Fimap MAGNA 65 Operating instructions

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 1 di 19
READ THE OPERATING AND MAINTENANCE MANUAL
Service of the Console
The console allows to:
-set the chopper card for a personalised behaviour of the traction motor
-read the type of the alarm for a correct and easy trouble shooting
-test the different electric values and the state of the electric circuit relative to the traction
Use of the Console
The use of the instrument is very easy and comparable to one of the most common electronic devices
(such as mobile phones).
The sequence to follow always for the console connection is:
1. SWITCH OFF THE GENERAL KEY of the machine
2. take off the connector E from the chopper
3. connect the console in place of the connector E. If the operation connection results to be difficult,
check that the connector is positioned in the correct direction.
4. switch on the key and work with the console
5. quit from all the programs (main menu of the ignition) and SWITCH OFF THE GENERAL KEY of the
machine
6. disconnect the console connector and plug in the connector E
THE WRONG OPERATION SEQUENCE CAN EASILY COMPROMISE
THE FUNCTIONALITY OF THE CHOPPER CARD OR OF THE CONSOLE

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 2 di 19
Menu of the Console
HEADING: the features of the console and of the chopper card: voltage and maximum current of the
chopper card, the working hours of the chopper card.
PARAMETER CHANGE: in this menu the parameters can be changed to personalise the machine. The
parameters that can be modified are : CUT BACK SPEED 1 (minimum speed machine) and the CUT BACK
SPEED 2 (medium speed machine). All the other parameters are decided in Fimap and they are
related to the traction motor. It is forbidden to change them without previous Fimap
authorisation.
TESTER: the quantities of the electric characteristics (traction motor voltage, state of power switch =
closed/open ...) are showed in this menu.
SAVE: this permits, once the parameters have been changed, to enter the new setting in a storage
location of the console.
RESTORE: this permits to restore on the chopper card a parameter setting which has been entered in
the console.
ALARMS: indicates a list of the last five alarms occurred on the machine. According to the alarm a
specific corrective action is adopted (see following paragraph).
PROGRAM VACC: this section is used to teach the chopper about the potentiometer which is assembled
on the machine. It is an operation to be carried when there is the alarm Vacc not ok, when the
pedal accelerator is being replaced, when the chopper card is being replaced. A wrong relation
between the potentiometer and the chopper card causes the machine stop.

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 3 di 19
Flow chart of the console
HEADING
PROGRAM
TESTER
LIST OF PARAMETERS
ROLL to select
PARAM SET to change
enter
out
enter
out DO YOU WANT TO
SAVE DATA ?
ENTER = change
OUT
=
no change
enter
enter
TEST LIST OF VALUES
to test
ROLL to select
PROGRAM
VACC
enter
out
Program for setting
pedal accelerator
MOTOR data
enter
out
R
O
L
L
R
O
L
L ente
r
out
enter
SAVE
enter
out
LIST OF free locations
Write on on a FREE
location
enter
enter
RESTORE
enter
out
LIST OF locations
(programs) to load on
the chopper card
Enter: Are you sure ?
ENTER = restore
OUT= no restore
out
Out: Are you sure?
ENTER = change
OUT= no change
enter / enter
ALARMS List of the last 5
alarms occurred
Out
This menù has
not to be
modified
This menù has
not to be
modified
Enter: Are you sure ?
ENTER = save
OUT= no save

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 4 di 19
Alarms and Decoder
The chopper card visualises an anomaly on two levels of information
1. through a red alarm led which blinks for a quantity of times relative to the type of anomaly
2. through a message on the console that specifies more details on the nature of the anomaly.
Following table reports for each alarm the possible anomaly and of how to proceed on the machine.
DIAGNOSIS LIST ALARMS
(for better understanding of the list refer also to the electrical layout)
Number of
blinkings MESSAGE NOTES
1 WATCH DOG
The test of self-diagnosis of the chopper card carried
out both on rest as in drive verifies an anomaly
Possible causes
-the logic of the chopper card is damaged
Actions
-replace the chopper card
1 EEPROM DATA KO
The data of the hourmeter inside the chopper card
Actions
-switch off and on again the key. If the problem will be
solved the counter will be reset.
1 EEPROM OFF LINE
The data of the hourmeter and of the alarm stored in
the chopper card are not correct
Actions
-switch off and on again the key. If the problem persists
replace the chopper card
-if the problem will be solved the data will be cancelled
1 EEPROM PAR KO
The memory of the chopper card has lost the
adjustment and operation data
Actions
-switch off and on again the key. If the problem persists
replace the chopper card
-if the problem will be solved the data will be replaced with
the standard data

