Basic Electric Presentation PDF

Basic Electric 1  Course Objectives During this course we will: Operate a manual and auto drive control systems ranging multimeter Explain and demystify CAN-BUS Perform proper battery...

Basic Electric 1  Course Objectives During this course we will: Operate a manual and auto drive control systems ranging multimeter Explain and demystify CAN-BUS Perform proper battery Electrical schematic maintenance and diagnosis interpretation and symbol Identify battery components identification Identify the differences between Practice soldering techniques AC and DC and how AC is Assemble various circuits generated Build an encoder tester using a Recognize the various types of schematic as referrence motors in use and their differences Familiarization with the various 2 Module 00 Overview Module 10 Meters and Testing Module 20 Batteries Module 30 AC vs DC Module 40 Motors Module 50 Drive Control Module 60 CAN-BUS Module 70 Symbols and Schematics Module 80 Soldering Techniques Module 90 Circuit Building Module 100 Encoder Tester Project 3  Module 10 Meters and Testing 4 Module 10 Meters and Testing Meters and Testing Objectives At the end of the module, you will be able to: Identify the different measurement readings on a meter Identify the range indication symbols Perform resistance readings Explain current, resistance, and voltage 5  Module 10 Meters and Testing Auto Range Meter Basic layout and function of an Auto Range Meter. Module 10 Meters and Testing Manual Range Meter Basic layout and function of a Manual Range Meter. Module 10 Meters and Testing Current Electrical current is electrons in motion. As current starts to flow in a circuit free electrons exert force on the next electron thus moving the electrons, this effect continues throughout the circuit. Current is measured in amperes or AMPS. The quantity of electrons flowing past a given point in one second equals one amp. ( over six billion electrons flow in one amp for one second ) Module 10 Meters and Testing Voltage Voltage = Pressure that causes electrons to flow in a circuit. When a circuit has an excess of electrons on one end, and a deficiency of electrons on the other end there is a difference in pressure. This difference causes current to flow from the high point of pressure to the low point of pressure. To maintain a constant flow of electrons, the voltage must stay constant. Module 10 Meters and Testing Resistance Movement of electrons are hindered by collisions with adjoining atoms of a material. This hindrance of electrons is the resistance of a conductor. Resistance varies in different types of materials. Increases in the number of electrons flowing cause more collisions and increases in conductor temperature. Increases in conductor temperatures cause atoms to move causing more collisions or higher  Module 10 Meters and Testing In the testing module we will use a hands on approach to gain an understanding how each type of meter differs from the other. Our exercise will use 10 different resistors to measure the different values of each resistor. We will also use some various components and follow the testing procedure for each component. This simulates real world testing with real parts. 11 Module 10 Meters and Testing Classroom Lab Exercise Resistance Readings Controller Test Transistor Test Resistor Codes 12  Module 10 Meters and Testing Meters and Testing Review You are now able to: Identify the different measurement readings on a meter Identify the range indication symbols Perform resistance readings Explain current, resistance, and voltage 13  Module 20 Batteries 14 Module 20 Batteries Batteries Objectives The battery is one of the most important components of an electric forklift. It provides power and weight and is very expensive. The battery is also one of the most neglected parts in a lift truck. It can cause a large verity of problems. So, when a lift truck problem occurs, you need to check the battery before starting to work on anything else. In this module you will learn to: Identify the components of a lead acid battery. Compare an industrial and an automotive battery. Describe the battery charging process. Identify battery-rating characteristics. Explain battery safety factors. Check cell voltage with a volt ohm meter (VOM) load test. Check specific gravity using a hydrometer. Battery maintenance 15 Module 20 Batteries What is a battery? See the following table below for the differences between the two types of batteries: Automotive battery (in an IC Industrial battery (in an electric truck) truck) Used for starting, lighting and ignition. Used to supply motive power for electric trucks. Designed for infrequent, very high current drains of short duration. Designed to be discharged continuously at relatively moderate Recharging starts as soon as the current drains. engine reaches operating speed. No practical way to recharge the Constantly being charged by the built battery during operation. in charger. Life span for an industrial battery in a lift truck, properly used and cared for, is about 5 years, sometimes longer. 16 Module 20 Batteries Components of a lead acid battery. Each lead acid battery is made up of cells. Each cell produces approximately 2.2 volts when fully charged. This means that a 36-volt battery would contain 18 such cells, and a 48-volt battery would contain 24 cells. Each battery cell is made up of several parts. Positive and Negative plates are isolated using separator plates. These plates are immersed in an electrolyte solution mixture of sulfuric acid and water. This is how a battery stores a chemical energy and converts it to electrical energy. 