Zamboni 450 ELECTRIC Service Manual
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Zamboni 450 ELECTRIC Service Manual

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MODEL
450
ELECTRIC
Zamboni USA
Zamboni Company USA, Inc.
15714 Colorado Ave.
Paramount, CA USA 90723-4211
(562) 633-0751
(562) 633-9365
REV 8/6/23
SERVICE MANUAL
Zamboni Canada
Zamboni Company Ltd.
38 Morton Ave. East, Box 1388
Brantford, ON Canada N3T 5T6
(519) 758-5000
(519) 758-0500
Zamboni Europe
Zamboni Europe AB
Murarmörkret 4
SE-811 74 Österfärnebo Sweden
+46 291 206 80
+46 291 206 83
Zamboni Quebec
Robert Boileau Inc.
1425 Boulevard Pitfield
Saint-Laurent, Quebec, Canada H4S 1G3
(514) 333-8420
(877) 333-8420
zamboni.com

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Дмитрий
June 4, 2025

На дисплее вместо кол-ва моточасов загорелось ERROR 1! Что за ошибка и как её устранить?!

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Summary of Contents for Zamboni 450 ELECTRIC

  • Page 1 MODEL SERVICE MANUAL ELECTRIC Zamboni USA Zamboni Canada Zamboni Europe Zamboni Quebec Zamboni Company USA, Inc. Zamboni Company Ltd. Zamboni Europe AB Robert Boileau Inc. 15714 Colorado Ave. 38 Morton Ave. East, Box 1388 Murarmörkret 4 1425 Boulevard Pitfield Paramount, CA USA 90723-4211 Brantford, ON Canada N3T 5T6 SE-811 74 Österfärnebo Sweden...
  • Page 2 MODEL SERVICE MANUAL ELECTRIC MANUFACTURER’S WARRANTY OPERATING INSTRUCTIONS TROUBLESHOOTING GUIDE PARTS LIST MAINTENANCE SCHEDULE / LOGS SEVCON GEN4 CONTROLLERS/ ® BMS FAULT CODES PARKER MOTOR SHEET BATTERIES/CHARGERS HYDROSTATIC DRIVE COMPONENTS WATER PUMP OPTIONS MEMOS AND UPDATES SAFETY BULLETIN...
  • Page 3 BACK MANUFACTURER’S WARRANTY...
  • Page 4 (2) years or 2,000 hours, whichever comes first, following shipment from our factory to the original user. The obligation of ZAMBONI under this warranty is limited to replacing at our factory any part or parts supplied by us, which shall, within the warranty period be returned to us with transportation charges prepaid, and which our examination shall disclose to our satisfaction to have been defective.
  • Page 5 BACK OPERATING INSTRUCTIONS Your machine’s Operating Instructions is now available as a separate file located in the Owner’s Area. Click Here If you need additional information, contact your Zamboni Authorized Distributor or Zamboni Customer Service.
  • Page 6 BACK TROUBLESHOOTING GUIDE...
  • Page 7 TROUBLESHOOTING GUIDE ® Zamboni Ice Resurfacer Many of the problems and corrective actions noted in this guide are visually demonstrated and discussed in our video presentations: "Conditioner Maintenance" and “Ice Resurfacer Operation” which accompany each new machine shipment. To achieve optimum results from your machine, your operations staff should review the videos and properly maintain your resurfacer.
  • Page 8 TROUBLESHOOTING GUIDE - Zamboni Ice Resurfacer Page 2 MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Conditioner leaving scratch Nick in blade * Sharpen on ice Foreign matter on runners * Check and remove foreign matter. File. or other parts of conditioner Difficult to adjust blade...
  • Page 9 TROUBLESHOOTING GUIDE - Zamboni Ice Resurfacer Page 3 MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Ice build-up in front of blade Dull blade * A sharp blade will create more agitation of the shaven snow at the blade edge than a dull blade. Sharpen blade so...
  • Page 10 TROUBLESHOOTING GUIDE – Zamboni Ice Resurfacer Page 4 MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Inadequate power of Engine RPM too low Check by selecting lower hydrostatic conveyor transmission selector setting and higher engine RPM. Faulty seal on conveyor Disconnect small drain hose from motor...
  • Page 11 BACK PARTS LIST Your machine’s Parts List is now available as a separate file located in the Owner’s Area. Click Here If you need additional information, contact your Zamboni Authorized Distributor or Zamboni Customer Service.
  • Page 12 BACK MAINTENANCE SCHEDULE / LOGS...
  • Page 13 MODEL PREVENTATIVE MAINTENANCE: GREASING SCHEDULE ELECTRIC THIS SCHEDULE HAS BEEN SET UP AS A GUIDE ONLY. MORE FREQUENT INTERVALS MAY BE REQUIRED DEPENDING ON OPERATING CONDITIONS. (EXAMPLE: DRIVING THE MACHINE OUTSIDE OF THE BUILDING ON UNPAVED OR HEAVILY SANDED PARKING LOTS.) ALL OF THE GREASE FITTINGS ON THE MACHINE COME EQUIPPED WITH RED PLASTIC DUST CAPS.
  • Page 14 MODEL PREVENTATIVE MAINTENANCE: GREASING SITES ELECTRIC VERTICAL AUGER BEARINGS HAND WHEEL U JOINT AND BEARING HORIZONTAL AUGER DRIVE CHAIN HORIZONTAL AUGER BEARINGS AUGER BEARING DUMP TANK FOOT PEDAL PIVOTS BRAKE PEDAL CONDITIONER LIFT BAR PIVOTS (4) DRIVE SHAFT UNIVERSALS AUGER BEARING CENTRAL GREASING STATION (ONE LOCATION ONLY) AUGER DRIVE CHAIN...
  • Page 15 MODEL PREVENTATIVE MAINTENANCE: INSPECTION SITES ELECTRIC Ice Making Water Fill Pipe Hydraulic Oil Sight Gauge Water Pump Belt Drive Transfer Case Differential Control Rod Universal Front Wheel Bearings Hydraulic Oil Sight Gauge Water Pump Front Axle Universals Drive Belt Hydrostatic Pump Hydraulic Double Pump...
  • Page 16 MODEL PREVENTATIVE MAINTENANCE SCHEDULE ELECTRIC Frequency Qty Per Machine DESCRIPTION DAILY HOURS ANNUALLY 1. Steering Cylinder. On the rod end, all models have a 1 or 2 greaseable tie-rod end. On the cylinder mounting end, there is either a greaseable bolt mount, a greaseable rod eye, or a lubed for life rod eye.
  • Page 17 MODEL PREVENTATIVE MAINTENANCE SCHEDULE (continued) ELECTRIC Frequency Qty Per Machine DESCRIPTION DAILY HOURS ANNUALLY 17. Snow Tank Door Pivots and Opening Links. (Some of the opening links are equipped with rod ends that are of the lubed for life style.) 18.
  • Page 18 MODEL ANNUAL MAINTENANCE INSPECTION AND SERVICE ELECTRIC ELECTRICAL • Electrical harness, check for wear points on chassis and inside instrument panel • Check operation of ignition switch, all lighting, all switches, and optional electrical accessories HYDRAULIC SYSTEM • Check for proper oil level •...
  • Page 19 MODEL ANNUAL MAINTENANCE INSPECTION AND SERVICE (continued) ELECTRIC DRIVE TRAIN • Inspect condition of frame, crossmembers and all structural supports and related hardware • Inspect for broken or flat leaf springs • Check u-bolts and all axle mounting hardware • Check for play in axle bearings, steering components and front wheel bearings •...
  • Page 20 MODEL ANNUAL MAINTENANCE INSPECTION AND SERVICE (continued) ELECTRIC WASH WATER / ICE MAKING WATER SYSTEM AND SNOW TANK • Check and clean screen • Flush out wash water tank • Inspect condition of water control valves and rods • Check impellor, pump condition and wiring •...
  • Page 21 BACK SEVCON GEN4 CONTROLLERS/ ® BMS FAULT CODES...
  • Page 22 Gen4, Nano, Evo5, GpAC and espAC Fault Codes Level LED Flashes Type Display Message Description Recommended Action 0x4481 Warning F12001 Handbrake Fault Handbrake is active when direction selected. Release handbrake 0x4541 Warning F15001 Fan Fault No speed feedback from external heatsink fans Check operation of heatsink fans 0x4542 Warning...
  • Page 23 Gen4, Nano, Evo5, GpAC and espAC Fault Codes Level LED Flashes Type Display Message Description Recommended Action SinCos Encoder Min Max Values are heading towards a voltage rail Thermal or mechanical variation is causing the sincos encoder to 0x46C2 Warning F11102 SinCos Tracking Warning or converging together.
  • Page 24 Gen4, Nano, Evo5, GpAC and espAC Fault Codes Level LED Flashes Type Display Message Description Recommended Action 0x4D41 Severe F35001 Motor Isolation Fault Motor isolation contactor is open circuit Check isolation contactor and wiring 0x4D42 Severe F35002 Motor Open Circuit Fault Motor terminal is open circuit or disconnected from controller Check motor wiring.
  • Page 25 Gen4, Nano, Evo5, GpAC and espAC Fault Codes Level LED Flashes Type Display Message Description Recommended Action 0x5184 Very Severe F46004 Analogue Output On with No Failsafe Internal hardware failsafe circuitry not working Internal hardware fault 0x5185 Very Severe F46005 Analogue Output Off with Failsafe Contactor driver not working Internal hardware fault...
  • Page 26 Gen4, Nano, Evo5, GpAC and espAC Fault Codes Level LED Flashes Type Display Message Description Recommended Action EMCY message received from non-Sevcon node and anonymous 0x5381 Very Severe F44101 CANopen anon EMCY level 4 Check status of non-Sevcon nodes on CANbus EMCY level (0x2830,0) is set to 4.
  • Page 27 BMS Fault Codes List F61000 Mul*plexer F61001 Mul*plexer F61002 Mul*plexer • Host Sanity Error: Indicates an error in the message sequence number from the host. This suggests that a Host Sanity Error message has been lost F61003 • Low SOC warning: indicates that at least one module’s state of charge has dropped below the value that was Low SOC warning set in the BMS configura*on process F61004...
  • Page 28 BMS Fault Codes List - Continued F64005 Under Voltage State F64006 Over Current Charge • Over Current Charge: indicates that the charge current to at least one module is too high F64007 Over Current Charge • Over Current Discharge: indicates that the discharge current from at least one module is too high. F65000 Over Current Discharge F65001...
  • Page 29 BACK PARKER MOTOR SHEET...
  • Page 30 Global Vehicle Motors GVM Series Technical Manual PVD 3668_GB - 1 – PVD3668_GB_GVM_November 2016.docx...
  • Page 31 EU DECLARATION OF CONFORMITY We , Parker Hannifin Manufacturing France SAS Electromechanical & Drives Division Europe Etablissement de Longvic 4 Boulevard Eiffel - CS40090 21604 LONGVIC Cedex - France manufacturer, with brand name Parker, declare under our sole responsibility that the products BRUSHLESS SERVOMOTORS TYPE GVM satisfy the arrangements of the directives : Directive 2014/35/EU : “Low Voltage Directive”, LVD...

  • Page 32: Table Of Contents

    Table of Content INTRODUCTION ............................5 1.1......................5 URPOSE AND INTENDED AUDIENCE 1.2..............................5 AFETY 1.2.1. Principle ............................. 5 1.2.2. General Safety Rules ........................ 6 PRODUCT DESCRIPTION ......................... 8 2.1. URL ............................8 UICK 2.2............................8 VERVIEW 2.3.
  • Page 33 4.1.2. Handling ........................... 63 4.1.3. Storage ............................ 64 4.2............................64 NSTALLATION 4.2.1. Mounting ..........................64 4.2.2. Preparation ..........................65 4.2.3. Mechanical assembly ......................65 4.3........................66 LECTRICAL CONNECTION 4.3.1. Cable connection ........................66 4.3.2. Resolver / Encoder / Thermistor cable handling ..............67 4.4.

  • Page 34: Introduction

    1. INTRODUCTION 1.1. Purpose and intended audience This manual contains information that must be observed to select, install, operate and maintain PARKER GVM motors. Installation, operation and maintenance of the equipment should be carried out by qualified personnel. A qualified person is someone who is technically competent and familiar with all safety information and established safety practices;...

  • Page 35: General Safety Rules

    1.2.2. General Safety Rules Generality DANGER: The installation, commissioning and operation must be performed by qualified personnel, in conjunction with this documentation. The qualified personnel must know the safety (C18510 authorization, standard VDE 0105 or IEC 0364 as an example) and local regulations. They must be authorized to install, commission and operate in accordance with established practices and standards.
  • Page 36 Mechanical hazard Brushless synchronous motors can accelerate in milliseconds. Running the motor can lead to other sections of the machine moving dangerously. Moving parts must be screened off to prevent operators coming into contact with them or to protect the people against a shaft failure.

  • Page 37: Product Description

    2. PRODUCT DESCRIPTION 2.1. Quick URL All informations and datas are avaible on : http://www.parker.com/eme/mgv 2.2. Overview The GVM motors from Parker are innovative solutions, specifically designed for Mobile applications for Traction, Implement or Auxiliary functions. The GVM motors are brushless synchronous servomotors, with permanent magnets, with a Water or Oil cooling system and a resolver / encoder speed sensor.

  • Page 38: General Technical Data

    2.4. General technical data Motor type Permanent-magnet synchronous motor Magnet material Rare earth magnets Number of poles Size: GVM142 GVM210 No of poles: Mechanical interface Different interfaces for Implement and Traction Sizes (square motor dimension) 142, 210 Degree of Protection IP67 as standard ;...

