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tse1000/tse550/tse600 drive motor controller product manual

1. 20 A BEFORE YOU BEGIN tetro Geen ete ite tme 20 B MOUNTING THE CONTROLLER emen 21 C WIRING etapas 21 1 COnnectingEOWEE css sex s6 xi tr dai 21 2 Connecting the 8 Pin Harness sese 21 3 Connecting Input Switches eese 22 4 Wiring Harness Identification s5 se eriee 25 S Power Cables tet eret IEEE 26 D PROGRAMMING THE CONTROLLER TO SUIT THE TRUCK 41 L R quired SettiDgs oos de tee e ee 1011011492 41 2 Optional Set ngs 4 oet prete diete nir bed 41 3 Programmable Parameters rea 42 E POWERING UP THE TRUCK eater Rire ipe eee e Q46 44 F INSTALLATION PROBLEM IDENTIFICATION een 44 L Installation Basics eret a tegeret 44 2 Itthe Diagnostics Pails oiu Rede ittis 44 IV ADJUSTING TRUCK PERFORMANCEA 51 A gt DRIVING FEEL nisse GE 51 L Speed and Acceleration cette i 51 2 BRAKING sess bh oe eo ita 51 3 Speed Limits Cutbacks 51 B TIME DELAY L u a aan ap te ten ee e eee e dei 51 1 Contactor Change Tll me eese eene 51 2 Direction Change Forgive Time eE eeseeeseers 52 3 SRO Debounce Time tree EI ee IT Le benkene 52 4 Power Steering
2. 9 650 ls NM on e 9 400 7 900 S CONTROLS 5 125 6 000 Figure 1 Mechanical Layout Navitas Technologies Ltd 6 Power Wiring Schematic The following diagram represents the flow of power through an electric vehicle using an TSE1000 TSE550 000 Battery Sense e Direction Contactors Armature Accelerator amp Other Inputs SE325 175 Micro MOSFET s processor Plug Transistors Control Braking Diodes Contactor SRE Drives Bus Field Figure 2 General Power Wiring Layout Navitas Technologies Ltd IL HOW IT WORKS The following section describes in detail how the controller works This section covers all of the vehicle s switches contactors and other controls as well as current limits interlocks and other functions of the controller If a particular feature is programmable you will find the programming icon the picture of the ProBit shown below beside the programming instructions The step by step instructions for wiring are found in Chapter II Installation Procedures beginning on page 20 A KEY SWITCH The key switch provides battery voltage to the controller and therefore the controller will not work until this switch is connected The controller requires a 10 20 Amp fuse at this switch B PLUG BRAKING Plug braking lets the driver change directions without stopping the truck first The cont
3. AN y TL 1 TSE1000 TSE550 TSE600 DRIVE MOTOR CONTROLLER PRODUCT MANUAL VERSION 2 1 Change this Update Version Copyright O 2015 by Navitas Vehicle Systems Ltd Navitas Vehicle Systems Ltd 500 Dotzert Crt Waterloo Ontario N2L 6A7 TABLE OF CONTENTS TABLE OF CONTENTS 1I L INTRODUCTION ssssesosssssssssisssorescsessssssosssoesosossesssessorsssessssssssosssssscossss Ay ABOUT THIS MANUAL eiii rra ient etn ip tarte casan eine 1 B THE FUNDAMENTALS OF NAVITAS TECHNOLOGY 2 C TSE1000 AND TSE550 MOTOR CONTROLLERS 2 1 Reduced Maintenance and Repair en 3 2 Improved Performance esee ene een enne 3 3 Fleet Managementa nx oed 3 4 Driver Safety and Vehicle ProtecfIOI eene 4 3z Exterior Dimensions assess estas nest aai ge e wees 5 6 Power Wiring Schematic eee 6 A KEY SWITCH scsi sir o DIOC 7 B PLUG BRAKING uti tede ee qom eed eee 7 C SAFE SEQUENCING ted ette aede 11 61081146 i e eT data ender 8 D DEAD MAN SWITCH SRO SWITCH asss 8 E ACCELERATOR SWITCH AND SERVICE BRAKE SWITCH 8 E ACCELERATOR us S retient i e tnc stet 8 1 Throttle minimum and Throttle maximum 9 2 Drive Feel
4. Orange Blue Green Red Ly v d C1 C8 Figure 9 Connector Pins Navitas Technologies Ltd 5 Power Cables Before connecting the power cables you need to know what kind of motor you have The most common motor is 4T meaning it has four terminals however the TSE1000 TSE550 TSE600 supports 3T 5T and 6T motors as well 3T Wire the motor as in the 3T Motor Wiring Diagram page 27 4T Wire the motor as in the 4T Motor Wiring Diagram page 30 and refer to the step by step instructions for the 4T motor given on page 29 ST Wiring for 5T motors takes some interpretation because motor manufacturers aren t consistent in the way they label the terminals and because there is more than one way to connect the two fields See 5T Motors page 31 for complete details 6T These motors are also not labeled consistently Complete details are given in 6T Motors on p 35 NOTE An emergency battery disconnect device and a main fuse 400 Amp for the TSE1000 and 250 Amp for the TSE550 is recommended must be used between the battery positive and the controller 26 Navitas Technologies Ltd ST Motor N lt E E FORWARD REVERSE Optional o BYPASS i l B A F A F B Fuse SE325 SE175 Disconnect Battery Figure 10 3T Motor Wiring Diagram a 3T Motor Navitas Technologies Ltd 28 Navitas Technologies Ltd b 4T Motors The foll
5. key switch 7 22 trouble shooting 44 I Installation 21 Interlocks 14 accelerator service brake 8 15 lift pump 42 speed limit switches 13 SRO 14 throttle direction 9 K Key Switch 7 wiring 22 L Lift Pump 11 interlock 42 55 lift time 19 used with speed limits 13 wiring 23 M Maintenance periodic maintenance 54 PM clock 19 reduced 3 MOSFETs 2 4 Motor 3T 29 AT 30 31 ST 32 34 35 6T 36 38 39 current limits 16 55 programming 16 trouble shooting 46 47 49 wiring 28 P Plug Braking 7 58 programming 40 50 direction change time 51 parameters 42 trouble shooting 49 Navitas Technologies Ltd Potentiometer 8 21 types 10 wiring 24 Programmins 2 40 acceleration 40 50 battery voltage 40 BDI 14 bypass 12 41 contactor change time 40 50 contactor voltage 40 debounce time 51 direction change time 51 drive feel 50 field weakening 13 41 lift SRO interlock 12 parameters table 41 plug braking 40 50 resetting timers 55 speed limits 13 41 50 steering continuation 11 51 throttle 40 throttle polarity 9 top speed 40 50 R RTN return to neutral dead man switch 8 interlocks 15 safe sequencing 8 throttle 8 S Safe Sequencing 4 8 59 linked to lift pump 12 throttle settings 9 trouble shooting throttle settings 45 SCRs 2 Seat Switch 24 service brake interlock 4 Service Brake Switch 8 Specifications di
6. 1 Reduced Maintenance and Repair 2 Improved Performance The TSE1000 TSE550 TSE600 use highly efficient MOSFETs instead of SCRs SCR controls create a lot of heat while they operate This heat shortens the life of those controllers and can set the truck into thermal cutback In contrast the TSE1000 TSE550 TSE600 performs at lower temperatures and does not waste energy through heat dissipation The TSE1000 TSE550 TSE600 also offers more than twenty programmable performance settings You can use your controller with the factory preset levels or you can program the controller to suit the strengths and weaknesses of your particular vehicle 3 Fleet Management A unique feature of NAVITAS technology is the ability to collect information about vehicle use The TSE1000 TSE550 clocks on times drive times and lift times making fleet management statistics readily available Managers can more easily collect accurate information on average time to repair justify the purchase of new vehicles or determine how to make better use of the current fleet In addition each TSE1000 TSE550 TSE600 can store the settings for several operators so that the same truck can be used safely and efficiently in more than one shift Navitas Technologies Ltd 4 Driver Safety and Vehicle Protection The TSE1000 TSE550 includes standard features which increase the safety of operation and protect the vehicle from misuse These features include several interlocks and a numbe
7. As you press the accelerator use a current meter to measure the current into the A1 terminal of the motor If the reading is greater than 200 Amps there is a short somewhere in the motor 47 Navitas Technologies Ltd PROBLEM TRUCK CANNOT REACH TOP SPEED OR THE TRUCK APPEARS TO BE IN CUTBACK 1 CHECK Are the speed limits OK O Check all the speed limit inputs into the controller The speed levels for these switches may be set too low or a speed limit input may have been connected accidentally In either case the truck might not have enough power to start from a stop TO TEST 1 Check the voltage between each speed limit cutback input and B You should read no voltage at these inputs 2 If speed limits have been wired in temporarily disconnect them If the problem disappears when speed limits are disconnected you may have to increase the maximum speed for these inputs Plug in the ProBit and put the truck up on blocks so you can see the wheels move at low levels and try raising the speed limits O Check the maximum speed setting to make sure it is not too low If it is too low the truck may not be getting the power it needs to start from a stop TO TEST Plug in the ProBit and check that the Maximum Speed is not set too low This level will be different for each truck and each situation 2 CHECK Is the controller in cutback O Check whether any of the TSE1000 TSE550 TSE600 cutbacks have been set off For example if t
8. CONTROLLER PASSES STARTUP DIAGNOSTICS BUT WHEN A DIRECTION IS SELECTED THE DIRECTION CONTACTOR AND POWER STEERING PUMP CONTACTOR BOTH COME IN AND IMMEDIATELY FALL OUT AGAIN 1 CHECK Is the steering pump contactor OK 9 Check for shorts in the power steering pump contactor coil TO TEST Use an Ohm meter to measure the resistance across the coil You should read more than 5 Ohms 2 CHECK Is the contactor voltage parameter set correctly O Check whether or not all the contactors voltage setting will work for all the truck s contactor coils If the truck uses contactors with different voltages the contactor voltage that you have set may be OK for the direction contactors but too high or too low for the pump contactor coils In this case you should replace the contactors so all of them have the same voltage You can try setting the contactor coil voltage somewhere in between the different coil voltages to see if you can find a voltage that works but we strongly recommend that you use contactor coils with the same rating PROBLEM THE TRUCK RUNS BUT PLUGGING IS MUCH TOO HARSH OR MUCH TOO SOFT 1 CHECK Is the A F bar on the controller wired properly O Make sure that the A F bar is properly connected to the A2 terminal on the motor AND to the normally closed terminal of both direction contactors 2 CHECK Are the plug braking parameters set correctly O Check the setting for plug braking strength and decceleration You m
9. F3 are mixed up and you will have to interchange them Disconnect the battery with the key switch on to discharge the capacitors and then turn the key switch off Switch the wires on F1 and F3 and re lable the terminals Test the truck again 9 If the wheels spin forward when the direction selector is forward the truck is wired correctly 2 Fields for Weakening 1 Choose the terminal which you think is shared by both field windings Label this terminal F2 If you are not sure which is which you can guess In step 7 you will be able to tell if this guess is right 2 In the same way you can guess which terminal is F1 and which is F3 and label them At this point you should ignore the field weakening contactor and leave F2 unconnected Wire the truck as shown in the 5T Motor Wiring Diagram Fields for Weakening p 34 Review the instructions for connecting the 4T motor if necessary 3 After completing the wiring check to make sure the connections are correct especially around the forward and reverse contactors Plug in the battery and turn on the key switch If you do not hear the forward contactor and then the reverse contactor pull in refer to section F Installation Problem Identification on p 44 31 Navitas Technologies Ltd 4 Before testing the truck set the parameters as described in section Programming the Controller To Suit the Truck p 41 5 With the truck still on blocks power up the controller Slowly drive
10. SRO input is connected to B before the direction selector is engaged and before the accelerator is activated The SRO must remain connected to B and the direction must remain selected for the SRO to remain satisfied SRO forgive times allow the SRO input to be temporarily disconnected from B for example the driver bounces from the seat momentarily and the direction input selector to be temporarily in neutral for example changing directions for plug braking This time is set at 1 4 second Under some conditions the controller forces an RTN Return to Neutral This happens for example when the battery current limit is momentarily exceeded or the controller finds a contactor error When an RTN occurs the SRO must be satisfied again see Safe Sequencing p 8 Navitas Technologies Ltd 2 Brake Accelerator Switch This input must be connected to B When it is not connected to B the motor output is 0 although the contactors will operate 3 Battery Discharge The Battery Discharge interlock prevents batteries from discharging too deeply See Battery Discharge Interlock p 14 Q LOW VOLTAGE CUTOUT If under any circumstances the battery voltage falls below 18 volts the controller will shut down It will not operate any contactors or provide any output and other network devices may not be active R TEMPERATURE LIMITS If the controller temperature exceeds 85 C the controller limits the motor current in an attempt
11. at a lower speed 3 Motor Current Limit Electric DC motors typically have two different current ratings 1 An absolute maximum peak current Any draw above this level will damage the motor via arcing at the brushes etc 2 A design current rating If this limit is exceeded for long periods of time or on a frequent basis the motor will deteriorate through overheating 15 Navitas Technologies Ltd You can set separate levels for these two limits in the current limits section of the ProBit a Peak Limit The peak limit protects the motor brushes and commutator from the effects of short term current demands High torque conditions such as stalling draw currents that can exceed this limit If the limit is exceeded the controller decreases motor output until the current is lower than the limit Using the ProBit you should set this level to the absolute maximum current that the motor can withstand Manufacturer s specifications for the motor will list this level for each motor b Average Limit Although electric motors can handle large current draws for a short period of time the continuous duty current that they can withstand is generally much lower Continuing currents larger than the continuous rating of the motor will burn out the motor windings The TSE1000 TSE550 TSE600 lets you set the average limit separately from the peak limit If the average current to the motor exceeds this limit the controller decreases the