17  Charged Module 20 Batteries How a battery is discharged and charged. In any battery, an electrochemical reaction occurs so that the sulfuric acid in the electrolyte temporarily bonds to the positive and negative plates. The resulting chemical reaction changes both the positive plate lead peroxide and the negative plate sponge lead to a lead sulfate composition. When a battery is connected to an electrical load, the chemical energy in the battery is converted to usable electrical energy. Voltage and electrical potential develops because of dissimilar metal composition of the positive Discharged and negative plates when immersed in the electrolyte solution. The dissimilarity of lead peroxide (positive plate) and sponge lead (negative plate) causes the sulfuric acid in the electrolyte to bond temporarily to the plates. The resulting chemical reaction changes both the positive plate and negative plate to a lead sulfate composition. As the plates approach a lead sulfate composition, their ability to attract sulfuric acid, and thus induce a chemical reaction, is weakened. No chemical reaction means there will not be any electrical potential. So the battery is “discharged”, or, its chemically induced electrical potential is used up. 18 Module 20 Start of Batteries charge How a battery is discharged and charged. Charging the battery reverses this process. Once current is conducted into the battery, the water, sulfuric acid, and the lead sulfate react. Sulfuric acid returns to the water, the electrolyte mixture approaches its former composition, and the plates return to their lead peroxide and sponge lead 4hrs into charge composition. Battery and lift truck manufactures recommend batteries discharge to 80% of their capacity before recharging. This is to protect the battery and lift truck. The specific gravity of a fully charged battery should be 1.280. A discharged battery on average will be 1.130. The specific gravity ratio is amount of sulfuric acid to water. 19  Gassing Module 20 Batteries How a battery is discharged and charged. The last part of charging is called gassing. During this phase of charging, the battery gets hot. The increase in temperature allows the sulfuric acid to mix with the water to get the solution strength back up. Sometimes, operators will quick charge their battery during lunch or End of charge breaks. A quick or opportunity charge is ineffective because it doesn’t allow the chemicals to mix. It takes 8hrs to charge a battery. Quick charging will shorten the life of a battery. An operator should use the battery for 8hrs, charge the battery for 8hrs and let it cool for 8hrs. 20 Module 20 Batteries How is a battery rated? The battery’s weight accounts for a large percentage of the forklift’s capacity and installing an undersized battery can cause stability issues. Research the counterweight requirement by reviewing the forklift’s data tag and measure the maximum space available in the battery compartment. Also, learn the level of voltage the forklift is designed to handle. Battery capacity is rated in ampere (amp) hours. The higher the amp hour, the more power the battery will deliver under specified conditions of temperature, rate of discharge and final voltage. To maximize the production and run time of your forklift, purchase the highest rated amp-hour capacity battery that will fit into the battery compartment. Also, since electric forklift motors very often have to work in unison with batteries to function properly, make sure that your motor is consistently well-maintained, as well. Typical voltage options will include 24V, 36V, 48V, 80V and are available in both lead acid or lithium-ion options. 21  Module 20 Batteries Common Battery Hazards Electrolyte sulfuric acid is an extremely strong acid, even small amounts can burn fabric and skin. Spills should be cleaned up using an absorbent such as bicarbonate of soda. If you are exposed to acid on any part of your body, go to the nearest wash station and flush the affected area for at least 15 minutes with water. Then seek medical attention. Only trained, experienced battery service personal should add sulfuric acid to electrolyte. Do not attempt to add sulfuric acid to a batteries electrolyte solution. 22  Module 20 Batteries Common Battery Hazards Gases Batteries produce a mixture of Hydrogen and Oxygen gas at all times. When in the proximity of batteries: DO’s Don’t - Keep area well ventilated. - - Open any device when charging. Smoke - Use open flame - Keep vent caps secure in battery cells. - Create electrical arcs or sparks Vent caps allow gasses to escape during the - Light fires charging cycle, so they should be clean and In good working order at all times. - Always turn the charger off before disconnecting the battery. Failure to do so can cause a large spark that can potentially cause gasses to explode. 23  Module 20 Batteries Common Battery Hazards Electricity Batteries are capable of producing a very high rate of discharge. The most common instance, a direct short can cause great personal injury and severe battery damage. Always refer to manufactures’ guidelines for safe handling and charging procedures. Its also recommended to remove all conductive jewelry like watches and rings when servicing and charging batteries. 24  Module 20 Batteries Common Battery Hazards Battery weight The lead and electrolyte mixture necessary in battery construction produce heavy battery weight as a result. Industrial lead acid batteries, for example, can average one ton in weight. Handle batteries with care to prevent injury or damage when using or charging batteries in the lift truck. Use proper tools to remove a battery and always keep the removal route clear of obstacles. Never put yourself between a stationary object and the battery when removing a battery. Lastly make sure when installing a battery that I meets the required weight for the lift trucks specifications. There is a minimum and maximum weight indicated on the data tag, make sure the batteries weight falls in that range or safe operation. 