⚡ AC Inverter Settings - Flexi Forklift
Document:
42400-03 Rev A
Date:
18/02/2015
Application:
Flexi VNA/Euro/G4/Himax
Model:
AC3
Function:
Traction Node 2
System Overview
ℹ️ About This Configuration
This document contains the complete AC inverter configuration for Flexi VNA/Euro/G4/Himax forklifts with Schabmuller traction motors. The settings are optimized for a 48V system with 600A RMS maximum current.
Key System Specifications
Battery Voltage
48V
Maximum Current
600A RMS
Motor Power
10 kW
Motor Poles
4
Inverter & Motor Details
| Component | Specification |
|---|---|
| Inverter Model | AC3 |
| Maximum Current | 600A RMS |
| Battery Voltage | 48V |
| Function | Traction Node 2 |
| Flash Version | AC3T2CF CNR1.09 |
| Motor Supplier | Schabmuller |
| Motor Model | TSA240-200-210 |
| Motor Power | 10 kW |
| Motor Poles | 4 |
| Encoder | 80 Pulses/Rev (Traction Motor) |
✅ Configuration Status
This is a complete, tested configuration for Flexi forklift traction applications. All parameters have been optimized for the Schabmuller TSA240-200-210 motor.
Overview
/ Specifications
Complete Specifications
Inverter Specifications
| Parameter | Value |
|---|---|
| Model | AC3 |
| Maximum Current (RMS) | 600A |
| Battery Voltage | 48V |
| Function Type | Traction - Node 2 |
| Flash Version | AC3T2CF CNR1.09 |
Motor Specifications
| Parameter | Value |
|---|---|
| Supplier | Schabmuller |
| Model | TSA240-200-210 |
| Power Rating | 10 kW |
| Number of Poles | 4 |
| Encoder Type | Traction Motor |
| Encoder Resolution | 80 Pulses/Revolution |
Application Details
| Parameter | Value |
|---|---|
| Application Type | Flexi VNA/Euro/G4/Himax |
| Function | Traction Control |
| Node Number | 2 |
| Document Number | 42400-03 |
| Revision | A |
| Date | 18/02/2015 |
Overview
/ Set Option Menu
Set Option Menu
ℹ️ Menu Purpose
The Set Option menu controls fundamental operating modes and features of the inverter. These settings determine how the inverter responds to inputs and manages various control functions.
| Option | Setting | Description |
|---|---|---|
| Display Type | 0 | Display configuration |
| Hour Counter | Seat | Hour meter counts when seat is occupied |
| Battery Check | On | Monitors battery voltage and charge |
| Cutback Mode | Present | Speed reduction feature enabled |
| Hydro Key ON | Off | Hydraulic control from key switch |
| Stop On Ramp | Off | Auto-stop on incline disabled |
| Aux Output #1 | Battery Alert | Auxiliary output configured for low battery warning |
| Pedal Braking | Digital | Brake pedal input type |
| Set Temperature | Analogue | Temperature sensing method |
| Cutback on A12 | On | Speed reduction on input A12 |
| Aux Function | Off | Additional auxiliary function |
| Check Pump Hydro | Off | Hydraulic pump monitoring |
| Battery On Start | Off | Battery check at startup |
Overview
/ Adjustment Menu
Adjustment Menu
⚠️ Calibration Settings
These adjustments calibrate the inverter to the specific potentiometer, battery, and vehicle characteristics. Incorrect settings can affect performance and safety.
Potentiometer Calibration
Set Pot Brk Min
0.4
Set Pot Brk Max
4.5
Throttle 0 Zone
5%
Throttle X Point
45%
Throttle Y Point
25%
Battery Configuration
Set Battery Type
48V
Adjust Battery
Set to batt volt
Custom Adjustments
Adjustment #04
120 Degrees
Adjustment #03
35 Degrees
Adjustment #02
5
Adjustment #01
4
BDI Reset
30%
System Configuration
Load HM from MDI
OFF
Check Up Done
OFF
Check Up Type
NONE
PWM on main cont
Off
PWM on aux cont
Off
Overview
/ Parameter Changes
Parameter Change Menu
ℹ️ About Parameters
These parameters control the operational characteristics of the vehicle including acceleration, braking, speed limits, and timing functions.
Acceleration & Braking Parameters
| Parameter | Value | Description |
|---|---|---|
| Acceleration Delay | 2 | Rate of acceleration increase (level 2) |
| Release Braking | 8 | Braking force when accelerator released |
| Inversion Braking | 6 | Braking force during direction change |
| Pedal Braking | 6 | Braking force from brake pedal |
| Speed Limit Brake | 5 | Braking at speed limits |
| Brake Cut Back | 5 | Reduced braking in cutback mode |
| Maximum Current | 9 | Maximum motor current level (level 9) |
Speed Limit Parameters
| Parameter | Value | Description |
|---|---|---|
| Max Speed Fwd | 155 Hz | Maximum forward speed |
| Max Speed Back | 155 Hz | Maximum reverse speed |
| (Load Height) Cutback Speed | 20% | Speed reduction when load is raised |
| Curve Cutback | 55% | Speed reduction in curves |
| Cutback Speed 2 | 60% | Secondary speed reduction level |
| Creep Frequency | 0.6 Hz | Minimum speed for fine control |
| Backing Speed | 0 Hz | Automatic backing speed (disabled) |
Timing Functions
| Parameter | Value | Description |
|---|---|---|
| Backing Time Level | 0 | Duration of automatic backing (disabled) |
| Aux. Time | 0.8 | Auxiliary function timing |
| Batt Lift Time | 2.0 | Battery lift delay time |
Overview
/ Hardware Settings
Hardware Setting Menu
⚠️ Critical Settings
Hardware settings are fundamental to motor control. Incorrect values can cause poor performance, motor damage, or safety issues. These settings are highlighted in yellow in the original document.