12. driver must operate the truck s controls The order is as follows 1 satisfy the SRO sit on the seat of a rider stand on the floor panel of a standup or lower the operating arm of a walkie 2 select a direction 3 press the accelerator The controller will not operate the truck if these steps are taken out of order 59 Navitas Technologies Ltd SRO Static Return to Off A safety feature cotrolled by the circuitry of the truck Most trucks contain a switch or series of switches designed to ensure that the operator is in control of the vehicle As long as the switches are closed the controller will function normally If one of the switches opens the controller should shut down since the operator may no longer be in safe control of the vehicle The most common SRO switches are the seat switch in a sit down truck and the foot pedal in a standup System Error This term refers to problems in the operation of the truck and its parts For example a welded contactor overheating low battery voltage When a system error occurs the controller shuts off power to the drive motor 60 VII INDEX 1 A see Bypass A Acceleration drive feel 9 50 for speed limit switches 13 programming 40 42 Accelerator 8 21 accelerator switch 8 programming 40 switch 15 trouble shooting 46 trouble shooting 45 46 types 10 wiring 23 24 B Battery Discharge Interlock 4 12 14 55 trouble shooting 53 Belly Button Swi
13. if you have contactors that are new or in good repair 2 Direction Change Forgive Time The controller has an adjustable forgive time to allow the driver to brake plug braking by changing directions If the direction switches stay in neutral for longer than this forgive time the driver must go through the startup sequence again before the controller will produce an output 3 SRO Debounce Time The SRO debounce time is the maximum time that the SRO dead man switch can be disconnected without setting off the SRO protection Normally whenever the SRO switch is disconnected the TSE1000 TSE550 TSE600 will return the truck to neutral The SRO debounce time however allows the SRO to be disconnected momentarily for instance when the driver shifts position or bounces from the seat This time is set at 0 255 seconds 4 Power Steering Continuation After the direction switches have returned to neutral or an SRO is set off the steering pump contactor is left on for a preset time to allow powered steering while the truck may be coasting This time may be adjusted to suit individual preferences 52 Navitas Technologies Ltd V SERVICING YOUR TRUCK AND CONTROLLER 1 Trouble Shooting The table below gives a point form list of some of the problems and causes a lift truck might experience In general these problems will only occur if wiring has come loose or been changed or if components are wearing out If you require installation t
14. is selected O Check the direction switch inputs to the controller to make sure they are properly connected TO TEST Use a voltmeter to measure the voltage between each input and B You should read full battery voltage O Check the direction contactor connections to the motor Field windings to ensure that the A F bar is connected to the normally closed side of the direction contactors 2 CHECK Is field weakening working properly O Check whether field weakening is installed properly if you have wired it in TO TEST Temporarily disconnect the field weakening contactor and recheck the operation of the truck If the truck works in both directions without field weakening check that the common terminal and normally open terminal of the field weakening contactor are connected to the common terminals of the direction contactors 3 CHECK Are the motor fields wired properly 49 Navitas Technologies Ltd 9 Double check the motor wiring especially if you are working with a ST or 6T motor see the Power Cables section pages 26 to 39 If the field windings are not polarized correctly one field winding may cancel the other in one or both directions TO TEST Place a current meter on the A terminal of the controller leading to the Al terminal on the motor Select the direction that is not working and press on the accelerator throttle If you get a high current reading then the fields are canceling one another PROBLEM THE
15. it tracks are the battery capacity for use in BDI and various times relating to the truck s operation Battery Discharge estimate of the usable charge remaining in the battery Periodic Maintenance Clock time since last maintenance check Operating Time total amount of time power has been on Lifting Time total amount of time the pump contactor has been on total time the truck has been out of neutral SRO Time total time the SRO switch has been on Table 5 Data Logging 1 Periodic Maintenance PM Time This clock keeps track of the time elapsed since the last maintenance on the truck In order for the system to work properly the clock should be cleared each time maintenance is performed on the truck 18 Navitas Technologies Ltd 2 Operating Time This clock tracks the total amount of time that the controller has been on This time cannot be cleared and continues through the life of the controller 3 Lifting Time This clock tracks the amount of time that the lift pump contactor has been on since it was last cleared If the lift pump contactor is not wired to the TSE1000 TSE550 TSE600 controller i e if a separate lift pump controller is used then this clock will always be 0 4 SRO Time This clock keeps track of the amount of time that the SRO or dead man switch has been on since it was last cleared 5 Running Time This clock keeps track of the amount of time that the truck has been running i e the time a dir
16. key switch Reconnect the battery and turn on the key switch i If you are using a field weakening contactor use the ProBit to set the field weakening parameters as discussed n Field Weakening p 12 F1 F2 F1 P Fi LI F2 PE F2 Parallel Single Series F1 Series Single Figure 14 6T Field Configurations NOTE For clarity the direction contactors are not shown 36 Navitas Technologies Ltd FORWARD REVERSE SE325 SE175 Disconnect Battery Figure 15 6t Motor Wiring Diagram Series Single Navitas Technologies Ltd 38 Navitas Technologies Ltd FORWARD REVERSE SE325 SE175 Disconnect Battery Figure 16 6t Motor Wiring Diagram Parallel Navitas Technologies Ltd 40 Navitas Technologies Ltd D PROGRAMMING THE CONTROLLER TO SUIT THE TRUCK 1 Required Settings Before running the truck you must set the following parameters with the ProBit For more information on how to set these levels please see the ProBit manual Battery voltage The battery voltage parameter must be set to the voltage rating for the battery This information is required for the battery discharge interlock to work correctly and for the contactor voltage settings to be correct Contactor voltage As shipped the contactor voltage is set to B In other words whatever voltage you set for B will automatically be set for the contactors You can adjust the contactor vol
17. motor current to a safer level In this way the controller allows large peak currents and thus peak torque s while still protecting against the damage caused by prolonged lugging or truck misuse such as attempting to pull more than the truck was designed for 4 Controller Limits The final current limit protects the controller against excessively high current levels This limit varies with battery voltage temperature and other factors The levels described here show the worst case you might experience The limits for the TSE1000 are illustrated here in Figure 6 and those for the TSE550 are shown in Figure 7 below During periods of peak current the controller uses a protective control algorithm to provide the highest possible currents without damaging the system As the temperature of the controller increases the controller will begin to use this algorithm sooner i e at lower currents and will lower the maximum allowable peak current At temperatures above 85 C the current limit is reduced significantly The controller is shut down at 95 C Maximum Motor Current 0 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 Temperature degrees C Figure 6 Maximum allowable motor current for TSE1000 16 Navitas Technologies Ltd 600 500 400 300 200 ET E g H 4 3 H o d El 100 0 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 Temperature degrees C Figure 7 Maximum allowable motor cur
18. of error codes is outlined in the tables below See the ProBit Manual for a complete list If the controller fails any of these tests it will disable the truck Each time the key is turned off and on the diagnostics will run again and continue to fail until the problem is solved Navitas Technologies Ltd ERROR start up DESCRIPTION Sticky direction contactor Either a direction contactor is welded or there is a short between F and AF 21 Bypass contactor error Either the bypass contactor is welded or there is a short between F and AF been found been found Table 3 Errors Recorded During Start Up Diagnostics ERROR run time DESCRIPTION o Parameter fault The controller found and corrected an error in the parameters Battery current limit The current limit for the battery has been exceeded Direction switch conflict Both direction switches were selected at the same time Shorted lift contactor The lift contactor is shorted or drawing too much current Other shorted contactor One of the vehicle s other contactors is shorted Welded direction contactor One of the direction contactors is welded 35 Welded bypass contactor The controller is being bypassed either by a welded contactor or a critical malfunction in the controller Table 4 Errors Recorded During Run Time Diagnostics 2 Data Logging The TSE1000 TSE550 TSE600 controller keeps track of the operating conditions of the truck for later use Some of the items
19. of the pump contactor coil through the lift and tilt switches in parallel to the switched side of the key switch O Connect the brown wire to the negative side of the pump contactor coil All models use a lift pump to control the main lift but some also use an auxiliary pump to control steering tilting and side shifting If you are installing the controller without a pump controller in one of these models connect it as follows Connect the pump contactor coil to the lift switch Connect the auxiliary pump as in the instructions for the steering pump 3 Connecting Input Switches 9 Plug the 9 wire harness onto the upper right hand set of pins Make sure that the white black wire is connected to the last pin on the right Refer to Connector Pins on p 25 a Service Brake Accelerator Switch The white black wire is used to connect both the service brake switch and the accelerator switch If the truck has a brake switch it must be a normally closed switch i e open when you the service brake is on If the truck has an accelerator switch it must be a normally open switch i e closed when you step on the accelerator If the truck has both switches they must be connected in series The white black wire must then be connected to the switched side of the key switch 22 Navitas Technologies Ltd b SRO The static return to off switch is connected according to the class of truck as follows Riders run the white red wire
20. the bypass nor the field weakening contactor can be pulled in The second parameter is called the pull in level Field weakening is activated when the motor voltage is above Bypass level but the motor current is lower than the pull in level The pull out level is the motor current above which the field weakening contactor will pull out The following table shows how these three levels work together VOLTAGE HIGHER VOLTAGE LOWER THAN THAN BYPASS LEVEL BYPASS LEVEL MOTOR current ower Tili weakening Til vinis THAN PULL IN LEVEL P presi MOTOR CURRENT HIGHER Doida FE wenn THAN PULL IN LEVEL AND 77 y ps out MOTOR CURRENT LOWER I THAN PULL OUT LEVEL Field weakening Field weakening contactor drops out contactor drops out MOTOR CURRENT HIGHER THAN PULL OUT LEVEL Table 2 Field Weakening Functioning NOTE The pull in level MUST be less than the pull out level L SPEED LIMIT SWITCHES Speed Limit Switches also called Cutback Switches allow you to limit the motor voltage which controls speed when the truck is operating under specified conditions For example you can program the truck so that the top speed cuts back whenever the mast is fully raised There are three speed limit switches which can be interlocked for three different conditions and three different top speeds As shipped the speed limits are set to 80 60 and 40 of maximum speed and acceleration braking remains at 100 For example when a mast mi
21. the truck in the forward and then the reverse directions to make sure the wheels spin properly 6 If the truck does not run in either direction check your wiring especially around the contactors If you cannot correct the problem in this way refer to section F Installation Problem Identification p 44 7 If the wheels spin backward when the direction selector is forward switch the labels for the Fl and F3 terminals Disconnect the battery with the key switch on to discharge the capacitors and then turn the key switch off Switch the wires on F1 and F3 and re test the truck If the truck still runs backwards then your guess on F2 was wrong You will need to begin again at step 2 using another terminal as F2 8 If you are using field weakening the contactor may now be connected so that when it is closed F2 is connected to F3 You must set the field weakening parameters see Field Weakening p 12 before using the truck 32 Navitas Technologies Ltd ST Motor A2 A1 F1 F2 F8 L FORWARD 4 REVERSE Optional 0 BYPASS E B A F A F B Fuse SE325 SE175 Disconnect Dattery Figure 12 5T Motor Wiring Diagram Fields for Direction Navitas Technologies Ltd ST Motor F2 i Optio 5 FIEI FORWARD WEAK REVERSE Optiona BYPASS Disconnect Battery Figure 13 ST Motor Wiring Diagram Fields for Weakening Navitas Technol
22. through the emergency brake switch if you have one and the seat switch and connect it to the switched side of the key switch Stand ups run the white red wire through the emergency brake switch if you have one and the dead man switch and connect it to the switched side of the key switch Walkies run the white red wire through the emergency brake switch usually mounted at the bottom of the main control arm and connect it to the switched side of the key switch c Speed Limit Switches The use of limits is optional If you are not using limits OClip and insulate the ends of the white brown white orange and white purple wires and proceed to the next step If you are using limit switches they should be connected according to the class of your truck as follows Riders run the white brown wire through the switch for limit 1 and connect it to the switched side of the key switch Run the white orange wire through the switch for the second limit and connect it to the switched side of the key switch Run the white purple wire through the switch for the third limit and connect it you guessed it to the switched side of the key switch Stand ups follow the instructions for riders Walkies NOTE the controller parameters must be set with the ProBit to support the belly button switch Run the white brown wire through the belly button switch and connect it to the switched side of the key switch Limit 2 can be used to reduce speed whe
