Transcript Technical_presentation_BR652 4.68 Mb
Technical presentation Nilfisk BR 652/752
1
Welcome to the technical presentation on Nilfisk BR652, battery ride on scrubber.
The aim of the training is to provide you with technical points of the machine.
Technical specifications
2
Cleaning width Squeegee width Solution/clean water tank capacity Solution flow Vacuum system motor power Drive system motor power Maximum speed Standard batteries running time Total electrical consumption Brush motor power Brush speed Brushpressure with extra-pressure function OFF Brushpressure with extra-pressure function ON
BR 652 BR 752
650 mm 710 mm 890 mm 80 l da 1 a 3 l/min.
420 W 300 W 6 km/h 2,5 - 3,5 h
BR 752C
710 mm 60 A 2 x 400 W 230 rpm 30 kg 48 kg 32 kg 50 kg 2 x 600 W 720 rpm 35 kg
Control Panel
ECOFLEX Brush/pad-holder deck lifting/lowering switch and vacuum switch Brush/pad-holder extra-pressure switch. With the cylindrical brush deck installed, this switch is disabled.
Squeegee lifting/lowering and vacuum system on/off switch
3
Battery charge indicator Hour counter (When the machine is started) and solution level (While using the machine) Ignition key Reverse gear switch Silent mode Solution flow switch adjustment and level LED
4
Steering wheel
New steering wheel integrate all working functions for easier operations: The membrane panel switch connected to the control board, all integrated into the steering wheel.
5
Drive system
• • • • New drive unit Motor 300W @ 4200 rpm IP 44 Easy replaceable tire Motor electrical input check: 5 - 7 A at 24V without load and maximum forward speed
Speed Pedal
6
• • • • New pedal Voltage modulation signal by HALL effect sensor No potentiometer = no adjustment required One only part = no serviceable component Higher reliability (over 10 million cycles)
Parking brake
Electromagnetic brake on the top of the drive motor. Not used as speed brake but parking/stationary brake.
The machine speed braking is given by the controller and can be adjusted (see program option on service manual) To move the machine with power off pull the lever or just insert a spacer to keep the lever pulled.
7
8
Drive system TROUBLESHOOTING
THE MACHINE DOES NOT MOVE
Possible causes: 1.
The motor brushes are worn (replace).
2.
3.
4.
5.
6.
7.
8.
The motor (M3) is malfunctioning (repair or replace).
The under-seat microswitch is broken (replace).
The pedal potentiometer (RV1) is broken (replace).
The brake (BRK) is activated (deactivate).
Function electronic board fuse (F2) open circuit (replace).
Function electronic board (EB1) is faulty The function electronic board error codes indicate the drive system faults (see the Function Electronic Board Error Code paragraph).
Brush deck
• • • • 3 different brush deck versions 1.
2.
3.
BR 652 BR 752 BR 752C 2 brushes/pads 2 brushes/pads 2 cyl. brushes – scrubbing width 660 mm – scrubbing width 710 mm – scrubbing width 710 mm The squeegee is the same size 890mm/35“ for BR 652 - BR 752 - BR 752C DISK and CYLINDIC deck are not interchangeable due to specific chassis with different deck support “Magic deck” is the unique feature of the brush deck which move to the inner of curve depending of the steering rotation. For a better drying even without the side splash guard.
9
Magic Deck
Exploded view of the mechanical mechanism allow the deck support to move upon the drive unit rotation.
In case deck impact, force is not transmitted back to steering thanks to release springs.
Note when installing the driving wheel assembly and the deck support the gears must have arrows (J) aligned.
10
11
Brush motor
• • • • DISC Motor 400W @ 2800 rpm IP40 Motor electrical input check: • 3 to 4 A at 24V (without load for each single motor) Easy replaceable carbon brushes • • CYLINDRIC Motor 600W @ 1800 rpm Electrical input check: 4 to 6 A, at 24V (without load for each single motor) Easy replaceable carbon brushes
12
Deck system TROUBLESHOOTING
1.
2.
3.
4.
5.
6.
7.
8.
9.
Function electronic board (EB1) is faulty (replace).