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 5 di 19
Number of
blinkings MESSAGE NOTES
2 INCORRECT START
Incorrect starting sequence
Possible causes
-error in the sequence Key/drive selection made by the
operator
-the micro pedal and/or micro drive are stuck
-wiring not correct
Actions
check the starting sequence which is:
-switch on the key
-select drive (forwards/backwards)
-press the accelerator
-check that the drive microswitch and the manipulator
forward/backward traverse selector do not have the
contacts stuck and that they work correctly
-verify the continuity of the circuit that connects the micro
drive pedal, the chopper card and the drive manipulator.
3 VMN LOW
The first check recognises a voltage VMN lower than the
25% of the battery voltage
Possible causes
-wrong connections on the motor
-motor current leakage to the ground
Actions
-check that the motor terminals are well isolated from the
motor casing both inside and outside the motor. Verify that
there is not dirt that causes current leakage between the
terminals and the motor body
-verify that the motor is not wet and in case dry with an air
flow
-check that the connections on the motor and on the
chopper card are correct (verify the type of traction motor
assembled, the correct wiring and the connections on the
chopper VMN, positive and negative)
if the problem persists replace first the chopper card and, if
necessary, also the motor
3 VMN HIGH
Starting test check possible faults on the power circuit
branch .
Possible causes
-chopper power branch damaged
-MOSFET logic control damaged
Action
-replace the chopper card

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 6 di 19
4 VACC NOT OK
The chopper card recognizes an anomaly in the mechanical
stroke of the accelerator
Possible causes
-the operator switched on the machine with the
accelerator pressed down or he pressed down the
accelerator before the selection of forward or backward
traverse
-the seat microswitch does not work
-the potentiometer and/or the chopper card has been
changed and the relating values between the two
components are to be re-programmed
-a cable between the potentiometer and the chopper card is
interrupted
-the potentiometer is faulty
-the PROGRAM VACC (see chapter Adjustment and
Inspection) has not been carried out correctly
Actions
- check the correct sequence to get traverse
-check the continuity of connections between the
potentiometer accelerator and chopper card
-re-program the chopper card with PROGRAM VACC (see
chapter Adjustment and Inspection)
- check the functionality of the potentiometer (it could be
broken) and replace it if necessary (re-programming then
the chopper card)
5 I HIGH AT STAND
The chopper card tests if on rest the signal of the
current is zero. Otherwise, it blocks the traction
Possible causes
-defective current sensor
-fault in the feedback circuits, or in the logic or on the
chopper card
Actions
- replace the chopper card
6 NPOT NOT OK
Test on working condition: the negative point brings is
at a wrong
Possible causes
-the potentiometer is not well connected to the chopper card
-potentiometer defected
Actions
-check the good connections potentiometer – chopper card
-check the potentiometer efficiency

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 7 di 19
7 TH PROTECTION
The chopper card works out of the temperature range
(-30°C + 70°C)
Possible causes
-chopper card faulty
-the machine runs in braking condition and the chopper gets
overheated
Actions
-check the temperature of the site where the machine works
-check the consumption of the traction motor
8 DRIVER SHORTED
COIL SHORTED
The driver that controls the driver power switch do not
operate properly
Possible causes
-the driver is defected
Actions
-replace the chopper card
32
permanent
blink
BATTERY LOW
Battery level too low: the chopper card cuts the power to the
traction motor for its safeguard
Actions
check the charge of the batteries
check the cleanliness and the good connections on the
chopper card of the cable that come from the battery
permanent
switched on FORW BACK
The alarm is indicated when both the forward and backward
requests are activated simultaneously
Possible causes
-wiring not correct
-microswitch forward or backward stuck
Actions
-check the correct functionality of the contacts of the
manipulator
-verify the wiring relative to the manipulator
-if the defect persists replace the chopper card