23. to lower the temperature If the temperature continues to rise the controller shuts down completely at 95 C and will operate normally again after it cools down S CURRENT LIMITS 1 Overview The current limits in the TSE1000 and TSE550 protect the motor battery and the controller The controllers include three current limits 1 Battery Current Limit a fixed limit on the current the controller can draw from the battery This current limit responds very quickly 2 Peak Motor Current Limit a short term fast current limit that controls the absolute maximum current that the controller can supply to the motor 4 Average Motor Current Limit a long term limit on the current that the controller can supply to the motor This limit protects the motor from the overheating of long term peak currents 2 Battery Current Limit If the battery current exceeds its limit 650 Amps for the TSE1000 400 Amps for the TSE550 the controller immediately sets the output to zero and returns the truck to neutral see Safe Sequencing p 8 The controller will operate normally again after the SRO is satisfied and error code 5 will show on the ProBit The battery current limit protects against short circuits and shorted windings The battery current limit can be exceeded during excessive loading For example a battery in good condition going up a 15 grade under full load at full accelerator may exceed the limit This ramp may be climbed successfully
24. unnecessary accessories from the output of the key switch in case they are overloading the fuse 2 CHECK Does the ProBit show a contactor error ejr you find a contactor error check the contactor voltage setting with the ProBit If the voltage is set too low the controller may not have the power to pull in the contactors TO TEST Try increasing this voltage 9 Check the forward and reverse contactor wiring to ensure that 1 the contactor commons are connected to the field winding 2 the normally open sides of the direction contactors are connected to the F power bar on the controller 3 the normally closed sides of the direction contactors are connected to the A F power bar TO TEST Measure the voltage between B and the direction contactor commons If they are connected properly a volt meter will measure full battery voltage Disconnect the battery and measure the resistance in three places between both direction contactor commons between the normally closed sides of both direction contactors and between the normally open side of both direction contactors The ohm meter should measure nearly zero Ohms a short across each of these points O Next check the contactor coils One side of the coils should be connected to the TSE1000 TSE550 TSE600 and the other to the key switch B Note if there are suppression diodes built into the contactors make sure the coils are polarized properly TO TEST Check the direction contacto
25. As you press the accelerator throttle slowly the meter should travel from roughly 5 volts to O volts 3 CHECK Is the wiring for the direction switches OK 91 the truck passes all of the checks above and the problem remains check the wiring of the direction switches into the controller TO TEST Use a voltmeter between the chosen switch input and B You should read full battery voltage whenever a direction is selected 46 Navitas Technologies Ltd 1 CHECK Is the brake accelerator switch wired properly 9 Even if you have not connected these switches check the wiring around the brake accelerator switch This switch can be a little more complicated than most If it is wired incorrectly the TSE1000 TSE550 TSE600 may be disabled and the truck will not move TO TEST Use a voltmeter to check the voltage between the brake accelerator input pin and B Voltage should be equal to full battery voltage 2 CHECK Is the battery voltage parameter set correctly 9 Check the battery voltage parameter to make sure that it is set at the manufacturer s rating for the battery TO TEST Plug in the ProBit and ensure that the proper battery voltage is set and that the battery on your truck is sufficiently charged for normal use 3 CHECK Are the speed limits OK 9 Check all the speed limit inputs into the controller The speed levels for these switches may be set too low or a speed limit input may have been connected accidental
26. Continuation essere 52 V SERVICING YOUR TRUCK AND CONTROLLER 53 L Trouble Shootmg siririn u ua ettet e etes 53 A PERIODIC MAINTENANCE erre 54 l OVELVIEW c2 04 osso RU PI DH es iyd 54 2 A MPH ci e E E D E etae Caper 54 B WHAT TO DO WHEN THE TRUCK CUTS OUT OR CUTS BACK 55 1 Speed Limit Cutback Switches eee 55 2 Battery Discharge Interlock BD 25 ee 55 3 Over Current LImIts ice role petere RERO 55 4 Over Temperature LITHI 5 5 eene 55 5 Direction Contactor Failure e 56 A NAVITAS TECHNOLOGIES TSE1000 TSE550 WARRANTY 57 B THE PROBIL eine tie e e ea t t i atte 57 C TECHNICAL SPECIFICATIONS eere H 57 t Power Handini oia 57 2 Input Prot cti DDuiu u o tec ect e a e a Dee dde 58 3 Contactor Drive Specifications tt ng 58 D GLOSSARY teste eio ee ch bee Bae ERR lid 59 L INTRODUCTION A ABOUT THIS MANUAL This manual outlines the use of the TSE1000 TSE550 and TSE600 motor controllers from Navitas Technologies From time to time the manual will also refer to other NAVITAS products the ProBit the PSE1000 and PSE550 pump controlllers and the display In general we have tried to provide the information you will need to make these products work with the TSE1000 TSE550 TSE600 but for a mor
27. SES O ms AD Amas wise E direction change forgive time max time direction switches can remain in 0 15 1 sec 0 5 sec eutral without setting off the SRO power steering continuation ontinuation of steering power after SRO is 0 1600 sec set off bypass threshold Fz of maior ouput fom bypass pickup delay ime motor output must remain at bypass level Field weakening pickup roror caren i o usa field weakening dropout 10 1000A 230A current limit maximum motor current for TSE1000 O 1000 Amps 1000 Amps O EI E O CIN UE current limit average motor current Peak Continuous for TSE1000 O 1000 Amps 325 Amps O EZ IZ O CI Po Amps lift interlock hether or not lift is locked at low battery kenable disable enable levels SRO lift interlock hether or not lift is locked when SRO is set enable disable off contactor hold voltage anufacturer s specified hold voltage 12V B contactor pull in voltage anufacturer s specified pull voltage 12V B contactor change time aximum time allowed for contactor to pull 0 15 1 sec in or out 43 Navitas Technologies Ltd ime spent at pullin voltage throttle maximum P ercentage of full accelerator travel 0 100 throttle minimum percentage of deviation from full accelerator 0 100 23 rest position hrssiicabanenyvompeTsEO os bypass onon whether or not bypass ciui used pno for Each of these levels can be programmed sep
28. TSE1000 TSE550 controller is designed to operate with batteries with a nominal voltage of 24 V to 48 V The TSE600 is designed to operate with a nominal battery voltage of 24v to 48v The TSE1000 is rated for 325A continuous average current with 1000 A peak current The TSE550 is rated for 175A continuous average current with 550 A peak current The TSE600 is rated for a 260A continuous average current with a 600A peak current See also Controller Limits p 16 57 Navitas Technologies Ltd 2 Input Protection All the inputs on the TSE1000 TSE550 TSE600 except for the main power connections and the NAVITAS bus are protected against accidental mis wiring 3 Contactor Drive Specifications The controllers built in contactor drivers will supply a drive voltage from 12V to B and a drive current of up to 2A Note that the controller detects a fault condition if the contactor current is greater than 2 A 58 Navitas Technologies Ltd D GLOSSARY Current Multiplication The increase in current seen in a motor when driven at low chopping levels The average voltage that the motor is driven with is lower than the battery voltage supplied to the controller Since the controller is highly efficient the power supplied to the motor must equal the power supplied to the controller This can only be the case if the current in the motor rises by the same factor that the average voltage to the motor dropped Cutback A condition in which th
29. Technologies Ltd cool down The efficient design of the TSE1000 TSE550 TSE600 should prevent this condition from occurring under normal use 5 Direction Contactor Failure If either contactor fails to pull in or drop the controller will return to zero The controller records an error code for contactor failures The controller will not start again until the contactor is fixed and the controller is turned off and back on again f contactor errors occur for no apparent reason the contactor change time may be set too low The controller will also stop if it detects a shorted coil in one of the contactors The only way to get the controller to start in this case is to turn off the truck fix the coil and then turn the truck back on again 56 Navitas Technologies Ltd VI APPENDICES A NAVITAS TECHNOLOGIES TSE1000 TSE550 TSE600 WARRANTY You have received with your TSE1000 or TSE550 motor controller a copy of the full warranty complete with legalese This explanation does not in any way replace the warranty but rather is our attempt to explain it the way we would if we did not have a lawyer THE PURPOSE OF THE NAVITAS TECHNOLOGIES WARRANTY The purpose of our warranty is to allow us to make sure the item you receive lives up to our standards We want you to receive the best we have to offer and if perchance you don t we want to have an opportunity to make things right But even though we at Navitas Technologies are of above averag
30. afety and vehicle protection 1 Reduced Maintenance and Repair Several features of the TSE1000 TSE550 TSE600 reduce wear and tear on contactors motors and batteries and also increase the reliability of the controllers themselves These savings alone support the change to NAVITAS technology since the cost of one motor rebuild can more than pay for an NAVITAS retrofit FEATURE ADVANTAGE BENEFIT Cold Contactor Whenever the direction contactors are pulled in or out the Reduces contactor tip Switching motor voltage is set momentarily to O This reduction in wear current eliminates arcing Low Contactor The voltage required to hold a contactor in is lower than the Increases life of Hold Voltage voltage needed to pull it in The TSE1000 TSE550 and contactor coils and TSE600 allow you to set a low contactor hold voltage so lowers fuel that less heat is passed through the coils consumption Peak Motor Current This limit protects the motor against very high surges of Protects the brushes and Limit current commutator Average Motor This limit allows temporary peaks of current but prevents Reduces burn outs and Current Limit long term currents which are higher than recommended lengthens life of motor motor ratings windings Diagnostics The controller keeps watch over several functions of the Reduces time to repair vehicle and keeps a record of problems as they arise This record is a valuable maintenance tool Table
31. ance will be O Ohms 20000 Ohm Po E P Increasing Speed Increasing Speed You must be sure that the wiper is at the center of the potentiometer when the direction switches are in neutral If it is offset in either direction by a significant amount the truck will not travel in that I direction because the accelerator will seem to be activated and the truck will fail the safe sequencing Figure 4 Bi check directional 20K Potentiometer c 5000 Ohm Pot Integrated Direction Switches Other twist grip and lever accelerators use this arrangement The 5000 Ohm potentiometer is wired as explained in a 5000 Ohm Pot Separate Direction Switches p 10 In this case the cam assembly in the accelerator not only switches the direction but also turns the potentiometer in the same direction either side of neutral 3 d 10000 Ohm 4 Terminal Pot Integrated Direction Switches 4 10200 Ohm Pot AQ 2 The final arrangement for twist grip and accelerator levers appears in Figure 5 The center tap terminal I 4 see figure 5 is wired to the controller input throttle 1 and the wiper is wired to the input throttle 2 The two potentiometer endpoints are left open In this configuration the accelerator throttle value will travel from 0 Ohms at rest to 5000 Ohms at full speed Using the ProBit you must reverse the throttle polarity for this pot since it works backwards from the usual configuration lan Increasing Speed Increasi
32. arately for forward and reverse E POWERING UP THE TRUCK Your truck is now ready for use When you turn power on you should hear the forward and reverse contactors pull in as the controller goes through the startup diagnostics The most commonly requested settings have been preprogrammed in the controller for your convenience however they may be changed with the ProBit to suit your preferences We hope you enjoy the smoother feel and more reliable performance of your TSE1000 or TSE550 If you have questions that are not answered here please contact your dealer F INSTALLATION PROBLEM IDENTIFICATION 1 Installation Basics When installing a new controller you should double check the wiring as you go Wiring errors are much harder to find later on The wiring of B and B to the controller power bars is particularly important NOTE Improper wiring of the B and B connections can cause permanent damage to the controller The controller is not protected against reversed battery connection Inserting the Wiring Harness You can insert the wiring harness connectors upside down if you push hard Please check the alignment before you resort to brute force If the connectors are improperly inserted the controller will not work but no damage should occur Checking Error Codes The TSE1000 TSE550 TSE600 will find most wiring flaws during start up diagnostics and errors will be reported by the ProBit The ProBit identifies each error
33. attery is low the controller pulls the contactor out so that the driver must have the battery recharged before continuing See Battery Discharge Interlock p 14 for more information Navitas Technologies Ltd For added safety the lift pump contactor can be programmed to turn on only when the safe sequence is followed This measure ensures that the hydraulics will work only when the driver is in the proper driving position You can set this interlock in the miscellaneous timings section of the ProBit J BYPASS 1 4 CONTACTOR The bypass contactor sometimes called the 1 A contactor was used in older controllers to bypass the controller and supply full battery voltage directly to the motor Previous generations of controllers use inefficient power devices These controllers have a large voltage drop and overheat quickly under heavy loading Because of this drain of power some of the voltage that might go to the motor is consumed by the controller To lessen these problems a bypass feature was introduced in some models Bypass is essentially a switch in parallel with the controller When the bypass contactor is closed the flow of current bypasses the controller and all its inefficiencies In this way bypass allows full battery voltage to go to the motor and allows the controller to cool down Bypass can be dangerous because it removes the regulation of the controller while the bypass contactor is pulled in Under these con