25  Module 20 Batteries Basic battery precautions By taking these three simple precautions, you can limit the possibility of personal injury and battery damage. Inspection When receiving or putting a battery in service, check for wet spots which indicate leakage. Wipe the battery dry and recheck for any signs of leakage. Installing Use approved lifting and installation equipment and procedures. Check the battery compartment for sign of corrosion, which indicate leakage. Make sure terminals and connections are free of corrosion. Secure the battery in the compartment with factory equipped retainers, and make sure the compartment is well ventilated. Battery weight When installing a battery, make sure to check the minimum weight required on the trucks data tag and match it with the battery. This is critical for truck operation, the battery acts as counterweight when lifting a load. If a battery is to light, extra weight needs to be added to meet the minimum requirements shown on the data tag of the truck. All modifications to forklift must pass manufactures approval to meet federal OSHA standards. 26  Module 20 Batteries Performing a hydrometer test A battery is made up of a number of cells. Each cell in turn Is made up of a combination of lead (negative plate), and lead peroxide (positive plate), and electrolyte that react with each other to trigger a chemical reaction. This creates voltage. The voltage causes current to leave the battery and flow through the circuit. As this takes place acid is absorbed into the plates. A hydrometer reading can tell you how much acid is in the electrolyte solution. This is called a specific gravity test or a hydrometer test. It can help you determine if the electrolyte is part of the batteries problem. A specific gravity reading in a typical lead acid battery should be between 1.160 and 1.320. At 1.280 to 1.320 the battery is fully charged and ready to use. If the battery is at 1.160 or just above, the battery is at 80% discharge and should be charged. If specific gravity never reaches 1.280 to 1.320 after charging, consult your local battery service for repair. This is caused mainly from overfilling the battery. Electrolyte boils out when charging and only water is added to refill battery once charging is complete. 27  Module 20 Batteries Performing VOM (load) test With the battery connected to the unit, insert the positive and negative leads from your meter into the battery connection. Raise the mast slightly and tilt forward to the maximum travel and hold for 15 seconds. Watch your meter to see what the voltage drops to. For industrial lead acid batteries, the voltage should not drop below 80% of rated capacity. For example, a 36V battery needs recharge or repair if it drops below 28.8V under load. A 48V battery if it drops below 38.4 it needs recharge or repair. Once a charge is applied you can rerun the same test. If the same drop occurs an individual cell may be the cause of the problem. Test each cell to determine the cell that needs repair or replacement. Contact your local battery service provider to make needed repairs if a cell is deemed bad. To test a battery cell put positive meter lead on one lead connector and the negative lead on the other connector of the cell. The image above shows meter lead location to test one cell of the battery. Each cell should read 2.20 volts per cell fully charged (no load). Under load 2.20 will 28 drop to approximately 2.0 volts. If there is a large voltage drop, this would indicate a potential  Module 20 Batteries Battery maintenance FOLLOW THESE SIMPLE RULES FOR LONG LIFE AND TOP PERFORMANCE. Daily Connect battery to an automatic-start charger. If using manual start, press the start or daily button. After charge and before the work-shift, take a hydrometer reading on a single pilot cell to make certain of a full charge on the battery. Weekly Add pure water to all cells. When the battery is at the end of the charge cycle, top off the water level to approximately 1/4” below the bottom of the vent well. Its also best to provide an Equalize charge on the battery to properly mix the electrolyte and water. Monthly Take a specific gravity reading on all cells with a hydrometer after charge, If the readings average less than the specific gravity of 1.280 to 1.290, check the charger output. If one or two cells read more than 20-points less than the average, circle those readings and check for improvement at the next monthly reading. If the low cells do not improve, contact your local battery representative for service. Also make sure to wipe down the top of the battery with a neutralizing cleaning agent and inspect cable leads and connector for fraying, loose connectors or burned contact areas. 29 Module 20 Batteries Shop Lab Exercise Specific Gravity Readings Load battery Safety Note: Sulfuric acid is a significant component of the electrolyte solution Please use all personal protective equipment (PPE): Glasses Gloves 30  Module 20 Batteries Batteries Review You now know how to: Identify the components of a lead acid battery. Compare an industrial and an automotive battery. Describe the battery charging process. Identify battery-rating characteristics. Explain battery safety factors. Check cell voltage with a volt ohm meter (VOM) load test. Check specific gravity using a hydrometer. Battery maintenance 31  Module 30 AC vs DC 32 Module 30 AC vs DC AC vs DC Objectives In this module we will cover: Identify the differences between AC and DC Understand how AC current is generated from a DC source Which types of current can be stored 33 Module 30 AC vs DC  “DC” stands for “Direct Current” meaning voltage or current that maintains constant polarity or direction over time  “AC” stands for "Alternating Current," meaning voltage or current that constantly changes polarity or direction over time Blade Motion Band Saw (DC) Jigsaw (AC)  The comparison of direct current (DC) to alternating current (AC) may be likened to the comparison of these two saw types. Module 30 AC vs DC AC (Alternating Current)  AC is the most efficient form of electrical power, both in generation and in transmission  For this reason, it is used to transmit power at high voltage across great distances  However, electrical energy can only be stored as DC Module 30 AC vs DC AC (Alternating Current)  To convert high voltages to lower voltages, and vice versa, we use the process of Electro-Magnetic Induction.  The device for converting voltages using induction is called a Transformer.  