1 - BYD ECB Electric Training
1 - BYD ECB Electric Training
1 - BYD ECB Electric Training
Power System
Control System
Traction System
Lifting System
Steering System(Priority valve)
Low Voltage System
Harness System
Electric System working Chart
Power
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wire
Control wire Low Voltage
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Traction Steering
Steering Priority
Lifting
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1. Power System
Power system include the following parts:
Battery Module
Power to the truck.
Battery Management System (BMS)
Check the state of the battery, and control the charging and
discharging of the battery.
Charging System
Charging the battery.
DC/DC Voltage Transfer System
The voltage converter transfer the battery 80V to 12V for the low
voltage system.
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2. Control System
Control system include the following parts:
Controller
Controller is the main part of the truck, it works as a human brain. It receives
the signal of sensors and switches, and turn the driver’s operation command
into the working control of the motor.
Sensors and Feedback System
The system receives the working state and the operator’s command, and
transfer the signal into Volt or Current signal and send to controller.
Display System
The display system is the interface for the driver to read the truck information,
and also the driver can do some menu setting in the display system.
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3. Traction System
Traction motor.
Traction motor transfer the electric power to mechanical power,
and power the traction system.
4. Lifting System
Pump motor.
Pump motor turn the electric power into oil pressure, and push the
mast moving, pressure transfer to kinetic power and potential power.
Provide stable and reliable pressure for the hydraulic system.
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5. Steering System
Steering system is priority steering system, power from the pump
motor.
Hydraulic oil supply to the steering unit through the priority valve,
then priority valve divide the oil to the steering cylinder.
6. Low Voltage System
The low voltage system include the following parts:
Lights
Lights include head light and beam light. Use for illumination and
shows driving signal to other people and driver for safety.
Alarm System
Alarm system include turning light, braking light width light, beacon
and horn. These components use to show the working state to other
person around for safety.
7. Harness
Harness connect all the electric component, is the neural network of
the truck.
2. Electric and control
Power System
ECB units – 80V Battery
One battery module with 12 cells, total voltage about 40V;Two battery
modules series to 80V battery system
Each battery module connect to one Sampling device(BIC),collect the
temperature and voltage information from the battery and send the
information to BMS.(inside one battery pack must pack with one Device 1
and one device 2)
Power System
BMS: monitor the battery status and control charging and discharging.
Current Sensor: measure the current from the positive cable and send to
BMS.
12V main contactor: BMS control the open and close of the contactor.
12V controller contactor: BMS control the contactor, when the contactor
close, 80V to Pin3(Key) of the controller.
Power System
80V/12V DC/DC control logic:
1. Battery permanent 80V to DC/DC.
2. Ignition on, 80V+ to DC/DC, DC output 12V to
the low voltage system.
3. While charging, charger provide 12V to
Charger Relay(KA2), disconnect battery 80V
to DC/DC.
4. Emergency switch off the 80V+ power to
DC(ON/OFF).
5. DC/DC total capacity 300W, left about 100W.
80V Battery
12+
12-
Charging Pot
Ignition
Fuse
12-
Low
12V Output
Voltage
12+
Ignition
Emergency SW
Power System
Power on procedure
Display send
out 0x384
Ignition 80V/12V message.
on BMS power on, Contactor
DC/DC
monitor battery close
output 12V
Display send
Battery
out 0x384
output
message.
80V
Close Pre-charger
controller output Pre-charger
contactor voltage go up charging
to 65V in 5s.
Controller
Fuse
12V Contactor KA1: Controller Contactor
KA2:Charging Relay
Current Sensor
KA3:BMS Relay
Battery
Fuse
On Relay
On Relay
BMS fuse Switch
BMS
T
BIC
V
CAN
Ignition on, 80V+ to 80V/12V DC/DC and output 12V.
DC/DC output 12V to BMS, contactor, display, light, etc.
BMS supply 12V to BIC, BIC collect battery voltage and temperature information.
BMS supply 15V to current sensor, measure circuit current.
BMS analyze the battery information and check if the battery is in good condition or not, also send
battery information to display.
Display send out 0x384 message, BMS close the controller contactor(KA1) and the 12V main
contactor. So 80V to Pin3, enable the controllers.
Power System
Power on procedure
Power System Fuse
Charging Procedure Box
Contactor
Charging Pot
Battery
BMS
Charging Control :
1. Connect to charger, charger supply 12V to Coil of BMS Relay(KA3), KA3 NO terminal close, 12V
power to BMS; KA3 NC terminal open, cut off 12V power to display, MFA and light.
2. BMS collect the battery Volt and Temp information, check if the battery is in good condition, then
close the 12V main contactor, charging allow; If not ok, open the contactor, alarm “Connect bat.”
on the display.
3. Charger supply 12V to the coil of the Charging Relay(KA2), KA2(NC Relay) cut off the battery
80V+ to the 80V/12V DC/DC, so during charging if the ignition on, the DC/DC will not working and
no 12V output to the electric device.
Control System
Controller
Controller is the brain of the truck, receive the signal of the sensors and
switches, supply current to the motor, operate the command from the driver.
Node
Model
Left Middle Right
Main controller close the 80V main contactor, then the controller can perform
the high-power work, supply 53Vac power to the motor.
