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AC-3 FLASH INVERTER - User Manual

1. 600 RMS for 3 Maximum current 96 eti ead ace 450 A RMS for 3 Booster all version 10 of maximum current for some seconds Operating TO QUENCY 8 kHz External temperature range r 30 C 40 Maximum inverter temperature at full power 75 22 Block diagram ADWZPODB AC 3 FLASH INVERTER User Manual Page 7 93 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC 3 FLASH inverters need some external parts in order to work The following devices complete the kit for the AC 3 FLASH installation 3 1 Microswitches The microswitches must have a contact resistance lower than 0 1 ohm and a leakage current lower than 100 pA When full load connected the voltage drop between the key switch contacts must be lower than 0 1 V The microswitches send a voltage signal to the microprocessor when a function request for ex running request is made 3 2 Accelerator unit Page 8 93 The accelerator unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration CPOT A16 Ampseal connector version A11 Amp Saab 29 poles connector version A15 Amp Saab 42 poles connector version A1 Molex Minifit version signal ranges from 0 to 10 V Potentiometer value should be in the 0 5 10 kohm
2. ADWZPODB AC 3 FLASH INVERTER User Manual output the PWM reduces the voltage at the loads on the auxiliary output down to 62 of the battery voltage AUX STOP A7 Amp Saab 29 poles OUTPUT ON A9 Amp Saab 42 poles BEHAVIOUR ON A SLOPE RAMP B9 Minifit A28 Ampseal OUTPUT The truck is electrically hold on a It drives the coil of a slope when the time set by electromagnetic brake auxiliary time parameter is BRAKE ON The hydraulic steering function elapsed the brake is applied and request is sent to the pump the 3 phase bridge is released inverter by the can bus link Do not use this combination if the negative brake is not installed The truck is not electrically hold on a slope but comes down It drives the coil of a very slowly when the time set electromagnetic brake by auxiliary time parameter is BRAKE OFF The hydraulic steering function elapsed the brake is applied request is sent to the pump and the 3 phase bridge is inverter by the can bus link opened Do not use this combination if the negative brake is not installed It drives the coil of a hydraulic The truck is electrically hold on a HYDRO steering contactor slope when the time set by CONT ON The hydraulic steering function auxiliary time parameter is request is also sent to the pump elapsed the truck comes down inverter by the can bus link very slowly till the flat is reached It drives the coil of a hydraulic HYDRO OFF
3. Accelerator potentiometer positive 10 V output keep load gt 1 kO SEAT input it must be connected to the SEA T microswitch it is active high Forward direction request input It must be connected to the forward direction microswitch active high Backward direction request input It must be connected to the backward direction microswitch active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function PB SR HB input It must be connected to the exclusive hydro microswitch or to the accelerator enable switch Active high see also OPTION chapter Brake request input It must be connected to the brake pedal switch active high Speed reduction handbrake input Active low switch opened See also OPTION chapter BACKING FORW Inching function forward direction input It must be BACKING BACK SAFETY ENC A ENC B NPOT CPOT CANT CAN H CANL NPOTB CPOTB connected to the inching forward switch Active high Inching function backward direction input It must be connected to the inching backward switch Active high If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Phase A of encoder Phase B of encoder Negative of accelerator unit tested for wire disconnection diagnosis Accelerator potentiometer wiper CAN termination connect to CAN H A18 to insert can termination resistance High level CAN BUS volta
4. Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 4 Set the MAXIMUM CURRENT Current using the table on Chapter 8 5 1 Set the Acceleration Delay requirements for the machine Test the parameters in both directions Set the FREQUENCY CREEP level starting from level 0 6 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly Set the Speed Reductions as required Make adjustments to SPEED Check the performance with the accelerator pedal totally depressed If the machine is a forklift check the performance with and without load ADWZPODB AC 3 FLASH INVERTER User Manual Page 71 93 9 RELEASE BRAKING Operate the machine at full speed Release the accelerator pedal Adjust the level to your requirements If the machine is a forklift check the performance with and without load 10 INVERSION BRAKING Operate the machine at 2596 full speed Whilst travelling INVERT the Direction Switch Set a soft Level of Inversion Braking When satisfactory operate the machine at Full Speed and repeat If the machine is a Forklift repeat the tests and make adjustments with and without load The unlade full speed condition should be the most representative condition 11 PEDAL BRAKING If used Operate the machine at full Speed Release the accelerator pedal and press the Pedal Brake Set braking leve
5. TESTER 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the MOTOR VOLTAGE Display 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display 9 When you have finished Press OUT 10 The Display shows 11 Press OUT again and return to Opening Zapi Display MAIN MENU TESTER Remember it is not possible to make any changes using TESTER All you can do is measure as if you were using a pre connected multimeter Page 76 93 ADWZPODB AC 3 FLASH INVERTER User Manual 9 OTHER 9 1 Description of Console SAVE function The SAVE function allows the operator to transmit the Parameter values and Configuration data of the controller into the Console memory It is possible to load 16 different programmes The information saved in the Console memory can then be reloaded into another inverter using the RESTORE function The data that is available via the SAVE function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The Level of the Battery ADJUST BATTERY Flow Chart showing how to use the SAVE function of the Digital Console ZAPI VD D 550A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu 2 5 MAIN MENLI 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until SAVE PARAM appear
6. ADWZPODB AC 3 FLASH INVERTER User Manual Page 47 93 7 4 Connection drawing Combi configuration 7 4 4 Ampseal and Molex Spox connectors AM KEY NCHRONOUS LOGIC 5 BOARD 8 5 lt 2 lt mmi EA TEMP SENSOR CONSDLE L azp E CAN A7 7 SAFETY 7 MODE CONSOLE AUX CO Page 48 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 4 2 Amp Saab 29 poles connector 7 E I LT Y L 7 1 1 Y ADWZPODB AC 3 FLASH INVERTER User Manual Page 49 93 7 4 3 Amp Saab 42 poles connector A K iA 2 7 M 7 7 gt c Tec Y 7 7 7 7 7 7 5 7 Y N et Page 50 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 4 4 Minifit connectors f BACKIN 7 7 KV 7 Y 7 v 7 7 7 Y 7 3 7 2 SR A Mo 4 7 ADWZPODB AC 3 FLASH INVERTER User Manual Page 51 93 8 PROGRAMMING amp AD
7. encoder with differential output A14 A22 A32 E5 B phase B of encoder A23 A19 E6 B phase B inverted encoder with differential output ADWZPODB AC 3 FLASH INVERTER User Manual Page 15 93 2 Connection of encoder with differential outputs 5 V power supply Minifit connectors 3 Connection of encoder with open collector output 5 V power supply Minifit connectors w 4 Connection of encoder with open collector output 12 V power supply Minifit connectors VERY IMPORTANT It is necessary to specify to Zapi in the controller order the type of encoder used in terms of power supply electronic output and n of pulses for revolution because the logic unit must be set in the correct way by Zapi 4 2 6 Main contactor and key connection The connection of the main contactor can be carried out following the drawing in the figure 16 93 ADWZPODB AC 3 FLASH INVERTER User Manual connection of the battery line switches must be carried out following ZAPI instructions If a mechanical battery line switch is installed it is necessary that the key supply to the inverter is open together with power battery line if not the inverter may be damaged if the switch is opened during a regenerative braking An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes 4096 more than the battery nominal voltage or if the key is switched o
8. 1st SPEED 2nd SPEED 3rd SPEED 4th SPEED HYDRO SR microswitches Connected to the power supply through a microswitch CH with a 10 A fuse in series If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Batt Lift potentiometer wiper Negative of lift potentiometer tested for wire disconnection diagnosis Free analog input used for auxiliary potentiometer Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output This input allows the customer to select the software for traction or lifting application Configuration MODE Open not connected Traction inverter MODE Close connected with A6 Pump inverter Input for potentiometer lifting enable input it is active HIGH Input for first speed request it is active HIGH Input for third speed request it is active HIGH Input for hydraulic steering request Active high Speed reduction input Active low switch opened This is a digital input free for customer request ADWZPODB AC 3 FLASH INVERTER User Manual A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 ADWZPODB AC 3 FLASH INVERTER User Manual 4th SPEED 2nd SPEED 12V 5V ENC GND ENC A ENC B CANT CANL CANH PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH Input for fourth speed request it is active HIGH Input
9. Active high Inching function backward direction input It must be connected to the inching backward switch Active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function KEY PLC PBRAKE SEAT SAFETY PTHERM CM NLC NBRAKE SR HB GND NTHERM input It must be connected to the exclusive hydro microswitch or to the accelerator enable switch Active high see also OPTION chapter Connected to the power supply through a microswitch CH with a 10 A fuse in series Positive of main contactor coil Positive of the electromechanical brake coil SEAT input it must be connected to the SEAT microswitch it is active high If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Input for motor temperature sensor Common of SR PB SEAT microswitches Negative of main contactor coil Output for driving a brake or an hydraulic steering contactor coil it drives the load to Batt maximum current 3 A Speed reduction handbrake input Active low switch opened See also OPTION chapter Batt Batt ADWZPODB AC 3 FLASH INVERTER User Manual Page 29 93 C1 CAN L Low level CAN BUS voltage I O C2 CAN L OUT Low level CAN BUS voltage I O C3 CAN H High level CAN BUS voltage I O C4 CAN H OUT High level CAN BUS voltage I O D1 Batt D2 MODE This input allows the customer to select the software for traction or li