  • Page 39: Product Code

    2.5. Product Code GVM 210 150 AA W A A A TA 1 G Motor Code : Series : GVM - Motor GVK – Kit Frame : Outer width of motor in mm Stack : Length of motor lamination stack 075** 150* 200*...

  • Page 40: Technical Data

    3. TECHNICAL DATA 3.1. Motor selection 3.1.1. Altitude derating From 0 to 1000 m : no derating From 1000 to 4000 m : torque derating of 5% for each step of 1000 m for GVM motors. 3.1.2. Cooling temperature Water cooled motor Standard datasheets are available for water cooling without Glycol and inlet temperatures of 25°C or 65°C (see total flow required if Glycol is added on §...
  • Page 41 Selection of the motor : The motor corresponding to the duty cycle has to provide the rms torque M at the rms speed(*) without extra heating. This means that the permanent torque M available at the average speed presents a sufficient margin regarding the rms torque M rms.

  • Page 42: Inverter Selection

    3.1.4. Inverter selection The Inverter selection depends on at first on the available voltage and then on its rated power, nominal current and maximum electrical frequency have to be achieved by the drive and by the flux weakening ratio. Please refer to the drive technical documentation for any further information and to select the best motor and drive association.

  • Page 43: Current Limitation At Stall Conditions (I.e. Speed < 3 Rpm)

    3.1.5. Current limitation at stall conditions (i.e. speed < 3 rpm) Recommended reduced current at speed < 3 rpm:   reduced Warning: The current must be limited to the prescribed values. If the nominal torque has to be maintained at stop or low speed (< 3 rpm), the current must not exceed 70% of I (permanent current at low speed), in order to avoid any excessive overheating of the motor.
  • Page 44 Ip = Peak current In = Nominal current for a define speed (For low speed In=Io) tp = duration of the peak current in the cycle. tc = duration of the cycle Irms = Thermal equivalent current. ( Irms=√(Ip²*tp/tc) ) Tcp = Thermal time constanst of the copper.

  • Page 45: Motor Characteristics And Inverter Association

    3.2. Motor characteristics and inverter association The torque vs speed graph below explains different intrinsic values of the next tables. Peak Torque Mmax Intermittent Operating Area Rated Power Nn ,Mn Rated Torque Constant Power Continuous Operating Area Flux Weakening Rated Nmax Speed Rated...

  • Page 46: Low Voltage Associations With Natural Convection

    3.2.1. Low Voltage Associations with Natural Convection These associations without liquid cooling are typically dedicated to EHP due to the low speed level available. GVM with a contact surface at 60°C – Characteristics given for an optimal inverter/motor association Battery Rated Rated Rated...
  • Page 47 GVM with a contact surface at 60°C – Characteristics with Low Voltage MC drive association Battery Rated Rated Rated Rated Peak Peak Peak Max. Efficiency Torque Power Current Speed Torque power Current Speed at Rated Motor Drive Voltage Mmax Nmax Power Supply (N.m)

  • Page 48: Low Voltage Associations With Liquid Cooling

    3.2.2. Low Voltage Associations with Liquid Cooling GVM with input coolant at 65°C – Characteristics given for an optimal inverter/motor association Battery Rated Rated Rated Rated Peak Peak Peak Max. Pure Efficiency Torque Power Current Speed Torque power Current Speed Water at Rated Motor...
  • Page 49 GVM with input coolant at 65°C – Characteristics with Low Voltage MC drive association Battery Rated Rated Rated Rated Peak Peak Peak Max. Pure Efficiency Torque Power Current Speed Torque power Current Speed Water at Rated Motor Drive Voltage Mmax Nmax Flow Power...

  • Page 50: High Voltage Associations With Liquid Cooling

    3.2.3. High Voltage Associations with Liquid Cooling GVM with input coolant at 65°C – Characteristics given for an optimal inverter/motor association Battery Rated Rated Rated Peak Peak Peak Max. Pure Efficiency Rated Power Current Speed Torque power Current Speed Water at Rated Motor Torque...
  • Page 51 GVM with input coolant at 65°C – Characteristics with High Voltage MD drive association Battery Rated Rated Rated Rated Peak Peak Peak Pure Efficiency Torque Power Current Speed Torque Power Current Speed Water at Rated Motor Drive Voltage Flow Power Supply (N.m) (kW)
  • Page 52 Battery Rated Rated Rated Rated Peak Peak Peak Pure Efficiency Torque Power Current Speed Torque Power Current Speed Water at Rated Motor Drive Voltage Flow Power Supply (N.m) (kW) (Arms) (rpm) (N.m) (kW) (Arms) (rpm) (l/min) GVM210 - Three-phased - Liquid cooled at 65°C GVM210-050-QRW MD-4A-80-053-00 38.4 9.26...
  • Page 53 GVM with input coolant at 25°C – Characteristics given for an optimal inverter/motor association Rated Rated Rated Rated Peak Peak Max. Speed speed Power Torque Speed Current Torque Current Speed Motor Torque Current Mpeak I peak Nmax (kW) (Nm) [rpm] [Arms] [Nm] [Arms]...

  • Page 54: Typical Efficiency Maps Without Flux-Weakening

    3.2.1. Typical Efficiency Maps without Flux-Weakening Caution: The efficiency curves are typical values. They may vary from one motor to an other Caution: The efficiency curves are given for an optimal motor control (no voltage saturation and optimal phase between current and EMF) Caution: The efficiency curves do not include the losses due to the switching frequency.
  • Page 55 GVM142-050 in Motor operation mode : GVM142-050 in Generator operation mode : - 26 – PVD3668_GB_GVM_November 2016.docx...
  • Page 56 GVM142-075 in Motor operation mode : GVM142-075 in Generator operation mode : - 27 – PVD3668_GB_GVM_November 2016.docx...
  • Page 57 GVM142-100 in Motor operation mode : GVM142-100 in Generator operation mode : - 28 – PVD3668_GB_GVM_November 2016.docx...
  • Page 58 GVM210-050 in Motor operation mode : GVM210-050 in Generator operation mode : GVM210-100 in Motor operation mode : - 29 – PVD3668_GB_GVM_November 2016.docx...
  • Page 59 GVM210-100 in Generator operation mode : GVM210-150 in Motor operation mode : - 30 – PVD3668_GB_GVM_November 2016.docx...
  • Page 60 GVM210-150 in Generator operation mode : - 31 – PVD3668_GB_GVM_November 2016.docx...
  • Page 61 GVM210-200 in Motor operation mode : GVM210-200 in Generator operation mode : - 32 – PVD3668_GB_GVM_November 2016.docx...
  • Page 62 GVM210-300 in Motor operation mode : GVM210-300 in Generator operation mode : - 33 – PVD3668_GB_GVM_November 2016.docx...
  • Page 63 GVM210-400 in Motor operation mode : GVM210-400 in Generator operation mode : - 34 – PVD3668_GB_GVM_November 2016.docx...

  • Page 64: Time Constants Of The Motor

    3.2.2. Time constants of the motor 3.2.2.1. Electric time constant:   elec With following values given in the motor data sheet inductance of the motor phase to phase [H], ph_ph resistance of the motor phase to phase at 25°C [Ohm]. ph_ph Example: Motor series GVM210-400-DPW...
  • Page 65  For a GVM motor, the mechanical time constant represents the duration needed to mech reach 63% of the final speed when applying a voltage step without any resistant torque, if the electrical time constant is much smaller than the mechanical time constant. An overall summary of motor time constants is given later.

  • Page 66: Dimension Drawings

    3.3. Dimension drawings 3.3.1. GVM142 outline drawings - 37 – PVD3668_GB_GVM_November 2016.docx...
  • Page 67 - 38 – PVD3668_GB_GVM_November 2016.docx...

  • Page 68: Gvm210 Outline Drawings

    3.3.2. GVM210 outline drawings - 39 – PVD3668_GB_GVM_November 2016.docx...
  • Page 69 - 40 – PVD3668_GB_GVM_November 2016.docx...
  • Page 70 - 41 – PVD3668_GB_GVM_November 2016.docx...

  • Page 71: Motor Mounting

    3.4. Motor mounting 3.4.1. Motor mounting environment Ideally mount motors: In a location away from, or shielded from other vehicle heat sources such as exhaust, or catalytic converters etc. In a location that will benefit from air flow while the vehicle is in motion. In location that is protected from flying rocks, debris, road salt, or other contaminants that could damage cabling and connections.

  • Page 72: Frame Recommendation

    3.4.3. Frame recommendation Warning : The user has the entire responsibility to design and prepare the support, the coupling device, shaft line alignment, and shaft line balancing. Frame supporting the GVM must be even, sufficiently rigid and shall be dimensioned in order to avoid vibrations due to resonances.

  • Page 73: Cooling

    3.6. Cooling 3.6.1. General recommendations Danger: It is compulsory to start the cooling system before starting the motor. Danger: The Inlet temperature and the water flow have to be monitored to avoid any damage. Caution: When motor is no more running, the cooling system has to be stopped 10 minutes after the motor shut down.

  • Page 74: Additives For Water As Cooling Media

    3.6.2. Additives for water as cooling media Please refer to motor technical data for coolant flow rates. The inner pressure of the cooling liquid must not exceed 5 bars. Caution: To avoid the corrosion of the motor cooling system (aluminum or copper), the water must have anti-corrosion additive.

  • Page 75: Flow Rating According To Glycol Concentration

    3.6.3. Flow rating according to glycol concentration Use of the graph above - Example If the motor needs 10 l/min with 0% glycol, If application needs 20% glycol, the water flow must be 10,6 l/min, If application needs 40% glycol, the water flow must be 11,8 l/min. Main formulas Power dissipatio...

  • Page 76: Gvm Internal Pressure Drop

    3.6.4. GVM Internal Pressure Drop These values do not take into account the customer cooling connection. With Water-Glycol 50% - input at 65 °C : - 47 – PVD3668_GB_GVM_November 2016.docx...
  • Page 77 With Oil with a 46 cSt viscosity (@40°C) – input at 65°C : - 48 – PVD3668_GB_GVM_November 2016.docx...

  • Page 78: Chiller Selection

    3.6.5. Chiller selection This section describes how to choose the chiller. The chiller is able to extract the heat from the motor losses with the water circulation. The motor losses (= power to extracted by the chiller) depend on the efficiency and motor power : ...

  • Page 79: Liquid Cooling Diagram

    3.6.6. Liquid cooling diagram Recommendation: The use of a filter allows reducing the presence of impurities or chips in the liquid circuit in order to prevent any obstruction. This section shows typical liquid cooling diagram: There is no recommendation on liquid inlet and outlet position Chiller or Exchanger Pump...
  • Page 80 No Parallel Circuit Chiller or Exchanger without flow control Pump GVM motor To other(s) device(s) No Serial Circuit Pump GVM motors - 51 – PVD3668_GB_GVM_November 2016.docx...

  • Page 81: Coolant Connections

    3.6.7. Coolant Connections : GVM142 : Coolant inlet / outlet are ORB-4 SAE J1926-1 with thread 7/16-20 UNF GVM210 : Coolant inlet / outlet are ORB-8 SAE J1926-1 with thread 3/4-16 UNF These parts can be provided by Parker as follows : 2 options are available for the GVM fittings : Male Stud Connector Male Stud Elbow...

  • Page 82: Thermal Protection

    3.7. Thermal Protection Protection against thermal overloading of the motor is provided by three PTC thermistors and two KTY temperature sensor (one is a redundant spare) built into the stator winding as standard. The thermal sensors, due to their thermal inertia, are unable to follow very fast winding temperature variations.

  • Page 83: Temperature Measurement With Kty Sensors

    3.7.2. Temperature measurement with KTY sensors: Motor temperature can also be continuously measured by the drive using a KTY 84-130 thermal sensor built in to the stator winding. KTY sensors are semiconductor sensors that change their resistance according to an approximately linear characteristic. The required temperature limits for alarm and tripping can be set in the drive.

  • Page 84: Power Electrical Connection

    3.8. Power electrical connection 3.8.1. Cables sizes In every country, you must respect all the local electrical installation regulations and standards. Cable selection depends on the cable construction, so refer to the cable technical documentation to choose wire sizes Some drives have cable limitations or recommendations; please refer to the drive technical documentation for any further information.

  • Page 85: Motor Cable Length

    Conversion Awg/kcmil/mm² : kcmil mm² 0000 (4/0) 000 (3/0) 00 (2/0) 67.4 0 (1/0) 53.5 83.7 42.4 66.4 33.6 52.6 26.7 41.7 21.2 33.1 16.8 26.3 13.3 20.8 10.5 16.5 8.37 13.1 6.63 10.4 5.26 8.23 4.17 6.53 3.31 4.10 2.08 2.58 1.31...

  • Page 86: Mains Supply Connection Diagrams

    3.8.3. Mains supply connection diagrams Caution: A bad tightening on the cable or a too small cable section can generate an overheating and damage the motor. Parker can provide High Power cables, to be placed between the motor and the drive, with standard lengths of 1, 2, 3 or 4 meters.
  • Page 87 3.8.3.1. Motor connection For Parker High Power cables, please follow the next 5 steps : Please use M6 x 10 to fix the terminals (tightening torque : see p61) - 58 – PVD3668_GB_GVM_November 2016.docx...
  • Page 88 For the specific case of High Voltage Low Power drives : Parker can supply 4 meter length Power cable which part number is HVLP-D-M-CABLE. To connect the motor, please follow the 7 next steps. - 59 – PVD3668_GB_GVM_November 2016.docx...
  • Page 89 Please use M6 x 10 to fix the terminals (tightening torque : see §4.2.1) Take care to close non-used cable glands As previously, Parker can provide 4 meter length power cable to take place between the drive and the battery (with 2 interlock wires) which part number is HVLP-B-D-CABLE. 3.8.3.2.