As the magnetic field in the primary coil dies, it induces a similar magnetic field in the secondary coil Module 30 AC vs DC AC (Alternating Current)  Internal view of a typical household transformer  Common household uses: Computer, PDA, Cordless Phone, Clock Radio Module 30 AC vs DC AC (Alternating Current)  A three-phase AC controller uses six small controllers to create the + and – sides of three separate AC sine waves. Module 30 AC vs DC AC (Alternating Current) Q: How do we get an AC sine wave form from a DC power supply? A: An AC controller uses polarity-switched, pulse width modulated DC to create an “artificial” AC sine wave Battery Voltage Single Phase AC sine wave Module 30 AC vs DC AC (Alternating Current)  In the AC induction motor, the three phase supply (A,B,C) is connected to three sets of field coils.  The three phases create a rotating magnetic field. AC Motor  As the magnetic field rotates, it is “chased” by the rotor. This is the basis for induction motor operation. Module 30 AC vs DC AC (Alternating Current)  AC motor construction tend to be simpler than DC motors.  This translates into greater reliability and lower cost of manufacture. Module 30 AC vs DC DC (Direct Current) What is DC Current? DC stands for Direct Current, although it is often referred to as “DC Current”. DC current is defined as a unidirectional flow of electric charge. In DC current, the electrons move from an area of negative charge to an area of positive charge without changing direction. This is unlike alternating current (AC) circuits where current can flow in both directions. DC current can flow through conducting material like wire and also flow through the semiconductors. 42 Module 30 AC vs DC DC (Direct Current) The battery is the best example of a DC source. In a battery, the electrical energy produced from the chemical energy stored in the battery. When a battery is connected in a circuit, it provides a constant flow of charge from negative to the positive terminal of the battery. A rectifier is used to convert alternating current to direct current. And the inverter is used to convert direct current to alternating current. 43 Module 30 AC vs DC Which way does DC Current Flow? The current is known as the flow of charge or electrons. The direction of the current depends on the direction of the flow of charge. The electrons flow from the negative end of the battery to the positive end of the battery. Then also, the current indicates directions in a direction from positive to the negative end. Benjamin Franklin observed that something moving through the conductor. But at that time, protons and electrons are not discovered. So, he does not know what is moving through the conductor. He assumed that current flow from higher concentration region to lower concentration region. And he called a higher concentration region as positive and lower concentration region as negative. Therefore, the current flows from positive to negative. And this direction is known as the conventional direction of the flow of current. After the invention of electron and proton, it is confirmed that current moves from negative to the positive end of the battery. But still, we are assuming the direction of current as of the conventional method. 44  Module 30 AC vs DC AC vs DC Review You should now know: Identify the differences between AC and DC Understand how AC current is generated from a DC source Which types of current can be stored 45  Module 40 Motors 46 Module 40 Motors Motors Objectives In this module we will cover: What a motor is How a motor operates Different types of motors Which motors are commonly used Motor components Motor maintenance 47  Module 40 Motors Overview What is an Electric Motor? An electric motor (or electrical motor) is an electric machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor’s magnetic field and electric current in a wire winding. This interaction generates a force (as per Faraday’s Law) in the form of torque which is applied to the motor’s shaft. Electric motors can be powered by direct current (DC) sources, such as batteries or rectifiers. Or by alternating current (AC) sources, such as inverters, electric generators, or a power grid. In this module we will look at the different types of electric motors, cover best practices for maintenance and repair, and what components make up an electric motor and how to test them. 48  Module 40 Motors Magnetism Before we look at what makes up an electric motor, lets take a look at the key principle that makes it work. Magnetism is the root of motor operation, here we’ll take a look at how the principals of magnetism affects the motors output. https://electronics.howstuffworks.com/motor.htm Magnetic properties 49 Module 40 Motors Types of Electric Motors A permanent magnet Motor doesn’t have field windings, instead it has permanent magnets surrounding the armature. Only the armature receives current from the power source. This motor will typically found in Steering circuits. Permanent Magnet Motor Module 40 Motors Types of Electric Motors A Series-wound Motor offers excellent starting and stalling torque. They have high torque at low speeds and high speed when low torque is required. The rotating speed for a given voltage depends on the force required to turn the armature shaft against the load. These motors were very common in older lift trucks. They were mainly used for drive and hydraulic pump activation. Series Wound Module 40 Motors Types of Electric Motors A Compound Wound Motor features two sets of field windings never shorted to each other. The purpose of this shunt field is to develop a very strong magnetic field causing slow armature rotation. This motor will basically have a constant speed regardless of the load size or weight. Compound Wound Motor Module 40 Motors Types of Electric Motors The Compound/Series Wound Motor is similar to a compound wound motor except the shunt field windings can be switched on and off allowing precise speed control. More on-time means the slower the vehicle will travel. Compound/Series Wound Motor Module 40 Motors Types of Electric Motors A Series Wound with Shunt Field Motor is basically a series-wound motor with a device to divert current from the field windings, creating a much weaker field. This is known as field weakening, field weakening usually occurs at higher speeds. The rabbit button on walkie riders is a good example of how this works. Series Wound with Shunt Field Module 40 Motors Types of Electric Motors On a SEPEX Motor, the armature is controlled completely separate from the fields giving precise speed and torque when required. The field terminals are usually much smaller than the armature terminals. Separately Excited motors ( SEPEX ) Module 40 Motors Types of Electric Motors AC Motor An AC Motor uses a controller to control the stator of the motor. This stator is made up of three separate phases U, V, W. The rotor is comprised of an iron core that reacts from the pulsing of U, V, W. This is what causes the motor to turn. Torque and Speed are controlled from inputs to the controller from sensors in the system. Then an output signal is sent to the motors to meet the demands.  