10. Areal undervoltage overvoltage situation happened B Fault in the hardware section of the logic board which manages the overvoltage protection Replace the logic card LOGIC FAILURE 2 Fault in the hardware section of the logic board which manages the phase s ADWZPODB AC 3 FLASH INVERTER User Manual voltage feedback Replace the logic board 5 LOGIC FAILURE 3 Fault in the hardware section of the logic board which manages the hardware current protection Replace the logic board 6 INCORRECT START This alarm signals an incorrect starting sequence Possible causes A running microswitch failure B error in sequence made by the operator C incorrect wiring D ifthe default persists replace the logic 7 ENCODER ERROR Two consecutive readings of the encoder speed are too much different in between because of the inertia of the system it is not possible the encoder changes its speed a lot in a short period Probably an encoder failure has occurred e g one or two channels of the encoder are corrupted or disconnected Check both the electric and the mechanical encoder functionality Also the electromagnetic noise on the sensor bearing can be a cause for the alarm 8 CAPACITOR CHARGE Follows the charging capacitor system When the key is switched ON the inverter tries to charge the capacitors through a power resistance and check if the capacitors are charged within a timeout If this is not true an alarm is signalled the
11. LIFT ENABLE 1st SPEED HYDRO REQ SR ENCODER ENCODER ENCODER ENCODER MODE SAFETY 3rd SPEED DIG IN 2nd SPEED 4th SPEED Lift potentiometer positive 10 V output keep load gt 1 Batt Input for motor temperature sensor Batt Battery negative This output can be used for drive the main contactor coil single pump configuration or to drive an auxiliary load combi configuration Output for driving an hydraulic steering contactor coil it drives the load to Batt maximum current 3 A Positive of the auxiliary output Common of LIFT ENABLE 1st SPEED 2nd SPEED ard SPEED 4th SPEED HYDRO SR microswitches Connected to the power supply through a microswitch CH with a 10 A fuse in series Lift potentiometer wiper input Negative of lifting potentiometer tested for wire disconnection diagnosis Free analog input High level CAN BUS voltage I O Low level CAN BUS voltage I O Input for potentiometer lifting enable input it is active HIGH Input for first speed request it is active HIGH Input for hydraulic steering request Active high Speed reduction input Active low switch opened Incremental ENCODER connector see chapter 4 2 5 Incremental ENCODER connector see chapter 4 2 5 Incremental ENCODER connector see chapter 4 2 5 Incremental ENCODER connector see chapter 4 2 5 This input allows the customer to select the software for traction or lifting application
12. This parameter determines the motor temperature level at which the Motor temperature alarm is signalled The range is from 70 to 160 with 10 steps This parameter must be adjusted only if the Set temperature menu Set option parameter is programmed Analog 9 ADJUSTMENT 03 This parameter isn t used 10 ADJUSTMENT 02 It adjusts the lower level of the battery discharge table 11 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table 12 FROM For explanation of this point see the instrument handbook 13 CHECK UP DONE Turn it On when the asked Maintenance service has been executed to cancel the CHECK UP NEEDED warning 14 CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEEDED warning OPTION 1 CHECK UP NEEDED warning on the hand set after 300 Page 58 93 ADWZPODB AC 3 FLASH INVERTER User Manual hours OPTION 2 Equal to OPTION 1 but performances are reduced down to 50 after 340 hours OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 15 PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the main contactor coil ON the PWM reduces the voltage at the loads on the main contactor coil down to 6296 of the battery voltage 16 PWM ON AUX OUT OFF the inverter applies the battery voltage to the loads on the auxiliary
13. 1 Traction The following parameters can be modified 1 ACCELERATION DELAY It determines the acceleration ramp 2 RELEASE BRAKING It controls the deceleration ramp when the travel request is released 3 INVERS BRAKING It controls the deceleration ramp when the direction switch is inverted during travel 4 PEDAL BRAKING It determines the deceleration ramp when the travel request is released and the brake pedal switch is closed 5 SPEED LIMIT BRK Deceleration ramp when the pedal position is changed but not completely released 6 BRAKE CUTBACK It determines the deceleration ramp when the speed reduction input becomes active and the motor slow down 7 MAX SPEED FORW It determines the maximum speed in forward direction 8 SPEED BACK It determines the maximum speed in backward direction 9 CUTBACK SPEED Speed reduction when the cutback switch is active 10 CURVE CUTBACK Determines the speed reduction in curve only if the eps is present 11 FREQUENCY CREEP Minimum speed when the forward or reverse switch is closed but the accelerator is on a minimum position 12 MAXIMUM CURRENT This parameter changes the maximum current of the inverter 13 BACKING SPEED It determines the speed in inching function 14 BACKING TIME It determines the time of the inching function 15 AUXILIARY TIME It determines the time that the truck is hold on the ramp if the stop on ramp option is ON The following table shows the different values
14. AC 3 FLASH INVERTER User Manual Contents 1 INTRODUCTION isiin 6 2 SPEGIEIGATION 7 2 1 Technical SSC 7 2 2 Block MAI ANI 7 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 8 3 1 Microswitches 8 3 2 Accel rator a EO TOSS 8 33 Other analog Control 9 34 Speed oce 9 4 INSTALLATION HINTS bee 11 4 1 Material M T 11 411 Connection cables nn 11 UTE 11 41 3 11 4 2 Installation of the 12 4 2 1 Positioning and cooling of the controller 12 42 2 Wings power Cablee 12 4 2 3 Wirings CAN connections and possible interferences 13 4 2 4 X Wirings connections a 15 4 2 5 Connection of the encoder 44000 15 4 2 6 Main contactor and key 16 4 2 7 X Insulation of truck 17
15. Configuration MODE Open not connected Traction inverter MODE Close connected with A5 Pump inverter If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Input for third speed request it is active HIGH This is a digital input free for customer request Input for second speed request it is active HIGH Input for fourth speed request it is active HIGH Da DH Page 33 93 6 2 3 Amp Saab 42 poles connector Page 34 93 A1 A2 4 5 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 PPOT BATT PPOT AUX MOT TH NTHERM BATT NAUX PAUX NHYDRO PHYDRO CM KEY SAFETY BATT CPOT NPOT AN IN MODE LIFT ENABLE 151 SPEED 3rd SPEED HYDRO REQ SR DIG IN Lift potentiometer positive 10 V output keep load 1 Batt Auxiliary potentiometer positive 10 V output keep load gt 1 Input for motor temperature sensor Batt Batt This output can be used to drive the main contactor coil single pump configuration or to drive an auxiliary load combi configuration Positive of the auxiliary output Output for driving an hydraulic steering contactor it drives the load to Batt Maximum current 3 A Positive for the hydraulic steering contactor Common of LIFT ENABLE
16. High level CAN BUS voltage I O A36 PCLRXD Positive serial reception A37 NCLRXD Negative serial reception A38 PCLTXD Positive serial transmission A39 NCLTXD Negative serial transmission A40 GND Negative console power supply 41 12 Positive console power supply A42 FLASH It must be connected to A41 for the Flash memory programming Page 28 93 ADWZPODB AC 3 FLASH INVERTER User Manual 6 1 4 Molex Minifit connectors A1 A2 4 5 A7 8 9 10 11 12 13 14 1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 CPOT PPOT NPOT CM FORW BW PB CPOTB PPOTB NPOTB BATT BACK FORW BACK BACK Accelerator potentiometer wiper Potentiometer positive 10 V output keep load gt 1 KQ Negative of accelerator unit tested for wire disconnection diagnosis Common of FW BW BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches Forward direction request input It must be connected to the forward direction microswitch active high Backward direction request input It must be connected to the backward direction microswitch active high Brake request input It must be connected to the brake pedal switch active high Brake potentiometer wiper Brake potentiometer positive 10 V output keep load gt 1 Batt Batt Inching function forward direction input It must be connected to the inching forward switch
17. OUTPUT KO The uP checks the driver of the electromechanical brake If the status of the driver output does not correspond to the signal coming from the uP the alarm is signalled Replace the logic 20 HIGH TEMPERATURE Controller temperature is greater than 75 The maximum current is reduced proportionally to the temperature increase The controller stops at 100 If the alarm is signalled when the controller is cold A check the wiring of the thermal sensor B thermal sensor failure C logic failure 21 MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal overtakes the cut off level If it happens when the motor is cold check the wiring If all is ok replace the logic board 22 THERMIC SENSOR KO The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range When this alarm is signalled check the connection of the sensors 23 MOT TH SENSOR KO The range of motor temperature sensor is always checked and a warning is signalled if it is out of range When this alarm is signalled check the connection of the sensors 24 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this link depends on the software version It is signalled if the inverter does not receive any message from the CAN BUS line First of all check the wiring If itis ok the problem is on the logic board which must b
18. chapter 4 2 5 F1 PCLRXD Positive serial reception F2 NCLRXD Negative serial reception PCLTXD Positive serial transmission F4 NCLTXD Negative serial transmission F5 GND Negative console power supply F6 12 Positive console power supply F7 FLASH It must be connected to F8 for the Flash memory programming F8 FLASH It must be connected to F7 for the Flash memory programming ADWZPODB AC 3 FLASH INVERTER User Manual Page 37 93 63 Description of power connections View of the power bars I BATI fo 1 Negative of the battery Positive of the battery U V W Connection bars of the three motor phases follow this sequence and the indication on the motor Page 38 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 DRAWINGS F Mechanical drawing Optional Power Fuse i Y c r ay XO 7 JS f 4 x c Z s V Ss 2 E US amp Y 82 1 lt n 1 gt s fu 300 ADWZPODB AC 3 FLASH INVERTER User Manual Page 39 93 2 Connection drawing Tractio