  • Page 90: Feedback System

    3.9. Feedback system 3.9.1. Resolver A resolver determines the rotor position. Its signals are processed by the drive in order to control the stator currents, the speed and the position. Resolver 2 poles transformation ratio = 0.5 – code A GVM142 GVM210 Parker part number...

  • Page 91: Sin-Cos Encoder (Low Voltage Application)

    3.9.2. Sin-Cos Encoder (low voltage application) Parker part number 220285P0002 Electrical specification Values @ 500 Hz Input voltage 5 Vrms ± 5% Input current 20 mA maximum Encoder accuracy ± 0,5° maxi 720 Ω Internal serial impedance Sin-Cos Encoder Signal connector VA (Cos) VB (Sin)

  • Page 92: Commissioning, Use And Maintenance

    4. COMMISSIONING, USE AND MAINTENANCE 4.1. Reception, handling, storage 4.1.1. Equipment delivery All the GVM motors are strictly controlled during manufacturing, prior to shipping. Upon receipt it, it is necessary to verify the motor condition and confirm it has not been damaged during transit.

  • Page 93: Storage

    4.1.3. Storage Before being mounted, the motor has to be stored in a dry place, without rapid or significant temperature variations in order to avoid condensation. If the GVM motor has to be stored for a long time, verify that the shaft end and the flange are coated with corrosion proof product.

  • Page 94: Preparation

    4.2.2. Preparation Once the motor is installed, it must be possible to access to the wiring, and read the manufacturer’s plate. Air must be able to circulate freely around the motor for cooling purposes. Clean the shaft using a cloth soaked in white spirit or alcohol. Pay attention that the cleaning solution does not get on to the bearings.

  • Page 95: Electrical Connection

    4.3. Electrical connection Warning : Check that the power to the electrical inverter is safely off prior to make any connections. Warning : The wiring must comply with the inverter commissioning manual, with recommended cables, the standard and the local regulations Warning : The GVM motor must be grounded by connecting to an unpainted section of the motor.

  • Page 96: Resolver / Encoder / Thermistor Cable Handling

    4.3.2. Resolver / Encoder / Thermistor cable handling Danger: before any intervention the drive must be stopped in accordance with the procedure. Caution: It is forbidden to disconnect the Encoder cable under voltage (high risk of damage and sensor destruction). Warning: Always wear an antistatic wrist strap during encoder handling.

  • Page 97: Maintenance Operations

    4.4. Maintenance Operations Generality DANGER: The installation, commissioning and maintenance operations must be performed by qualified personnel, in conjunction with this documentation. The qualified personnel must know the safety local regulations. They must be authorized to install, commissioning and operate in accordance with established practices and standards.

  • Page 98: Troubleshooting

    4.5. Troubleshooting We provide hereunder a symptom list in regard with their possible cause. This is not an exhaustive list so in case of trouble, please refer to the associated inverter manual (the diagnostic board indications will help you investigating) or contact us at: http://www.parker.com/eme/repairservice.
  • Page 99 BACK BATTERIES/CHARGERS...
  • Page 100 IGBT – HF Hybrid IGBT – HF Hybrid Universal Battery Chargers Universal Battery Chargers THE MOST ADVANCED TECHNOLOGY THE MOST ADVANCED TECHNOLOGY MAXIMIZES BATTERY LIFE AND PERFORMANCE, MAXIMIZES BATTERY LIFE AND PERFORMANCE, REDUCE ENERGY USE AND CARBON EMISSION REDUCE ENERGY USE AND CARBON EMISSION Technology: IGBT-HF Hybrid Converter ...
  • Page 101 IGBT – HF Hybrid IGBT – HF Hybrid Universal Battery Chargers Universal Battery Chargers Product Specifications Product Specifications AC INPUT Single-phase 220-230-240 VAC ± 10% STANDARD VOLTAGES Three-phase 220-240, 400, 440, 480, 600 VAC ± 10% Frequency 50/60 Hz ± 5 Hz EFFICIENCY >93% Single-phase models >90%...
  • Page 102 IGBT – HF Hybrid IGBT – HF Hybrid Universal Battery Chargers Universal Battery Chargers When the AC input is restored, the charger restarts from the exact point of interruption, and it completes the charge cycle normally. The charger adds a random delay on start (from 3 to 20 seconds). When many chargers are connected to the same AC source, this feature prevents all the chargers from turning on simultaneously and causing a high AC input current spike.
  • Page 103 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL LIiON Series Lithium-ion Charging Station USER'S MANUAL Oct 2017 v.1I0 Page 1/30...
  • Page 104 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL INTRODUCTION This manual contains instructions and suggestions for the users of LION Series battery chargers. Before to install, use or repair the charger, it's necessary to read and understand this manual completely.
  • Page 105 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL 2. SAFETY INSTRUCTIONS AND WARNINGS GENERAL Battery chargers can cause injury or death, or damage to other equipment or property, if the user does not strictly observe all safety rules and take precautionary actions. Safe practices must be learned through study and training before using this equipment.
  • Page 106 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL BURN AND BODILY INJURY PREVENTION The battery produces very high currents when short circuited, and will burn the skin severely if in contact with any metal conductor that is carrying this current. Do not permit rings on fingers to come in contact with battery terminals or the cell connectors on top of the battery.
  • Page 107 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL DESCRIPTION The LION Series charging stations are based on high frequency IGBT technology. They are programmable and universal, and they are equipped with a complete, active protection system, which includes Reverse Polarity, Short Circuit, Overtemperature, Wrong Battery, Anti-Arcing, and more.
  • Page 108 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL The startup sequence, the thermal protection and the polarity protection of the charger are managed by the POWER REGULATION BOARD, which receives signals from several sensors that are located inside of the charger. The LION Series charging stations are available in a variety of models, with output power ranging from 5 to 125kW, and output voltages up to 700 VDC.
  • Page 109 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL The following picture shows an example of Lithium-IOn charger with high output current rate. The internal back side is shown in the following image. Page 7/30...
  • Page 110 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL Another back charger thopology (example 500A output current) may be as follows: Page 8/30...
  • Page 111 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL INPUT CHARACTERISTIC A) BREAKERS AND/OR INPUT FUSES PROTECTION INPUT VOLTAGE NOMINAL 3x480/600Vac +/-10% 50/60Hz  In order: to avoid the intervention of the input fuse caused to the inrush current, it’s advisable to use –...
  • Page 112 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL 5.INSTALLATION In order to avoid the intervention of the input fuse caused to the inrush current, it’s advisable to use CH fuses, gG type(like Italweber/Omega/Bussmann) To avoid the intervention of the braker, due to the inrush current, it’s advisable to use breakers with D or K curve. Page 10/30...
  • Page 113 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL Conditions of use: Operating /Storage temperature: -5°C to 45°C • Relative humidity: less than 75% • WARNING ! The charger can be installed by qualified personnel only! To avoid the risk of injuries, the user is not allowed to open the cabinet.
  • Page 114 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL GROUNDING AND LINE CONNECTION If the charger is to be connected to the AC power supply with a flexible jacketed cable, one having a separate grounding conductor should be used. If, for any reason, an input cable which does not include a grounding conductor is used, the equipment must be grounded with separate conductor.
  • Page 115 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL 5.1.INSTALLATION / LINE VOLTAGE CHANGEOVER INSTRUCTIONS ·Remove the screws and open the front door of the charger ·Locate the AC Input Terminal Block and the Ground Connector. Refer to Figure 5 -1. ·Bring utility wires from the Utility Distribution Panel through conduit, and route them to the AC Input Terminal Block Grounding Connector.Refer to Figure 5 -1.
  • Page 116 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL 5.2.AC VOLTAGE SETTING INSTRUCTION ·Remove the screws and open the front door of the charger ·Locate the Transformer Taps Terminal Block and the three wires marked with the letter A , B and C.
  • Page 117 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL Figure 5-3-Label near Auxiliary Transformer Terminal Block Figure 5-4- Input Black wire on the Auxiliary Transformer Page 15/30...
  • Page 118 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL Setting 3x480Vac Close the cabinet; • With disconnect switch on AC input power line on position “OFF” or “OPEN”, connect • the power cable coming from the charger to the switch and, then, install the fuses in the switch.
  • Page 119 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL Output cables configurations There are two possibilities for the output cable connection, depending by the output current: Single output cable pair • Double output cable pair • The picture which follows shows an example of single output cable pair.
  • Page 120 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL SIGNAL WIRES (Anti Arcing and PWM Control) The following images may be different with your station (it depend from customizing, or ...), for any questions/issue during installation, contact Bassi staff. The basic set of the Auxiliary Signals is composed by four wires: BMS CURRENT CONTROL SIGNAL (PWM) •...
  • Page 121 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL SIGNAL WIRES (HI-LO, ENABLE, Anti Arcing ) The following images may be different with your station (it depend from customizing, or ...), for any questions/issue during installation, contact Bassi staff. The basic set of the Auxiliary Signals is composed by four wires: HI-LO •...
  • Page 122 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL OPTIONAL SIGNAL WIRES If the CAN bus signalling feature is installed you will find the CAN bus twisted pair in the aux terminal block. Depending by the output cable configuration, the output side of the terminal block may or may not be wired into the output power line.
  • Page 123 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL For addictional infos on the CAN bus protocol implemented on the charger see the attached document - Functional Specification For Serties LiIon-Charger - BMS Managed INSTALLATION INPUT AC PROCEDURE MODEL KF These chargers for wall mount installation are provided with input cable.
  • Page 124 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL 6. OPERATION PRELIMINARY CHECKS Inspect the charger completey for loose screws, electrical connections or other • damages; Check that all the ventilation slots are not obstructed to assure proper air flow; •...
  • Page 125 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL If the battery voltage is between the minimum and maximum threshold, and the PWM • signal is in the range 10-90%, the charger turns on automatically after 5 seconds. The display shows the messages: POWERSTAGE STARTUP...
  • Page 126 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL LED STATEMENT – FRONTAL LABEL-TYPE.1 While the charge is in progress, the charge parameters continuously showed on the display. The LEDs indicate the charge status: LED 1 - L1: Constant Current / Constant Voltage –...
  • Page 127 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL LED STATEMENT – FRONTAL LABEL-TYPE.2 While the charge is in progress, the charge parameters continuously showed on the display. The LEDs indicate the charge status: LED – FULL: Charge Complete LED –...
  • Page 128 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL CHARGE CYCLE In any moment, it's possible to visualize additional information, by pressing the buttons UP/DOWN. [Charge State] Represents the operating condition of the charger [BMS Value] Duty Cycle of the PWM signal received by the BMS [Temperature] Operating temperature of the charger powerstage...
  • Page 129 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL AUTOMATIC AND MANUAL CHARGE TERMINATION WARNING ! DON'T disconnect the battery from the charger while it is being charged. ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT ! AUTOMATIC CHARGE TERMINATION: •...
  • Page 130 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL HISTORY LOG At the end of each charge cycle, the charging station saves the relevant charge data into the DATA LOGGER memory. The history log can be accessed at any moment, even while a charge cycle is in progress. It's sufficient to scroll the menu using the UP-DOWN buttons, until the display will visualize the message: MENU STATS...
  • Page 131 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL GROUP 1: CHARGE COMPLETED Charge completed successfully. Unplugged after Charge completed successfully. GROUP 2: MANUAL STOP Charge stopped manually GROUP 3: BATTERY DISCONNECTED The battery has been disconnected before the begin of the charge, while the charger was waiting for the programmed Start Time window.
  • Page 132 LIiON Series Charging Stations – LI - G -series – v.1I0 User's MANUAL Emergency Stop! BMS in fault. K2(202dec) Emergency Stop! CAN BUS line in fault. K3(203dec) Emergency Stop! Charger internal fault GROUP 5: WARNING MESSAGES The battery has been disconnected while the charge was in progress. Output fuse blown, Or AC Input in error Internal temperature probe malfunction Can bus.
  • Page 133 Battery Charger Service and Programming Manual Document ID 0XMACA00010000ULV0 Revision number Revision date 03- 2022 English Francais Italiano ‘Original instructions’ English Deutsch Italiano Francais...
  • Page 134 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 TABLE OF CONTENTS [EN] INTRODUCTION ............................2 [EN] IMPORTANT SAFETY INSTRUCTION ......................3 [EN] DESCRIPTION AND THEORY OF OPERATION ....................7 [EN] INSTALLATION ............................7 [EN] PROGRAMMING ............................14 [EN] OPERATION ...............................18...

  • Page 135: [En] Important Safety Instruction

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 CEC LBSC SPECIFICATIONS – Industrial Battery Chargers 2. IMPORTANT SAFETY INSTRUCTION 2.1 IMPORTANT SAFETY INSTRUCTION (a) THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS (b) WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION.
  • Page 136 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 (l) CONNECT AND DISCONNECT DC OUTPUT CLIPS ONLY AFTER SETTING ANY CHARGER SWITCHES TO THE OFF POSITION AND REMOVING AC CORD FROM THE ELECTRIC OUTLET. NEVER ALLOW CLIPS TO TOUCH EACH OTHER (m) FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE.
  • Page 137 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 2.2 IMPORTANT NOTES • Only experienced and qualified personnel, knowledgeable on batteries and safety requirements involved, most perform installation and maintenance. • Installation and wiring must comply with all the applicable local and the national electrical codes. •...
  • Page 138 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 • This charger has been designed for indoor use only. It must be installed in a well ventilated, cool, dry and clean place. Do not expose to rain, snow, moisture, dust and corrosive substances. •...