Module 40 Motors Maintenance Maintenance is key to keeping electric motors working at peak performance. Here we will discuss what is needed to properly maintain an electric motor. Maintenance Activities according to Frequency Frequent checks (3 Months or Less) Clean motor of any dust or oil. Use compressed air to blow out motor, this should be done in a well-ventilated area wearing proper PPE. Visually check for oil and grease from bearings. Technician to examine the starter switch, fuses and tighten loose connections. 57 Module 40 Motors Maintenance Maintenance Activities according to Frequency Every 6 months Check and replace brushes that are more than half worn. Examine brush holders and clean them if dirty. Clean motor, blowing out dirt from windings, and wipe commutator Check and brushes. brush pressure and position. Check operating speed or speeds. Technician to examine and tighten loose connections. Visually check drive, for smooth running, absence of vibration. Check motor foot bolts. 58 Module 40 Motors Maintenance Maintenance Activities according to Frequency Annually Remove and renew grease in ball or roller bearing. Test insulation. Clean out magnetic dirt that may be attached to poles. Check the commutator for smoothness and slot damage. Examine connections of commutator and armature Inspect coils. bands. armature 59 Module 40 Motors Maintenance Conclusi on Electric motors are used in many installations (industrial, commercial and residential), thus they have several important applications that allow the propulsion of trains, automobiles, compressors, pumping systems, etc. For this reason, its maintenance is very important for the operational continuity of the processes carried out since its components wear out and deteriorate according to the volume of work as well as the passage of time. The main reason for preventive maintenance is to reduce the interruption of the service due to corrective maintenance, which is why adequate planning of preventive maintenance is essential in an electric motor. 60 Module 40 Motors AC motor breakdown DC motor breakdown In this section we will cover the components of an AC motor and a DC motor and how to test each type of motor. 61 Module 40 Motors Components and testing Fault zone preventative maintenance on dc motors includes electrical testing and visual inspection of the armature, commutator, brushes and fields. Over the years, people have been performing insulation to ground tests on DC equipment to evaluate the condition of insulation, particularly with regard to moisture and dirt. These parameters are valuable readings when taken under similar conditions at various times. High insulation resistance values do not necessarily indicate high dielectric strength. Insulation that is mechanically damaged may show high resistance values but fail at relatively low dielectric test voltages. Insulation resistance varies inversely to the temperature of the motor. As the temperature increases, resistance will decrease. Approximately 8 to 15°C temperature rise will half the resistance. Checking brushes and commutator condition are very important parts of an effective PM program. The brush face condition can provide valuable insight into the motor operation. The commutator surface condition can also indicate how the motor is reacting to various load and atmosphere conditions. 62 Module 40 Motors Armature Visual inspection of the armature should include the search for cracked or brittle insulation, loose or broken banding, and any dirt or oil contamination. Leakage to ground testing of the armature indicates the relative condition of the insulation. Performing a bar-to-bar resistance check will indicate any shorted windings or defective solder joints at the risers. Infrared inspection of the armature can reveal overheating of the brushes, commutator, as well as loose or hot connections on the risers. The ideal temperature for proper commutation is between 120-140 °F. 63  Module 40 Motors Fields Visual inspection of the field coils will reveal cracked or brittle insulation. Leakage to ground testing provides a general assessment of the insulation condition. The most common method used to check for shorted windings is to perform a drop test. In this test an ac voltage, normally 110 volts, is applied to the field leads. The voltage drop across each field pole is measured with a voltmeter. In a healthy motor, all voltage drops should be equal. Figure above shows a typical leakage to ground profile graph. 64 Module 40 Motors Commutator Commutator film is developed by the chemical reaction that takes place between the copper surface of the commutator, the graphite surface of the brush and the air surrounding both. This film is very delicate and any variation in load or atmosphere can destroy it. Where poor commutation is present excessive physical wear will result on both the commutator and the brushes. The following pages indicate common conditions that contribute to poor commutation. 65 Module 40 Motors Commutator When inspecting the commutator in a motor, look for signs of damage. Frequent visual inspections of commutator surfaces can warn you when any of these conditions are developing so you can take early corrective action. 