19. charging phase s voltages contactor drives can bus interface if the switch sequence for operation is correct and if the output of accelerator unit is correct ADWZPODB AC 3 FLASH INVERTER User Manual Page 21 93 2 Standby diagnosis in stby that checks watchdog circuit phase s voltages contactor driver current sensor can bus interface 3 Diagnosis during operation that checks watchdog circuits contactor driver current sensors can bus interface 4 Continuous diagnosis that check temperature of the inverter motor temperature Diagnosis is provided in two ways The digital console can be used which gives a detailed information about the failure the failure code is also sent on the Can Bus Page 22 93 ADWZPODB AC 3 FLASH INVERTER User Manual 6 DESCRIPTION OF CONNECTORS 6 1 Connectors of the logic Traction configuration The AC 3 FLASH has been designed to be produced with four different types of connector an AMPSEAL 35 poles connector together a MOLEX SPOX 8 poles connector used to connect the Console one AMP SAAB 29 poles connector one AMP SAAB 42 poles connector or six Molex Minifit connectors 6 1 1 Ampseal and Molex Spox connectors A1 A2 4 5 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 12 5V GND FORWARD BACKWARD Positive of encoder power supply Negative of encoder power supply
20. for second speed request it is active HIGH Positive of encoder power supply Negative of encoder power supply Phase A of encoder Phase B of encoder CAN termination connect to CANH A35 to insert can termination resistance Low level CAN BUS voltage I O High level CAN BUS voltage I O Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to A41 for the Flash memory programming Page 35 93 6 2 4 Molex Minifit connectors Page 36 93 A1 A2 4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 C1 C2 C3 C4 CPOT PPOT NPOT CM LIFT ENABLE 151 SPEED 3rd SPEED AN IN PPOT AUX HYDRO REQ SR DIG IN KEY PAUX PHYDRO 4th SPEED SAFETY PTHERM CM NAUX NHYDRO 2nd SPEED GND NTHERM CAN L CAN L OUT CAN H CAN H OUT Lift potentiometer wiper Lift potentiometer positive 10 V output keep load gt 1 Negative of lift potentiometer tested for wire disconnection diagnosis Common of LIFT ENABLE 1st SPEED 3rd SPEED HYDRO SR microswitches Input for potentiometer lifting enable input it is active HIGH Input for first speed request it is active HIGH Input for third speed request it is active HIGH Free analog input u
21. main contactor is not closed Possible reasons A check if the charging resistance is opened B The charging circuit has a failure C There is a problem on the power modules 9 VMN LOW VMN HIGH The test is carried out during initial diagnosis and in standby Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor towards ground B controller failure replace it 10 PEDAL WIRE KO This alarm is signalled if a fault is detected in the accelerator wiring NPOT or PPOT cable is interrupted 11 VACC NOT OK The test is made in standby This alarm indicates that the accelerator voltage is 1 V greater than the minimum value programmed by the PROGRAM VACC function Possible causes A the potentiometer is not correctly calibrated ADWZPODB AC 3 FLASH INVERTER User Manual Page 89 93 B the potentiometer is defective 12 STBY HIGH Test carried out in standby Check if the current is O If not verified an alarm is signalled which inhibits machine operations Possible causes A current sensor failure B logic failure first replace the logic if the defect persists replace the power unit 13 SEAT KO This alarm is present in combi systems traction pump The pump compares the status of the seat input with the value transmitted by the traction via CAN BUS The alarm is signalled if the two values a
22. not responsible for any problem that arises from wiring methods that differ from information included in this Manual During periodic checks if a technician finds any situation that could cause damage or compromise safety the matter should be bought to the attention of a Zapi Agent immediately The Agent will then take the decision regarding operational safety of the machine Remember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER ADWZPODB AC 3 FLASH INVERTER User Manual Page 93 93
23. of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 12 3RD SPEED SWITCH Status of the third speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 13 4TH SPEED SWITCH Status of the fourth speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 14 HYDRO SPEED REQ Status of the hydro speed request of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 15 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 16 VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition it is expressed in a percentage of the full voltage 17 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 18 BATTERY CHARGE The percentage Charge level of the battery ADWZPODB AC 3 FLASH INVERTER User Manual Page 75 93 Flow Chart showing how to use the TESTER function of the Digital Console Yom ZAPI VD D 1 Opening Zapi Display 2 Press ENTER to go into the General menu MAIN 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until mug TESTER MENU appear on the display goa 5 The Display shows
24. power supply Positive console power supply It must be connected to B8 for the Flash memory programming It must be connected to B7 for the Flash memory programming ADWZPODB AC 3 FLASH INVERTER User Manual 6 1 2 Amp Saab 29 poles connector A1 A2 4 5 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 ADWZPODB AC 3 FLASH INVERTER User Manual PPOT NPOTB PTHERM NTHERM PLC CM KEY CPOT NPOT CPOTB CAN H CAN L FORW BW BACK FORW BACK BACK ENCODER ENCODER ENCODER ENCODER MODE SAFETY PB Accelerator and brake potentiometers positive 10 V output keep load 1 kO Batt Input for motor temperature sensor Batt Battery negative Negative of main contactor coil Output for driving a brake or an hydraulic steering contactor coil it drives the load to Batt maximum current 3 A Positive of main contactor coil Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches Connected to the power supply through a microswitch CH with a 10 A fuse in series Accelerator potentiometer wiper Negative of accelerator unit tested for wire disconnection diagnosis Brake potentiometer wiper High level CAN BUS voltage Low level CAN BUS voltage I O Forward direction request input It must be connecte
25. the battery discharge calculation for the complete system is carried out by the traction inverter the information about the pump inverter consumption is sent on the can bus line from the pump inverter to the traction inverter So the correct programming for the Battery check option is traction inverter ON pump inverter OFF 3 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected to Minifit A3 Amp Saab 29 poles A4 Amp Saab 29 poles A25 Ampseal input ANALOG analog motor thermal sensor 84 is connected between B6 and B12 Minifit A3 and A4 Amp Saab 29 poles A4 and A5 Amp Saab 42 poles A24 and A25 Ampseal the curve can be customized on a customer request NONE no motor thermal sensor switch is connected SUBMENU ADJUSTMENTS 1 SET BATTERY TYPE It selects the nominal battery voltage 2 ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller 3 THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve see also curve below 4 THROTTLE X POINT This parameter changes the characteristic of the accelerator input curve 5 THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve ADWZPODB AC 3 FLASH INVERTER User Manual gt gt gt gt VACC MIN and are values programmable by the Program Vacc function 6 ADJUSTMENT 04 This parameter dete
26. 1 WATCH DOG The test is made in both running and standby It is a self diagnosing test within the logic If an alarm should occur replace the logic 2 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ON again replace the logic If the alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values 3 LOGIC FAILURE 1 This alarm signals that an undervoltage overvoltage protection operation has occurred Two possible reasons A Areal undervoltage overvoltage situation happened B Fault in the hardware section of the logic board which manages the overvoltage protection Replace the logic card ADWZPODB AC 3 FLASH INVERTER User Manual 4 5 6 7 8 9 10 11 LOGIC FAILURE 2 Fault in the hardware section of the logic board which the phase voltage feedback Replace the logic board LOGIC FAILURE 3 Fault in the hardware section of the logic board which manages the hardware current protection Replace the logic board CHECK UP NEEDED This is a warning It is an information for the user that the programmed time for maintenance is elapsed INCORRECT START This alarm signals an incorrect starting sequence Possible causes A running microswitch failure B error in sequence made by t
27. 3 Wirings connections and possible interferences CAN stands for Controller Area Network It is a communication protocol for real time control applications CAN operates at data rate of up to 1 Megabits per second It was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic modules of a vehicle connected as illustrated in this image CAN Controller Transceiver 12052 The best cable for can connections is the twisted pair if it is necessary to increase the immunity of the system to disturbances a good choice would be to use a cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded n a system like an industrial truck where power cables carry hundreds of Ampere there are voltage drops due to the impedance of the cables and that could cause errors on the data transmitted through the can wires In the following figures there is an overview of wrong and right layouts of the cables routing Wrong Layout Module 3 The red lines are can wires The black boxes are different modules for example traction controller pump controller and display connected by canbus The black lines are the power cables ADWZPO0DB AC 3 FLASH INVERTER User Manual Page 13 93 14 93 This is apparently a good layout but can bring to errors in the c
28. 43 Protection and safety features a 17 4 3 1 Protection 4404424441 4 0 nennen nennen entren 17 4 3 2 AZ 00 M 18 sbs 18 45 Various suggestions eT C 20 5 OPERATIONAL FEATURES 21 5 1 ici m RI M 21 6 DESCRIPTION OF CONNEGTORBDB 23 6 1 Connectors of the logic Traction configuration 2 23 6 1 1 Ampseal and Molex Spox connectors a 23 6 1 2 Amp Saab 29 poles 25 6 1 3 Amp Saab 42 poles connectlor 0 27 6 1 4 Molex Minifit connectors 29 6 2 Connectors of the logic Pump 31 6 2 1 Ampseal and Molex Spox 31 6 2 2 Saab 29 poles connector 33 6 2 3 Saab 42 poles connector a 34 6 2 4 Molex Minifit connectors nr 36 6 3 Description of power 38 f DRAWINGS 39 7 1 Mechanical drawing 39 7 2 Conn