  • Page 139: [En] Description And Theory Of Operation

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 3. DESCRIPTION AND THEORY OF OPERATION Battery chargers receive energy from the main AC source (three-phase), and provide a controlled and isolated DC (direct current) output, suitable for charging batteries. The DC output voltage and current follow pre-defined characteristics (usually called “charging curves”...
  • Page 140 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PHYSICAL INSTALLATION Choose your installation location to: • Avoid temperature and humidity extremes. • Minimize moisture and dust. • Provide adequate air circulation to prevent the buildup of fumes. •...
  • Page 141 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSTALLATION OF DC OUTPUT PLUG Certified DC Output connector, sufficiently rated in volts and amperes, must be installed in the field by a qualified technician. INSTALLATION OF AC INPUT CABLE and PLUG Depending on the applicable local regulations and the electrical ratings of the chargers, certain units are supplied with AC input cable &...
  • Page 142 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 AC INPUT PROTECTION AND INSTALLATION DEVICES – NorthAmerica Installation requires an upstream Listed UL / CSA Certified fuses of Type CC, J or RK5 MODEL AC INPUT AC FUSES AC Input 208V 3~60Hz AC 39 A 50A, 200kA...
  • Page 143 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 4.1 INSTALLATION 3-phase 3x230/400Vac 50Hz 4.1.1 NOMINAL VOLTAGE SELECTION Remove screws from the top and left/right sides in order to open the top cover of the charger. If the charger model is designed for AC Multi Input.
  • Page 144 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 4.2 INSTALLATION 3-phase 3x208/240/480Vac 60Hz 4.2.1 NOMINAL VOLTAGE SELECTION Remove screws from the top and left/right sides in order to open the top cover of the charger. If the charger model is designed for AC Multi Input.
  • Page 145 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 4.3 INSTALLATION 3-phase 3x480/600Vac 60Hz 4.3.1 NOMINAL VOLTAGE SELECTION Remove screws from the top and left/right sides in order to open the top cover of the charger. If the charger model is designed for AC Multi Input.

  • Page 146: [En] Programming

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 5. PROGRAMMING HMI HUMAN MACHINE INTERFACE The charger interface contains: A) 4x LEDs a. Red b. Green c. Blue d. Alarm/Warning B) 1x Push Button → button (EQ) EQUALIZE C) 1x Push Button →...
  • Page 147 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 CONTROL BOARD The charger is controlled by the new “GE00” Control Board. This board is built in different configurations, depending on the presence of certain key components. Control Board GE00 (Bottom View) Control Board GE00 (Top View) Control Board GE00 (Top View)
  • Page 148 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PRELIMINARY INSPECTION Before connecting a battery and proceeding with the programming sequence, make sure that the Charger has been installed by a qualified electrician, according with the instructions reported in this manual. Before using the charger, it's necessary to control that the ventilation openings are not obstructed, and that all the safety precautions reported in this manual are respected.
  • Page 149 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PARAMETER 4: CAN BUS MSG SPEED Programmable values: 125k, 250k, 500k, 1M Default value: 250k NOTE: This parameter sets can bus message speed (baud rate) PARAMETER 5: NOMINAL VOLTAGE [only in ADMINISTRATOR MODE] NOTE Usually it’s not necessary to change these parameters.

  • Page 150: [En] Operation

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 6. OPERATION CONTROL BOARD OPERATION At the connection of the battery, if the battery and the AC input are properly connected, the charger cycle starts automatically. According to the internal settings, the charge DC current follows the programmed curve.
  • Page 151 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 WARNING SIGNALS The ALARM/WARNING RED LED will start blinking in these cases: Manual Stop Warning Events MANUAL STOP DANGER! Do not disconnect the battery while it’s being charged! Always stop the charger by pushing the STOP button, before disconnecting the battery.
  • Page 152 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 HOT DISCONNECTION DANGER! Do not disconnect the battery while it’s being charged! Always stop the charger by pushing the STOP button, before disconnecting the battery. When the RED, GREEN or BLUE led blinks, the charger is active. Do not disconnect the battery! When the RED, GREEN or BLUE led shows a SOLID colour, it is possible to disconnect the battery.

  • Page 153: [En] Control Board Alarms And Troubleshooting

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 7. CONTROL BOARD ALARMS AND TROUBLESHOOTING If the Alarm/Warning LED is solid means that the charge cycle or an Equalization cycle has been interrupted due to an alarm. The display shows the cause of the alarm: Battery voltage too high Gassing Voltage not reached.
  • Page 154 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 7.2 TIME OUT – END VOLTAGE NOT REACHED The battery voltage hasn't reached the end point within 12 hours of charge. Please check the battery nominal voltage and the charger nominal matching. Please check the AC input mains value and check the internal AC input setting of the charger.
  • Page 155 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 7.4 BATTERY TYPE MISMATCH CASE A) BATTERY NOMINAL VOLTAGE LOW The battery voltage is too low: the charge cycle doesn't begin. CASE B) BATTERY NOMINAL VOLTAGE HIGH The battery voltage is too high: the charge cycle doesn't begin.

  • Page 156: [Fr] Introduction

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 8. 8. INTRODUCTION Ce manuel contient des instructions de sécurité importantes, des mises en garde et des avertissements à suivre par le personnel responsable de l'installation, de la maintenance et du fonctionnement des chargeurs de batterie.
  • Page 157 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 BATTERIE QUE LES CABLES C.C. LE PERMETTENT. (K) NE PAS FAIRE FONCTIONNER LE CHARGEUR DANS UN ESPACE CLOS ET NE PAS GêNER LA VENTILATION. (L) METTRE LES INTERRUPTEURS DU CHARGEUR HORS CIRCUIT ET RETIRER LE CORDON C.A. DE LA PRISE AVANT DE METTRE ET D’ENLEVER LES PINCES DU CORDON C.C.
  • Page 158 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 BATTERIE, PUIS RACCORDER LA PINCE NÉGATIVE (NOIRE) DU CHARGEUR À L’EXTRÉMITÉ LIBRE DU CÂBLE. (n.5) NE PAS SE PLACER FACE À LA BATTERIE POUR EFFECTUER LE DERNIER RACCORDEMENT. (n.6) RACCORDER LE CORDON D’ALIMENTATION C.A.
  • Page 159 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 DANGER! SUBSTANCES CORROSIVES • Les batteries plomb-acide contiennent une solution d'acide sulfurique (H 2 SO 4), qui est capable de graves brûlures cutanées et peut entraîner une cécité permanente en cas de projection sur les yeux.

  • Page 160: Description Et Théorie De Fonctionnement

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 10. 10. DESCRIPTION ET THÉORIE DE FONCTIONNEMENT Les chargeurs de batterie reçoivent l'énergie de la source AC principale (triphasée ou monophasée) et fournissent une sortie DC (courant continu) contrôlée et isolée, adaptée pour charger les batteries. La tension et le courant de sortie DC suivent des caractéristiques prédéfinies (généralement appelées «courbes de charge»...
  • Page 161 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 11. 11. INSTALLATION DANGER! MISE EN GARDE! Le chargeur ne peut être installé, configuré et entretenu que par du personnel qualifié. DANGER! MISE EN GARDE! Lisez et comprenez le chapitre 2 «Consignes de sécurité importantes» avant l'installation, configuration, entretien ou utilisation du chargeur.
  • Page 162 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSTALLATION PHYSIQUE Choisissez votre emplacement d'installation pour : • Évitez les températures et l'humidité extrêmes. • Minimiser l'humidité et la poussière. • Assurez une circulation d'air adéquate pour éviter l'accumulation de vapeurs. •...
  • Page 163 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSTALLATION DE LA FICHE DE SORTIE DC Le connecteur de sortie DC certifié, suffisamment évalué en volts et ampères, doit être installé sur le terrain par un technicien qualifié. INSTALLATION DU CÂBLE ET DE LA FICHE D'ENTRÉE AC Selon les réglementations locales en vigueur et les caractéristiques électriques des chargeurs, certaines unités sont fournies avec un câble d'entrée AC et prise (modèles enfichables) et d'autres sont fournies...
  • Page 164 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 DISPOSITIFS D'INSTALLATION ET DE PROTECTION D'ENTRÉE AC - Amérique du Nord L'installation nécessite un fusible en amont homologué UL / CSA de type CC, J ou RK5 MODEL AC INPUT AC FUSES...
  • Page 165 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 DISPOSITIFS D'INSTALLATION ET DE PROTECTION D'ENTRÉE AC - Europe/Asia/Australia 11.1 INSTALLATION 3-phasée 3x230/400Vac 50Hz 11.1.1 SÉLECTION DE LA TENSION NOMINALE Retirez les vis des côtés supérieurs gauche / droit afin d'ouvrir le capot supérieur du chargeur. Si le modèle de chargeur est conçu pour une entrée multiple AC.
  • Page 166 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 11.2 INSTALLATION 3-phasée 3x208/240/480Vac 60Hz 11.2.1 SÉLECTION DE LA TENSION NOMINALE Retirez les vis des côtés supérieurs gauche / droit afin d'ouvrir le capot supérieur du chargeur. Si le modèle de chargeur est conçu pour une entrée multiple AC.
  • Page 167 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 11.3 INSTALLATION 3-phasée 3x480/600Vac 60Hz 11.3.1 SÉLECTION DE LA TENSION NOMINALE Retirez les vis des côtés supérieurs gauche / droit afin d'ouvrir le capot supérieur du chargeur. Si le modèle de chargeur est conçu pour une entrée multiple AC.
  • Page 168 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 12. 12. PROGRAMMATION HMI HUMAINE MACHINE INTERFACE L'interface du chargeur contient: K) 4x LEDs a. Rouge b. Vert c. Bleu d. Avertissement / alarme B) 1x bouton poussoir → (EQ) EGALISATION C) 1x bouton poussoir →...
  • Page 169 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 CARTE DE COMMANDE Le chargeur est contrôlé par la nouvelle carte de contrôle «GE00». Cette carte est construite dans différentes configurations en fonction de la présence de certaines composantes clés et a les SECTIONS D'ENTREE / SORTIE suivantes : Carte de commande GE00 (vue dessous) Carte de commande GE00 (vue de dessus)
  • Page 170 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSPECTION PRÉLIMINAIRE Avant de connecter une batterie et de procéder à la séquence de programmation, assurez-vous que le chargeur a été installé par un électricien qualify conformément aux instructions indiquées dans ce manuel.
  • Page 171 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PARAMÈTRE 4: CAN BUS MSG SPEED Valeurs programmables: 125k, 250k, 500k, 1M Valeur par défaut: 250k PARAMÈTRE 5: TENSION NOMINALE [Uniquement EN MODE ADMIN] REMARQUE Il n'est généralement pas nécessaire de modifier ces paramètres. Veuillez contacter le fabricant pour plus de détails Valeurs programmables: 12, 24, 36, 48, 60, 72, 80, 96 Vdc (V.nom)
  • Page 172 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 13. 13. FONCTIONNEMENT FONCTIONNEMENT DE LA CARTE DE CONTRÔLE Lors de la connexion de la batterie, si la batterie et l'entrée CA sont correctement connectées, le cycle du chargeur démarre automatiquement.
  • Page 173 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 SIGNAUX D'AVERTISSEMENT La LED avertissement/alarme commencera à clignoter dans les cas suivants: - arrêt manuel Événements d'avertissement ARRÊT MANUEL DANGER! MISE EN GARDE! Arrêtez toujours le chargeur en appuyant sur le bouton STOP avant de déconnecter la batterie.
  • Page 174 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 DÉCONNEXION À CHAUD DANGER! MISE EN GARDE! Ne déconnectez pas la batterie lorsqu'elle est en cours de charge! Arrêtez toujours le chargeur en appuyant sur le bouton STOP avant de déconnecter la batterie.

  • Page 175: Alarmes De La Carte De Contrôle Et Dépannage

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 14. 14. ALARMES DE LA CARTE DE CONTRÔLE ET DÉPANNAGE Si la LED ROUGE d'alarme / d'avertissement est fixe, cela signifie que le cycle de charge ou un cycle d'égalisation a été...
  • Page 176 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 14.2 TIME OUT - TENSION DU FIN NON ATTEINTE La tension de la batterie n'a pas atteint le point du fin dans les 12 heures suivant la charge. Veuillez vérifier la tension nominale de la batterie et la correspondance nominale du chargeur.
  • Page 177 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 14.4 MAUVAIS TYPE DE BATTERIE Conditions défectueuses possibles: A) ERREUR DE TENSION NOMINALE DE LA BATTERIE Le courant de charge est trop élevé: le chargeur s'arrête immédiatement. B) TENSION NOMINALE DE LA BATTERIE FAIBLE La tension de la batterie est trop faible: le cycle de charge ne démarre pas.