66  Module 40 Motors Motors Review You are now able to identify: What a motor is How a motor operates Different types of motors Which motors are commonly used Motor components Motor maintenance 67  Module 50 Drive Control 68 Module 50 Drive Control Drive Control Objectives EV-1 from 1996-1999 In this module we will cover: Evolution of electric control systems Curtis Control 2015-Present 69 Module 50 Drive Control EV Drive Control system Drive control has gone through many changes as technology has advanced. In the beginning GE produced the EV-1 control system. This was used in the mid 90’s and later evolved into the EV-100 and the EV-100LX. These systems used many mechanical components to achieve the control needed for use in a forklift. During this period almost every electric forklift manufacture was using this drive control in their products. When trouble shooting use manuals to find testing procedures for items associated with the fault. Some great resources to use are Flight Systems EV troubleshooting or Yale’s EV troubleshooting manual. These two books are what I personally used in the field to repair these type trucks. 70  Module 50 Drive Control Solid-state Drive Control Today's equipment uses all solid-state control With only a few mechanical components to it. These systems took all the components from The old EV systems and now have it all housed in a controller. Curtis, Zappi, GE are a few companies that produce drive control technology. When troubleshooting always reference the most up to date service manual for proper testing procedures. 71  Module 50 Drive Control Drive Controls Review In this module we came to know: Evolution of electric control systems 72  Module 60 CAN-BUS 73 Module 60 CAN-BUS CAN-BUS Objectives In this module we will cover: What CAN-BUS is How to test CAN-BUS Why CAN-BUS is used What uses CAN-BUS 74 Module 60 CAN-BUS What is a Can-Bus CAN Bus (Controller Area Network) is a data line which allows the System? transmission of information between components. Linde Can-Bus consists of 2 wires (Can-Hi and Can-Lo) with paralleled terminating resistors at each end. 2 Can-Bus Can-Bus 2 (internal) LDC—Power module or Engine Systems. Can-Bus 1 (external) LDC--Display—Current Sensor —Diagnostics—Other Controls. What is the measured resistance for a Can- Bus? Each terminating resistor measures 120 ohms. An intact Can-Bus circuit should measure 60 ohms with two terminating resistors. What is the measured Can-Bus voltage? Can-Hi = 2.6v Can-Lo = 2.4v  Module 60 CAN-BUS This illustration shows the layout Of the CAN-BUS networks in a Linde Electric unit.  Module 60 CAN-BUS CAN-BUS Review In this module we covered: What CAN-BUS is How to test CAN-BUS Why CAN-BUS is used What uses CAN-BUS 77  Module 70 Symbols and Schematics 78 Module 70 Symbols and Schematics Symbols and Schematics Objectives In this module we will cover: How to use a schematic for diagnosis and troubleshooting What schematic symbols represent Linde designation numbers Wire color designation How to check voltage How to determine circuit resistance The differences between series and parallel circuits 79  Module 70 Symbols and Schematics Overview This module will cover how to use a schematic for diagnostic and troubleshooting. In this module we will cover what the symbols represent on the unit. We’ll also cover how to understand Linde’s number and letter designation for connectors, components, wire color much more. 80 Module 70 Symbols and Schematics Symbols 81 Module 70 Symbols and Schematics Component Id and Function Number 82  Module 70 Symbols and Schematics Identifying Components Linde Schematics Function Numbers Designations 0- Engine A Units 1- Traction B Sensors 2 –Hydraulic C Capacitors 3- Accessory Drive E Lamps 4- Signal Devices F Fuse 5 –Lighting G Batteries-Starters-Alternators 6 –Display Units H Reporting Device- Horn-BUA 7 –Seat Belt K Relays- Contactors 8 –Mast Positioning L Coils - Inductors 9- Wipers, Air Con, Radio M Motors N Control Units P Display Units Example = 1X1:4 R Resistors 1 = Function Number X = Designation S Switches 1 = Sequential Number :4 = Pin Number T Transformers U Modulators, Inverters, etc 1X1:4 = Traction connector 1 pin 4 V Semi Conductors – Diodes X Plug Connectors Other Examples Y Solenoid Valves 2Y1 – Hydraulic Solenoid Valve # 1 Z Suppressor Circuits 2Y2 – Hydraulic Solenoid Valve # 2 0B2 - Engine Sensor # 2 5K1 - Lighting Relay # 1 6P1 - Display Unit # 1 4H1 – Signal Device Horn # 1 4F1 - Signal Devise Fuse # 1 83 Basic IC and Electric Truck Troubleshooting Procedures Module 70 Symbols and Schematics Connector Pin Layout 84 Module 70 Symbols and Schematics 1B4 = Brake sensor 3X2 = Steer column sensor connector K1 = Contactor Coil Traction 1Y1 = Release solenoid park brake valve A2 = unit hydraulic (LHC) 1X6 = Brake sensor connector controller 3B2 = Steer column sensor 1Y3 = Delayed solenoid park brake valve A:48 = LHC, connector A, pin 48 85 1S2 = Park brake switch Module 70 Symbols and Schematics 86 Module 70 Symbols and Schematics Wire connections 87 Module 70 Symbols and Schematics Total resistance formula. The total resistance in a parallel circuit is found by dividing 1 by each resistor value, then adding all sums together and dividing 1 by the total of all sums. It will be lower than the lowest resistor in the circuit. Example: You have 3 resistors in your circuit, 3,8 and 8 ohm. 1/3=.333, 1/8=.125, and1/8=.125.333+.125+.125=.583 1/.583=1.71 ohms of total resistance. The total resistance in a series circuit is found by adding each resistors value. Example: you have 3 resistors in your circuit, 120,60 and 100 ohm. 120+60+100=280 ohms of total resistance. 88 Module 70 Symbols and Schematics Checking Voltage via Multi-meter 1. Determine where to measure ( Negative or Positive ) Some circuits use battery Negative and other circuits use Component Negative 2. Measure supply voltage. Is it acceptable? 