80V main
contactor
Control System
Pre-Charger
Input cable(Red) and output cable(Yellow) are separately connect to the front
terminal and the rear terminal, the 80V+ from battery box connect to the front
terminal of the contactor, the same point where the pre-charger input cable
connect, 80V+ charge the pre-charger first, if the voltage at pre-charger output
cable(Controller B+) go up higher than 65V in 5s, controller close the 80V main
contactor.
Note: if in 5s, the voltage between B+ and B- lower than 65V, means pre-
charging fail, alarm pre-charging fail on display or red battery light, controller
error code 407 in 0x3011.
Pre-charger
Control System
Pre-charger
Pre-charger help to protect the controllers, when power on, voltage of B+ will go
up smoothly, when higher than 65V in 5s, close the main contactor, not close the
contactor immediately when Pin3 gets 80V+, if not the Spike high voltage will
damage the controllers
Pre-charger
Controller
Fuse
12V Contactor KA1: Controller Contactor
KA2:Charging Relay
Current Sensor
KA3:BMS Relay
Battery
Fuse
On Relay
On Relay
BMS fuse Switch
BMS
T
BIC
V
CAN
Control System
Install extra device and get 80V+ from the 80V main contactor, should connect
to the input cable of the pre-charger where connect to the battery output cable.
Note: if connect to the pre-charger output terminal, before the 80V main
contactor close, if the device is already on, the device will get the power
through the pre-charger, if the current high than the capacity of the pre-charger,
it will damage the pre-charger.
Get the
80V+ from
this terminal
Control System
Cooling fans
Controller is high power consumption component, during working generates a lot of
heating, to avoid that the controller stop working because of high temperature, so
cooling fans mounted on top to blow the air from top to bottom to carry the heat
from the controller.
Fans not working, controller temperature higher than 80℃, limit power output.
Temperature higher than 95℃, cut off the power output.
Overheating alarm, red motor light on display.
Control System-Sensor and Feedback
Basic truck seat (OPS function)
Only when the driver on the seat, the OPS is active, traction and pump function
are allowed.
Control System-Sensor and Feedback
Comfort truck seat (OPS function)
Only when the driver on the seat, the OPS is active, traction and pump function
are allowed.
11. MFA
12. Seat
14. OPS
Control System-Sensor and Feedback
Comfort truck-MFA
● 80V/12V DC/DC converter supply 12V to MFA(PIN1 and PIN2)
Move the fingertip sensor, controller get the analog signal from the fingertip, if
the value is in the active range, the controller running the pump motor and
supply 24V current(0~800mA) to the coil on the E-valve, move the spool and
open the oil-way.
Lifting coil
2Pin connector
2Pin connector
Control System-Sensor and Feedback
Comfort truck
Fingertip signal
0.5~4.5V
DC/DC supply 12V to these switches, operate the lever and activate the lifting,
tilting or side shift switch, 12V to the controller PIN, active the pump function,
running the pump motor pump the hydraulic oil to the cylinders.
Control System-Sensor and Feedback
Basic truck – switch on the manual valve
The sensor mounted on the bottom of the lifting-lowering valve, when pull
the lifting lever, the signal of the sensor will rise, the controller receive the
signal and control the pump motor different speed when the value
change, to lower the consumption.
Control System-Sensor and Feedback
Basic truck
In case that when no driver on the seat and operate the lowering lever, the
mast will lower.
12V lowering
valve
Control System-Sensor and Feedback
Acceleration Sensor – Need Calibration
The acceleration sensor integrate the digital switch and the analog
sensor:
Digital switch: the switch is off in the initial position, press down the pedal, the
switch is activated.
Analog sensor: when the digital switch is on, and the controller will control the
speed of the traction motor depend on the value of the sensor.
Steering Accel
sensor Sensor
Controller
Digital
Switch
Control System-Sensor and Feedback
Steering Sensor – Need Calibration
Steering sensor send the voltage value to the controller, and the controller
calculate the steering angle of the steering axle, and synchronize control the left
and the right traction motors, also limit the maximum speed when in driving in
the corner for safety.
4-wheels truck
3-wheels truck
Control System-Sensor and Feedback
Brake and braking light
Button1
Button2
Button3
Drive Mode
OK Indicate
SOC Direction
Total KM
Speed Mode
Total Hour
Voltage
ECB use KDS 53Vac motor, traction motor and pump motor, the working logic
is the same, only the specification is different.
Encoder
Temp. Sensor
Encoder Wheel
Rotator
Stator
Traction System
Motor and controller connection
Steering Accel
Sensor Sensor
Controller
Accel enable
switch
Traction System
Sensor Measurement
Controller
12V
A
B 0V
Error code
• Encoder:
800 、 801 、 802 、 803 、 804 、
805 、 810 、 811 Ω V
• Temp.
sensor:800 、 801 、 810 、 811
、 600 、 601 、 602 、 603 、 604 Multimeter
万用表
Traction System
Motor Tem. Sensor R-T conversion table (KTY84-150)
Traction System
Encoder – speed sensor
Encoder function:
● feedback the motor speed and direction to the controller.
● two output signals, 90° phase difference.
AC motor encoder is an incremental encoder, commonly used external
plug-in and built-in. it can output two signals with 90° phase difference.
controller counting the motor feedback pulse signal, and calculate the
motor speed; determine the direction of the rotation of the motor by the phase
sequence the two pulse signals.
Lifting System-Steering System
Pump motor
Encoder
Temp. Sensor
Encoder Wheel
Stator Rotator
Low Voltage System – Light and Alarm
Light Switch
Front Light(LED
Basic Truck:
Comfort Truck:
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