  • Page 178: Importanti Precauzioni Per La Sicurezza

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 15. INTRODUZIONE Questo manuale contiene importanti istruzioni di sicurezza, precauzioni e avvertenze, che devono essere seguite da personale qualificato responsabile dell'installazione, manutenzione e funzionamento dei caricabatterie. Si consiglia di leggere e comprendere integralmente questo manuale per garantire un funzionamento sicuro e affidabile di questa apparecchiatura.
  • Page 179 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 ATTENZIONE! Sostanze Corrosive • Le batterie al piombo-acido contengono una soluzione di acido solforico (H2SO4), che è in grado di provocare ustioni cutanee molto gravi e può provocare cecità permanente se spruzzata sugli occhi.
  • Page 180 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 17. DESCRIZIONE I caricabatterie ricevono energia dalla sorgente AC principale (trifase o monofase) e forniscono un'uscita DC (corrente continua) controllata e isolata, adatta per caricare le batterie. La tensione e la corrente in uscita DC seguono caratteristiche predefinite (chiamate "curve di carica"...
  • Page 181 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSTALLAZIONE DEL CARICABATTERIE Scegliere la posizione di installazione: • Evitare temperature e umidità estreme. • Ridurre al minimo l'umidità e la polvere. • Fornire un'adeguata circolazione dell'aria per prevenire l'accumulo di calore. •...
  • Page 182 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSTALLAZIONE DEL CONNETTORE DI USCITA Il connettore di uscita, deve essere installato sul campo da un tecnico qualificato. Il connettore deve essere correttamente selezionato per l’applicazione in volt e ampere, e certificato secondo le norme vigenti.
  • Page 183 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 INSTALLAZIONE PROTEZIONI TENSIONE DI INGRESSO – Nord America L’installazione richiede fusibili certificati UL / CSA tipo CC, J or RK5 MODEL AC INPUT AC FUSES AC Input 208V 3~60Hz AC 39 A 50A, 200kA HPS.12-US AC Input 240V 3~60Hz AC 34 A...
  • Page 184 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 18.1 INSTALLAZIONE TRIFASE 3x230/400Vac 50/60Hz 18.1.1 SELEZIONE TENSIONE NOMINALE Rimuovere le viti dai lati superiore e sinistro / destro per aprire il coperchio superiore del caricatore. Se il modello di caricabatterie è...
  • Page 185 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 18.2 INSTALLAZIONE TRIFASE 3x208/240/480Vac 60Hz 18.2.1 SELEZIONE TENSIONE NOMINALE Rimuovere le viti dalla porta frontale del caricatore. Se il modello di caricatore è progettato per AC Multi Input. Impostare la morsettiera interna in base alla tensione AC nominale fornita dalla rete AC Mains AC Mains...
  • Page 186 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 18.3 INSTALLAZIONE TRIFASE 3x480/600Vac 60Hz 18.3.1 SELEZIONE TENSIONE NOMINALE Rimuovere le viti dalla porta frontale del caricatore. Se il modello di caricatore è progettato per AC Multi Input. Impostare la morsettiera interna in base alla tensione AC nominale fornita dalla rete 18.3.2 IMPOSTANZIONE TRASFORMATORE AUSILIARIO Impostare la presa primaria del trasformatore ausiliario, in base alla tensione AC nominale fornita dalla...
  • Page 187 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 19. PROGRAMMAZIONE INTERFACCIA SCHEDA DI CONTROLLO L'interfaccia del caricatore contiene: -A) 4x LED 1. Rosso 2. Verde 3. Blu 4. Alarm/Warning B) 1x Tasto → tasto (EQ) EQUALIZZAZIONE C) 1x Tasto →...
  • Page 188 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 METODO DI PROGRAMMAZIONE COME ATTIVARE LA MODALITA DI PROGRAMMAZIONE UTENTE Tenere premuto per 5 secs il tasto STOP / RIAVVIO il display mostra “PASSWORD”, premere il tasto EQ per 4 volte consecutive COME ATTIVARE LA MODALITA DI PROGRAMMAZONE MANUTENTORE Tenere premuto per 5 secs il tasto STOP / RIAVVIO il display mostra “PASSWORD”, premere il tasto...
  • Page 189 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PARAMETRO #1: OROLOGIO/DATA [DATE/TIME] Valori Programmabili: Anno/Mese/Giorno HH/mm PARAMETRO #2: RATE INPUT PLUG Valori Programmabili: 16 A, 32 A, 63 A, 125 A, DISABLED Valore di Default: DISABLED PARAMETRO #3: TEMPO INIZIO CARICA [ON.CH START>STOP] Valori Programmabili: Ore del Giorno...
  • Page 190 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PARAMETRO #14: [CHAGER IDENTITY] funzione di calibrazione PARAMETRO #15: POTENZA MASSIMA DI USCITA [MAXIMUM POWER] Valori Programmabili: 100 Watt, …, 80000 Watt Valore di Default: 34200 Watt NOTA: Questo parametro imposta un limite massimo per la potenza di uscita.
  • Page 191 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 PARAMETRO #25: SEZIONE CAVI [DC CABLE SECTION] Valori Programmabili: 1 mmq, …, 250 mmq, DISABLED Valore di Default: 70 mmq PARAMETRO #26: INTERVALLO ACCESSIBILE TENSIONE DI INIZIO CARICA [RANGE VOLT START] Valori Programmabili: 6,…130V Valore di Default:...
  • Page 192 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 20. FUNZIONAMENTO FUNZIONAMENTO DELLA SCHEDA DI CONTROLLO Al collegamento della batteria, la scheda di controllo si accende. Se la batteria e l'ingresso AC sono collegati correttamente, il ciclo del caricabatterie si avvia automaticamente. In base alle impostazioni interne, la corrente DC di carica segue la curva programmata.
  • Page 193 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 RITARDO ALL’AVVIO È possibile impostare un ritardo all'avvio, in modo da consentire alla batteria di raffreddarsi prima di iniziare il processo di carica, o per consentire al caricabatterie di caricare energia nella batteria durante fasce orarie con energia a prezzi ridotti.
  • Page 194 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 DISCONNESSIONE IN FASE DI CARICA ATTENZIONE! Non disconnettere la batteria durante le fasi di carica. RISCHIO DI ESPLOSIONE! Prima di disconnettere la batteria, interrompere la carica premendo il tasto STOP/RIAVVIO Quando il LED ROSSO o VERDE o BLU lampeggia, il caricabatterie è...

  • Page 195: Allarmi E Risoluzione Problemi

    Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 21. ALLARMI E RISOLUZIONE PROBLEMI Se il LED “Allarme/Warning” è fisso ROSSO significa che il ciclo di carica o il ciclo di equalizzazione è stato inaspettatamente interrotto a causa di un allarme. Condizione di allarme Il LED ALARM/WARNING è...
  • Page 196 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 21.2 ERRORE TEMPO MASSIMO La carica non ha raggiunto la fine entro il tempo massimo stabilito. Si prega di controllare la tensione nominale della batteria e la corrispondenza nominale del caricatore. Verificare il valore della rete di ingresso AC e controllare l'impostazione dell'ingresso AC interno del caricabatterie.
  • Page 197 Battery Charger/ Chargeur de Batterie Service Manual/ Manuel de Service 0XMACA00010000ULV0 – Rev 4 21.4 ERRORE BATTERIA Di seguito le possibili condizioni di guasto: CASO A) TENSIONE NOMINALE BATTERIA BASSA La tensione della batteria è troppo bassa: il ciclo di carica non inizia. CASO B) TENSIONE NOMINALE BATTERIA ALTA La tensione della batteria è...
  • Page 202 POGO STICK WASHER M12 CABLE SUPPORT SHIM (OPTIONAL) NUT M12 SCREW M8 BASE PANEL WASHER M8 NUT M8 CORNER PILLAR SHORT BAR Assembled Stand - Possible Positions for CABLE SUPPORT BAR WASHER M8 LONG BAR SCREW M8 TP/TL CHARGER STAND Assembly instructions...
  • Page 208 455,7 mm [17,94 in] 5,5 mm 460 mm 528,8 mm [18,11 in] [0,2 in] [20,8 in] Weight Kg. __ Weight lbs __ codice / code descrizione / description page/pages ISO 2768-m tolerances in mm 1 / 1 0 -> 6 mm 6 ->...
  • Page 209 650,8 mm [25,62 in] 650,8 mm 5,5 mm 585 mm [25,6 in] [ 0,2 in] [23 in] E ( 1 : 6 ) Weight Kg. __ Weight lbs __ ISO 2768-m codice / code descrizione / description page/pages tolerances in mm 1 / 1 0 ->...
  • Page 210 N.2 x OPTIONAL 0303325_P 0303597D N.2 x A-A ( 1 : 10 ) 0303325_1 OPTIONAL ISO 2768-m codice / code descrizione / description page/pages tolerances in mm 1 / 1 STAND G1 0 -> 6 mm 6 -> 30 mm data / date disegnato / designed note...
  • Page 211 13 mm 560 mm [ 0,51 in] [22,05 in] OPTIONAL 212,5 mm [8,37 in] 0303325_P 0303597D 0303325_1 212,5 mm OPTIONAL [8,37 in] 480 mm A-A ( 1 : 10 ) [18,9 in] 212,5 mm 703,3 mm [8,37 in] [27,69 in] ISO 2768-m codice / code descrizione / description...
  • Page 212 U-Charge ® Battery Managment System (BMS) U-Charge Battery Management Systems are designed to enable multiple system implementation options and advanced command and control ability. The BMS is compatible with U-Charge XP battery and Power modules. Overview Features U-Charge Battery Management Systems (U-BMS) are •...
  • Page 213 Specifications Dimensions (LxWxH) mm 188mm x 229mm x 42mm* Dimensions (LxWxH) inches 7.4” x 9” x 1.65”* Weight 0.72 kg/1.6 lbs External communication CAN 2.0b, 125, 250, 500 Kbit/s, standard frames External control signals Control signal for line, pre-charge & charger contactors Monitoring parameters State-of-charge, error codes, system pack balance Isolation...
  • Page 214 New Features for U-Charge ® 24XP Series Lithium Ion Batteries The 24XP series modules are designed for material handling applications. Specific materials and elements were chosen to meet the demanding safety requirements of UL2580 and UL2271 (certifications pending). Better in Every Way Valence’s lithium iron...
  • Page 215 User Friendly Terminals In addition to Valence 24XP series terminals being internally monitored for temperature excursions, each terminal incorporates two M8 threaded holes. These can be used in a number of ways. High Current Situations For high current situations, a user may choose to use a dual hole cable lug with 25.4mm (1 inch) centered holes.
  • Page 216 BACK HYDRAULIC DRIVE COMPONENTS...
  • Page 268 BACK WATER PUMP...
  • Page 269 MAKING MODERN LIVING POSSIBLE Service Manual Series 40 M46 Variable Pumps powersolutions.danfoss.com...
  • Page 270 Service Manual Series 40 M46 Variable Pumps Revision history Table of revisions Date Changed June 2014 Danfoss layout - add HC EDC Control October 2010 corrections to port location illustration March 2010 Fix Osaka address March 2009 added spool alignment illustration May 2008 Fixed the illustrations October 2007...
  • Page 271 Service Manual Series 40 M46 Variable Pumps Contents Introduction Overview......................................5 Warranty......................................5 General instructions..................................5 Remove the unit..................................5 Keep it clean....................................5 Replace all O-rings and gaskets............................. 5 Safety precautions....................................6 Unintended machine movement............................6 Flammable cleaning solvents..............................6 Fluid under pressure.................................. 6 Personal safety.....................................
  • Page 272 Service Manual Series 40 M46 Variable Pumps Contents Control Neutral Adjustment..............................25 Minor repair Standard procedures, removing the pump..........................28 Displacement limiter..................................28 Pressure filtration adapter................................29 Charge pump....................................30 Shaft seal, roller bearing and shaft replacement........................32 SCR valves......................................33 Charge pressure relief valve...............................34 Bypass valve.....................................

  • Page 273: Overview

    Service Manual Series 40 M46 Variable Pumps Introduction Overview This manual includes information for the installation, maintenance, and minor repair of the Series 40 M46 pump. It includes a description of the unit and its individual components, troubleshooting information, and minor repair procedures. Performing minor repairs requires the unit to be removed from the vehicle/machine.

  • Page 274: Safety Precautions

    Service Manual Series 40 M46 Variable Pumps Introduction Safety precautions Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system. Unintended machine movement Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.

  • Page 275: Symbols Used In Danfoss Literature

    Service Manual Series 40 M46 Variable Pumps Introduction Symbols used in Danfoss literature WARNING may result in injury Tip, helpful suggestion CAUTION may result in damage to product or Lubricate with hydraulic fluid property Reusable part Apply grease / petroleum jelly Non-reusable part, use a new part Apply locking compound Non-removable item...

  • Page 276: The System Circuit

    Service Manual Series 40 M46 Variable Pumps Introduction The angle of the swashplate controls the volume of fluid displaced into the system. The servo piston sets swashplate angle. The pump control modulates servo piston position by varying differential pressure across the piston. Cross section view Gerotor Ball bearing...

  • Page 277: Pump Schematic

    Service Manual Series 40 M46 Variable Pumps Introduction System circuit diagram Reservoir Heat exchanger bypass Control handle Filter Displacement Heat control exchanger valve Variable Cylinder block displacement assembly motor Cylinder block assembly Charge relief valve Bypass valve Output shaft Charge pump Loop flushing module...

  • Page 278: Fluid And Filter Maintenance

    Service Manual Series 40 M46 Variable Pumps Fluid and filter maintenance Fluid and filter recommendations To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness when servicing. Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor.

  • Page 279: Initial Startup Procedures

    Service Manual Series 40 M46 Variable Pumps Initial startup procedures General Follow this procedure when starting-up a new pump installation or when restarting an installation in which the pump was removed. Ensure pump is thoroughly tested on a test stand before installing. Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.

  • Page 280: Required Tools And Pressure Measurements

    Service Manual Series 40 M46 Variable Pumps Required tools and pressure measurements Required tools The service procedures described in this manual can be performed using common mechanic’s hand tools. Special tools, if required, are shown. When testing system pressures, calibrate pressure gauges frequently to ensure accuracy.
  • Page 281 Service Manual Series 40 M46 Variable Pumps Required tools and pressure measurements Port locations P106 604E 11026743 • Rev BA • June 2014...

  • Page 282: Troubleshooting

    Service Manual Series 40 M46 Variable Pumps Troubleshooting Overview This section provides general steps to follow if undesirable system conditions occur. Follow these steps until you solve the problem. Some of the items are system specific. For areas this manual covers, we reference the section.

  • Page 283: System Will Not Operate In One Direction

    Service Manual Series 40 M46 Variable Pumps Troubleshooting Item Description Action SCR (System Check / Relief) Valves A partially activated SCR valve or SCR valves with Verify that the SCR valve is seating properly and is relief settings too low may generate heat within at the correct relief setting.