3. If the component being measured has a return signal, measure it. Example: potentiometer in this case has 2 return signals 89  Module 70 Symbols and Schematics Checking Voltage via Multi-meter 1. Unplug Both connectors 2. Check resistance from end to end All Linde wires should measure less than 0.5 ohms from end to end 3. Measure resistance between each wire of the circuit Unless the wires are directly connected. There should be no resistance between the wires of a circuit. ( OL Not 0.0 ) 4. Measure resistance from each individual wire to frame There should be no resistance to frame ( OL Not 0.0 ) The exception is Ground wires on IC trucks ONLY. 90 90 Module 70 Symbols and Schematics Linde Break-Out Box 91  Module 70 Symbols and Schematics Symbols and Schematics Review You can now: Use a schematic for diagnosis and troubleshooting Identify schematic symbols Identify Linde designation numbers Explain Wire color designation Check Voltage with a voltmeter Calculate circuit resistance Explain differences between series and parallel circuits 92  Module 80 Soldering Techniques 93 Module 80 Soldering Techniques Soldering Techniques Objectives In this module we will cover: How to properly use a soldering iron What soldering is What tools are used How to desolder Safety tips to consider when using soldering irons 94  Module 80 Soldering Techniques Overview In this module we will use a hands-on approach to teach soldering techniques for use making repairs to electrical equipment and components. Cover what soldering is, what tools are used, how to de-solder components and safety tips to use when soldering. 95 Module 80 Soldering Techniques Soldering What Is Soldering? If you were to take apart any electronic device that contains a circuit board, you’ll see the components are attached using soldering techniques. Soldering is the process of joining two or more electronic parts together by melting solder around the connection. Solder is a metal alloy and when it cools it creates a strong electrical bond between the parts. Even though soldering can create a permanent connection, it can also be reversed using a de-soldering tool. 96  Module 80 Soldering Techniques Soldering Tools Soldering Tools The good thing about learning how to solder is the fact that you don’t need a lot to get started. Below we’ll outline the basic tools and materials you will need for most of your soldering projects. Soldering Iron A soldering iron is a hand tool that plugs into a standard 120v AC outlet and heats up in order to melt solder around electrical connections. This is one of the most important tools used in soldering and it can come in a few variations such as pen or gun form. For beginners, it’s recommended that you use the pen style soldering iron in the 15W to 30W range. Most soldering irons have interchangeable tips that can be used for different soldering applications. Be very cautious when using any type of soldering iron because it can heat up to 896′ F 97 which is extremely hot.  Module 80 Soldering Techniques Soldering Tools Soldering Station A soldering station is a more advanced version of the basic standalone soldering pen. If you are going to be doing a lot of soldering, these are great to have as they offer more flexibility and control. The main benefit of a soldering station is the ability to precisely adjust the temperature of the soldering iron which is great for a range of projects. These stations can also create a safer workspace as some include advanced temperature sensors, alert settings and even password protection for safety. 98  Module 80 Soldering Techniques Soldering Tools Soldering Iron Tips At the end of most soldering irons is an interchangeable part known as a soldering tip. There are many variations of this tip and they come in a wide variety of shapes and sizes. Each tip is used for a specific purpose and offers a distinct advantage over another. The most common tips you will use in electronics projects are the conical tip and the chisel tip. Conical Tip – Used in precision electronics soldering because of the fine tip. Because of its pointed end, it’s able to deliver heat to smaller areas without affecting its surroundings. Chisel Tip – This tip is well-suited to soldering wires or other larger components because of its broad flat tip. 99 Module 80 Soldering Techniques Soldering Tools Brass or Conventional Sponge Using a sponge will help to keep the soldering iron tip clean by removing the oxidation that forms. Tips with oxidation will tend to turn black and not accept solder as it did when it was new. You could use a conventional wet sponge but this tends to shorten the lifespan of the tip due to expansion and contraction. Also, a wet sponge will drop the temperature of the tip temporarily when wiped. A better alternative is to use a brass sponge as shown below. 100 Module 80 Soldering Techniques Soldering Tools Soldering Iron Stand A soldering iron stand is very basic but very useful and handy to have. This stand helps prevent the hot iron tip from coming in contact with flammable materials or causing accidental injury to your hand. Most soldering stations come with this built in and also include a sponge or brass sponge for cleaning the tip. 101  Module 80 Soldering Techniques Solder Types Solder is a metal alloy material that is melted to create a permanent bond between electrical parts. It comes in both lead and lead-free variations with diameters of.032″ and.062″ being the most common. Inside the solder core is a material known as flux which helps improve electrical contact and its mechanical strength. For electronics soldering, the most commonly used type is lead-free rosin core solder. This type of solder is usually made up of a Tin/Copper alloy. You can also use leaded 60/40 (60% tin, 40% lead) rosin core solder but it’s becoming less popular due to health concerns. If you do use lead solder, make sure you have proper ventilation and that you wash your hands after use. When buying solder, make sure NOT to use acid core solder as this will damage your circuits and components. Acid core solder is sold at home improvement stores and is mainly used for plumbing and metal working. As mentioned earlier, solder does come in a few different diameters. The thicker diameter solder (.062″) is good for soldering larger joints more quickly but it can make soldering smaller joints difficult. For this reason, it’s always a good idea to have both sizes on hand for your different projects. 