29. ENLI PROGRAM VAGG 15 When finished the Console shows 16 Press OUT again to return to the Opening Zapi Menu ADWZPODB AC 3 FLASH INVERTER User Manual Page 83 93 10 AC 3 FLASH DIAGNOSTIC TRACTION CONFIGURATION The alarms are signalled by a diagnostic LED 1 blink 2 blinks 3 blinks 4 blinks 5 blinks 6 blinks 7 blinks 8 blinks long blink no blink logic failure NATCHDOG EEPROM KO LOGIC FAILURE 1 LOGIC FAILURE 2 LOGIC FAILURE 3 CHECK UP NEEDED running request on start up or error in seat sequence double direction request or encoder problem INCORRECT START HANDBRAKE FORW BACK ENCODER ERROR phase voltage or capacitor charge failure CAPACITOR CHARGE VMN LOW VMN HIGH failure in accelerator VACC NOT OK PEDAL WIRE KO PEDAL FAILURE failure of current sensor STBY HIGH DATA ACQUISITION failure of contactor driver SOIL SHORTED DRIVER SHORTED CONTACTOR DRIVER AUX OUTPUT KO CONTACTOR OPEN CONTACTOR CLOSED excessive temperature HIGH TEMPERATURE MOTOR TEMPERATURE THERMIC SENSOR KO MOT TH SENSOR KO failure of can bus or problem in the SAFETY circuit CAN BUS KO SAFETY SAFETY KO discharge battery or wrong battery voltage LOW BATTERY WRONG SET BATT problem in a remote module WAITING FOR NODE 10 1 Analysis of alarms displayed on console Page 84 93
30. GITA ANALOG DIGITAL NONE ON OFF PRESENT ABSE ON OFF ADJUSTMENTS SET POT SET 20 VACC SETTING MIN MAX NOT AVAILABLE SET BAT THROTTLE THROTTLE ADJUST ADJUST LOAD HM CHECK CHECK U PWM O ADJUST BATTERY THROTTLE 1 ADJUSTME ADJUSTME UP BR 0 FROM MD DONE gt TYPI MAIN CONT PWM ON AUX OUT 24 36 48 72 80 96V ON O ON OFF NONE OPTION ON OFF ON OFF 1 2 ADWZPODB AC 3 FLASH INVERTER User Manual OR EXCLUSIVE HYDRO BRAKE 8 3 2 Pump configuration HEADING MAIN MENU C lt DELAY 0 9 SET MODEL CONNECTED TO 0 255 DECELER DELAY 0 9 Lo MAX SPE gt Hz Hz EED FINE ED FINI SET OPTIONS HOUR COUNTER RUNNING KEYON 4TH SPEED BATTERY CHECK ON OFF HYD SPEED FINE SET TEMPERATURE DIGITAL ANALOG NONE MAXIMUM CURRENT AUXILIARY TIME TESTER MOTOR VOLTAGE STMENTS SET BATTERY TYPE 24 36 48 72 80 96V FREQUENCY Hz ADJUST BATTERY V ENCODER Hz THROTTLE 0 ZONI SLIP VALUE Hz THROTTLE X POINT CURRENT RMS A Y POINT TEMPERATURE ADJUSTMENT 04 OR TEMPERAT ADJUSTMENT 03 ADJUSTMENT 0 9 ON OFF ADJUSTMENT 01 0 9 CH LOAD HM FROM ON OFF 2ND SPEED CH ON OI ON CONT ON OFF 3RD SPEED N OI PWM ON AUX
31. ING F Status of the inching function forward direction input VB active entry of closed switch OFF GND non active entry of open switch 14 BACKING B Status of the inching function backward direction input ON VB active entry of closed switch OFF GND non active entry of open switch 15 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF non active entry of microswitch 16 BRAKE SWITCH The level of the Pedal Brake Microswitch ON VB active entry of Brake pedal Microswitch OFF GND active entry of microswitch 17 EXCLUSIVE HYDRO Status of the exclusive hydro input VB active entry of closed switch OFF GND non active entry of open switch 18 BRAKEPEDAL POT The percentage of the pressure on the brake pedal 100 if the pedal is totally pressed 096 if the pedal is released 19 HAND BRAKE The level of the Handbrake Microswitch ON GND active entry of Handbrake Switch open switch OFF VB non active entry of microswitch closed switch 20 VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition it is expressed in a percentage of the full voltage 21 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 22 BATTERY CHARGE 1 2 3 4 5 6 7
32. ISSIONS Three ways can be followed to reduce the emissions A SOURCE OF EMISSIONS finding the main source of disturb and work on it B SHIELDING enclosing contactor and controller in a shielded box using shielded cables C LAYOUT a good layout of the cables can minimize the antenna effect cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level ADWZPODB AC 3 FLASH INVERTER User Manual Page 19 93 2 ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid also for immunity Additionally further protection can be achieved with ferrite beads and bypass capacitors ELECTROSTATIC IMMUNITY Three ways can be followed to prevent damages from ESD A PREVENTION when handling ESD sensitive electronic parts ensure the operator is grounded test grounding devices on a daily basis for correct functioning this precaution is particularly important during controller handling in the storing and installation phase B ISOLATION use anti static containers when transferring ESD sensitive material C GROUNDING when a complete isolation cannot be achieved a good grounding can divert the discharge current trough a safe path the frame of a truck can works like a local earth ground absorbing excess charge So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by
33. It enables compensation for non symmetry of the mechanical system between directions The operation is performed by operating the pedal after entering the PROGRAM function Flow Chart showing how to use the PROGRAM VACcC function of the Digital Console 1 Opening Zapi Display 2 Press ENTER to go into the General Menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display 5 The Display will show 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown 8 Press ENTER to clear these values Display will show 0 0 9 Select Forward Direction close any interlock Switches that may be in the system 10 Slowly depress the accelerator pedal or tiller butterfly to its maximum value The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction 11 Select the Reverse Direction and repeat Item 10 12 When finished press OUT 13 The Display will ask ARE YOU SURE 14 Press ENTER for yes or OUT for NO ZAPI VD D 550A 00000 MAIN PARAMETE ood MENU R CHANGE MAIN MENU 5 4 8 PROGRAM VAGG 4 8 ARE YOU SURE YES ENTER NO OUT nM ADWZPODB AC 3 FLASH INVERTER User Manual MAIN M
34. JUSTMENTS USING DIGITAL CONSOLE 8 1 Adjustments via Console Adjustment of Parameters and changes to the inverter s configuration are made using the Digital Console In the Ampseal connector version the Console is connected to the B Molex Spox connector of the inverter In the Minifit connectors version the Console is connected to the F connector of the inverter In the Amp Saab 42 poles connector version the Console can be connected to inverter cabling the pins of the console connector to the pins of the inverter connector In the Amp Saab 29 poles connector version it isn t possible to directly connect the console to controller console must be physically connected to another controller in the CANBUS net then virtually connected to AC 3 FLASH inverter Page 52 93 ADWZPODB AC 3 FLASH INVERTER User Manual 82 Description of Console amp Connection CONSOLE CONNECTOR ee x 1 INN A 4 9 NS K 7 DISPLAY 1 PARAM IMAX SPEED I ACC SPEED II BRAKING SPEED III S TESTS R BRAKE HIDRO SP SP HIDRO TIME 3 SAVE SP RED COMPENS BY PASS FIELD WEAK I MOT 5 ALARMS V MOT VMN MOT M SW TEST 6 PROGRAM PEDAL 7 MOTOR DATA tt 21 ROLL ENTER SET BUTTONS ai nt ROLL OUT SET iJ bl Digital consoles used to com
35. ODEL Menu 7 The display will shows the first OPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 Desired OPTION appears 10 Press SET UP or SET DOWN button in order to modify the changes 11 New OPTION appears 12 Press OUT to exit the Menu 13 Confirmation request appears 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 SET OPTIONS Menu appears 16 Press OUT again Display now show the Opening Zapi Menu ADWZPODB AC 3 FLASH INVERTER User Manual ZAPI VD D BOV 550A 00000 Bod ood CONFIG MENU SET OPTIONS E EH HOUR COUNTER RUNNING Bod Bod BATTERY CHECK OFF BATTERY ON Bo ARE YOU SURE YES ENTER NO OUT CONFIG MENU SET OPTIONS Page 63 93 Flow chart showing how to make changes to ADJUSTMENT Menu 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The display will show SET MODEL 4 Press ROLL UP or ROLL DOWN button until ADJUSTMENTS Menu appears 5 ADUUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will shows SET BATTERY TYPE 8 Press ROLL UP or ROLL DOWN button until the desired parameter is reached 9 The desired parameter appears 10 Press SET UP or SET DOWN button to modify the adjustment 11 Press OUT 12 Press ENTER
36. OR 3 blinks phase voltage or capacitor charge failure CAPACITOR CHARGE VMN LOW VMN HIGH 4 blinks failure in accelerator NOT OK PEDAL WIRE KO 5 blinks failure of current sensor STBY HIGH SEAT KO DATA ACQUISITION 6 blinks failure of contactor driver SHORTED DRIVER SHORTED CONTACTOR DRIVER OPEN AUX OUTPUT KO 7 blinks excessive temperature HIGH TEMPERATURE MOTOR TEMPERATURE THERMIC SENSOR KO 8 blinks failure of can bus or problem in the SAFETY circuit CAN BUS SAFETY long blink discharge battery or wrong battery voltage LOW BATTERY WRONG SET BAT no blink problem in a remote module WAITING FOR NODE 11 1 Analysis of alarms displayed on console Page 88 93 1 2 3 4 WATCH DOG The test is made in both running and standby It is a self diagnosing test within the logic If an alarm should occur replace the logic EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ON again replace the logic If the alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values LOGIC FAILURE 1 This alarm signals that an undervoltage overvoltage protection operation has occurred Two possible reasons A
37. OUT ON OFF SPEED ON OI HYDRO SPEED REQ ON OI CUTBACK SWITCH ON OFF VOLTAGE BOOSTER BATTERY VOLTAGE v BATTERY CHARGE x SAVE PARAMETER M s CODE ALARMS h CC PROGRAM VACC VACC SETTING MIN MAX STEER TABLE NOT AVAILABLE ADWZPODB AC 3 FLASH INVERTER User Manual Page 55 93 84 Function configuration 8 4 1 Traction Page 56 93 Using the CONFIG MENU of the programming console the user can configure the following functions see OPERATIONAL FEATURE chapter for an explanation of hydraulic steering function SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers travel time only KEYON the counter registers when the key switch is closed 2 BATTERY CHECK ON the battery discharge level check is carried out when the battery level reaches 10 an alarm is signalled and the maximum current is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled 3 CUTBACK MODE PRESENT B10 Minifit A28 Amp Saab 29 and 42 poles 9 Ampseal input is managed as a cutback speed input ABSENT 10 Minifit A28 Amp Saab 29 and 42 poles 9 Ampseal input is managed as an handbrake input 4 HYDRO KEY ON ON OFF if this option is programmed ON the traction inverter manages an hydraulic steering function when the key is switched ON only if the aux output 1 option is programme
38. OWN to mun display the next parameter mun 7 The names of the Parameter appears on the RELEASE BRAKING Display LEVEL 5 8 When the desired Parameter appears the Display will show a Level Number that will be Between 0 and 9 Press either PARAM Top Right or SET Bottom Right buttons to change the Level value RELEASE BRAKING LEVEL 6 9 The Display will show the New Level 10 When you are satisfied with the results of the changes you have made press OUT ARE YOU SURE YES ENTER NO OUT 11 The Display asks ARE YOU SURE 12 Press ENTER to accept the changes or press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters MAIN MENU PARAMETER GHANGE 13 The Display will show 8 6 Programming console functions Functional configuration see 8 1 8 2 8 3 8 4 Parameter programming see 8 5 8 6 Tester the user can verify the state of the following parameters TRACTION PUMP motor voltage 96 motor voltage 96 frequency Hz frequency Hz Page 70 93 ADWZPODB AC 3 FLASH INVERTER User Manual encoder Hz encoder Hz slip value Hz slip value Hz current rms A current rms A temperature C temperature motor temperat motor temperature C accelerator V accelerator V forward switch ON OFF lifting switch ON OFF backward switch ON OFF 1st speed switch ON OFF enable swit