  • Page 284: Neutral Difficult Or Impossible To Find

    Service Manual Series 40 M46 Variable Pumps Troubleshooting Item Description Action Servo pressure There is an insufficient pressure differential across Check servo pressures to verify sufficient pressure the servo piston. delta. Verify that the servo supply and drain paths are unobstructed and that each orifice is of the correct size and free of debris.

  • Page 285: Electrical Troubleshooting

    Service Manual Series 40 M46 Variable Pumps Troubleshooting Item Description Action Charge pressure (in stroke) There is low charge pressure resulting from internal Repair or replace the component or components leakage within the system. within the system causing the internal leakage. Servo pressure There is insufficient pressure differential across the Check servo pressures at port M4 and M5 to verify...

  • Page 286: Adjustments

    Service Manual Series 40 M46 Variable Pumps Adjustments Standard procedures, inspections, and adjustments Before working on the pump, clean all dirt and grime from the outside of the pump and surrounding area. Caution Contamination can damage internal components and void the manufacturer’s warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines.

  • Page 287: Engaging The Bypass Function

    Service Manual Series 40 M46 Variable Pumps Adjustments Charge pressure adjustment 1 in. 11/16 in Charge pressure gage port P106 634E Engaging the bypass function Test the bypass function with the pump installed on the machine. The bypass function is engaged by unscrewing the bypass valve.

  • Page 288: System Check/Relief (Scr) Valves

    Service Manual Series 40 M46 Variable Pumps Adjustments Using the bypass function Bypass check valve 5/8 in P106 633E System check/relief (SCR) valves The SCR valve is a high pressure relief valve and a system check valve in combination. Whenever an SCR valve is replaced or opened, opperate the pump in its full range of functions to ensure proper machine operation.

  • Page 289: Displacement Limiter Adjustment

    Service Manual Series 40 M46 Variable Pumps Adjustments Installing the SCRs 1-1/4 in 176 Nm [130 ft•lb] 1103 1103 1-1/4 in 176 Nm [130 ft•lb] P106 635E Displacement limiter adjustment Pump may have a displacement limiter on each side of the servo. Each limiter may be adjusted to a different setting.

  • Page 290: Swashplate Neutral Adjustment

    Service Manual Series 40 M46 Variable Pumps Adjustments Displacement limiter adjustment 9/16 in P106 626E Swashplate neutral adjustment With the pump properly plumbed, primed, and mounted on a vehicle or test stand, use this procedure to adjust mechanical neutral. If pump is on a vehicle, securely block the wheels to prevent movement. Measured data •...

  • Page 291: Manual Displacement Control Neutral-Return Bracket Adjustment

    Service Manual Series 40 M46 Variable Pumps Adjustments 6. Use a 1/4 hex wrench to hold the servo adjustment screw in place, and a 9/16 hex wrench to tighten servo lock nut (115). Torque to 37 N•m [27 lbf•ft]. 7. Shut down prime mover and remove previously installed gauges and fittings. Plug ports MA, MB, M4, and M5.

  • Page 292: Electric Displacement Control/Hydraulic Displacement Control Neutral Adjustment

    Service Manual Series 40 M46 Variable Pumps Adjustments 6. Shut down prime mover and remove previously installed gauges. Plug ports M4, M5. Torque to 37 N•m [27 lbf•ft] Manual displacement control bracket adjustment 1210 3/8 in Neutral bracket P106 631E Electric Displacement Control/Hydraulic Displacement Control Neutral Adjustment With the pump properly plumbed, primed, and mounted on a vehicle or test stand, use this procedure to adjust the pump displacement control to neutral position.

  • Page 293: Hc Edc Control

    Service Manual Series 40 M46 Variable Pumps Adjustments EDC / HDC control adjustment Adjustment screw 5/32 in Lock nut 9/16 in P106 643 HC EDC Control Control Neutral Adjustment All functions of the Electric Displacement Control (EDC), are preset at the factory. If necessary, adjust the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating.
  • Page 294 Service Manual Series 40 M46 Variable Pumps Adjustments Locknut 13 mm Adjusting screw 12 N•m [9 lbf•ft] 4 mm Servo pressure gauge port M5 0 - 50 bar [0 - 1000 psi] 3/16 in 19 N•m [14 lbf•ft] Servo pressure gauge port M4 0 - 50 bar [0 - 1000 psi] 3/16 in 19 N•m [14 lbf•ft]...
  • Page 295 Service Manual Series 40 M46 Variable Pumps Adjustments Neutral Adjustment (EDC) (bottom view) Solenoid shaft Control spool Adjusting screw (cam) Feedback pin Maximum adjustment less than 120° P106 046E Illustration shows how cam on adjusting pin rotates to adjust for neutral position after pump is re- installed.

  • Page 296: Minor Repair

    Service Manual Series 40 M46 Variable Pumps Minor repair Standard procedures, removing the pump Before working on the pump, clean all dirt and grime from the outside. If the pump has an auxiliary pump attached, remove both pumps as a single unit.Tag all hydraulic lines as they are disconnected and plug all open ports to ensure that dirt and contamination do not get into the pump.

  • Page 297: Pressure Filtration Adapter

    Service Manual Series 40 M46 Variable Pumps Minor repair Inspection Inspect all parts for damage. Inspect the mating surfaces of the servo cover (902) and pump housing for scratches, grooves, and other damage. Inspect threads of screws and nuts for damage. Replace any damaged parts.

  • Page 298: Charge Pump

    Service Manual Series 40 M46 Variable Pumps Minor repair 2. Using a 1/2 hex wrench, install three screws (806). Torque to 30 N•m [22 lbf•ft]. 3. Lubricate and install O-ring (810A) onto plug (810). Using an 11/16 in. hex wrench, install plug (810). Torque to 37 N•m [27 lbf•ft].
  • Page 299 Service Manual Series 40 M46 Variable Pumps Minor repair Charge pump removal/installation 1506 9/16 in 30Nm [20 ft•lb] 1502 9/16 in 43Nm [32 ft•lb] 1503 1505 1504 P106 636E Inspection Inspect the gerotor (603) and gerotor cover (155) for wear, scratches or pitting. If any component shows signs of wear, scratching, or pitting, relpace all components.

  • Page 300: Shaft Seal, Roller Bearing And Shaft Replacement

    Service Manual Series 40 M46 Variable Pumps Minor repair Shaft seal, roller bearing and shaft replacement The shaft assembly is serviceable without removing the front cover of the pump, but the charge pump must be removed first. Orient the pump on the work surface so the shaft is pointing up with the charge pump (603) and key (605) removed from shaft.

  • Page 301: Scr Valves

    Service Manual Series 40 M46 Variable Pumps Minor repair Reassembly 1. Using a snap ring pliers, install snap-ring (133 ). Lubricate and press bearing (131) onto shaft. Install second snap-ring (133). 2. Install shaft and bearing assembly into front cover. Rotate shaft to align with block-splines. Ensure bearing is installed deep enough to clear snapring groove.

  • Page 302: Charge Pressure Relief Valve

    Service Manual Series 40 M46 Variable Pumps Minor repair SCR valves 1-1/4 in 176 Nm [130 ft•lb] 1103 1103 1-1/4 in 176 Nm [130 ft•lb] P106 635E Charge pressure relief valve Replace the charge pressure relief valve components if they are damaged or if you suspect failure. See Charge pressure relief valve on page 18, for adjustment instructions.

  • Page 303: Bypass Valve

    Service Manual Series 40 M46 Variable Pumps Minor repair Charge pressure relief valve 1 in P106 638E Bypass valve Removal 1. Using a 5/8 in. hex wrench, remove bypass valve (1001). 2. Remove and discard O-ring (1003) and backup ring (1002). Inspection Inspect the sealing surfaces of the pump for nicks or scratches.

  • Page 304: Manual Displacement Control

    Service Manual Series 40 M46 Variable Pumps Minor repair Bypass valve 1001 5/8 in 20 Nm [15 ft•lb] 1002 1003 P106 653E Manual displacement control Removal 1. Using a 3/8 in. hex wrench, remove screw (1210). Remove manual control spool assembly from pump housing.

  • Page 305: Electronic Displacement Control/Hydraulic Displacement Control

    Service Manual Series 40 M46 Variable Pumps Minor repair Alignment slot Servo piston P107 958E 3. Install neutral return spring (1214), neutral return bracket (1216), handle (1215), and washer (1235) onto spool (1207). 4. Using a 1/2 in. hex wrench, install lock nut (1213). Torque to 15 N•m [11 lbf•ft]. 5.

  • Page 306: Mdc Orifice Repair

    Service Manual Series 40 M46 Variable Pumps Minor repair Inspection Inspect control spool for scratches, grooves, and other damage. If spool is damaged, or you suspect control malfunction, replace entire control unit. Inspect sleeve bore in housing for damage. Reassembly 1.

  • Page 307: Edc/Hdc Orifice Repair

    Service Manual Series 40 M46 Variable Pumps Minor repair Install Pipe plug (1219) with thread lock. Apply a few drops before installation. MDC orifice repair 1401 1/8 in 1219 3/16 in P106 654E EDC/HDC orifice repair Removal 1. Remove servo covers. See Displacement limiter on page 28, for servo cover removal and installation instructions.

  • Page 308: Hc Edc Control Repair

    Service Manual Series 40 M46 Variable Pumps Minor repair EDC/HDC orifice repair 3/8 in 2161 1403 1404 3/8 in 9/16 in P106 655E HC EDC Control Repair 1. Using a 5 mm internal hex wrench, remove the six cap screws (D250). 2.
  • Page 309 Service Manual Series 40 M46 Variable Pumps Minor repair Proper screen orientation P106 519E 6. Install the control module and six cap screws (D250). Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the center of the control module when installing control.
  • Page 310 Service Manual Series 40 M46 Variable Pumps Minor repair Torque sequence 11026743 • Rev BA • June 2014...

  • Page 311: Torque Chart

    Service Manual Series 40 M46 Variable Pumps Torque chart Fastener size and torque chart Item Fastener Wrench size Torque Servo piston cover screws 3/8 hex 15 N•m [11 lbf•ft] Servo piston cover screws 3/8 hex 15 N•m [11 lbf•ft] Front cover screw T50 Torx 58 N•m [43 lbf•ft] Front cover screws...
  • Page 312 Service Manual Series 40 M46 Variable Pumps Torque chart Hardware locations 1210 1213 (2places) (6 places) Side (2 places) Front 1506 Rear (3 places) (3 places) (2 places) 1102 1001 (2 places) (5 places) P106 604E (2 places) (5 places) Bottom 1101 11026743 •...
  • Page 313 Products we off er: Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electronic components. We specialize in providing state-of-the-art technology and solutions that • excel in the harsh operating conditions of the mobile off -highway market. Building on our extensive Bent Axis Motors applications expertise, we work closely with our customers to ensure exceptional performance for a •...
  • Page 314 MAKING MODERN LIVING POSSIBLE Technical Information Axial Piston Pumps Series 40 M46 powersolutions.danfoss.com...
  • Page 315 Technical Information Series 40 M46 Pumps Revision history Table of revisions Date Changed May 2015 more corrections to tandem pumps model code March 2015 correction to tandem pumps model code January 2015 minor edits January 2015 added port callouts - HC EDC drawings November 2014 corrections to shaft options July 2014...
  • Page 316 Technical Information Series 40 M46 Pumps Contents Specifications Design Specifications..................................5 Technical Specifications.................................5 Operating Parameters..................................5 Options.........................................6 Fluid specifications..................................6 General Information M46 Pumps......................................7 M46 Variable Pumps..................................7 System Circuit Diagram..................................8 Schematic Diagram..................................8 Features and Options Features........................................9 Options.........................................9 Operating Parameters Fluids........................................10 Viscosity......................................10 Temperature....................................10 Charge Pressure....................................10...
  • Page 317 Technical Information Series 40 M46 Pumps Contents Auxiliary Mounting Pads and Auxiliary Pumps........................35 Manual Displacement Control (MDC) - Options AB, AC, AK, AW, and GB..............36 Hydraulic Displacement - Options BA, BB and BC......................39 Electrical Displacement Control- Options CE, CG, CM, and CN..................41 High Current Electric Displacement Control - Options HA (12Vdc) and HB (24Vdc)..........44 Control signal requirements..............................46 Connector....................................46...

  • Page 318: Specifications

    Technical Information Series 40 M46 Pumps Specifications Design Specifications Series 40 Pumps Product line In-line, axial piston, variable, positive displacement pumps Pump type Clockwise (CW) or counterclockwise (CCW) available Direction rotation Discretionary, the housing must be filled with hydraulic fluid Installation position Suction or charge pressure filtration Filtration configuration...

  • Page 319: Options

    Technical Information Series 40 M46 Pumps Specifications Minimum (intermittent cold degrees C [degrees F] - 40° C [- 40° F] Fluid Temperature start) 82.2° C [180° F] Continuous 104.4° C [220° F] Maximum Intermittent (1) Intermittent equals a short period of time at less than one minute per incident and not exceeding two percent of duty cycle based on load life.

  • Page 320: General Information

    Technical Information Series 40 M46 Pumps General Information M46 Pumps M46 pumps are designed for medium power applications with maximum loads of 345 bar [5000 psi]. These pumps can be combined with other products in a system to transfer and control hydraulic power. M46 pumps provide an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation.

  • Page 321: System Circuit Diagram

    Technical Information Series 40 M46 Pumps General Information System Circuit Diagram Reservoir Heat exchanger bypass Control handle Filter Displacement Heat control exchanger valve Fixed displacement motor Cylinder Cylinder block block assembly assembly Charge relief valve Bypass valve Output shaft Charge pump Loop flushing module...