34. ay be able to raise or lower these levels to improve the feel See section B Plug Braking p 7 for more explanation on parameters that can affect plug braking If problems persist and cannot be resolved please contact your nearest authorized NAVITAS dealer for additional support Before calling please ensure that you have thoroughly checked all wiring and followed any appropriate steps recommended above 50 Navitas Technologies Ltd IV ADJUSTING TRUCK PERFORMANCE The TSE1000 TSE550 TSE600 is highly programmable The feel performance and some interlocks are adjustable to fit the individual truck and its operating conditions This adjustment is accomplished through the use of the ProBit The ProBit allows the installer to adjust the programmable features of the controller s operation Detailed instructions on the use of the ProBit to adjust the controller can be found in the ProBit user s manual For more a summary of the programmable parameters see the chart on page 42 A DRIVING FEEL The parameters related to drive feel are set in the performance section of the ProBit The speed and acceleration of the controller can be set independently for forward and reverse 1 Speed and Acceleration The top speed of the truck motor voltage can be set as a percentage 0 100 of maximum possible speed motor voltage You can set separate levels for forward and reverse In most cases you will want to set this to 100 Although this s
35. ch SRO Switch below 2 Select a direction 3 Press the accelerator Each time drivers start the truck from a stop they must take their place and return the direction selector to neutral before selecting a direction and accelerating If a driver operates the controls out of order the controller returns the truck to neutral The controller also causes a Return To Neutral or RTN for other safety reasons including SRO see Dead Man Switch SRO Switch below and battery current limit see Battery Current Limit p 15 D DEAD MAN SWITCH SRO SWITCH The dead man switch the brake switch in walkies returns the truck to neutral RTN if a driver falls off After RTN the truck will coast to a stop This switch is connected to the seat in rider trucks and to the floor panel in stand ups When the driver is in correct driving position the dead man switch is closed and the controller reads a voltage Whenever the driver gets off the seat or floor panel or lets go of the operating arm in a walkie the switch opens and the voltage reading stops To start the truck again drivers must carry out the safe sequencing steps E ACCELERATOR SWITCH AND SERVICE BRAKE SWITCH The accelerator switch and the service brake switch do not appear in every model of lift truck When these switches are used they provide an additional level of safety The accelerator switch is an additional check on the accelerator and the brake switch prevents the contro
36. cro switch indicates that the lift is up the truck speed can be limited to 80 The performance levels for each of the speed limit switches can be set in the ProBit s performance section Each limit can be set as from 0 200 of top motor output speed This range allows each switch to be used as either a cutback switch or an overdrive switch NOTE When speed is limited to less than 95 the bypass and field weakening contactors will not pull in M NAVITAS BUS This set of inputs is the backbone of the NAVITAS system It allows multiple NAVITAS products displays ProBit multiple controllers pump controllers drive controllers to be connected together so that they operate in concert Navitas Technologies Ltd For example if both a drive motor controller and a pump controller are used the drive motor uses information from the pump motor to improve the accuracy of the battery gauge The drive controller tells the display what the battery status is and tells the pump controller to turn off when the battery is discharged Cables and wiring harnesses are supplied as needed Due to the nature of electronic communication you must use only the NAVITAS harnesses The pins for the bus see theConnector Pins diagram on page 25 should be treated with care because their inputs are not protected N BATTERY MONITOR The motor controller has a built in battery monitor which judges the battery state by keeping track of battery volta
37. d B5 DEAD EMERG MAN BRAKE _ Lo rc 4277 wh blk Bi 175 SERVICE ACCEL BRAKE SPEED LIMIT 1 L FE SPEED LIMIT 2 x22 y wh ord bs SPEED LIMIT 3 v mur po d _wh arn pg ACCELERATOR B7 C1 C6 C3 C2 C4 Cb Navitas Technologies Ltd LEGEND FUSE RESISTOR CONNECTOR SWITCH NC SWITCH NO CONTACTOR COL CONTACTOR SWITCHNO CONTACTOR SPDT MOTOR ARMATURE MOTOR FIELD OPTIONAL ITEM BYPASS LE FORWARD gry REVERSE blu A STEERING LIFT BYPASS Figure 8 Connection Diagram 4T Motor 24 Navitas Technologies Ltd 4 Wiring Harness Identification I O DESCRIPTION WIRE COLOR AS BUS PNA Em PNA A3 pas A2 PNA pa d Ss forward input A EEE aee e ele forward input white yellow T UTPUT orange OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT C8 INPUT Table 6 Wiring Harness Pin Identification zz dl ala A 3 3 5 Z Z AE Z Z 317 ale d 131313 B B B B B B B ZIZ ale AS A4 A3 A2 Al 8 7 5 4 3 2 1 ci C2 C3 C4 C5 C6 C7 C8 SRE BUS W Grey W Blue W Brown W Purple W Yellow W Green W Red W Orange W Black A5 Al B10 BY B5 B1 Brown Yellow Grey
38. ditions the motor and the battery can be abused and if the contactor welds the truck will run away NAVITAS controllers do not need to be bypassed The TSE1000 and TSE550 use technology that is much more efficient than the older technology They consume significantly less energy and they perform at lower temperatures For these reasons the regulation of the controller never has to be removed for the sake of efficiency However if you want to you can continue using the bypass feature with the TSE1000 TSE550 TSE600 If your truck has been using bypass we recommend that you take a trial period without it and compare the performance See Bypass p 21 for installation You can program the bypass option using three parameters in the Bypass Field Weakening section of the ProBit 1 The bypass enable lets you turn the bypass on or off If you turn the bypass on you must be sure to connect the bypass contactor 2 The bypass level is measured as a percentage of battery voltage usually set at 95 When the output of the controller reaches this level and stays there for a preset time it pulls in the bypass contactor When the controller output is ready to drop below this level again the controller drops out the contactor 3 The bypass delay is measured by the length of time the controller must hold the bypass level before the contactor pulls in usually about 5 seconds To avoid the severe arcing that can occur in these conditions the c
39. e acceleration These settings are adjustable in the performance section of the ProBit The maximum motor voltage speed is measured as a percentage of battery voltage and may be adjusted independently for forward and reverse Acceleration is measured by the amount of time it takes to travel from zero to full motor voltage Acceleration may also be set differently for forward and reverse The maximum speed applied motor voltage and acceleration settings are used as reference points for the speed limit switches See L Speed Limit Switches p 13 3 Throttle Polarity The controller can be programmed to reverse the polarity of the accelerator throttle so that 5000 Ohms is full speed and O Ohms is rest You will need to set the throttle minimum and maximum after you change throttle polarity NOTE The potentiometer always defaults to 5000 Ohms when there is a faulty connection Therefore if a wire comes loose when the polarity is reversed the truck will go to full speed Navitas Technologies Ltd 4 Accelerator Configurations As shipped the TSE1000 TSE550 TSE600 requires a two terminal resistive potentiometer of 5000 Ohms but it can be installed to work with other pots as well The four standard potentiometer types for lift trucks are 1 a 5000 Ohm three terminal potentiometer with separate direction switches 2 a 20000 Ohm three terminal potentiometer with integrated direction switches 3 a 5000 Ohm three t
40. e average motor current protection limits the continuous average motor output to the preset level It responds slowly to changes allowing peak demands and cuts back only when the average current limit has been exceeded for several minutes Likewise once the controller has cut back the motor output it waits until the output remains below the average current limit for several minutes before returning to higher outputs c Battery Current Limit The battery current limit protects the controller against excessive draws from the battery If this limit is exceeded the controller will record the appropriate error code This limit should only be exceeded under very heavy loads such as a short across the motor If a limit of this sort occurs the controller will remain shut down until the direction selector is returned to neutral and the driver goes through the safe startup sequence If the load that caused the cutback is not removed the controller will cutback again Repeated attempts to start up the controller without clearing this load may damage the controller 4 Over Temperature Limit The controller can be damaged by operating it at excessive temperatures For this reason if the controller detects an high temperature condition it cuts back the output accordingly The TSE1000 TSE550 TSE600 will cut output to zero if its temperature exceeds 95 C If an over temperature condition occurs the only way to clear it is to allow the controller to 55 Navitas
41. e controller s normal operating output is reduced or limited below its programmed maximum Default A setting that is programmed into the controller when it leaves the factory These preset values should work for most trucks but can be adjusted for a more exact match with the vehicle The controller will use the default level unless another level is programmed into it Operating Error An operating error is a mistake made by the driver The most common such mistake is the failure to use safe sequencing i e get into proper operating position choose a direction and then press the accelerator Parameter An operating level or value that the controller uses to regulate one of its functions I e the setting for maximum speed or the setting for acceleration Plug Braking A method of electrically braking a series motor Supply a small drive voltage that would drive the motor in the opposite direction to its current direction of rotation provides a field that brakes the motor This method of braking generates high motor currents that are dissipated in the motor and in plug braking diodes placed in the controller for this purpose RTN Return to Neutral An internal state of the controller In the RTN the operator must go through the safe startup sequence before the controller will operate Generated in response to a number of events including SRO and battery current limit Safe Sequencing Safe sequencing refers to the order in which the
42. e decency we are not looking for chances to make up for other people s mistakes And so as you may have guessed our warranty does not apply when damage results from failure to follow the instructions in this manual or from flagrant disregard for the laws of nature gravity inertia lift trucks don t float etc TERMS OF THE TSE1000 TSE550 TSE600 WARRANTY We promise to replace or repair any defective item within twelve 12 months or 2000 hours of normal operation whichever comes first We figured that should give you enough time to find even the smallest defect If something should go wrong contact your area NAVITAS dealer and you will receive a replacement controller at no cost B THE PROBIT The ProBit is designed to help you customize other NAVITAS products The ProBit will recognize the controller and present the appropriate customization options Full details on how to set specific parameters are found in the ProBit manual The parameters themselves are explained in this manual To use the pendant 1 Plug the ProBit connector into the top left connector on the controller The connector goes in easily in one position but it can be forced in incorrectly Please be careful to observe the correct connector orientation 2 Turn on the key switch The ProBit will now show the welcome menu You can now follow the instructions in the ProBit manual to adjust controller parameters C TECHNICAL SPECIFICATIONS 1 Power Handling The
43. e direction contactor coils OK O Check the direction contactor coil inputs into the controller to see if they are shorted to negative TO TEST Set the Ohm meter to the low resistance scale and check the reading between each contactor coil terminal and B If you read O Ohms the coil is shorted to negative 9 Recheck coil wiring TO TEST Run through the installation instructions and diagrams on pages 26 to 39 2 CHECK Is the battery connected to the controller properly O Check the connection of B to make sure that it is not connected to both the B and the B bars on the controller PROBLEM THE TRUCK ACCELERATES PROPERLY AND APPEARS TO WORK UNTIL IT REACHES A HIGH SPEED AT WHICH POINT THE TRUCK CUTS OUT 1 CHECK Is bypass enabled even though the truck does not have a bypass contactor O Check the bypass parameter to make sure it is not enabled If the bypass is enabled when the truck has no bypass contactor when the controller reaches a high output it will attempt to pull in a non existent bypass contactor and will shut itself down NOTE This problem may occur in only one direction because of the way the bypass settings have been configured TO TEST Plug in the ProBit and go to the bypass menu You can read there whether or not this feature is enabled PROBLEM THE TRUCK WORKS BUT ONLY IN ONE DIRECTION 1 CHECK Does the forward contactor pull in when forward is selected and reverse when reverse