39. RO CM MODE PPOT AUX KEY BATT BATT PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH Positive of the auxiliary output Output for driving an hydraulic steering contactor it drives the load to Batt Maximum current 3 A Positive for the hydraulic steering contactor Common of LIFT ENABLE 1 ST 2ND 3RD 4 TH HYDRO SR microswitches This input allows the customer to select the software for traction or lifting application Configuration MODE Open not connected inverter MODE Close connected with A35 Pump inverter Auxiliary potentiometer positive 10 V output keep load gt 1 Connected to the power supply through a microswitch CH with a 10 A fuse in series Batt Batt Traction Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to B8 for the Flash memory programming It must be connected to B7 for the Flash memory programming ADWZPODB AC 3 FLASH INVERTER User Manual 6 2 2 Amp Saab 29 poles connector A1 A2 4 5 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 ADWZPODB AC 3 FLASH INVERTER User Manual PPOT NPOTB PTHERM NTHERM NAUX NBRAKE PAUX CM KEY CPOT NPOT AN IN CAN H CAN L
40. RY operation by console 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The Display will show SET MODEL 4 Press ROLL UP button until ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will show the first OPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 ADJUST BATTERY appears 10 Press SET UP or SET DOWN button in order to increase or decrease respectively Set the value read by an external meter 11 Battery value appears on the display 12 Press OUT to exit the Menu 13 Confirmation request appears 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 ADJUSTMENTS Menu appears 16 Press OUT Display now show the Opening Zapi Menu ZAPI VD D 550A 00000 CONFIG CONFIG SET MODEL MENU MENU ADJUSTMENTS SET BATTERY TYPE BOV ADJUSTMENT BATTERY 82 1V ADJUSTMENT BATTERY 84 ARE YOU 5V SURE YES ENTER NO OUT CONFIG ADJUST ADWZPODB AC 3 FLASH INVERTER User Manual 8 5 Parameter regulation In addition to the input configuration parameter modification is made directly by ZAPI on customer specifications or by the customer making the adjustments using the programming console 8 5
41. Saab 42 poles connector A1 A2 4 5 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 PPOT NPOTBR PPOTB MOT TH NTHERM PBRAKE CM KEY SAFETY MODE FORWARD BACKWARD PB Accelerator potentiometer positive 10 V output keep load 1 kO Batt Brake potentiometer positive 10 V output keep load gt 1 Input for motor temperature sensor Batt Batt Negative of main contactor coil Positive of main contactor coil Output for driving a brake or an hydraulic steering contactor coil it drives the load to Batt maximum current 3 A Positive of the electromechanical brake coil Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches Connected to the power supply through a microswitch CH with a 10 A fuse in series If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Batt Accelerator potentiometer wiper Negative of accelerator unit tested for wire disconnection diagnosis Brake potentiometer wiper Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output This input allows the customer to select the
42. The percentage Charge level of the battery MOTOR VOLTAGE This is the voltage supplied to the motor by the inverter it is expressed as a percentage of the full voltage which depends of the battery voltage FREQUENCY This is the frequency of the voltage and current supplied to the motor ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency CURRENT RMS Root Mean Square value of the motor current TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices MOTOR TEMPERATURE This is the temperature of the motor if the option is programmed None see chapter 8 4 2 it shows 0 ADWZPODB AC 3 FLASH INVERTER User Manual 8 ACCELERATOR The voltage the accelerator potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 LIFTING SWITCH Status of the lifting switch ON VB active entry of closed switch OFF GND non active entry of open switch 10 15 SPEED SWITCH Status of the first speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 11 2ND SPEED SWITCH Status of the second speed switch
43. VA ELECTRONIC OLEODYNAMIC INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma 59 42028 POVIGLIO RE ITALY Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it web www zapispa it END User Manual AC 3 FLASH INVERTER Copyright 1975 2006 Zapi S p A rights reserved The contents of this publication is a ZAPI S p A property all related authorizations are covered by Copyright Any partial or total reproduction is prohibited Under no circumstances will Zapi S p A be held responsible to third parties for damage caused by the improper use of the present publication and of the device devices described in it Zapi spa reserves the right to make changes or improvements to its products at any time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication therefore does not reflect any changes in the characteristics of the product as a result of updating VA MAP is a registered trademark property of Zapi S p A NOTES LEGEND EY The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention The symbol is used inside this publication to indicate action characteristic very important as for security Pay special attention to the annotations pointed out with this symbol Page 2 93 ADWZPODB
44. an line The best solution depends on the type of nodes modules connected in the network If the modules are very different in terms of power then the preferable connection is the daisy chain Correct Layout Module 1 Module 2 Note Module 1 power gt Module 2 power gt Module 3 power The chain starts from the BATT post of the controller that works with the highest current and the others are connected in a decreasing order of power Otherwise if two controllers are similar in power for example a traction and pump motor controller and a third module works with less current the best way to deal this configuration is to create a common ground point star configuration Correct Layout Module Module 2 Center the Ground connection Module 3 Note Module 1 power Module 2 power gt Module 3 power In this case the power cables starting from the two similar controllers must be as short as possible Of course also the diameter of the cable concurs in the voltage drops described before higher diameter means lower impedance so in this last example the cable between the minus of the Battery and the common ground point pointed by the arrow in the image must be dimensioned taking into account thermal and voltage drop problems ADWZPODB AC 3 FLASH INVERTER User Manual Can advantages The complexity of today systems needs more and more data signal and information must flow
45. at which the parameters can be set ADWZPODB AC 3 FLASH INVERTER User Manual Page 67 93 PROGRAMMED LEVEL UNIT B ol ol oo 53 gt j ACCELERATION DELA Y RELEASE BRAKING INVERS BRAKING PEDAL BRAKING SPEED LIMIT BRK Sec BRAKE Sec MAX SPEED FORW MAX SPEED BACK CUTBACK SPEED CURVE CUTBACK FREQUENCY CREEP MAXIMUM CURRENT BACKING SPEED BACKING TIME AUXILIARY TIME Sec Sec n J Alro n N N 2 The acceleration time shown is the time from 0 Hz to 100 Hz This is the ideal ramp calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load The braking feature is based upon deceleration ramps The value shown in the table is the time to decrease the speed from 100 Hz to 0 Hz This is the ideal ramps calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load MAXSPEEDFORW to Sec After changing a parameter press ENTER to confirm data when requested by the message on the console Parameters modif
46. ch ON OFF 2nd speed switch ON OFF seat switch ON OFF 3rd speed switch ON OFF backing f ON OFF 4th speed switch ON OFF backing b ON OFF hydro speed req ON OFF cutback switch ON OFF cutback switch ON OFF brake switch ON OFF voltage booster 96 exclusive hydro ON OFF battery voltage V brakepedal pot 96 battery charge 96 hand brake ON OFF voltage booster 96 battery voltage V battery charge 96 Save function for storing data Restore function for loading parameters on another inverter Display of the last 5 alarms including hour meter value and temperature at the moment of the alarm Accelerator range programming records the minimum and maximum useful accelerator stroke values for both direction of running See the console manual for a detailed description of function and parameters 8 7 Sequence for Ac Inverter Traction setting When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display If the controller is not configured to your requirements follow the sequence detailed here following Remember to re cycle the Key Switch if you make any changes to the controller s configuration 1 2 3 4 5 6 7 8 Select the Options required See Chapter 8 1 8 4 Select and set the Battery Voltage See Chapter 8 4 Confirm correct installation of all wires Use the Console s TESTER function to assist
47. d to the forward direction microswitch active high Backward direction request input It must be connected to the backward direction microswitch active high Inching function forward direction input It must be connected to the inching forward switch Active high Inching function backward direction input It must be connected to the inching backward switch Active high Incremental ENCODER connector see chapter 4 2 5 Incremental ENCODER connector see chapter 4 2 5 Incremental ENCODER connector see chapter 4 2 5 Incremental ENCODER connector see chapter 4 2 5 This input allows the customer to select the software for traction or lifting application Configuration MODE Open not connected Traction inverter MODE Close connected with A5 Pump inverter If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Brake request input It must be connected to the brake pedal switch active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function Page 25 93 input must be connected to the exclusive hydro microswitch or to the accelerator enable switch Active high see also OPTION chapter A28 SR HB Speed reduction handbrake input Active low switch opened See also OPTION chapter A29 SEAT SEAT input must be connected to the SEAT microswitch it is active high Page 26 93 ADWZPODB AC 3 FLASH INVERTER User Manual 6 1 3 Amp