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 8 di 19
Chopper card setting
1. Switch OFF the general key and plug in the special
connector. The OFF condition is necessary to save the
memory card from loss of data).
2. Switch ON the general key
3. The model of the card (name, volts and amps) and the chopper
working hours appear on the display MX v.2.1
HOURS .0
4. press ENTER to get the main menu
5. you read the first option of the main menu: PROGRAM= CHANGE
PARAMETERS
6. press ENTER again to enter in this first branch of the main menu
where you can check and eventually modify the parameters of the
card. To move through the parameters use the button ROLL and
check if you have the situation below mentioned:
* SELECT MENU *
1- PROGRAM
CHOPPER MX BASIC PROFY/
KLINIK
1. ACCELERATION DELAY 6 6 ACCELERAZIONE SECONDI
2. CUTBACK SPEED 1 9 0 I RIDUZIONE DI VELOCITA' % VOLT
3. CUTBACK SPEED 2 6 6 II RIDUZIONE DI VELOCITA' % VOLT
4. COMPENSATION 9 4 COMPENSAZIONE DI POTENZA % AMP
5. TRACTION IMAX 9 9 CORRENTE MASSIMA % AMP
6. BRAKING 5 5 FRENATURA IN RALLENTAMENTO % AMP
7. RELEASE BRAKING 2 2 FRENATURA A RILASCIO % AMP
8. INVERSION BRAKING 1 1 FRENATURA INVERSIONE MARCIA % AMP
9. MAX SPEED FORW 9 9 MASSIMA VELOCITA' AVANTI % VOLT
10.MAX SPEED BACK 8 8 MASSIMA VELOCITA' INDIETRO % VOLT
11.CREEP SPEED 1 1 VELOCITA' MINIMA DI PARTENZA % VOLT

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 9 di 19
7. At the end press OUT and confirm ENTER if some parameter has been changed.
ATTENTION: PLEASE DO NOT CHANGE ANY PARAMETERS RELATED TO THE SAFETY
USE CONDITION OF THE MACHINE LIKE THE ONCE RELATED TO ACCELERATION,
BREAKING,. ECC. ONLY THE DIFFERENT SPEED VALUES CAN BE MODIFIED (CUTBACK
SPEED 1 – 2 and MAX SPEED FORWARD)
IN CASE OF LOSS OF DATA:
To set automatically the right values of all the parameters please
find out the menu "RESTORE PARAM." by using the ROLL button * SELECT MENU *
4 - RESTORE
1. Press ENTER
2. SELECT the program Mod. 03 (or the memory where the list has
been stored with the SAVE program). Use the ROLL button to run
through)
SELECT PROGRAM:
Mod. 03
3. Press ENTER to confirm the restore operation
4. Answer to the question “ARE YOU SURE?” by pressing ENTER to
confirm the operation (OUT to cancel and exit) ARE YOU SURE?
YES=ENTER NO=OUT
5. Press ENTER to confirm the restoring operation
6. Wait until the message WAIT stands still written on the display WAIT!
7. When all the parameters are refreshed and updated the heading
specified on the left appears on the display: SELECT MENU
RESTORE

ADJUSTMENT
AND
INSPECTION MAGNA 65-70-75-83 Doc. 10004978
Issued 27/03/2008
Rev. 00
Pag. 10 di 19
PROGRAM VACC
8. Run through the different menus moving from the menu RESTORE
to the menu PROGRAM VACC (to relate the pedal accelerator
stroke to the chopper card)
BE CAREFUL: EACH TIME YOU REPLACE THE CHOPPER CARD
AND/OR THE PEDAL ACCELERATOR THE FOLLOWING
INSTRUCTIONS MUST BE DONE
SELECT MENU
RESTORE PARAM.
9. Stop your run when you read “PROGRAM VACC”
10.Press ENTER to go into the menu
SELECT MENU
PROGRAM VACC
11.You read first the values set up on the chopper that have to be
refreshed. VACC SETTING
4,8 4,8
12.Press ENTER again to be ready to teach to the chopper card the new
stroke
13.Now you can start your operations: 0.0 0.0
14.Select the forward drive direction and press down slowly the pedal
from the top until the end of its stroke
15.Repeat the same operation with the backward drive direction
16.You can read now on the screen the new values FORW BACK
4,9 4,9
17.Press OUT
18.Read the two different choice to go ahead: ENTER to confirm the
new values, OUT to cancel and exit
ARE YOU SURE?
YES = ENTER NO =
OUT
19.Press ENTER to confirm
20.Run through the different menus to come back to the heading as
showed on the left SELECT MENU
PROGRAM
21.Press OUT to come back to the main heading. SWITCH OFF the
key and then disconnect the console. MX V.2.1
HOURS