44. e limit by exceeding the safe operating temperature of the controller Use the ProBit to check the limits section The truck occasionally stops for no reason You may have a faulty SRO switch Check and replace if necessary at all and must be taken through the proper startup sequence before it will move again Table 7 Problem Identification A PERIODIC MAINTENANCE 1 Overview Periodic maintenance sometimes referred to as preventative maintenance is a system for reducing repairs by regularly checking the condition of all parts The TSE1000 TSE550 TSE600 controller provides a number of features that improve periodic maintenance Among the TSE1000 TSE550 TSE600 features for periodic maintenance are a series of internal clocks One of these clocks is the PM time This clock records the amount of time that the controller has been on since the clock was cleared during the last maintenance check This clock can be used to simply record the amount of time the truck has been running since the last periodic maintenance period or it can be used as one qualifiers to decide when periodic maintenance should be performed i e periodic maintenance is performed every four weeks or whenever the PM timer reaches 200 hours 2 Procedure Some of the other tools that may be used during periodic maintenance are described below a Checking Errors The TSE1000 TSE550 TSE600 saves a record of the errors that occur while they are running These errors
45. e may not be satisfied Double check that the controls are being activated in the correct order Truck does not run Direction contactor Brake switch may not be satisfied Check the wiring and switch for the brake pulls in when a direction is selected but the Maximum speed may be set too low Check and adjust the maximum speed truck does not move Truck occasionally fails to change Direction switches may be wearing out Check and replace if necessary dirotan Contactor change time may be a little too short Check and lengthen if necessary see Programming the Controller To Suit the Truck p 51 Truck runs for five minutes and then loses Battery Discharge Interlock BDI may have fired Check the battery the top end cuts back and the lift refuses condition Make sure the battery size is consistent with that expected by the to operate controller Adjust the controller to the proper battery size if necessary Truck shuts down when subjected to a You may have exceeded the battery current limit for this controller Lighten heavy load the load or circumstances causing the heavy draw 53 Navitas Technologies Ltd Truck loses top end cuts back after Battery Discharge Interlock BDI may have fired because you are using all extended use the usable capacity of your battery Check the battery condition You may be exceeding the average current limit Use the ProBit to check the limits section You may have passed the temperatur
46. e the capacitors by connecting the B power bar to B through a resistor or after the controller is wired by turning on the key switch with the battery disconnected A BEFORE YOU BEGIN Before beginning installation position the truck with its drive wheels raised off the ground and the battery disconnected You will need a number of parts to install your controller properly 1 Wiring A complete set of new wires for the control signals is available with every TSE1000 and TSE550 controller Although it is possible to use the existing wiring doing so creates unnecessary risks because the wiring may have been modified in the past or may be worn Contactors You can wire the truck using the existing forward reverse lift pump and steering pump contactors as well as field weakening and bypass contactors if the truck uses them All the contactors in the truck should have the same voltage Accelerator Potentiometer As shipped the controllers are set to use a standard 5000 to 0 Ohm potentiometer The TSE1000 TSE550 TSE600 will work with any class of potentiometer log semi log linear although accelerators with linear potentiometers are easiest to install The controller will support any power rating 1 2 watt or larger however the system will function best with a mechanically rugged pot e g 2 watts If you plan to use the existing accelerator please make sure it is clean and in good working order before you begin You will fi
47. e thorough explanation of these items you will need to consult their respective product manuals IF YOU ARE DOING A QUICK INSTALLATION go to chapter III and read sections A D These sections give you instructions for wiring your truck and controller and programming the basic settings you will need Please note that first installations should not be done quickly because of the damage that may result from incorrect proceedures IF YOU ARE NEW TO NAVITAS TECHNOLOGY chapter I will give you a helpful overview of what NAVITAS control systems can do for your truck and your management of the truck Chapter II then goes through each circuit switch and contactor explaining how the controller works with each of these IF YOU ARE HAVING TROUBLE WITH AN INSTALLATION refer to chapter III section F for help in identifying the problem For additional information you can turn to the appropriate section of chapter II for more detailed explanation of how a particular feature works IF THE TRUCK NEEDS SERVICE chapter II section V will give you information on error codes which can help to pinpoint the problem and chapter IV gives instructions for servicing your truck Introduction 1 Navitas Technologies Ltd B THE FUNDAMENTALS OF NAVITAS TECHNOLOGY POWER fuel built in MICRO efficiency lift interrupt MOSFETS reduced diagnostics PROCESSORS high integrated reliability battery guage adjustable interactive drive feel display pega it po ink
48. ection has been selected since it was last cleared Navitas Technologies Ltd HI INSTALLATION PROCEDURES If this is the first time you are installing an TSE1000 TSE550 TSE600 please read through all of the directions before you begin If you have any questions about installation please call your dealer or contact Navitas Technologies at 519 725 7871 Dealer affix stamp here This part of the manual includes instructions and diagrams for wiring an TSE1000 TSES50 TSE600 It also explains the basics of programming the controller so that it will suit the specifications of the particular truck battery contactors etc These two sections are essential reading The final section gives trouble shooting tips for the problems you might encounter in the installation Even though it is a helpful section we hope you never have to read it You can install the controller by following the steps outlined below These steps are essential to the proper functioning of your controller and truck Please follow them with care Please also check that the other parts of the truck battery motor coils etc are in good working order We cannot take any responsibility for damage resulting from failure to follow the details of these instructions CAUTION When working with the controller please remember that its capacitors stay charged for years High voltages may appear on the controller connections even when the battery is not connected You can discharg
49. ection repeatedly discusses speed control motor controllers cannot directly control the speed of a vehicle speed is controlled as a function of the applied motor voltage A particular voltage will not always result in the same speed Conditions like load and grade will change the speed that is possible for a given voltage Acceleration is defined in terms of time An acceleration of two seconds means that it will take two seconds to advance from stop to full speed Again as with speed the acceleration for forward and reverse can be set at different levels 2 Braking Plug braking strength is set as a level of motor current Under most circumstance the default setting of 280 Amps for the TSE1000 and 140 Amps for the TSE550 will give soft plugging You will likely want to increase this value However you should increase this time gradually since settings that are too high may generate very large torque s 3 Speed Limits Cutbacks The TSE1000 TSE550 TSE600 provides three speed cutbacks for general use Each cutback is set to a different percentage of maximum speed motor voltage The factory defaults are 80 for cutback 1 60 for cutback 2 and 40 for cutback 3 Cutback levels may be set from 0 to 200 of the maximum speed motor output you have set When a cutback is set over 100 it will act as an overdrive Acceleration times will shift directly to cutback conditions i e if acceleration is set at 2 seconds in cutback the truck w
50. ed B if you have not already done so 29 Navitas Technologies Ltd 4T Motor FORWARD REVERSE Optional o BYPASS B A F A F B Fuse SE325 SE175 T pm j Disconnect Battery Figure 11 4T Motor Wiring Diagram Navitas Technologies Ltd c ST Motors You face two problems when wiring a 5T motor First of all motor manufactures are not consistent in labeling 5T motors Secondly there are several different ways to connect the fields together This section discusses a method of verifying the terminal labels and a way of choosing an arrangement for field connections However if you are doing a retrofit we recommend that you connect the fields as they were 5T motors have two fields that share a common terminal These motors usually appear in one of two configurations 1 Fields for Direction in European trucks predominantly one field is used for the forward direction and the other field is used for the reverse direction In this configuration field weakening cannot be used 2 Fields for Weakening in North American trucks predominantly the fields are used in combination for field weakening After choosing a configuration you must determine how the terminals are connected to the fields and then choose a field configuration 1 Fields for Direction 1 Choose the terminal which you think is shared by both field windings Label this terminal F2 If you are not sure wh
51. er pulling in when changing directions If you have good contactors you should be able to set the change time as low as 0 150 seconds which gives no noticeable delay when changing directions In general if this value is set too low the controller will fail diagnostics when switching contactors and if it is set too high there will be a noticeable delay when switching directions Plugging strength As shipped the plugging strength is set to 280 Amps for the TSE1000 and 140 Amps for the TSE550 In almost all cases you will find this to be soft plugging i e the truck will coast for a long time before it stops and you will want to strengthen it The other setting to adjust is deceleration This time determines how long the truck will take to reach maximum plugging strength The default is set at 0 4 sec See p 7 B Plug Braking for more help Acceleration The acceleration level lets you set the time it takes to go from 0 volts to full motor output As shipped the controller is set to 2 seconds See p 9 Drive Feel in section F Accelerator for more help Top speed As shipped this parameter is set to 100 of the full motor voltage You can lower this level if you have an application that requires less than full truck speed Speed Limit Cutbacks If you have connected any of the cutback switches you should adjust the cutback levels to provide the appropriate top speeds motor voltages for each of the cutbacks The factory preset levels are as f
52. er terminal F2 6 Disconnect the battery cable with the key on to discharge the capacitors You have now completed Step 1 and identified the field windings and the terminals In Step 2 you must decide how to connect the fields to the controller If you are doing a retrofit the best option is to connect the fields as they were before Usually the 6T motor allows field weakening without the use of an additional resistor Less commonly the 6T can be treated like a 4T motor and a field weakening resistor can be used These instructions assume no field weakening resistor The fields can be connected in 3 configurations as shown in the table below and in figure 14 Parallel high Single AT motor high Series low You can use a contactor driven by the controller s field weakening output to switch between the single and series configuration see figure 19 to get maximum torque and maximum speed If you do not want to use a field weakening contactor connecting the fields in parallel 6t Motor Wiring Diagram Parallel is a good compromise 35 o tA W N Navitas Technologies Ltd Select the configuration you wish to use Disconnect the battery with the key switch on to discharge the capacitors If you are using the field weakening contactor connect the coil as discussed in Field Weakening page 22 Connect the power cables as shown in the drawing for the configuration you have chosen Turn off the
53. erminal potentiometer with integrated direction switches and 4 a four terminal center tapped 10000 Ohm potentiometer 5000 Ohm Pot A Ho N N Increasing Speed t Accelerator Increasing Speed Accelerator 2 a 5000 Ohm Pot Separate Direction Switches Figure 3 Unidirectional Figure 5 shows the arrangement for a resistive pedal accelerator The accelerator controls the speed 5K Potentiometer and direction is controlled by a separate switch or set of switches The controller wire called accelerator 1 should be tied to one end of the pot and the wire for accelerator 2 should be tied to the wiper as shown in figure 3 p 10 The connection from the wiper to the other end of the potentiometer is optional The two ends of the accelerator should be wired so that the accelerator travels from 5000 Ohms to O Ohms as it is pressed b 20000 Ohm Pot Integrated Direction Switches This arrangement is sometimes used in twist grip or lever accelerators where a single accelerator controls both the speed and direction The switches for the direction selection are generally activated by an internal cam The two ends of the potentiometer are wired together to the controller input accelerator 1 see Figure 4 p 10 The wiper is wired to the input accelerator 2 When the wiper is in the center of the potentiometer this circuit will have an effective resistance of 5000 Ohms when the wiper is at either end the effective resist
54. fect on the operation and feel of plug braking 1 direction change time and ii contactor change time i The time you can leave the direction selector in neutral when moving from forward to reverse is known as a forgive time If the switches are in neutral for longer than this forgive time the controller sets off an RTN or Return to Neutral see Safe Sequencing p 8 The driver must then go through the start up sequence again Since drivers have different habits when changing directions you can set this time to allow for their speed of shifting directions See the ProBit manual for more information on setting parameters ii The time allowed for a direction contactor to pull in will change the way plug braking feels If you set this time high the plugging may appear to lag for a moment while the controller waits for the contactor to pullin If you set the time too low the truck will fail diagnostics A good contactor should be able to change in 0 15 seconds but older contactors may be slower Navitas Technologies Ltd C SAFE SEQUENCING Safe sequencing is a safety feature which ensures the accelerator cannot be activated accidentally The safe sequence is the order in which the driver must operate the vehicle controls The correct operating sequence is 1 Get into safe operating position seated on the seat in a rider or standing on the floor panel in a stand up This is the position that closes the SRO switch see Dead Man Swit