48. d as hydro contactor or as exclusive hydro 5 STOP ON RAMP ON the stop on ramp feature truck electrically hold on a ramp is managed for a time established by auxiliary time parameter After this time the behaviour depends on the aux output 1 option programming see also the following table OFF the stop on ramp feature is not performed 6 AUX OUTPUT 1 BRAKE B9 Minifit A7 Amp Saab 29 poles A9 Amp Saab 42 poles A28 Ampseal output drives an electromagnetic brake coil see also the table below HYDRO CONT the inverter manages an hydraulic steering function when the direction input or brake pedal input are active or a movement of the truck is detected EX HYDRO the inverter manages an hydraulic steering function when the exclusive hydro input is active 7 PEDAL BRAKING ANALOG The mechanical brake pedal has a switch and a potentiometer installed When the accelerator is released and the pedal brake is pushed the inverter performs an electrical braking whose intensity is proportional to the brake pedal potentiometer The minimum intensity is established by the Release braking parameter when the brake pedal is slightly pressed brake switch close but brake potentiometer at the minimum The maximum intensity is established by the Pedal braking parameter when the brake pedal is fully pressed brake potentiometer at the maximum In the middle positions the ADWZPODB AC 3 FLASH INVERTER Use
49. e ZAPI VD D 1 Opening Zapi Display 550A 00000 2 Press ENTER to into the General menu MAIN PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until mun RESTORE PARAM appears on the Display mun MAIN MENLI RESTORE PARAM 5 The Display will show 6 Press ENTER to go into the RESTORE PARAM Function unun 7 The Display shows the type of Model stored DO with a Code Number V1 8 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display 01 API V1 9 Press ENTER to commence the Restore operation 10 The Display will ask YOU SURE ani YES ENTER NO OUT 11 Press ENTER for YES or OUT for No ADWZPODB AC 3 FLASH INVERTER User Manual Page 79 93 12 You can see the items that are being stored the inverter memory whilst the RESTORE routine is happening STORINCG ADGELER DELAY MAIN RESTORE PARAM 13 When finished the Console displays 14 Press OUT to return to the Opening Zapi Display Page 80 93 ADWZPODB AC 3 FLASH INVERTER User Manual 9 3 Description of ALARMS menu The microprocessor in the controller remembers the last five Alarms that have occurred Items remembered relative to each Alarm are the code of the alarm the number of times the particular Alarm occ
50. e has to be exposed to These tests are carried out at determined levels of electromagnetic fields to simulate external undesired disturbances and verify the electronic devices response 3 The second type of immunity ESD concerns the prevention of the effects of electric current due to excessive electric charge stored in an object In fact when a charge is created on a material and it remains there it becomes an electrostatic charge ESD happens when there is a rapid transfer from a charged object to another This rapid transfer has in turn two important effects A this rapid charge transfer can determine by induction disturbs on the signal wiring and thus create malfunctions this effect is particularly critical in modern machines with serial communications canbus which are spread everywhere on the truck and which carry critical information B in the worst case and when the amount of charge is very high the discharge process can determine failures in the electronic devices the type of failure can vary from an intermittently malfunction to a completely failure of the electronic device IMPORTANT NOTE it is always much easier and cheaper to avoid ESD from being generated than to increase the level of immunity of the electronic devices There are different solutions for EMC issues depending on level of emissions immunity required the type of controller materials and position of the wires and electronic components 1 EM
51. e replaced 25 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circuit gets active and opens the drivers of LC and EB and stops the machine Verify the SAFETY input connection 26 SAFETY KO This alarm is present in combi systems traction pump If a stopping alarm is detected on the pump the traction also stops The failure must be looked for in the pump inverter 27 BATTERY LOW If the battery check option is ON a battery discharge algorithm is carried out When the charge level is 1095 this alarm is signalled and the current is reduced to the half of the programmed level 28 WRONG SET BATT When the key is turned ON the controller check the battery voltage and verifies it is within a window around the nominal value Replace the battery with a correct battery 29 WAITING FOR NODE The controller receives from a remote module via CAN Bus the information that it isn t possible to close the LC the module isn t ready locked in an alarm state Verify the other modules to determinate in which of them there is the problem ADWZPODB AC 3 FLASH INVERTER User Manual Page 87 93 11 AC 3 FLASH DIAGNOSTIC PUMP CONFIGURATION The alarms are signalled by a diagnostic LED 1 blink logic failure EEPROM KO LOGIC FAILURE 1 LOGIC FAILURE 2 LOGIC FAILURE 3 2 blinks running request on start up error in seat sequence or encoder problem INCORRECT START ENCODER ERR
52. ection drawing Traction 40 7 2 1 Ampseal and Molex Spox 40 7 2 2 Saab 29 poles connector r 41 7 2 3 Saab 42 poles 42 ADWZPODB AC 3 FLASH INVERTER User Manual Page 3 93 10 11 12 13 7 2 4 Molex Minifit connectors 000600 mem a 43 7 3 Connection drawing Pump configuration 44 7 3 1 Ampseal and Molex Spox 44 7 3 2 AMP Saab 29 poles connector 45 7 3 3 Saab 42 poles connector rss 46 7 3 4 Molex connectors t ktm rnt ata 47 7 4 Connection drawing Combi configuration 48 741 X Ampseal and Molex Spox 48 7 4 2 Saab 29 poles 49 7 4 8 Saab 42 poles connector essen 50 7 4 4 Molex Minifit connectors enne 51 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 52 8 1 Adjustments via Console e a Bed 52 8 2 De
53. er heat dissipation Ensure that the wiring of the cable terminals and connectors is carried out correctly A Fit transient suppression devices to the horn solenoid valves and contactors not connected to the controller The heat generated by the power block must be dissipated For this to be possible the compartment must be ventilated and the heat sink materials ample The heat sink material and system should be sized on the performance requirement of the machine Abnormal ambient air temperatures should be considered In situations where either ventilation is poor or heat exchange is difficult forced air ventilation should be used The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle 4 2 2 Wirings power cables Page 12 93 The power cables length must be as short as possible to minimize power losses They must be tightened on controller power posts with a Torque of 13 15 Nm The AC 3 FLASH module should only be connected to a traction battery Do not use converters outputs or power supplies For special applications please contact the nearest Zapi Service Centre Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label A higher battery voltage may cause power section failure A lower voltage may prevent the logic operating ADWZPODB AC 3 FLASH INVERTER User Manual 4 2
54. ff before the battery power line is disconnected 4 2 7 Insulation of truck frame As stated by EN 1175 Safety of machinery Industrial truck chapter 5 7 there shall be no electrical connection to the truck frame So the truck frame has to be isolated from any electrical potential of the truck power line 4 3 Protection and safety features 4 3 1 Protection features The AC 3 FLASH is protected against some controller injuries and malfunctions Battery polarity inversion It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery polarity and for safety reasons Connection Errors All inputs are protected against connection errors Thermal protection If the controller temperature exceeds 75 the maximum current is reduced in proportion to the thermal increase The temperature can never exceed 100 External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP54 Molex Minifit connectors IP65 Ampseal and Amp Saab connectors Protection against uncontrolled movements The main contactor will not close if The Power unit is not functioning The Logic is not functioning perfectly The output voltage of the accelerator does not fall below the minimum voltage value stored with 1 V added Running microswitch in closed position Low battery charge When the battery charge is low the maxi
55. from a node to another CAN is the solution to different problems that arise from this complexity simplified design readily available multi sourced components and tools lower costs less and smaller cables improved reliability fewer connections analysis of problems improved easy connection with a pc to read the data flowing through the cable 4 2 4 Wirings connections After crimping the cable verify that all strands are entrapped in the wire barrel Verify that all the crimped contacts are completely inserted on the connector cavities cable connected to the wrong can lead to short circuits and failure so before turning on the truck for the first time verify with a multimeter the continuity between the starting point and the end of a signal wire For information about the mating connector pin assignment see the chapter description of the connectors 4 2 5 Connection of the encoder 1 3 FLASH is fit for different types of encoder To control AC motor with Zapi inverter it is necessary to install an incremental encoder with 2 phases shifted of 90 The encoder power supply can be 5 12 V It can have different electronic output Ampseal Amp Amp Minifit Saab Saab 29 poli 42 poli A1 A20 A29 E1 5 12 V positive of encoder power supply A2 A23 A30 E2 GND negative of encoder power supply A13 A21 A31 phase A of encoder A22 A18 4 phase inverted
56. fting application Configuration MODE Open not connected Traction inverter MODE Close connected with A5 Pump inverter 1 6 Incremental ENCODER connector see chapter 4 2 5 F1 PCLRXD Positive serial reception F2 NCLRXD Negative serial reception F3 PCLTXD Positive serial transmission F4 NCLTXD Negative serial transmission F5 GND Negative console power supply F6 12 Positive console power supply F7 FLASH It must be connected to F8 for the Flash memory programming F8 FLASH It must be connected to F7 for the Flash memory programming Page 30 93 ADWZPODB AC 3 FLASH INVERTER User Manual 6 2 Connectors of the logic Pump configuration The AC 3 FLASH has been designed to be produced with four different types of connector an AMPSEAL 35 poles connector together a MOLEX SPOX 8 poles connector used to connect the Console one AMP SAAB 29 poles connector one AMP SAAB 42 poles connector or six Molex Minifit connectors 6 2 1 Ampseal and Molex Spox connectors A1 A2 4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 ADWZPODB AC 3 FLASH INVERTER User Manual 12V 45V ENC GND PPOT 4 TH LIFT ENABLE 1ST DIG IN 3 RD 2 ND HYDRO SR SAFETY CAN L NPOT AUX CPOT AUX ENC A ENC B BATT MOT TH NAUX Positive of encoder power supply Nega