Control Features
Compensation
On
Slip Control
On
DC Link Comp.
On
Frequency Settings
Sat. Frequency
50 Hz
Braking Modulation
50 Hz
Voltage & Boost Settings
Minimum Voltage
3%
Boost at Low Freq.
30%
Boost at High Freq.
50%
Boost Corner Freq.
32 Hz
Braking Booster
0%
Slip Control Parameters
Slip Co-efficient
0
Max Slip Reset
0.6 Hz
Maxslip Low Freq.
1.9 Hz
Maxslip Inc.
2.0 Hz
Maxslip Freq.
20 Hz
Maxslip Freq.Inc.
80 Hz
Options & Compensation
Option 07 level
1
Option 08 level
1
Option 06 level
6
Flux Compensation
50
Aux Voltage #3 level
5
💡 About Highlighted Settings
Settings highlighted in yellow in the original document are critical hardware parameters specific to the Schabmuller TSA240-200-210 motor. These include:
- Saturation Frequency (50 Hz): Motor magnetic saturation point
- Braking Modulation (50 Hz): Regenerative braking frequency
- Boost Settings: Voltage boost at low and high frequencies for proper torque
- Slip Control: Parameters for traction control and wheel slip prevention
Overview
/ Special Adjustments
Special Adjustments Menu
⚠️ Advanced Settings
These are factory-level adjustments that should only be modified by trained technicians. Incorrect values can cause equipment damage.
| Parameter | Value | Status |
|---|---|---|
| Adjustment 1 | 105% | Fixed |
| Adjustment 2 | 104% | Fixed |
| Set Current | 600A | Maximum rated current |
| Set Temperature | Set to ambient | Temperature compensation baseline |
| Aux Output 1 | Level 5 | Auxiliary output configuration |
| Aux Output 2 | Level 8 | Auxiliary output configuration |
ℹ️ Current Setting
The Set Current value of 600A matches the inverter's maximum rating and the motor's continuous current capability. This ensures optimal performance without exceeding equipment limits.
Overview
/ Complete Menu List
Complete Menu Reference
✅ Quick Reference
This section provides all menu settings in a single comprehensive view for quick reference and configuration verification.
Menu: SET OPTION
| Display type | 0 |
| Hour Counter | Seat |
| Battery Check | On |
| Cutback Mode | Present |
| Hydro Key ON | Off |
| Stop On Ramp | Off |
| Aux Output # 1 | Battery Alert |
| Pedal Braking | Digital |
| Set Temperature | Analogue |
| Cutback on A12 | On |
| Aux Function | Off |
| Check Pump Hydro | Off |
| Battery On Start | Off |
Menu: ADJUSTMENT
| Set Pot Brk Min | 0.4 |
| Set Pot Brk Max | 4.5 |
| Set Battery Type | 48V |
| Adjust Battery | Set to batt volt |
| Throttle 0 Zone | 5% |
| Throttle X Point | 45% |
| Throttle Y Point | 25% |
| Adjustment # 04 | 120 Degrees |
| Adjustment # 03 | 35 Degrees |
| Adjustment # 02 | 5 |
| Adjustment # 01 | 4 |
| BDI Reset | 30% |
Menu: PARAMETER CHANGE
| Acceleration Delay | 2 |
| Release Braking | 8 |
| Inversion Braking | 6 |
| Pedal Braking | 6 |
| Speed Limit Brake | 5 |
| Brake Cut Back | 5 |
| Max Speed Fwd | 155 Hz |
| Max Speed Back | 155 Hz |
| (Load Height) Cutback Speed | 20% |
| Curve Cutback | 55% |
| Cutback Speed 2 | 60% |
| Creep Frequency | 0.6 Hz |
| Maximum Current | 9 |
| Backing Speed | 0 Hz |
| Backing Time Level | 0 |
| Aux. Time | 0.8 |
| Batt Lift Time | 2.0 |
Menu: HARDWARE SETTING
| Compensation | On |
| Slip Control | On |
| DC Link Comp. | On |
| Sat. Frequency | 50 Hz |
| Braking Modulation | 50 Hz |
| Minimum Voltage | 3 % |
| Boost at Low Freq. | 30 % |
| Boost at High Freq. | 50 % |
| Boost Corner Freq. | 32 Hz |
| Braking Booster | 0 % |
| Slip Co-efficient | 0 |
| Max Slip Reset | 0.6 Hz |
| Maxslip Low Freq. | 1.9 Hz |
| Maxslip Inc. | 2.0 Hz |
| Maxslip Freq. | 20 Hz |
| Maxslip Freq.Inc. | 80 Hz |
| Option 07 level | 1 |
| Option 08 level | 1 |
| Option 06 level | 6 |
| Flux Compensation | 50 |
| Aux Voltage #3 level | 5 |
Menu: SPECIAL ADJUSTMENTS
| Adjustment 1 | 105% (Fixed) |
| Adjustment 2 | 104% (Fixed) |
| Set Current | 600A |
| Set Temperature | Set to ambient |
| Aux Output 1 | Level 5 |
| Aux Output 2 | Level 8 |
Document 42400-03 Rev A| Date: 18/02/2015
Flexi VNA/Euro/G4/Himax Traction Configuration
Interactive reference created for technician use