55. ge and motor current When power is turned on the monitor makes a first estimate of the battery level and improves this estimate as time goes on It responds slowly to changing conditions This estimate of the battery level can be shown on the display or the ProBit The battery gauge is most accurate at low capacities below 50 and after the truck has been operating for 5 10 minutes O BATTERY DISCHARGE INTERLOCK The battery discharge interlock protects against over discharging the battery When the battery discharges to 0 usable charge 20 of total capacity the truck is given a 5 minute grace period to finish an urgent task When an NAVITAS dashboard display is used the driver is notified at the start of the 5 minute grace period After this period the lift contactor drops out and the truck goes into a limp mode to allow the driver to return to the charging area but not to do any productive work If the key is turned off and on again the 5 minute grace period is reactivated The limp speed is measured as a percentage of motor voltage It can be programmed with the ProBit The Battery Discharge Interlock can be disabled with the ProBit if you prefer to use external protection P INTERLOCKS 1 Static Return to Off see also Deadman switch p 8 For added safety the controller will not operate the direction contactors will not pull in unless the correct sequence is observed The SRO is satisfied if the
56. he battery voltage has not been set properly the controller may calculate a low charge based on that information It will then cut the truck back to limp mode TO TEST Plug in the ProBit and go to the cutbacks menu The ProBit will tell you whether the truck is in any kind of cutbacks If it appears to be in cutback because of low battery charge check your battery voltage parameter to make sure it was set correctly 3 CHECK Is the motor wired properly ejr you are working with a 5T or 6T motor double check that the fields are wired correctly These motors can be wired with multiple fields parallel for maximum speed or with multiple fields in series for maximum torque TO TEST Review the wiring instructions outlined on p 31 for 5T Motors and on p 35 for 6T Motors 1 CHECK Are the contactors OK O Check contactor coil wiring to ensure that the contactor connections to the controller are not shorted to negative TO TEST Use an Ohm meter to check between B and each of the contactor coil terminals You should measure a very high resistance i e no short circuits 9 Check for sticky contactor tips 2 CHECK Is the battery connected to the controller properly O Check the connection of B to make sure that it is not connected to both the B and the B bars on the controller 48 Navitas Technologies Ltd PROBLEM BOTH DIRECTION CONTACTORS COME IN SIMULTANEOUSLY UPON POWER UP 1 CHECK Are th
57. ich is which you can guess In step 7 you will be able to tell whether or not you chose correctly 2 In the same way you can make a guess for the F1 and F3 terminals and label them Wire the truck as shown in the 5T Motor Wiring Diagram Fields for Direction p 33 Review the instructions for connecting the 4T motor if necessary 3 After completing the wiring check to make sure the connections are correct especially around the forward and reverse contactors Plug in the battery and turn on the key switch You should hear the forward contactor and then the reverse contactor pull in If you do not hear any clicking refer to section F Installation Problem Identification p 44 4 Before testing the truck set the parameters described in section Programming the Controller To Suit the Truck p A1 5 With the truck still on blocks power up the controller Slowly drive the truck in the forward and the reverse directions to make sure the wheels spin properly 6 If the truck does not run in either direction check your wiring especially around the contactors If you cannot correct the problem in this way refer to section F Installation Problem Identification p 44 7 If the truck only runs in one direction then your initial guess on the common terminal the one you labeled F2 is wrong Choose another terminal and repeat the steps starting at 2 above 8 If the wheels spin backward when the direction selector is forward then F1 and
58. ill reach the cutback voltage in 2 seconds The cutbacks have a built in priority If more than one switch is activated at the same time the level for cutback 3 will always override the other two and the level for cutback 2 will always override cutback 1 For this reason you are safest to set cutback 3 as the lowest level and cutback 1 as the highest B TIME DELAYS Several programmable time delays also affect the operation and feel of the truck 1 Contactor Change Time The contactor change time is the maximum time allowed for the contactors to pull in or pull out This delay helps the diagnostics to work properly Whenever a contactor pulls in or out the controller measures the time it takes If a contactor has not pulled in the time you have set the controller will send out an error code The contactor change time also helps 51 Navitas Technologies Ltd to control cold switching Whenever a contactor is switched the controller temporarily shuts off voltage to the contactor until the change time elapses As shipped the contactor change time is set to 1 2 second which should be long enough for even the slowest contactors This length of time will however result in a noticeable delay as the controller waits for the contactors to change Where possible you will want to change shorten this time to give a smoother feel to direction changes You can set the contactor change time as low as 0 150 seconds which gives no noticeable delay
59. k the throttle minimum setting with the ProBit If the accelerator throttle is off a little and does not travel all the way back to rest 1t seem to be activated all the time see p 9 Throttle minimum and Throttle maximum for a fuller explanation When this happens the safe sequence is broken and the truck will not run see p 8 Safe Sequencing TO TEST 1 Plug in the ProBit and go to the throttle minimum menu 2 Leave the accelerator throttle at rest and check the reading for throttle position in the ProBit The ProBit will tell you exactly where the accelerator is sitting 3 Now check the ProBit for the setting for throttle minimum If the throttle position reading is higher than the throttle minimum then the accelerator will act as if it is always depressed and the direction contactors will not engage 4 Take the reading for throttle position and set this value plus about 5 as the new throttle minimum If you set the throttle minimum at exactly the accelerator position the diagnostics may occasionally fail because many mechanical accelerators do not return to the exact same rest position every time O Check the throttle polarity If the current accelerator rest position is very high the throttle polarity may be reversed In other words the accelerator throttle may need O Ohms at rest and 5k Ohms at full TO TEST Use a voltmeter to check the voltage between the throttle 1 pin on the controller and the throttle 2 pin
60. lers to give the vehicle the capabilities of a computer THE NAVITAS BUS All NAVITAS products can communicate together through a link called a BUS Because of this communication link our products act as a system rather than individual parts working alone For example when a pump controller is added to the motor controller they cooperate to determine battery levels and send that message to the display and the ProBit The BUS also enables you to install additional NAVITAS products over time C TSE1000 TSE550 TSE600 MOTOR CONTROLLERS The TSE1000 and TSE550 are drive motor controllers for electric lift trucks The TSE1000 is designed for trucks with 24 48 volt batteries and weight classes of up to 10 000 Ibs although it has been used in 12 000 Ib applications The TSE550 is IU S patents are pending on NAVITAS motor controller technology Navitas Technologies Ltd designed for 24 48 volt 2 000 5 000 Ib systems The TSE600 is designed for 60 96 volt 2 000 5 000 lb systems The ProBit lets you read the information stored in the controllers and it also allows you to change the settings that are programmed into them Service personnel can adjust operation to suit the truck and the operator The technology and innovation of the TSE1000 TSE550 offers four major advantages when compared with other control systems 1 reduced maintenance and repair 2 improved performance 3 fleet management features 4 driver s
61. ller from trying to drive the truck with the brake on The controller can be wired to use one both or neither of these switches When both are used they ensure that the truck will not move unless the brake is off and the accelerator is on If your truck does have an accelerator switch it must be a normally open switch that is closed when the accelerator is pressed and open when the accelerator is at its rest position The brake switch must be a normally closed switch that is open when the brake is on and closed when it is not When the controller reads no voltage from these switches that is when the switches are open the direction contactors will operate but the controller will not supply voltage to the motor F ACCELERATOR The accelerator controls the speed of the truck by controlling the motor voltage By pressing on the accelerator pedal the driver changes the drive motor voltage As explained earlier see Safe Sequencing p 8 the TSE1000 TSE550 TSE600 will cause an RTN if the accelerator is pressed out of sequence As shipped the TSE1000 and TSE550 require a standard 5000 ohm 1 2 watt or larger potentiometer with a reading of 5000 Ohms at rest and 0 Ohms at full speed A minimum 2 Watt potentiometer is recommended for mechanical stability The controller uses three settings called throttle maximum throttle minimum and throttle polarity to regulate the accelerator The TSE1000 and TSE550 are set up for 5K O ohm linear po
62. ly In either case the truck might not have enough power to start from a stop TO TEST 1 Check the voltage between each speed limit cutback input and B You should read no voltage at these inputs 2 If speed limits have been wired in temporarily disconnect them If the problem disappears when speed limits are disconnected you may have to increase the maximum speed for these inputs Plug in the ProBit and put the truck up on blocks so you can see the wheels move at low levels and try raising the speed limits O Check the maximum speed setting to make sure it is not too low If it is too low the truck may not be getting the power it needs to start from a stop TO TEST Plug in the ProBit and check that the Maximum Speed is not set too low This level will be different for each truck and each situation 4 CHECK Is the accelerator throttle working properly 9 Check the accelerator input on the controller to ensure that the accelerator is working properly TO TEST Use a voltmeter to check the voltage between the throttle 1 pin on the controller and the throttle 2 pin As you press the accelerator slowly the meter should travel from roughly 5 volts to O volts 9 Check the acceleration level If it is set too high the truck might have a long wait before it will get up to speed 5 CHECK Is the motor wiring OK 9 when all else fails check the motor wiring The armature or the field circuit may not be correct TO TEST
63. may give an early indication of potential problems on a truck The ProBit provides identifies these errors so they can be checked by maintenance personnel b Clearing Errors After reading the errors and dealing with any potential trouble spots they identify service personnel should clear the errors from the controller s memory If errors are not cleared they will continue to be reported every time the error codes are checked You can delete errors with the ProBit c Resetting Timers As part of periodic maintenance service personnel should reset the various clocks in the TSE1000 TSE550 TSE600 see table 5 Data Logging on p 18 for a list of these clocks If this information is being kept for use in a fleet management program then it should be recorded before the clocks are reset The timer information can also be used to determine the 3NOTE If you regularly exceed the average current limit or temperature limit then either the controller or the truck may be undersized for the task it is being asked to perform 54 Navitas Technologies Ltd level of use the truck has received and therefore the thoroughness of the periodic maintenance inspection it will receive The timers can be reset using the Clocks section of the ProBit B WHAT TO DO WHEN THE TRUCK CUTS OUT OR CUTS BACK Under some circumstances the truck will cut back from normal output to protect the system and the operator The various cutbacks their symptoms causes and co
64. mensions 5 general 3 Speed Limit Switches 4 13 55 programming 41 42 50 trouble shooting 46 47 wiring 24 SRO Switch 8 14 24 clocks 19 lift interlock 12 programmable timings 51 related parameters 42 trouble shooting 45 Steering 11 SRO interlock 42 51 trouble shooting 49 wiring 23 T Temperature limits 15 16 56 lower operating temp 4 trouble shooting 54 Throttle minimum and maximum 9 40 43 polarity 9 43 trouble shooting 45 46 53 Trouble Shooting 52 W Wiring 21 22 diagnostics 17 harness 27 43 10 pin 23 8 pin 22 Navitas Technologies Ltd
65. n the platform is raised and the driver is walking Run the white orange wire through the appropriate switch and connect it to the switched side of the key switch Clip and insulate the end of the white purple Wire d Forward OL ocate the forward switch in the directional control and connect its live side to the switched side of the key switch O Connect the white yellow wire to the switched side of the forward directional switch e Reverse 91 ocate the reverse switch in the directional control and connect its live side to the switched side of the key switch O Connect the white gray wire to the switched side of the reverse directional switch f Accelerator Connect the white green wire to one side of the accelerator potentiometer O Connect the white blue wire to the other side of the accelerator potentiometer NOTE The TSE1000 and TSE550 are set up for 5K O ohm linear potentiometers where 5K is rest and 0 is full speed but other potentiometers can be used as well If you are using a non linear pot make sure that the resistance at half accelerator is greater than 2500 Ohms If it is less than this level the truck will be jumpy See Accelerator p 8 for further assistance 23 EMERGENCY DISCONNECT STEERING 400A FUSE BATTERY LIFT LIFT PUMP STEERING PUMP Q FORWARD REVERSE 9 FIELD L ESISTOR R li WEAKENING red TT 20A KEY FUSE SWITCH TH FWD BM wh gry B9 REV ACA Nhlre