  • Page 322: Features And Options

    Technical Information Series 40 M46 Pumps Features and Options Features • Efficient Axial Piston Design • Compact, Lightweight Pumps • Worldwide Support • Low Noise • Single and Tandem Integrated Tandem Configurations • Manual, Hydraulic or Electric Control Options High Pressure Relief Valve (HPRV) - A high pressure relief valve limits the system pressure to protect the system from over-pressure.

  • Page 323: Operating Parameters

    Technical Information Series 40 M46 Pumps Operating Parameters Fluids Ratings and performance data are based on operating with premium hydraulic fluids containing oxidation, rust, and foam inhibitors. These include premium turbine oils, API CD engine oils per SAE J183, M2C33F or G automatic transmission fluids (ATF), Dexron II (ATF) meeting Allison C-3 or Caterpillar T0‑2 requirements, and certain specialty agricultural tractor fluids.

  • Page 324: Control Pressure

    Technical Information Series 40 M46 Pumps Operating Parameters Control Pressure Control pressure is the pressure in the servo system needed to position and hold the pump on stroke. Servo pressure depends on system pressure and speed. At minimum control pressure, the pump will run at reduced stroke depending on speed and pressure. Minimum control pressure at corner power holds the pump on full stroke at maximum speed and maximum pressure.

  • Page 325: Inlet Pressure

    Technical Information Series 40 M46 Pumps Operating Parameters For more information consult Pressure and Speed Limits BLN-9884, when determining speed limits for a particular application. During hydraulic braking and downhill conditions, the prime mover must be capable of providing sufficient braking torque in order to avoid pump over speed. This is especially important to consider for turbocharged and Tier 4 engines.

  • Page 326: System Design Parameters

    Technical Information Series 40 M46 Pumps System Design Parameters Sizing Equations Use these equations to help choose the right pump size and displacement for your application. Based on SI units Based on US units • n • η • n • η Flow (l/min) (US gal/min)

  • Page 327: Suction Filtration

    Technical Information Series 40 M46 Pumps System Design Parameters Cleanliness level and β -ratio Filtration (recommended Cleanliness per ISO 4406 22/18/13 minimum) Efficiency (charge pressure β-ratio β = 75 (β ≥ 10) 15-20 filtration) Efficiency (suction and β = 75 (β ≥...

  • Page 328: Redundant Braking System Requirement

    Technical Information Series 40 M46 Pumps System Design Parameters Charge filtration Strainer Reservoir Filter To Low Pressure with bypass side of loop and servo control Charge relief valve Charge pump To pump case P106102 Redundant Braking System Requirement Warning Unintended vehicle or machine movement hazard The loss of hydrostatic drive line power, in any mode of operation (forward, neutral, or reverse) may cause the system to lose hydrostatic braking capacity.

  • Page 329: Case Drain Usage For Tandem Pumps

    Technical Information Series 40 M46 Pumps System Design Parameters Case Drain Usage for Tandem Pumps The tandem housings are connected through the center section via a drilled hole. The charge relief valve discharges oil into the front housing. In order to provide positive flow through both housings, use a case drain in the rear housing.

  • Page 330: Hydraulic Unit Life

    Technical Information Series 40 M46 Pumps System Design Parameters Shaft loading parameters (continued) Force of cylinder block Thrust external load Force of charge pump Maximum external shaft moments Standard Bearing Me/N•m [in·lbf ] 186 [1650] External radial shaft load 270 R 90 R 180 R P100594...
  • Page 331 Technical Information Series 40 M46 Pumps System Design Parameters + ... +W + ... +W Refer to the Installation Drawings section to find pump length (L). Refer to the table Technical Specifications in the Specifications section, to find pump weight (W). An exact measure of W will depend on the pump’s features.

  • Page 332: Shaft Torques

    Technical Information Series 40 M46 Pumps System Design Parameters G-factors for sample applications (continued) Application Continuous (vibratory) Maximum (shock) acceleration acceleration (G Turf care vehicle Vibratory roller * Applications which experience extreme resonant vibrations require addition pump support. Shaft Torques Shaft selection Base shaft selection on a review of the maximum torque required by the application and the maximum torque available from the prime mover.

  • Page 333: Model Code - Single Pumps

    Technical Information Series 40 M46 Pumps Model Code - Single Pumps Single Pumps Product Frame Type C Swashplate Description Code Remarks Standard D - Seal Group Description Code Remarks Seal group for MDC Must select an MDC control Seal group for EDC/HDC/FNR Must select an EDC/HDC/FNR control E - Input Shaft/Auxiliary Spline Description...
  • Page 334 Technical Information Series 40 M46 Pumps Model Code - Single Pumps H - Charge pressure Description Code Remarks 19.5 bar 21.5 bar 25.0 bar EDC/HDC controls calibrated at 20.7 bar charge J - Filtration Description Code Remarks Suction, with charge pump Requires G: with charge pump Remote pressure, with charge pump Requires G: with charge pump...
  • Page 335 Technical Information Series 40 M46 Pumps Model Code - Single Pumps N - Control type Description Code Remarks MDC handle with (2) 10 mm diameter holes, standard spring Recommend AW with metered spool MDC with (3) 10 mm diameter holes, standard spring Recommend AK with metered spool MDC with (3) 10 mm diameter holes, U shaped, standard spring, metered spool...
  • Page 336 Technical Information Series 40 M46 Pumps Model Code - Single Pumps HC EDC - Servo A and B Servo A&B 0.046 inch 0.055 inch 0.037 inch 0.024 inch None S - Auxiliary mounting flange Description Code Remarks SAE A, side #2 lift bracket location E: Shaft to include 9T or 11T aux..

  • Page 337: Model Code - Tandem Pumps

    Technical Information Series 40 M46 Pumps Model Code - Tandem Pumps Tandem Pumps Product Frame Type Front Section Rear Section E - Input Shaft Description Code Remarks 15T 16/32 Spline Requires S: None aux.. pad 19T 16/32 Spline Requires S: SAE-B aux.. pad Tapered, 1 inch dia., 1.5 in/foot, square key without thru hole Includes key and nut.
  • Page 338 Technical Information Series 40 M46 Pumps Model Code - Tandem Pumps C - Swashplate group, front pump/Q - Swashplate group, rear pump Description Code Remarks Balanced D - Seal Group Description Code Remarks Seal group for MDC - Front pump Must select an MDC control Seal group for EDC/HDC/FNR - Front pump Must select an EDC/HDC/FNR control...
  • Page 339 Technical Information Series 40 M46 Pumps Model Code - Tandem Pumps N - Control type, front pump /Y - Control type, rear pump (continued) Description Code Remarks MDC handle with (2) 10 mm diameter holes, standard spring, metered spool MDC heavy duty handle with (4) 10 mm diameter holes, heavy P;...
  • Page 340 Technical Information Series 40 M46 Pumps Model Code - Tandem Pumps S - Auxiliary mounting flange and coupling (continued) Description Code Remarks SAE A, 11 tooth 16/32 spline SAE B, 11 tooth 16/32 spline T - Special hardrare Description Code Remarks Black paint, Danfoss tag, Layout A High capacity shaft bearing, black paint, Danfoss tag, Layout A NNR...

  • Page 341: Options

    Technical Information Series 40 M46 Pumps Options Shaft options Recommended mating splines for Series 40 splined output shafts should be in accordance with ANSIB 92.1 Class 5. Danfoss external splines are modified Class 5 Fillet Root Side Fit. The external splined Major Diameter and Circular Tooth Thickness dimensions are reduced in order to assure a clearance fit with the mating spline.
  • Page 342 Technical Information Series 40 M46 Pumps Options Code Description Maximum torque rating Rated torque Drawing Nm [lbf in] Nm [lbf in A, B, L, D 13-tooth 16/32 pitch (ANSI 226 [2000] 124 [1100] B92.1 1970 - Class 5) Coupling must not protrude beyond this surface G, H, J, K 15-tooth 16/32 pitch (ANSI...

  • Page 343: Tandem Pumps

    Technical Information Series 40 M46 Pumps Options Tandem pumps Code Description Maximum torque Drawing rating Nm [lbf in] Ø 25.4 mm [1.000 in] 362 [3200] 6.35 [0.250] sq. key Straight keyed - 44.45 [1.75] long Shipped with key 0.38 [0.015] min. R. on edges Mounting flange 25.4 [1.00] dia.

  • Page 344: Charge Pump

    Technical Information Series 40 M46 Pumps Options Shaft options Length Shaft Full spline Major Pitch No. teeth diameter diameter diameter 37.7 [1.485] 22.3 [0.88] 23.4 [0.92] 24.89 [0.9800] 20.638 [0.9375] 15 37.7 [1.497] 28.7 [1.13] 24.1 [0.95] 31.24 [1.230] 30.163 [1.1875] 19 Other shaft options may exist.

  • Page 345: Charge Pump Output Flow

    Technical Information Series 40 M46 Pumps Options Charge Pump Output Flow Flow at 19.5 bar charge relief setting, 70°C [160°F] inlet l/min US Gal/min M46 PT M46 PV 1000 2000 3000 4000 Speed min (rpm) T101302 Charge Pump Power Requirements Power at 19.5 bar charge relief setting, 70°C [160°F] inlet M46PT M46PV...

  • Page 346: High Pressure Relief Valve (Hprv) And Charge Check

    Technical Information Series 40 M46 Pumps Options The charge relief valve is factory set. If necessary, it can be field adjusted with shims. Charge Relief Valve Specs Type Cone poppet valve Available Setting 19.5-26.2 bar [285-380 psi] Adjustment Via shims inside of valve cartridge* Rise Rate Adjustment 2.3 bar [33 psi]/mm...

  • Page 347: Bypass Function

    Technical Information Series 40 M46 Pumps Options Check/high pressure relief valve specs Cartridge-style poppet valve Type 140-345 bar (2030-5000 psi) Setting Check only - no relief valve Option High pressure relief valve locations Bypass valve High pressure relief valve P100590 Bypass Function All M46 pumps are equipped with a loop bypass valve that connects the A and B sides of the working loop.

  • Page 348: Auxiliary Mounting Pads And Auxiliary Pumps

    Technical Information Series 40 M46 Pumps Options M46 Displacement limiter (side #2) Neutral Adjustable adjustment displacement Fixed screw limiter screw displacement limiter P100 592E Auxiliary Mounting Pads and Auxiliary Pumps Auxiliary mounting pads are available on all pumps. A sealed shipping cover is included as standard equipment on all mounting pads.

  • Page 349: Manual Displacement Control (Mdc) - Options Ab, Ac, Ak, Aw, And Gb

    Technical Information Series 40 M46 Pumps Options max. F min spline max. engagement Mounting for full flange (ref.) torque rating With undercut P Dia. Without undercut 0.8 [0.03] max. R Coupling max. 2.3 [0.090] recommended max. cutter clearance P100 636E Manual Displacement Control (MDC) - Options AB, AC, AK, AW, and GB The Manual Displacement Control (MDC) converts a mechanical input signal to a hydraulic signal with a spring centered 4-way servo valve, and ports hydraulic pressure to either side of a double acting servo...
  • Page 350 Technical Information Series 40 M46 Pumps Options • Simple-low cost design. • Pump output is maintained regardless of load. • Pump will return to neutral after prime mover shuts down. • Pump returns to neutral if external control linkage becomes disconnected from the control handle or if there is a loss of charge pressure.
  • Page 351 Technical Information Series 40 M46 Pumps Options MDC Response time Orifice diameter* mm [in] Average response time [seconds] Supply Drain Acceleration Deceleration 0.9 [0.036] 0.8 [0.031] 0.9 [0.036] 1.2 [0.046] 1.4 [0.054] 1.2 [0.046] None None *Contact Danfoss for special orifice combinations. External control handle torque requirements Standard spring Heavy duty spring...

  • Page 352: Hydraulic Displacement - Options Ba, Bb And Bc

    Technical Information Series 40 M46 Pumps Options Hydraulic Displacement - Options BA, BB and BC The Hydraulic Displacement Control (HDC) is a two stage design which uses a hydraulic input signal to operate a spring centered 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston.
  • Page 353 Technical Information Series 40 M46 Pumps Options Pump flow direction with HDC control (continued) Rear Tandem Higher pressure into control port: Port C Flow Port D Flow High Servo Gauge Port Refer to pump installation drawing for port locations. Response Time The time required for the pump output flow to change from neutral to full flow (acceleration) or full flow to neutral (deceleration) is a function of the size of the supply orifice in the control inlet passage and the size of the drain orifice in the control sleeve.

  • Page 354: Electrical Displacement Control- Options Ce, Cg, Cm, And Cn

    Technical Information Series 40 M46 Pumps Options HDC signal required for swashplate position Swashplate position (refer to above chart) Swashplate movement begins (point A) Full displacement reached (point B) Configuration [psid] [psid] 1.3±0.5 [19±7] 11.7±1.1 [170±16] 3.0±0.7 [44±10] 13.8±1.4 [200±20] 4.8±0.7 [70±10] 15.2±1.4...
  • Page 355 Technical Information Series 40 M46 Pumps Options EDC on M46 PV P100600 Pump flow direction with EDC control Input Shaft Rotation Positive signal to pin Single or Front Single coil or Dual coil in parallel A or C B or D A or C B or D Tandem...
  • Page 356 Technical Information Series 40 M46 Pumps Options EDC Hydraulic Schematic P104368 Response time The time required for the pump output flow to change from neutral to full flow (acceleration) or full flow to neutral (deceleration) is a function of the size of the orifices in the servo and supply passages. A range of orifice sizes is available to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application.

