Fimap MR60 User manual

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 1 di 16
VALIDITY
This document has validity since the serial number n° 211007724
Modification comparing to the previous document
Ref. Pag Description
2 Update picture for chopper card.
7 New pictures a d refere ce for MR 65-75-85
13 New pictures a d refere ce for MR 65-75-85
14 Update pictures for squeegee

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 2 di 16
READ THE USE A D MAI TE A CE MA UAL
CO SOLE CO FIGURATIO S A D SETTI GS
Console Services
The co sole allows you to:
- Program the chopper card to e sure the correct behaviour of the machi e;
- Test the electric compo e ts a d circuit regardi g the tractio system.
- Read the alarms to ide tify the error code easily.
Console use
The correct seque ce to co ect the co sole is:
1. TURN OFF the machi e by tur i g the mai key.
2. Co ect the co sole to the chopper card via the co ector o the board.
3. Tur o the machi e a d operate with the co sole.
4. Whe fi ish TURN OFF the machi e.
5. Disco ect the co sole from the machi e.
A BAD SEQUENCE N CONNECT NG AND UNCONNECT NG THE CONSOLE CAN EAS LY
DAMAGE THE CARD OR THE CONSOLE.

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 3 di 16
ALARM TABLE
Message Alarm What to do
ALARM A1
FW Switch ON Forward micro-switch on in turning on.
Put the potentiometer in idle position and
check that the forward micro-switch is
open.
ALARM A2
BW Switch ON Backward micro-switch on in turning on. Let the pedal stay in idle position and open the backward micro-switch.
ALARM A3
Pot. FAULT Potentiometer error Check the potentiometer harness.
ALARM A4
Ref OUT Neutral Potentiometer not correclty positioned
Put the potentiometer in the idle position
or if it already is in the right position,
adjust the potentiometer program.
ALARM A5
Over temperature Thermal protection Wait for 5 minutes and then check the traction motor absorption rate.
ALARM A6
POWER STAGE Damaged power stage Replace the chopper card.
ALARM A7
OVERCURRENT Overcurrent Check the motor cables: If connections
are regular and repeat the alarm, replace
the chopper card.
ALARM A8 POWER
FUSE/RELAY Power fuse or internal contactor damaged
Check the fuse on the + battery and
wiring, replace the chopper card if it
persists (General relay damaged).
ALARM A9
UNDERVOLTAGE Undervoltage Check the batteries for poor voltage.
ALARM A10
OVERVOLTAGE Overvoltage Battery voltage greater than 45V: check battery status
ALARM A11
Overload Current Current protection Check the motor current and possibly trim the electronic current control
ALARM A12
DISABLE ON Disabling active Check the status of the disabled.
ALARM A13
KEY-OFF Turn off sequence active Check the wiring on the ignition power key.
ALARM A14
EEPROM FAIL E²prom data reading failed Check the settings: if the alarm is repeated, replace the chopper card.

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 4 di 16
CHOPPER CARD CO FIGURATIO
Console Code: 431320
To e ter the parameter list:
1. Press the “MODE” butto .
2. The first parameter descriptio will appear, pressi g up or dow it is possible to scroll the
parameter list.
3. O ce o the parameter you wa t to cha ge, press the “MODE” butto to e ter i to the
parameter to modify the co figuratio (i modificatio co ditio the parameter
descriptio will bli k).
4. Cha ge the value usi g the “UP” a d “DOWN” butto s. O ce co figured correctly co firm
the cha ges by pressi g the “MODE” butto , this will co firm the cha ges.

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 5 di 16
PARAMETERS:
PARAMETER DEFAULT MMG
RESET TO DEFAULT D SABLE D SABLE
ACCELERATION RAMP
3 3
REVERSE RAMP 1,5 1,5
NEUTRAL RAMP 1 1
FORWARD SPEED 100 100
BACKWARD SPEED 60 60
MINIMUM SPEED 0 0
BATTERY VOLTAGE 24 24
SPEED REFERENCE si gle-e ded single-ended
REF. DEADBAND 0,2 50mV
BRAKE DELAY 2 0,5
MULTIMODE SPEED 50 50
MULTIMODE CURRENT
25 45
BW SAFETY TIME 0 0
BW SAFETY SPEED 0 0
LOW BATTERY 19 19
TIMEOUT RUN AWAIT
0 60
RUN-AWAY 0 14
CURRENT LIMIT 45 90
RATED CURRENT 15 25
OVERLOAD TIME 60 60
5-J1 HW CONFIG N.C. switch N.O. switch
6-J1 HW CONFIG N.O. switch N.C. switch
11-J1 HW CONFIG N.O. switch N.O. switch
ENABLE ALARM 1 ENABLE ENABLE
ENABLE ALARM 2 ENABLE ENABLE
ENABLE ALARM 3 ENABLE ENABLE
ENABLE ALARM 4 ENABLE ENABLE
ENABLE ALARM 12 ENABLE D SABLE
PASSWORD 0 0