66. nd more information on installing different types of accelerators in the section on Accelerator Configurations on p 10 Fuses The TSE1000 and TSE550 require a 10 20 Amp fuse mounted on the live side of the key switch They also require adequate main fuses from the battery 400 Amp for the TSE1000 and 250 Amp for the TSE550 20 Navitas Technologies Ltd 5 Miscellaneous You will also need thermal compound 4 bolts 3 8 miscellaneous wire at least 18 gauge and connection hardware e g connector bars B MOUNTING THE CONTROLLER After removing the existing controller its wiring and all unnecessary accessories locate a suitable mounting position for the TSE1000 TSE550 TSE600 and contactors The mounting surface must be flat and large enough to ensure good heat dissipation Remove paint from truck surfaces and apply a light coat of thermal transfer compound O Drill 4 holes using the mounting template included with the controller as your guide for bolt spacing Use the slots located in the four corners of the base of the controller to bolt it in place You must use four bolts equally torqued to secure the controller C WIRING NOTE Most of the terminals are protected against incorrect wiring However the controller is NOT protected against reversed battery connection You may refer to Figure 8 Connection Diagram 4T Motor p 24 for more help 1 Connecting Power NOTE Do not connect power to the controller un
67. ng Speed Accelerator Figure 5 Bi dirartinnal 1017 10 Navitas Technologies Ltd 5 Other Accelerators a Sevcontrol The Sevcontrol manufactured by Sevcon can be used with the TSE1000 TSE550 TSE600 You should begin by opening the cable and finding the red white green and black wires Connect the red wire to the key switch Connect the black wire to the accelerator 2 input pin on the TSE1000 TSE550 TSE600 Connect the green wire to the accelerator I pin on the TSE1000 TSE550 TSE600 You can connect the white wire to the accelerator brake input pin on the controller or you can leave it unconnected G DIRECTION CONTACTORS The TSE1000 TSE550 TSE600 controller requires direction contactors The forward and reverse direction contactors reverse the polarity of the motor field and in that way they change the direction of motor rotation The controller runs regular checks on the contactors whenever you start the truck and whenever you change directions It checks to make sure the contactors are pulling properly have not welded etc Because of these checks you will experience a slight delay whenever you start your truck and whenever you change directions see Startup Diagnostics p 17 You can adjust this delay by lengthening or shortening the contactor change time with the ProBit If the time is too long the truck will appear to be sluggish when changing directions If it is too short the truck will fail diagno
68. ogies Ltd d 6T Motors A 6T motor has 2 armature terminals and 4 field terminals because it has two separate field windings The field terminals are arranged in pairs one pair for each winding The first step in installation is to find out how the terminals are connected to the fields 1 Check the continuity between different pairs of terminals until you find the two pairs of terminals with a low resistance If you cannot group the terminals in this way the field windings likely require service Each pair of terminals with low resistance is a field winding 2 Complete the installation of the controller as though it were a 4T motor by ignoring one pair of terminals and hence one field winding 3 Disconnect the battery cable with the key on to discharge the capacitors and then turn the key switch off 4 Disconnect the cables from F1 and F1 and connect them across the other pair of terminals 5 Power up the controller Keep the truck elevated while you slowly drive it in the forward and then the reverse directions If the wheels spin forward when the direction selector is forward then the field winding terminal connected to the common pole of the forward contactor is F2 Label the F2 terminal Label the partner terminal F2 If the wheels spin backward when the direction selector is forward then the field winding terminal connected to the common pole of the reverse contactor is F2 Label the F2 terminal Label the partn
69. ollows cutback is 80 of motor output cutback 2 is 60 and cutback 3 is 40 You can connect each cutback independently to a switch and you can set each cutback level independently to any level of 0 200 but you should remember that if more than one switch is closed at the same time cutback 3 will always overrule the others and cutback 2 will always overrule cutback 1 See p 13 L Speed Limit Switches for more information 41 Navitas Technologies Ltd Bypass If you are using bypass you should set the bypass pull in level This level is the motor voltage at which the bypass contactor will pull in It can vary between 80 and 100 of battery voltage You can find a fuller explanation on p 12 in J Bypass 1 a Contactor Field Weakening If you are using field weakening you should set the field weakening pull in and pull out levels and the bypass pull in level Since these levels can be somewhat complicated please see p 12 Field Weakening for a fuller explanation 3 _Programmable Parameters The following table lists some of the parameters that can be programmed with the ProBit For a fuller explanation please see the ProBit manual Although all of these levels can be changed we recommend that you change only one or two at a time One parameter can significantly change other aspects of the truck s performance 42 Navitas Technologies Ltd max plugging strength motor current for TSE1000 O 1000 Amps 280 Amps DO MI
70. ommend that you give the truck a trial period without this feature to compare the results Be sure to insulate and secure the end of the green wire during this time If you wish to continue using bypass you may connect it as follows 21 Navitas Technologies Ltd Connect the positive side of the bypass contactor coil to the switched side of the key switch Connect the green wire to the negative side of the bypass contactor coil c Field Weakening If you are not using field weakening OClip and insulate the end of the yellow wire and proceed to step d If you are using field weakening Connect the positive side of the field weakening contactor coil to the switched side of the key switch Connect the yellow wire to the negative side of the field weakening contactor coil d Forward Connect the positive side of the forward contactor coil to the switched side of the key switch O Connect the orange wire to the negative side of the forward contactor coil e Reverse Connect the positive side of the reverse contactor coil to the switched side of the key switch Connect the gray Wire to the negative side of the reverse contactor coil f Steering Connect the positive side of the power steering contactor coil to the switched side of the key switch O Connect the blue wire to the negative side of the power steering contactor coil g Lift Pump Connect the positive side
71. ontroller output goes to 100 during the time the contactor is switched K FIELD WEAKENING Some trucks are equipped with a field weakening resistor to gain higher speeds with reduced torque The controller switches the resistor in and out using the field weakening contactor In cases where a truck has multiple field windings the controller uses field weakening to short out one of the field windings and so decrease the number of turns in the field The controller reads two levels to determine when to pull the contactor in and out 1 motor voltage and 2 motor current When a driver is operating on a flat surface with a light load the accelerator and the motor voltage will typically be at full and the motor current will be low When a truck is carrying a heavy load up a grade the current will be high When the controller detects the first set of conditions i e full motor voltage and low motor current the controller pulls in the field weakening contactor When the driving conditions change or the motor voltage drops to a preset level the controller pulls the contactor out again Navitas Technologies Ltd You can program field weakening with three parameters in the bypass field weakening section of the ProBit The first parameter the Bypass level is shared with the bypass contactor This level sets the motor voltage above which the field weakening contactor can be pulled in As long as the motor voltage is below this level neither
72. owing instructions give the general steps for connecting power cables Please see the 4T Motor Wiring Diagram on p 30 for further assistance 1 Connect the motor armature the Al terminal to the center power bar marked A on the controller 2 Connect the A2 terminal to the power bar marked A F on the controller 3 Connect F1 to the common terminal of the forward contactor see the diagram below 4 Connect F2 to the common terminal of the reverse contactor see the diagram below NOTE If the truck travels in reverse when you select forward interchange these two connections 5 Connect the normally closed side of the forward and reverse contactor block to the power bar marked AF on the controller 6 Connect the normally open side of the forward and reverse contactor block to the power bar marked F on the controller 7 If you are installing a bypass contactor connect it between the normally open side of the forward and reverse contactor block and the B terminal on the controller If the truck has been using bypass you must double check this routing since your old system may have connected the bypass contactor at B instead of B as in the TSE1000 TSE550 TSE600 2 If you are using a field weakening contactor connect it across the forward and reverse contactors at their common poles 3 Connect the positive battery cable to the power bar marked B on the controller and connect the negative battery cable to the power bar mark
73. r coils with an ohm meter The resistance should be higher than 5 Ohms 1 CHECK Does the ProBit show a contactor error Check the contactor settings particularly the contactor voltage and contactor change times If the contactor voltage is set too high it may cause a contactor coil overcurrent The contactor change time should be set high enough to allow the contactors to move in and out as they switch from forward to reverse TO TEST Start with the change time set to 1 0 second or more and then after passing the start up diagnostics you can lower it appropriately As you lower it leave a little extra time if you set it too close to the limits of your contactors you will get occasional errors since contactors do not always change at their fastest Older contactors in particular need more change time 0 5 seconds or more while newer contactors can be set quite low 0 150 seconds or faster 45 Navitas Technologies Ltd Next you can check the direction contactor wiring as described in the CHECKS section above 1 CHECK Is the SRO switch the dead man switch working O Check the SRO switch to make sure it is working properly TO TEST With the truck in NEUTRAL use a voltmeter to check the voltage between the SRO input on the TSE1000 TSE550 TSE600 and negative If the switch is working properly the input will measure battery voltage 2 CHECK Are the accelerator throttle parameters set correctly O Chec
74. r of current limits The safe sequencing interlock ensures that the driver is in safe control of the vehicle at all times The TSE1000 TSE550 TSE600 links together the dead man switch the accelerator and the direction switches so that the truck will not jerk or move by accident The battery discharge interlock ensures that the truck will not continue to draw current from a battery that needs to be recharged It ties the lift controls to the battery level so that drivers cannot continue to operate the lift after the battery has consumed all of its usable charge The TSE1000 TSE550 TSE600 service brake interlock shuts off all vehicle controls while the service brake is activated In this way the controller adds an extra level of safety to these mechanisms The speed limit cutbacks can be connected to mast switches In this way the TSE1000 TSE550 TSE600 will limit the speed of the vehicle as the lift mast is raised Current limits include the battery current limit the peak motor current limit and the average current limit The battery current limit regulates the amount of current the system can draw from the battery The peak motor limit controls the absolute maximum current to the motor The average current limit controls the continuous current to the motor so that the average duty will not be excessive 5 Exterior Dimensions Navitas Technologies Ltd The following diagram gives the case dimensions of the TSE1000 TSE550 TSE600
75. rent for TSE550 T STARTUP DIAGNOSTICS The controller runs a series of self diagnostic checks to ensure that it is working properly and that the truck is safe to operate The controller tests itself for internal shorts and then tests the system wiring and the contactors If any of the diagnostic tests fail the controller logs the information and returns the truck to neutral At start up the TSE1000 TSE550 TSE600 pulls in each of the direction contactors to check the path from the armature through the field These tests will fail if the motor is not wired correctly if the contactors do not pull in quickly enough or if the contactor coils are shorted Trucks may fail to pass this test after installation because of wiring errors U RUNTIME DIAGNOSTICS While the truck is running the TSE1000 TSE550 TSE600 continues to run checks for failures during operation These tests include checks for welded or failed contactors see Direction contactors p 11 If a failure is detected the controller will log an error code which identifies the problem You can use the ProBit to read the record of errors V ERRORS AND DATA LOGGING The TSE1000 TSE550 TSE600 controller keeps a record of errors and certain operating conditions This record may be read at any time using the ProBit It provides useful information for service and fleet management 1 Error Codes If the controller diagnostics find an error it is recorded for later reference A partial list
