN communication with engine is working (system status) Make sure not to be in programming mode Moving speed selector to forward/reverse, machine does not move: Check engine rpm: they must be low (engine RPM safety) Check if speed selector is connected correctly ( test inputs/outputs) Check if stabilizers (if installed) are up and the sensor is working Check if there is any safety active on transmission (system status or display) Check if transmission electro valves are connected and not shorted eee Machine does not change gear automatically ‘¢ Check if wheel rpm sensor is connected and working (on system status screen, frequency ‘must increase proportionally to machine speed) Check if automatic transmission parameters are correct (transmission management) Check if speed selector is not in F1 or RI position ‘¢- Check if transmission is on automatic mode During traveling, transmission goes to neutral by itself ‘* Check transmission safeties (system status) ‘© Cheok if wheel rpm sensor is connected and working (on system status screen, frequency must increase proportionally to machine speed)Not all speed are selected ‘© Check transmission safeties (system status) © Check if wheel rpm sensor is connected and working (on system status screen, frequency must increase proportionally to machine speed) Check if automatic transmission parameters are correct (transmission management) ‘© Check if speed selector is not in any position but F4 or R4 During shifting, engine loses power and boom can’t be moved Decrease ‘“declutch” timers in the shifting timing menu (programming mode) # Check if acceleration ramp to restore engine power is short enough (programming mode) Switching key off, engine does not shut off * Check if sign! “engine stop” is connected and working © Wait at least ten seconds before consider the fault (Powertronic can keep the engine at minimum for a while before shutting it off) During traveling, engine loses power Check if there is any speed limit control activated (system status or display) © Check if wheel rpm sensor is connected and working (on system status screen, frequency ‘must inerease proportionally to machine speed) 29 Gl wasneereerseces. TayAPPENDIX 1: Null-Modem Cable This cable is used in following conditions: © PC communication «Software update using the special tool Superloader DB9F 30 | [ANDERSSON SECIS RNCFANTUZZI| BLECTRONI Powertronic - V 1.2.x - 2577.010.0006 REGGIANE | DEPARTME! APPENDIX 2: Connectors Pin-out INPUTS (connector AMP 68 p) Stanal ei Description Type Notas iz 54 Waa oC bate POWER SUPPLY Fuse 2A be 3075055. 24 VOC ke se 30 be 28__ havoc key ND. 5.0675 NO int Pn = INPUTS RR 2 12 rine om (ck) DisTaUReN PN ME —Oaede ira 35 1 (GND 024) bsV=from shit iver int 19 pees? 74 = fom si av in 35 peas from shift ovr in ‘14 Fe speed ar baton ¥ iT 37 Engi san ee Vz only for VOLVO Eo ry 15 Jobing pec wh Vo ining: opens ncting kind 38 Paving bok acted v nid 16 ele swhoh aslo podat Vv =apiorle int 38 Babies ied Bev ~opsionie bint 47 neh ene. menvalaionatic 4 V fo si ver bins 10 hoe fom Lon ned sab) AV tom Lede fina 18 hock from Logon! dw sat) 4 V fom Legeenial fins 741 Foner ever Vem sit ever fae 19” Backward lever = em Tove rd 42 abn aware bon AUIS Pav optonat pte 20” [eabn backward bution DIGITAL zsV-opteral int 43 Reset engine ECU (24) ___b4V only or VOLVO Best fina 21 Emeivioas sit ans selection BABY BOARD 4 V— tom Leica bor 44 Ene shutoff = fom Logarta na m2 1 dors t in € iat pal HUTS. be Es to potonionsie (NT ANALOG. a Z psswoc} hie En = 2 ne at in? 2 it 2 RF 3 sve aiog power spy Resend i andoa nave . vo GND ___ Fuse 2A. Reserved fe ana pts 31 | spaseeny cay010.0006 OUTPUTS (connector AMP 68 p) ‘Shana! BIN Doser Notes tt 48 abi forwara = opbonal 2 47___babin optional 48 ate regulator pin 3 TMS = MEC — Galacte i 43 jon selector: pin 2 TMS INIOEF - MEG 5 (64) 64 Forward ev OFF, wy et dev ORE. 82 4 VOFE. 1 (4 oa eed 2 ev FF 2 eed 3 ev MORE, 2 dev IN/OFF = only for CAT tans 25 joe shut ot OFF - Cummins — MEC 3 5 ‘OUTeUTS = iu ‘ONIOFE E =. 4.324 VOC, ot [BABY BOARD 10 6 4 5 ‘27 fain GAN - ECOCAN 26 Main CAN - ECOCAN a Engine - SAE J1699 23 PAN Engine - SAE 11699 TMS Module: Actuator contro! - mechanical engines 7 Pa Bescripion ator arecion — pin 49ESK ator PW ~ pi 48 ESX oe forward pn 1 VDO. lor backwar pin 7 VDO" ND. ‘Actuator VDO on mechanical pump lever — mechanical engines ‘Signal Pu Desorption ue, ir Toward. pin 4 1S. row eec-back poleriometer ‘pin 23 EX elon ‘eed back polaniometer signal pin 29 €SX 8 eed-back polerilometer 3: In 1 ESK ite a] ick A ips TS, 32 ec SLERESOAS SESE REN y