57. ge Low level CAN BUS voltage I O Batt Brake potentiometer wiper ADWZPODB AC 3 FLASH INVERTER User Manual Page 23 93 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 B1 B2 B3 B4 B5 B6 B7 B8 Page 24 93 ENC A ENC B NTHERM PTHERM NMC PMC NBRAKE PBRAKE CM MODE PPOTB KEY BATT BATT PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output Batt Input for motor temperature sensor Negative of main contactor coil Positive of main contactor coil Output for driving a brake or an hydraulic steering contactor coil it drives the load to Batt maximum current 3 A Positive of the electromechanical brake coil Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches This input allows the customer to select the software for traction or lifting application Configuration MODE Open not connected Traction inverter MODE Close connected with A35 Pump inverter Brake potentiometer positive 10 V output keep load gt 1 Connected to the power supply through a microswitch CH with a 10 A fuse in series Batt Batt Positivo ricezione seriale Negative serial reception Positive serial transmission Negative serial transmission Negative console
58. ge the output which drives the main contactor coil is switched at high frequency 1 kHz with a duty cycle of 70 this feature is useful to decrease the power dissipation of the contactor coil Usea 10 A Fuse for protection of the auxiliary circuits For protection of the power unit refer to diagrams The Fuse value shown is the maximum allowable For special applications or requirements these values can be reduced Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow ADWZPODB AC 3 FLASH INVERTER User Manual Page 11 93 Installation of the hardware A Before doing any operation ensure that the battery is disconnected and when all the installation is completed start the machine with the drive wheels raised from the floor to ensure that any installation error do not compromise safety After operation even with the Key Switch open the internal capacitors may remain charged for some time For safe operation we recommend that the battery is disconnected and a short circuit is made between Battery Positive and Battery Negative power terminals of the inverter using a Resistor between 10 ohm and 100 ohm 4 2 1 Positioning and cooling of the controller Install the inverter with the base plate on a flat metallic surface that is clean and unpainted Apply a light layer of thermo conductive grease between the two surfaces to permit bett
59. given by the last letter the following list 32 pulses rev 64 pulses rev C 80 pulses rev D 128 pulses rev Page 10 93 ADWZPODB AC 3 FLASH INVERTER User Manual 4 INSTALLATION HINTS EY In the description of these installation suggestions you will find some boxes of different colours they mean These are information useful for anyone is working on the installation or a deeper examination of the content These are Warning boxes they describe operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator items which are important to guarantee system performance and safety 4 1 Material overview Before to start it is necessary to have the required material for a correct installation Otherwise a wrong choice of cables or other parts could lead to failures misbehaviour bad performances 4 1 1 Connection cables For the auxiliary circuits use cables of 0 5 section For power connections to the motor and to the battery use cables having section of 50 mm as a minimum For the optimum inverter performance the cables to the battery should be run side by side and be as short as possible 4 1 2 Contactors 4 1 3 Fuses The main contactor must be installed Depending on the position of a jumper installed in the logic board output which drives the main contactor coil is on off the coil is driven with the full battery volta
60. he operator C incorrect wiring D if the default persists replace the logic FORW BACK The test is carried out continuously An alarm is signalled when a double running request is made simultaneously Possible causes A defective wiring B running microswitch failure C incorrect operation D ifthe defect persists replace the logic HANDBRAKE The truck does not start because the handbrake switch is opened Possible Causes A defective wiring B failure of the microswitch C incorrect operation of the operator D ifthe defect persist replace the logic ENCODER ERROR Two consecutive readings of the encoder speed are too much different in between because of the inertia of the system it is not possible the encoder changes its speed a lot in a short period Probably an encoder failure has occurred e g one or two channels of the encoder are corrupted or disconnected Check both the electric and the mechanical encoder functionality Also the electromagnetic noise on the sensor bearing can be a cause for the alarm CAPACITOR CHARGE Follows the charging capacitor system When the key is switched ON the inverter tries to charge the capacitor through a power resistance and check if the capacitor are charged within a timeout If this is not true an alarm is signalled the main contactor is not closed Possible reasons ADWZPODB AC 3 FLASH INVERTER User Manual Page 85 93 86 93 the cha
61. ication is for proportional braking It should be in a 3 wire configuration Potentiometer value should be in the 0 5 10 kohm range Generally the load should be in the 1 5 mA to 30 mA range The CPOTB A21 A13 A17 A8 signal range is from 0 to 10 V 2 A25 Ampseal A3 Amp Saab 29 poles A4 Amp Saab 42 poles B6 Minifit PTHERM and A24 Ampseal A4 Amp Saab 29 poles A5 Amp Saab 42 poles B12 Minifit NTHERM connections are used for a motor thermal sensor It can be digital on off sensor normally closed or analog See also chapter 8 4 for more explanation 3 4 Speed feedback The motor control is based upon the motor speed feedback The speed transducer is an incremental encoder with two phases shifted at 90 The encoder can be of different types power supply 5 12 V electric output open collector NPN or PNP push pull line driver standard A and or differential A A B B output For more details about encoder installation see also chapter 4 2 5 Note The encoder resolution and the motor poles the controller can handle is specified in the home page display of the handset showing following headline AC3T2D ZP1 13 That means 3 traction controller AC 3 pump controller ADWZPODB AC 3 FLASH INVERTER User Manual Page 9 93 2 motor s poles pair number D 128 pulses rev encoder flash The encoder resolution is
62. ied and optimized on one unit can be stored by the console SAVE and then released RESTORE on another inverter thus allowing fast and standardized settings see console manual for details 8 5 2 Pump The following parameters can be modified 1 ACCELER DELAY Acceleration ramp 2 DECELER DELAY Deceleration ramp 3 MAX SPEED UP It determines the maximum lifting speed with a potentiometer control 4 MIN SPEED UP It determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed 5 CUTBACK SPEED Speed reduction when the cutback switch is active Page 68 93 ADWZPODB AC 3 FLASH INVERTER User Manual 6 1ST SPEED FINE First speed fine regulation 7 2ND SPEED FINE Second speed fine regulation 8 3RD SPEED FINE Third speed fine regulation 9 4TH SPEED FINE Fourth speed fine regulation 10 HYD SPEED FINE Hydro speed fine regulation 11 MAXIMUM CURRENT The maximum current of the inverter 12 AUXILIARY TIME Time delay when an hydraulic steering function request is switched off The following table shows the different values at which the parameters can be set UNIT 2 4 waxsmepue m e ss pue 125 s o ss 20 m o ps piso pes piso ios no 25 o ass amaso 20 o o 0 7 s
63. ins Female C12796 Female Ampseal pin harness side C12777 Female Molex Minifit pin harness side Page 92 93 ADWZPODB AC 3 FLASH INVERTER User Manual 13 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors moving and fixed contacts Electrical Contacts should be checked every 3 months Check the Foot pedal or Tiller microswitch Using a suitable test meter confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals Switches should operate with a firm click sound Microswitches should be checked every 3 months Check the Battery cables cables to the inverter and cables to the motor Ensure the insulation is sound and the connections are tight Cables should be checked every 3 months Check the mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every 3 months Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 months Checks should be carried out by qualified personnel and any replacement parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special requirements should be made after consulting a Zapi Agent The supplier is
64. ith current control inverter can drive an electromechanical brake Hydraulic steering function 1 traction inverter the traction inverter sends a hydraulic steering function request to the pump inverter on the can bus line see also OPTION chapter 8 4 moreover if the pump inverter is not present for ex tractor application the traction inverter can manage an hydraulic steering function by driving a hydro contactor which drive a hydraulic steering motor A28 Ampseal A7 Amp Saab 29 poles A9 Amp Saab 42 poles B9 Minifit output see also OPTION chapter 2 pump inverter the pump inverter manage an hydraulic steering function That is it drives the pump motor at the programmed speed for the programmed time High efficiency of motor and battery due to high frequency commutations Self diagnosis with indication of the fault shown by a flashing led Modification of parameters through the programming console Internal hour meter with values that can be displayed on the console Memory of the last five alarms with relative hour meter and temperature displayed on the console Test function within console for checking main parameters 5 1 Diagnosis The microcontroller continually monitors the inverter and carries out a diagnostic procedure on the main functions The diagnosis is made in 4 points 1 Diagnosis on key switch closing that checks watchdog circuit current sensor capacitor
65. l to your requirements 12 Set SPEED FORW 13 Set MAX SPEED BACK Reverse 14 Make the choice for the truck behaviour on a slope see chapter 8 4 If the Stop on ramp option is ON set the desired value of auxiliary time parameter 15 Set SET TEMPERATURE setting the motor thermal sensor type used Depending on the motor used it is necessary to set some parameters giving Zapi the motor curves it is possible to know the optimal setting in order to the motor runs efficiently 8 8 Sequence for Ac Inverter Pump setting Page 72 93 When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display If the controller is not configured to your requirements follow the sequence detailed here following Remember to re cycle the Key Switch if you make any changes to the controller s configuration 1 Select the Options required See Chapter 8 1 8 4 2 Select and set the Battery Voltage See Chapter 8 4 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the lift signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 4 5 Setthe MAXIMUM CURRENT Current using the table on Chapter 8 5 2 6 Setthe Acceleration and Deceleration Delay requirements for the pump 7 Setthe MIN SPEED UP level starting from 0 Hz The pump should just turn when