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 6 di 16
POTENTIOMETER SETTINGS
(Resister Settings)
1) Ensure the machine is TURNED OFF.
2) Connect the console to the machine.
3) Turn on the machine.
4) Enter into the parameter list using the “MODE” button.
5) Scroll down the list until you reach the parameter “Speed reference appears”
6) Press the “MODE” to enter into parameter to change the settings as below.
SPEED REFERENCE
single-ended
Select the “single-ended” option and confirm with “MODE”
CALIBRATION
Stop pos = 0.6 V
Put the pedal in the idle condition and confirm its value
using the “MODE” button.
CALIBRATION
Max pos = 2.7 V
Press completely the potentiometer and confirm the value
using the “MODE” button.
7) Turn off the Machine.
8) Disconnect the console.
9) Turn on the machine and perform a functional test to verify the adjustment.

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 7 di 16
Electric installation adjustment
1. Check
the electric installation functionality: switches,
contactors, motors, solenoid valve, power fuses and
thermal switches.
MR 60
MR 65/75/85

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 8 di 16
2. Check
the functionality and the potentiometer conditions
and the conditions of the direction micro-switches.
3. Check that when the micro-switch is pressed there
is about
0, mm of micro-switch lever movement clearance.
4. Check the conditions and the
connections of the power
cables and battery charger (option).

ADJUSTMENT AND
Battery check card adjustment
1. Check that when
turning on the machine the battery check
card has the following starting sequence:
-
Turning on of the LED which corres ond to the set
LED = “0”).
-
Turning on of all the LEDs (check of the lam s)
-
Turning on of the LEDs de ending on the charge of the
battery
2.
Check the hour meter is functioning correctly.
To check the settings
you sim ly need to turn on the machine
and check which is the fi
rst LED that turns on. Counting the
LEDs from
the left side any LED corres ond to a osition and
the LED which turn on
corres ond to the current set
Check that if the machine
is using
adjustment is on osition 1.
Check
that if the machine
adjustment is on osition 4.
WARNING: A wrong set-
u of the battery control card
com romise the ba
ttery efficiency and damage them
ermantely.
Battery charger adjustment
1. Check
that the battery charger set u is correct for the
battery ty e used on the machine.
2.
To adjust the battery charger act as follow:
-Lift u the sticker
on the front art of the battery charger.
-
Set u the di switches under the sticker following the
inst
ructions of the table below.
-Put the sticker
in its original osition.
ADJUSTMENT AND
INSPECTION MR60 65/75/85
Battery check card adjustment
turning on the machine the battery check
card has the following starting sequence:
Turning on of the LED which corres ond to the set
-u (red
Turning on of all the LEDs (check of the lam s)
Turning on of the LEDs de ending on the charge of the
Check the hour meter is functioning correctly.
you sim ly need to turn on the machine
rst LED that turns on. Counting the
the left side any LED corres ond to a osition and
corres ond to the current set
-u .
is using
wet cell batteries the
that if the machine
is using
GEL batteries the
u of the battery control card
will
ttery efficiency and damage them
Battery charger adjustment
that the battery charger set u is correct for the
battery ty e used on the machine.
To adjust the battery charger act as follow:
on the front art of the battery charger.
Set u the di switches under the sticker following the
ructions of the table below.
in its original osition.
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 9 di 16

ADJUSTMENT AND
INSPECTION MR60 65/75/85
Doc. 10023982
Emesso Giugno 2011
Ver. AB
Pag. 10 di 16
Battery charger with serial number from 470878.
Under the plastic cover you can see the dip switches as the
picture shows.
The dip switches has to be setted up as follow:
DP1 – DP2: Charge curve selection
GEL TROJAN
DP1 DP2
ON ON
WET CELL
DP1 DP2
ON OFF
GENERIC GEL o AGM
DP1 DP2
OFF ON
GEL EXIDE SONNENSCHEIN
DP1 DP2
OFF OFF
Other switches NCHANGEABLES
DP3 DP4 DP5 DP6 DP7 DP8
ON ON ON OFF OFF ON
Read carefully the battery charger use and maintenance manual
Charger warning codes:
ERROR
MESSAGE
CAUSE WHAT TO DO
E01 Over voltage on the
battery
Check the battery installed on the machine, the
installation of the power connections and the quality of
the power cables.
E02 Over temp of an
external probe.
Restart the battery charger if the problem is still there,
replace the battery charger.
E03 Charging phase issue Check the battery conditions and, if necessary, replace it.
SCt Charging cycle taking
too long
Check the battery conditions and, if necessary, replace it.
SCr Internal short circuit Replace the battery charger