Wiring harness between function electronic board (EB1) and brush motor electromagnetic switch (ES1) is damaged (repair).
Electromagnetic switch (ES1) is damaged (replace).
Fuse (F1) is open (replace).
Carbon rushes are worn (replace).
Motor (M1) is faulty (repair or replace).
Actuator (M5) end-of-stroke microswitches are broken (replace the actuator).
Actuator motor (M5) is broken (replace).
See the Electrical System chapter, controller error codes.
Solution System / ECOFLEX
Main component are located on the chassis under the solution tank and accessible from the rear of the machine Solution filter Solenoid valve Pump detergent
13
14
Solution System TROUBLESHOOTING
Incorrect solution to the brushes, to check:
1.
The solution filter is clogged/dirty 2.
(clean).
The solenoid valve (EV1) is broken or 3.
there is an open in the electrical connection (replace the solenoid valve/repair the electrical connection).
There is debris in the solution/clean water tank clogging the output hole (clean the tank) and/or debris in the 4.
5.
6.
solution/clean water hoses clogging the flow (clean the hoses).
The function electronic board (EB1) is faulty (replace).
The display electronic board (EB2) is faulty (replace).
The dashboard electronic board (EB3) is faulty (replace).
15
ECOFLEX TROUBLESHOOTING
Incorrect solution to the brushes, to check: 6 items previous page
7. The function electronic board (EB1) is not set for the operation with EcoFlex™ system (remove the jumper wire (J4) in front of the electronic board).
8. The pump (M4) is broken (replace).
Recovery system
Actuator no pre-adjustment needed.
Squeegee cable raising has pulley mechanism to allow wider squeegee movement with shorter actuator travel.
Note the correct cable layout for cable replacement VAC motor electrical consumption is 16 - 19 amps at 24V 3 stage motor SILENT MODE: board cut motor supply to 16V
16
17
Recovery system TROUBLESHOOTING
Incorrect drying, to check:
1.
The vacuum motor M2 is faulty (check the 2.
electrical input).
The vacuum motor carbon brushes are worn 3.
4.
(replace).
The wiring harness between function electronic board and vacuum system motor is damaged (repair).
The function electronic board (ES1) is 5.
6.
7.
damaged (replace).
The actuator squeegee (M6) is faulty (replace).
The actuator fuse (F4) is open (replace).
See the Electrical System chapter, function electronic board diagnosis.
Battery & onboard charger
Key switch “ON” the display show the current machine setting and charging curve (if equipped with onboard charger OPT) 6 settings available: OPT on-board charger • SPE 24V 20A high frequency • IP 55 • Fully controlled by machine electronics • Factory standard setting #1 WET @ 20Amps • Assembly instruction available for charger installation
18
Battery & charger curve selection
If the setting is to be changed, perform the following procedure: a. Turn the key switch “OFF”.
b. Press and hold the buttons “BRUSH “ and “VAC” at the same time, then turn the key switch “ON”.
c. Continue to hold the buttons until the battery meter LED light turns “ON” and “OFF” and then release both buttons.
d. Within 3 seconds, toggle the button “VAC” to select required charger setting (1 to 6 below):
SETTING 1 2 3 4 5 6 INDICATION 4 RED blinks 4 GREEN blinks 4 YELLOW blinks 2 RED blinks 2 GREEN blinks 2 YELLOW blinks BATTERY TYPE WET GEL-AGM GEL, EXIDE type® WET GEL-AGM GEL, EXIDE type® 19 CHARGING CURRENT STANDARD @ 20 amps REDUCED @ 15 amps (suggested for battery capacity < 160 Ah C5)
Machine cut-off threshold
20
Deep of discharge voltage approved for Exide battery:
21,6V GEL (= 1,8Vpc) 20,4V WET (= 1,7Vpc)
correspond to brush motor stop and red led flashing
FUNCTION BOARD
One only PCB integrate drive (include ESP sensor) and functions (motors, actuators, pressure sensor)
(A - B)
Power supply connection (+) and (-)
(C - D)
Drive motor connection (M1) and (M2).
(E)
Pressure switch module connection (J7A and J7B).