76. roller slows the vehicle down to a stop and speeds it up again in the opposite direction whenever the accelerator is pressed while the direction is changed A motor changes direction when the polarity of the motor field is reversed If the field is reversed while the armature is spinning the armature acts like a generator The energy generated in this way is directed through the plug braking diodes in the controller and dissipated through them and the armature The controller regulates the flow of current through the armature so that the truck will come to a stop and change directions smoothly The farther you push the accelerator the stronger the plug braking will be The feel and strength of plug braking can be changed with the ProBit Two main settings affect the operation of plug braking 1 plug braking strength motor current 2 deceleration the amount of time to get to maximum plugging strength You should adjust these levels one at a time since they affect one another 1 The ProBit allows you to set the strength of plug braking by changing the amount of armature current The amperage you set is the current you will get with the pedal to the floor The higher the amperage the stronger the plugging 2 Deceleration is set in seconds A setting of 0 4 seconds means that it will take 0 4 seconds from the time the driver changes direction until the motor to reaches full plugging current Two other parameters may have some ef
77. rouble shooting please see section F Installation Problem Identification beginning on page 44 Some of the causes described here are explained in more detail in that section SYMPTOMS POSSIBLE CAUSES Truck does not run Direction contactors Truck controller may not be wired correctly Check the wiring pages 26 39 do not pull in n sarap Contactor coils may be shorted Check the coils with an Ohmmeter Contactor pull in voltage or hold voltage may be set too low Check the contactor pull in and hold voltages see p 41 Truck does not run Only one direction Truck controller may not be wired correctly Check the wiring pages 26 39 COCOT DUNS AE Startup Contactor coils may be shorted Check the coils with an Ohmmeter The contactor change time may be set too low Check and increase if necessary see Programming the Controller To Suit the Truck p 51 Truck does not run Both direction The direction selection switches may be wired incorrectly or they may be contactors pull in during the startup faulty Check the wiring and test the switches diagnostics but not when a direction is The throttle minimum may be too low so that the startup sequence is not selected being satisfied Check the setting and make necessary corrections see Programming the Controller To Suit the Truck p 51 Throttle polarity may be backwards Verify the throttle polarity The SRO may not be satisfied Check the SRO switch and wiring The startup sequenc
78. rrective measures are described below The cutbacks and errors sections of the ProBit may be used to determine the cause of a cutback 1 Speed Limit Cutback Switches If any of the speed limit cutback switches are closed the controller will cutback to the preprogrammed level for that switch If none of these switches are connected this form of cutback will not occur See section L Speed Limit Switches on p 13 for more information 2 Battery Discharge Interlock BDI The TSE1000 TSE550 TSE600 keeps track of the battery capacity of the truck If the capacity drops to 0 or less usable capacity then the controller will cut back to limp speed after a five minute grace period The lift pump will also cut out under these conditions Turning the key off and on again will reset this timer allowing an additional five minutes of operation for urgent tasks 3 Over Current Limits The controller will also cutback if any of the current limits are exceeded The amount of the cutback and the length of time it lasts depends on the severity of the over current condition The effects of each of the current limit is described below a Peak Motor Current Limit Whenever the peak motor current limit is exceeded the controller will cut the motor output back to the level you have set It cuts back the motor output quickly in the face of excessive demands and quickly restores the output when the excessive load is removed b Average Motor Current Limit Th
79. s PROGRAMMABLE data em SRE MEMORY BUS POWER MOSFETs MICROPROCESSORS MOSFETs Metal Oxide Semiconductor Field Microprocessors give NAVITAS products their Effect Transistors give our controllers the ability to handle high power without consuming as much energy as SCR systems Controllers that use SCRs consume a lot of energy turning the SCR switch on and off and require an extra circuit to do so In contrast MOSFETs switch on and off without any extra circuitry or wasted energy They also switch much faster 20 000 times per second rather than 200 times for SCRs The results are more efficient use of energy and smoother quieter operation PROGRAMMABLE The programmable memory designed into every NAVITAS controller gives the operator a new level MEMORY of control over the vehicle s performance More than 20 vehicle functions which are stored in the controller s memory can be changed by the operator using the ProBit Top speed lift and speed interlocks and even the time it takes to pull contactors in can all be set and reset in the controllers programmable memory intelligence We use microprocessors to collect information from one part of the truck and apply it to another For example microprocessors calculate battery charge perform diagnostics regulate the motor speed according to the lift mast height and keep the system operating within thermal limits and current limits In short we use microprocessors in our control
80. s s eer pap PO NE RR 9 3 Throttle Polarity unie etre 9 4 Accelerator Configurations eese 10 25 Other Accelerators tee eta io eH TRU Ne andes 11 G DIRECTION CONTACTORS ee 11 H STEERING PUMP oiin aa e rtm ge Rd 11 L LJETAPBUME cti dt 11 J BYPASS 1 A CONTACTOR erii ette teet hen s 12 K FIELD WEAKENING iia ere ete 24 epe 641210 k9 12 L SPEED LIMIT SWITCHES rire tut eter te eee eti edge 13 M NAVITAS BUS s qu reto eee tete te 13 N BATTERY MONITOR eter t 01101150 0200111556 St eed 4y id 14 O BATTERY DISCHARGE INTERLOCK eee 14 P INTEREOCKS sists asta anata Onde eu nete 14 1 Static Return to Off see also Deadman switch p 8 14 2 Brake Accelerator Switch errar 15 3 Battery Discharde sives nest a 15 Q LOW VOLTAGE CUTOLUT unn fiar dd taa 15 Re TEMPERATURE LIMITS nennen pee tree GSE 15 S CURRENT EIMITS ei s ede Edited edge ede e e 15 LL OVvervVIEW nen ae Aae SE 15 2 Battery Current Lait eco eerte ei eei 15 3 Motor Current Limit y eere hit 15 4 Controller Limits es etiem eerte tle iaa des cando 16 T STAR TURP DIAGNOSTICS nte 17 U RUNTIME DIAGNOSTICS oirein itt tette tetti tote o b Lebe geret 17 V ERRORS AND DATA LOGGING eere emen rennen 17 ko Error Codes pieliin ee eee eere e tte 17 2 Data LODOS checa meets 18 HH INSTALLATION PROCEDURES
81. stics because the contactors will not be able to change in the time you have set If you find that the pull in time is too long and it cannot be reduced without failing contactor diagnostics then you should consider replacing the contactors with a faster set The factory setting for contactor change time 1s 1 2 second which should work with even the slowest contactors In most cases you will want to shorten this time If you have a good set of contactors you should be able to reduce the time to 0 15 seconds The controller will not pull in a direction contactor 1 when certain errors are detected and 2 if the controls are not operated in the safe sequence i e the accelerator is activated before the direction is selected etc H STEERING PUMP The steering pump contactor pulls in when a direction is correctly selected It drops out again some time after returning to neutral or some time after the dead man switch is opened These times are fully programmable in the miscellaneous timings section of the ProBit and are generally set to between 5 and 30 seconds See the ProBit manual for more detailed information I LIFT PUMP Power to the lift mechanisms is regulated by the lift pump contactor or by the NAVITAS PSE1000 PSE550 pump controller If you are using the PSE1000 PSE550 please see its manual for more details Normally the lift pump contactor can be pulled in whenever the key switch is on However when the b
82. tage to the level that is appropriate for the vehicle s contactors All the contactors must have the same voltage You can also set the contactor hold voltage to a separate lower level Throttle minimum As shipped the throttle minimum is set to 23 i e your accelerator can be off by 23 This level gives room for the inadequacies of most accelerators but it should be adjusted for the specific accelerator you are using If it is set too low then the controller will always fail the safe sequencing startup If it is set too high then you will not have full use of the accelerator See p 9 Throttle minimum and Throttle maximum for more help Throttle maximum As shipped the throttle maximum is set to 95 This level will work for most accelerators but should be adjusted for the specific accelerator you are using If it is set too low then only part of the accelerator will be used If it is set too high the controller will never reach full motor voltage and therefore never reach full speed See p 9 Throttle minimum and Throttle maximum for more help 2 Optional Settings In addition to these levels you will probably also want to adjust the following parameters Contactor change time This parameter controls the time it takes the contactors to pull in or out As shipped this time is set to 1 2 second so that it will work with even the slowest contactors but this level gives a noticeable delay between one contactor pulling out and the oth
83. tch wiring 24 BUS 2 14 27 58 Bypass 12 as it relates to throttle settings 9 effect on field weakening 13 errors 18 programming 41 trouble shooting 48 wiring 22 wiring the contactor 30 C Clocks 19 Contactors 11 21 bypass 12 change time 8 40 42 50 cold switching 3 error codes 19 errors and diagnostics 15 17 18 forward and reverse 11 hold voltage 42 installation 23 30 lift pump 12 polarization 22 steering pump 11 Navitas Technologies Ltd trouble shooting 44 47 48 49 53 56 voltage 42 hold voltage 3 40 pull in voltage 3 wiring harness 27 Current Limits 4 15 42 average 3 16 average motor 3 55 battery 15 error codes 19 controller 16 motor 16 peak 3 16 peak motor 3 55 D Data Logging 18 19 clocks 55 Dead Man Switch 8 debounce time 51 link to lift pump 11 trouble shooting 45 wiring 24 Deceleration plug braking 7 42 Diagnostics 3 contactor error 8 11 40 51 error codes 18 runtime 18 startup 11 17 trouble shooting 43 52 Drive Feel 9 50 E Efficiency increased 4 12 Errors 18 battery current 55 battery current limit 15 causing RTN 14 checking and clearing 54 contactor 44 51 56 diagnostics 17 18 trouble shooting 43 F Field Weakening 12 programming 41 trouble shooting 48 wiring 23 30 5T motors 32 6T motors 36 Fleet Management 4 clocks 55 information logging 18 Fuses 22
84. tentiometers where 5K is rest and 0 is full speed but other potentiometers can be used as well If you are using a non linear pot make sure that the resistance at half accelerator is greater than 2500 Ohms If it is less than this level the truck will be jumpy Navitas Technologies Ltd 1 Throttle minimum and Throttle maximum The throttle minimum and maximum can be set with the ProBit The values are measured as a percentage of full accelerator The throttle minimum must be set correctly It should be set just above the actual level the potentiometer reaches when it is at rest often this reading will be less than 5000 Ohms If this setting is wrong the controller may not operate because the accelerator will seem to be activated all the time and the safe sequencing interlock will be set off The throttle maximum is critical to attaining the maximum speed full battery voltage on the motor of the truck If it is set too low you will never get the full motor voltage or speed possible for the vehicle If it is set too high then the bypass contactor if it is used will be pulled in too soon see Bypass 1 a Contactor p 12 When this level is set properly the controller will operate most efficiently at a lower temperature and therefore with less chance of a thermal cutback and a longer controller life 2 Drive Feel The drive feel of the truck can be adjusted by changing the top speed motor voltage and th
85. til the entire installation is completed O Run a wire at least 18 gauge from a convenient B source after the emergency disconnect through a 10 20 Amp in line or dash mounted fuse to the live side of the key switch Connect the negative battery cable to the main connector bar on the controller labeled B 2 Connecting the 8 Pin Harness 9 pius the 7 wire harness onto the lower set of eight 8 pins on the controller Make sure that the orange wire is connected to the last pin on the left See Diagram I Controller Wiring ejr you are using polarized contactors please ensure that the coils are properly polarized as you connect them NOTE Please note that many other controllers switch the positive side of the contactor coils but the TSE1000 and TSE550 switch the negative side Be sure to check connections when using existing contactors a Key The steps which follow instruct you in connecting several wires to the switched side of the key switch Because of the number of wires involved you may wish to install a connector bar between the key switch and the controller Connect the red wire to the switched side of the key switch The key switch provides battery voltage to the control circuits b Bypass Because of the efficient performance of the TSE1000 TSE550 TSE600 bypass sometimes called 1 A is an unnecessary feature see Bypass 1 a Contactor p 12 If you are currently using bypass on your truck we strongly rec
86. with a code number and an explanation You can look up the code in the ProBit manual to get the fullest picture of what is happening Learning how to interpret and act on these error messages will help you to resolve problems quickly If the TSE1000 TSE550 TSE600 finds a problem during start up diagnostics it will not even attempt further tests and the truck will not operate You can check for error codes with the ProBit After you read the error you should delete it from memory otherwise the TSE1000 TSE550 TSE600 will continue to report it 2 If the Diagnostics Fail The following pages list typical problems which can arise during installation and help you to locate and correct the problem Along with checking these details you should also ensure that the truck s other components are in good working order e g the battery the accelerator etc 44 Navitas Technologies Ltd The only tools necessary for most debugging of an installation are a normal Volt Ohm Meter a current meter and the ProBit To check the input voltages to the controller insert a meter probe into the connector with the meter ground lead connected to the B bar 1 CHECK Does the ProBit power up properly 9f the ProBit does not work check the key switch and its fuse TO TEST Read the voltage at the controller s key switch input the red wire You should read full battery voltage when the key switch is on If you read no voltage temporarily remove all

tse1000/tse550/tse600 drive motor controller product manual

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