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