  • Page 357: High Current Electric Displacement Control - Options Ha (12Vdc) And Hb (24Vdc)

    Technical Information Series 40 M46 Pumps Options Pump displacement vs electrical control 100% Current in MA Current in MA 100% T101312 EDC Input Options Coil configuration (Point a) mA (Point b) mA Pin Connections Dual coil, using only one coil 23 ±...
  • Page 358 Technical Information Series 40 M46 Pumps Options Under some circumstances, such as contamination, the control spool could stick and cause the pump to stay at some displacement. A serviceable 125 μm screen is located in the supply line immediately before the control porting spool. P003 191 Pump displacement vs.

  • Page 359: Control Signal Requirements

    Technical Information Series 40 M46 Pumps Options Schematic diagram flow out B P108759 Control signal requirements Control current Voltage b mA Pin connections 12 V 1640 any order 24 V Factory test current, for vehicle movement or application actuation expect higher or lower value. Connector P003 480 Description...

  • Page 360: Response Times

    Technical Information Series 40 M46 Pumps Options Solenoid data (continued) Voltage Inductance 33 mH 140 mH IP Rating (IEC 60 529) + DIN 40 050, part 9 IP 67 IP Rating (IEC 60 529) + DIN 40 050, part 9 with mating connector IP 69K PWM signal required for optimum control performance.

  • Page 361: Three-Position Electrical Control - Options Da And Db

    Technical Information Series 40 M46 Pumps Options Unintended MOR operation will cause the pump to go into stroke. The vehicle or device must always be in a safe condition (i.e. vehicle lifted off the ground) when using the MOR function. The MOR plunger has a 4 mm diameter and must be manually depressed to be engaged.
  • Page 362 Technical Information Series 40 M46 Pumps Options FNR Control on M46 PV P100601 Pump flow direction with FNR control Input Shaft Rotation Single or Front Solenoid energized: Tandem Port A Flow Port B Flow Rear Tandem Solenoid energized: Port C Flow Port D Flow High Servo Gauge Port Refer to pump installation drawing for solenoid and port locations.
  • Page 363 Technical Information Series 40 M46 Pumps Options Response time The time required for the pump output flow to change from neutral to full flow (acceleration) or full flow to neutral (deceleration) is a function of the size of the orifices in the servo, supply and drain passages. A range of orifice sizes is available to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application.

  • Page 364: Port Locations

    Technical Information Series 40 M46 Pumps Port Locations Single Pump Charge Pump Inlet Case Outlet L1 1-1/16-12 Bypass Relief Valve (optional relief valve) (for port A) Servo Pressure Gage Port M4 All ports are straight thread O-ring boss 9/16 - 18 Charge Pressure per ISO 11926-1 and SAE J1926/1 Relief Valve...

  • Page 365: Tandem Pump

    Technical Information Series 40 M46 Pumps Port Locations Tandem Pump To remote filter D System Port D (pressure filter option) 1-5/16 - 12 Port C 7/8 - 14 Charge Pump Inlet S 1-5/16 - 12 Case Outlet L1 1-5/8 - 12 1-1/16 - 12 From remote filter E Bypass Front...

  • Page 366: Installation Drawings - Single Pump Dimensions

    Technical Information Series 40 M46 Pumps Installation Drawings - Single Pump Dimensions Auxiliary Mounting Flanges Contact Danfoss for individual dimension drawings Rear view (no pads shown) 7.4 min. 3/8-16 thd. [0.29] 20.3 [0.80] min. full thd. depth 1.96 (2) holes [0.077] 0.5 max R 106.38...

  • Page 367: Pump, Filtration/Charge Pump Options, Mdc, Displacement Limiter

    Technical Information Series 40 M46 Pumps Installation Drawings - Single Pump Dimensions Pump, filtration/charge pump options, MDC, displacement limiter 80.8 [3.18] 260.61 [10.26] Side #2 212.3 [8.36] 211.8 [8.34] 171.7 [6.76] 143.8 [5.66] 0.8 R max. [0.03] Pump [0.09] [0.28] 72.6 33.5 [1.32] Mounting...

  • Page 368: Installation Drawings - Tandem Pump Dimensions

    Technical Information Series 40 M46 Pumps Installation Drawings - Tandem Pump Dimensions Auxiliary mounting flange 91.8 1/2-13 [3.61] 26.4 [1.04] 59.7 [2.35] min. full thd. 89.9 79.8 [3.54] [3.14] 51.3 [2.02] 79.8 [3.14] No auxiliary mounting flange Mounting 474.9 8.38 flange (ref .) min.

  • Page 369: Rear Mounting Boss

    Technical Information Series 40 M46 Pumps Installation Drawings - Tandem Pump Dimensions Rear mounting boss 32.51 [1.28] M12 x 1.75 349 [13.74] 6H Thd. X2 P104425 L1001029 • Rev BG • May 2015...

  • Page 370: Pumps, Filtration/Charge Pump Options, Mdc, Displacement Limiters

    Technical Information Series 40 M46 Pumps Installation Drawings - Tandem Pump Dimensions Pumps, filtration/charge pump options, MDC, displacement limiters 212.3 [8.36] 493.0 [19.41] max 171.7 [6.76] Side #2 341.4 [13.44] 274.8 [10.82] 203.7 [8.02] Pump 13.2 0.8 R max. [0.52] [0.09] [0.03] [0.28]...

  • Page 371: Control Options - Installation Drawings

    Technical Information Series 40 M46 Pumps Control Options - Installation Drawings Control options, AC, AK Three hole control handle with standard spring Mounting flange location (ref .) 141.5 20° 20° [5.57] 3.18 19.05 [0.75] [0.125] 10.08 [0.397] 50.8 dia. (3) [2.00] R 29.5 [1.16] R...

  • Page 372: Options Ab, Aw

    Technical Information Series 40 M46 Pumps Control Options - Installation Drawings Options AB, AW Two hole control handle with standard spring Mounting flange location (ref .) 141. 5 20° 20° [5.57] 3.18 19.05 [0.75] [0.125] 10.08 [0.397] 50.8 dia. (3) [2.00] R 29.5 [1.16] R...

  • Page 373: Hc Edc Control

    Technical Information Series 40 M46 Pumps Control Options - Installation Drawings HC EDC Control Charge filtration port E ISO 11926-1 7/8-14 Bypass valve From remote filter (full open at two revolutions) 121.9 ± 2.5 103 ± 1.5 Charge gauge port for remote filtration with or w/o charge pump option System gauge port A 193.5 ±...

  • Page 374: Hydraulic Displacement Control (Hdc)

    Technical Information Series 40 M46 Pumps Control Options - Installation Drawings Hydraulic displacement control (HDC) 177.8 max. [7.00] 39.6 [1.56] to ports Port X1 Port X2 7/16 -20* 49.0 [1.93] 141.7 [5.58] Control pressure ports To ports (2) places 118.1 [4.65] Side view View X Variable pump with HDC...

  • Page 375: Option Ce

    Technical Information Series 40 M46 Pumps Control Options - Installation Drawings Option CE Electronic displacement control (EDC) 177.8 max. [7.00] Packard Weather-Pack Danfoss mating parts kit 4-way tower connector part no.K03384 (male terminals) (female terminals) View V 124.2 max. [4.89] Packard "Weather Pack"...

  • Page 376: Options Da, Db

    Technical Information Series 40 M46 Pumps Control Options - Installation Drawings Options DA, DB Three-position electric displacement control (FNR) Connector per ISO 4400 8.61 (2) Places [218.6] Side view View X front view Variable pump with FNR control Variable pump with FNR control not connected Terminal 1 Terminal 2...

  • Page 377: Reference Literature

    Technical Information Series 40 M46 Pumps Reference Literature Literature M46 systems may consist of a variety of pump, motor, valve and control combinations. Refer to the literature listed below for product information and specifications for M46 pumps and other Danfoss components.
  • Page 378 Products we offer: Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electronic components. We specialize in providing state-of-the-art technology and solutions • Bent Axis Motors that excel in the harsh operating conditions of the mobile off-highway market. Building on •...
  • Page 379 SERVICE INSTRUCTIONS ZAMBONI MODEL 11870-0011 Parts list Description Qty. 11870-0011 Screw End Cover (3 Per Kit) 18753-0332 End Cover 12062-0000 Gasket 816-0000 Impeller Natural Rubber 836-0008-P Wearplate 2574-0000 Body 11874-0000 Screw Cam (3 Per Kit) 91005-0040 Cam – Brass 834-0001...
  • Page 380 SERVICE INSTRUCTIONS Press seal seat assembly from bearing bore end towards im- IMPELLER REPLACEMENT: Remove end cover gasket. Pull peller bore. Remove bearing to shaft retaining ring. Support impeller out by grasping impeller with a Jabsco impeller puller. bearing and press on clutch drive end of shaft to remove shaft With a rotary motion in the direction the pump will be turn- from the bearing.
  • Page 381 BACK OPTIONS...
  • Page 382 BACK MEMOS AND UPDATES...
  • Page 383 BACK SAFETY BULLETIN...
  • Page 384 “CONDITIONER MAINTENANCE” AND BEING PROPERLY TRAINED FOR ITS SAFE OPERATION. OBSERVE ALL LABELS AND INSTRUCTIONS. The Zamboni ice resurfacer is to be operated by one person. The machine is not designed nor built to accommodate riders. See the Zamboni Company’s position on second seats and “riders” here: https://zamboni.com/no-riders/...
  • Page 385 Zamboni Safety Bulletin DM-2022F Familiarize yourself and your staff with these and other areas of potential hazard or danger: Conveyor intake Conveyor discharge opening Horizontal conveyor screw (view safety guard list DM-2 02 (view safety guard list DM-2 02 (view safety guard list DM-2 02...
  • Page 386 Inspect your machine to make sure that it is properly equipped with these guards and that all safety labels are in place. If safety labels are missing or painted over, replacements are available at no cost. Contact your Zamboni Authorized Distributor or Zamboni Customer Service. (https://zamboni.com/register-as-a-zamboni-product-owner/).
  • Page 387 Zamboni Safety Bulletin DM-2022F Everyone interacting with the ice resurfacer should be made aware of and held accountable for the use of PPE. Staff should have access to equipment and must be instructed on the importance of the proper use of PPE. Make sure that your facility follows local and regional standards and regulations regarding PPE.
  • Page 388 Zamboni Safety Bulletin DM-2022F U.S. EPA Information on air quality: https://www.epa.gov/indoor-air-quality-iaq/indoor-air-quality-and-ice-arenas The Ontario Recreational Facilities Association shares their air quality reference materials here: https://zamboni.com/air-quality-and-emissions/ Never operate ice resurfacing equipment in an enclosed rink without adequate ventilation. Make sure your ventilation system is working properly and turned on when operating the resurfacer.
  • Page 389 The Zamboni Company continues to build the Zamboni ice resurfacer with safety as a primary consideration. We have an ongoing effort to instruct arena owners and operators in the safe and proper operation of our machines.
  • Page 390 Safety Bulletin This bulletin should be printed or saved digitally and shared with all staff working on or around the Zamboni ice resurfacer. If you retain digital files on your machine's digital service manual (USB key ring) add this information and advise your staff of the update.
  • Page 391 You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. Contact Zamboni or your Zamboni Authorized Distributor for new labels at no cost.
  • Page 392 • Keep all guards in place. Do not operate the Zamboni machine if any guard is damaged or missing. • Check all controls and warning devices for proper operation.
  • Page 393 CNG powered vehicles before trying to extinguish. Make sure your staff knows how to properly use it. • Always have a properly maintained fire extinguisher located in the Zamboni machine room. Make sure your staff knows how to properly use it.
  • Page 394 Never use a match or open flame to check for leaks, use a soap solution. • Always close the LPG tank service valve when the Zamboni machine is parked for the night or for any extended length of time. •...
  • Page 395 Zamboni Safety Bulletin DM-2022F CNG Fuel System The installation of distribution, storage and dispensing (charging) systems and CNG cylinder charging must be done in accordance with locally applicable codes and standards. U.S. machine owners can reference the National Fire Prevention Association (NFPA) NFPA 52 Compressed Natural Gas (CNG) Vehicular Fuel Systems and any other applicable regulations.
  • Page 396 Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. • Repair any loose or damaged oil lines, tubes and hoses. Leaks can cause fires. Contact Zamboni or your Zamboni Authorized Distributor for repair or replacement.
  • Page 397 • Mount and dismount the ice resurfacer only where steps and/or handholds are provided. • Use both hands and face the Zamboni machine when mounting and dismounting. Use extra care when wet or slippery conditions exist. • Never get on or off a moving Zamboni machine. Never jump off the machine.
  • Page 398 Zamboni Safety Bulletin DM-2022F Parking • Park the Zamboni machine in authorized areas only. • Move the hydrostatic transmission control lever or directional switch to NEUTRAL. • Turn the key switch OFF and remove the key. • If possible, park the machine on a flat and level surface. If the machine is parked on any kind of grade, the wheels must be blocked with wheel chocks to prevent the vehicle from rolling away after it has been parked.
  • Page 399 Zamboni Safety Bulletin DM-2022F Optional Emission System Components Machines may be equipped with the following emission systems components: catalytic converter (two way and three way), engine controller and oxygen sensor(s). Some are optional and some are standard with all current model machines featuring them as standard equipment.
  • Page 400 All other kits contain physical guard panels to restrict operator access to moving components like augers and belts. Please note that for the installation of the KZ-77500 conditioner guard kit, drilling and assembly is required. To order, please contact your Zamboni Authorized Distributor and have your machine model number and serial number available.
  • Page 401 INTERLOCK KIT - 440 - 445 - 446 To order, please contact your Zamboni Authorized Distributor and have your machine model number and serial number available. Find your Local Zamboni Authorized Distributor at zamboni.com/distributor-locator ZAMBONI DM-2021G REV March, 2019 PAGE 2 OF 2...

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