(F)
Electrical component wiring harness connection (J1).
(G)
Foot board wiring harness connection (J3).
(H)
Frame wiring harness connection (J2).
(I)
Vacuum system wiring harness connection (VA+ and VA-).
(J)
Recovery tank wiring harness connection (J6).
(K)
Electromagnetic brake wiring harness connection (J5).
(L)
Brush deck actuator wiring harness connection (J4).
21
22
FUSE lay out
(F1)
50A fuse - Brush motors.
(F2)
100A MIDI fuse - Function electronic board (drive and vacuum system).
(F3)
3A blade fuse - Signal circuit.
(F4)
15A blade fuse - Deck and squeegee lifting actuator.
(ES1)
brush motor electromagnetic switch.
Function board ERROR CODES
Errors are shown on the display by “AL” +“XX” is the alarm code. The errors are repeated (in case of display malfunction) by the diagnostic LEDs (yellow and red) on the main board as following tables.
General Alarms (YELLOW LED + RED LED FLASHING)
Code = No. of flashes Meaning Condition Effect
G2 G3 G4 G5 G6 G7 G8
EEPROM error General thermal protection Blown F2 fuse Wrong KEY sequence No signal from BATTERY CHARGER Undervoltage Serial communication error with dashboard electronic board EEPROM error Heatsink temperature > 90 ° C V > 1V on F2 Wrong key sequence No signal from battery charger B+ - B < THRESHOLD2 for t >10” No signal or decoding error Function block + Default setting reset Function block Function block Function block The charging battery phase is not shown Function block No block
G9
Battery voltage drop DeltaV (neg.)> 3V on battery voltage Drive system + electromagnetic brake block
23
Function board ERROR CODES
Function Alarms (RED LED FLASHING)
Code = No. of flashes
F2 F3 F4 F5 F6 F7 F8
Meaning Condition Effect BRUSH motor amperometric protection Voltage higher than the safety threshold Brush electromagnetic switch output block VACUUM SYSTEM amperometric protection DECK ACTUATOR position irregularity Vacuum system abnormal electrical input > 30A for T>10s Vacuum system block End-of-stroke microswitch configuration not plausible or end-of-stroke not reached within 10” Deck actuator block VACUUM SYSTEM power section damage CC MOSFET Vacuum system block PRESSURE SWITCH signal fault Pressure switch Vout > 4.0V
Water level visualisation missing + water flow and % detergent management fault VACUUM SYSTEM output short circuit Function general relay fault I > 2 * 50A Always closed / opened Vacuum system block Function block
24
Function board ERROR CODES
25 Drive system alarms (YELLOW LED FLASHING)
Code = No. of flashes
t2 t3 t4 t5 t6 t7 t8
Meaning Amperometric protection intervention Electromagnetic brake not present Pedal input activated by ignition Drive system power section damage Pedal input not admitted Overcurrent (motor D.C.) Drive system relay fault Condition I > rated current for t > protection time Res. J5.1-J5.2 > 1k J3.8 > DEADL on ascend. front J3.6
CC MOSFET Res. J3.7-J3.9 > 10k or J3.8 > J3.7
I > 1.5 * IMAX Contacts always opened/closed
26
Function board ERROR CODES
DISPLAY
“---“ Other alarm indications on the display
Meaning Condition Water level signal missing or not as specified Pressure switch module signal > 4.0V or floating
“888” Off
Serial communication problem between dashboard electronic board and function electronic board Dashboard electronic board power supply missing Signal missing or errors J1.1 – J1.4 < 12V
27
BLACK-BOX
Handle programmer connect to port J9: 1.
Display the error codes, 2.
3.
4.
Display current values of setting, Change parameters, Show battery management data:
GB-N GC GD-N
Time of continuous use with discharged batteries Charging cycle interrupted before completion Charging phase duration Refer to service manual for details of programmer use and function modes ITALSEA UNIVERSAL PROGRAMMER, NILFISK P/N 9097297000
28
Wiring diagram (click to open)
Accessory Installation instructions (click to open)
29
Ecoflex KIT Onboard charger KIT
30