102 Module 80 Soldering Techniques Solder Types Rosen Core Solder Acid Core Solder 103  Module 80 Soldering Techniques Soldering Aids Helping Hand (Third Hand) A helping hand is a device that has 2 or more alligator clips and sometimes a magnifying glass/light attached. This clips will assist you by holding the items you are trying to solder while you use the soldering iron and solder. A very helpful tool to have in your workspace. 104  Module 80 Soldering Techniques Tinning The Tip Before you can start soldering, you need to prep your soldering iron by tinning the tip with solder. This process will help improve the heat transfer from the iron to the item you’re soldering. Tinning will also help to protect the tip and reduce wear. Step 1: Begin by making sure the tip is attached to the iron and screwed tightly in place. Step 2: Turn on your soldering iron and let it heat up. If you have a soldering station with an adjustable temp control, set it to 400′ C/ 752′ F. Step 3: Wipe the tip of the soldering iron on a damp wet sponge to clean it. Wait a few seconds to let the tip heat up again before proceeding to step 4. Step 4: Hold the soldering iron in one hand and solder in the other. Touch the solder to the tip of the iron and make sure the solder flows evenly around the tip. You should tin the tip of your iron before and after each soldering session to extend its life. Eventually, every tip will wear out and will need replacing when it becomes rough or pitted. 105 Module 80 Soldering Techniques Tinning The Tip 106 Module 80 Soldering Techniques Soldering Safety Soldering Safety Now that you know what tools and materials are required, it’s time to briefly discuss ways of staying safe while soldering. Soldering irons can reach temperatures of 800′ F so it’s very important to know where your iron is at all times. We always recommend you use a soldering iron stand to help prevent accidental burns or damage. Make sure you are soldering in a well-ventilated area. When solder is heated, there are fumes released that are harmful to your eyes and lungs. It’s recommended to use a fume extractor which is a fan with a charcoal filter that absorbs the harmful solder smoke you can visit sites like Integrated Air Systems for air filtration systems. It’s always a good idea to wear protective eye wear in case of accidental splashes of hot solder. Lastly, make sure to wash your hands when done soldering especially if using lead solder. 107  Module 80 Soldering Techniques Soldering Techniques Review In this module we have covered: How to properly use a soldering iron What soldering is What tools are used How to desolder Safety tips to consider when using soldering irons 108  Module 90 Circuit Building 109  Module 90 Circuit Building Circuit Builder Objectives In this module we will use a hands-on approach to construct several different types of circuits. This will be done using different components and a worksheet to construct an array of circuits to gain an understanding on how components work in a circuit. 110  Module 90 Circuit Building Circuit Building Worksheet The purpose of this worksheet is to familiarize students with basic circuits and how to hook up circuits with relays, switches, motors, etc… Following the descriptions below, hook up the circuits (pay attention to the voltage of components) and show the instructor that they work as described, after you finish all the circuits feel free to make you own circuits. Always feel free to ask questions if you are not sure of anything!! Always use the master disconnect switch and fuses 1. Make the motor, fan and buzzer work all together along with two lights, no switch or relays. 2. Make the fan, buzzer and one light work with the switch and one relay. 3. Make the motor and fan work with one relay, the lights work with another relay but have the switch turn on both at the same time. 4. Make the buzzer and fan work with one relay, one light work with another relay, using the switch to activate both, hook the motor up direct. 5. Make the fan work with one relay, the motor work with another relay, using the switch to activate both. Make it so the motor runs as soon as you close the master disconnect switch, but when you close the switch the motor stops and the fan starts. 6. Hook the lights in series; make them work with one relay and the switch. Also make the relay for the lights activate the other relay and make that relay run the fan. 7. Hook the buzzer, motor and fan in series with the switch. What happens when you close the switch? Why?? 8. Hook the motor and fan in series with the switch. Why does the fan run and not the motor? 9. Hook all the lights and the motor in series with the switch. Why does the motor run but the lights do not turn on? 10. Hook the lights, fan and buzzer in a parallel circuit with one relay and the switch. 11. Hook the lights and the fan in a parallel circuit, the motor and buzzer in a parallel circuit, using both relays and the switch to operate both circuits. 12. Hook up all components in a parallel circuit with one relay and the switch. 111  Module 100 Encoder Tester Project 112  Module 100 Encoder Tester Project Encoder Tester Objectives In this module you will: Construct an encoder tester using everything that we have covered this week. Use a schematic to correctly wire the system Use soldering to create good connections Use your creation to test a critical component of AC motors 113  Module 100 Encoder Tester Encoder Schematic Project Here is the schematic to be used in the construction of your encoder tester. Make sure, all connections are soldered and covered with shrink tubing to prevent shorts. Please ask questions if you are having any problems. 114  Module 100 Encoder Tester Project Circuit Builder Review In this module you accomplished: The construction of a tool you can use in your field Using a schematic to correctly wire the system Using soldering to create good connections Verified the quality of your work and put it into use 115 Questions? 116