66. layed on 84 AC 3 FLASH DIAGNOSTIC PUMP CONFIGURATION 88 11 1 Analysis of alarms displayed on console 88 RECOMMENDED SPARE PARTS FOR INVERTER 92 PERIODIC MAINTENANCE BE REPEATED AT TIMES INDICATED 93 Page 4 93 ADWZPODB AC 3 FLASH INVERTER User Manual APPROVAL SIGNS COMPANY FUNCTION INITIALS SIGN GRAPHIC AND LAYOUT FF PROJECT MANAGER FG TECHNICAL ELECTRONIC PP MANAGER VISA SALES MANAGER VISA PN Publication ADWZPODB Edition December 2006 ADWZPODB AC 3 FLASH INVERTER User Manual Page 5 93 1 INTRODUCTION Within the ZAPIMOS family the AC 3 FLASH inverter is the model suitable for control of 7 12 kW motors It has been expressly designed for battery electric traction It is fit for electric truck electric cars tractors and buses Page 6 93 ADWZPODB AC 3 FLASH INVERTER User Manual 2 SPECIFICATION 2 1 Technical specifications Inverter for AC asynchronous 3 phase motors Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chip Program Memory Digital control based upon a microcontroller 36 48 72 80 96 V Maximum current 36 48 600 RMS for 3 Maximum current 72 V V
67. mum current is reduced to the half of the maximum current programmed Protection against accidental Start up A precise sequence of operations are necessary before the machine will start Operation cannot begin if these operations are not carried out correctly Requests for drive must be made after closing the key switch ADWZPODB AC 3 FLASH INVERTER User Manual Page 17 93 4 3 2 Safety Features A ZAPI controllers are designed according to the prEN954 1 specifications for safety related parts of control system and to UNI EN1175 1 norm The safety of the machine is strongly related to installation length layout and screening of electrical connections have to be carefully designed ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions Furthermore ZAPI is available to develop new SW or HW solutions to improve the safety of the machine according to customer requirements Machine manufacturer holds the responsibility for the truck safety features and related approval AC 3 FLASH inverter electronic implements an hardware safety circuit which is able to open the Line Contactor LC and the Electric Brake EB and therefore to cut the power line stopping the machine via HARDWARE that is bypassing the software control of the LC and EB This safety circuit is driven by SAFETY input If safety input is connected to BATT the SAFETY circuit is inactive if the inpu
68. municate with AC inverter controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 02 ADWZPODB AC 3 FLASH INVERTER User Manual Page 53 93 8 3 Description of Standard Console Menu 8 3 1 Traction configuration PARAMETER CHANGE CONNECTED TO 0 2 Cn HEADING MAIN MENU ACCELER DELAY 0 9 SET MODEL RELEASE BRAKING 0 9 NVERS BRAKING 0 9 PEDAL BRAKING SPEED LIMIT BRK BRAKE CUTBACK MAX SPEED FORW MAX SPEED BACK CUTBACK SPEED CURVE REQUENCY CUTBACK CREEP MAXIMUM CURRENT 3ACKIN AUXILIA SPEED TIME SET OPTIONS TESTER MOTOR VOLTAGE SAVE PARAMETER RESTORE PARAMETER ALARMS PROGRAM VACC STEER TABLE Page 54 93 FREQUENCY ENCODER SLIP VALUE CURRENT RMS TEMPERATURE MOTOR TEMPERAT ACCELERATOR ORWARD SWITCH BACKWARD SWITCH ENABLE SWITCH SEAT SWITCH BACKING F BACKING BRAKE EXCLUSIVE HYDRO BRAKEPEDAL POT IANDBRAKE VOLTAGE BOOSTER BATTERY VOLTAGE BATTERY CHARGE lt s O st o O O O O oO O O lt gt 0 0 0 0 OF 0 0 0 1 0 HOUR COUNTER BATTERY CHECK CUTBACK MODE HYDRO KEY ON STOP ON RAMP AUX OUTPUT 1 PEDAL BRAKING SET TEMPERATURE AUX FUNCTION ENABLE FUNCTION CHECK PUMP HYDRO H RUNNING KEYON ON O PRESENT ABSE ON OFF ON O HYDRO CONTAC ANALOG DI
69. n configuration 7 2 1 Ampseal and Molex Spox connectors 5NIAISQ 015 l CANBUS 8 DR TEMP SENSOR B I EXPYDRD ENABLE 227 m m x lt i al lt w u m al a mj lt gt zc o Al al i ol 2 o um s zx f c u G 0 lt lt lt T lt NOUS YNCHR AS ION PRDGRAMMING FLASH 40 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 2 2 Amp Saab 29 poles connector ADWZPODB AC 3 FLASH INVERTER User Manual Page 41 93 7 2 3 Amp Saab 42 poles connector v3d INIddOLS x 2 4l N 5 Li n e m em lt E 9 2 p lt C MODE BOARD ASYNCHRONOUS FRAC 1198 Ae dL y 1194 42 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 2 4 Molex Minifit connectors ADWZPODB AC 3 FLASH INVERTER U
70. n phase Wait the end of the acquisition activity 18 MAIN CONTACTOR ALARMS SHORTED When the key is switched ON the uP checks the MC driver FF SR If it does not react in a correct way to the uP stimulus the alarm is signalled Replace the logic board The FF SR makes an hardware control of the current in the MC coil If this is too high it opens the MC and the alarm is signalled Check if there are external shortcircuit and if the ohmic value of the MC is correct otherwise replace the logic DRIVER SHORTED When the key is switched ON the uP checks that the MC coil driver is not shorted if it is this alarm is signalled replace the logic board CONTACTOR DRIVER When the initial diagnosis is finished the traction logic closes the MC and checks the voltage on the Drain of the driver If this is not low an alarm is signalled Replace the logic CONTACTOR OPEN The main contactor coil has been driven by the logic board but the contactor does not close Two possible reasons A the wires to the coil are interrupted or not well connected B the contact of the contactor is not properly working ADWZPODB AC 3 FLASH INVERTER User Manual CONTACTOR CLOSED The controller checks if the LC contact is closed when the coil isn t driven trying to discharge the capacitor bank If they don t discharge the fault condition is entered It is suggested to check the contactor contact if itis mechanically stuck or pasted 19 AUX
71. o oz os 2o 15 20 3o 10 50 The acceleration time shown is the time from 0 Hz to 100 Hz maximum selectable speed This is the ideal ramp calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load The deceleration time shown in the table is the time from 100 Hz to 0 Hz This is the ideal ramp calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load Adjustable with a 1 Hz resolution in the 0 to 200 Hz range After changing a parameter press ENTER to confirm data when requested by the message on the console Parameters modified and optimized on one unit can be stored by the console SAVE and then released RESTORE on another inverter thus allowing fast and standardized settings see console manual for details ADWZPODB AC 3 FLASH INVERTER User Manual Page 69 93 Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA ZAPI VD D 1 Opening Zapi Display 550A 00000 2 Press ENTER to go into the General Menu MAIN MENU 3 The Display will show PARAMETER GHANGE 4 Press ENTER to go into the Parameter Change facility ACCEL DELAY 5 The Display will show the first parameter VEL a 6 Press either ROLL UP and ROLL D
72. or is not properly working 16 AUX OUTPUT KO The uP checks the driver of the electromechanical brake If the status of the driver output does not correspond to the signal coming from the pP the alarm is signalled Replace the logic 17 HIGH TEMPERATURE Controller temperature is greater than 75 The maximum current is reduced proportionally to the temperature increase The controller stops at 100 If the alarm is signalled when the controller is cold A check the wiring of the thermal sensor B thermal sensor failure C logic failure 18 MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor Page 90 93 ADWZPODB AC 3 FLASH INVERTER User Manual or if the analog signal overtakes the cut off level If it happens when the motor is cold check the wiring If all is OK replace the logic board 19 THERMIC SENSOR KO The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range When this alarm is signalled check the connection of the sensors 20 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this link depends on the software version It is signalled if the inverter does not receive any message from the CAN BUS line First of all check the wiring If itis ok the problem is on the logic board which must be replaced 21 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circ
73. out machine validation based on existing norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies and the tests on the electromagnetic energy generated or received by an electrical device So the analysis works in two directions ADWZPODB AC 3 FLASH INVERTER User Manual 1 The study the emission problems the disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy we talk about conduction issues when guiding structures such as wires and cables are involved radiated emissions issues when it is studied the propagation of electromagnetic energy through the open space In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and generate RF energy but wires and cables have the key role to propagate the disturbs because they works as antennas so a good layout of the cables and their shielding can solve the majority of the emission problems 2 The study of the immunity can be divided in two main branches protection from electromagnetic fields and from electrostatic discharge The electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device There are well defined tests which the machin
74. r Manual electrical braking intensity is a linear function between minimum and maximum intensity DIGITAL The truck does not have a potentiometer installed on the mechanical brake pedal but only a microswitch when the accelerator pedal is released and the brake pedal is pushed brake switch closed the inverter performs an electrical braking following Pedal braking parameter 8 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected to B6 Minifit Amp Saab 29 poles A4 Amp Saab 29 poles A25 Ampseal input ANALOG an analog motor thermal sensor KTY 84 is connected between B6 and B12 Minifit A3 and A4 Amp Saab 29 poles A4 and A5 Amp Saab 42 poles A24 and A25 Ampseal the curve can be customized on a customer request NONE no motor thermal sensor switch is connected 9 AUX FUNCTION ON OFF ifthis option is programmed ON the traction inverter applies maximum braking and traction torque 10 ENABLE FUNCTION PRESENT A14 Minifit A27 Amp Saab 29 poles A26 Amp Saab 42 poles A7 Ampseal input is managed as accelerator enable input ABSENT 14 Minifit 27 Amp Saab 29 poles A26 Amp Saab 42 poles A7 Ampseal input is managed as exclusive hydro input Ws CHECK PUMP HYDRO ON OFF if this option is programmed ON if the traction inverter doesn t receive any messages by the pump inverter from the CAN BUS line the CAN BUS KO warning appears on the traction and
75. range generally the load should be in the 1 5 mA to 30 mA range Faults can occur if it is outside this range The Procedure for automatic potentiometer signal acquisition is carried out using the Console This enables adjustment of the minimum and maximum useful signal level PROGRAM VACC function in either direction This function is unique when it is necessary to compensate for asymmetry with the mechanical elements associated with the potentiometer especially relating to the minimum level The sequence of procedure is described in the programming console manual ADWZPODB AC 3 FLASH INVERTER User Manual gt gt 3 5v 9 1C V E 2 Z 2 7 f Z Yj N Z N Z Z X a 77 N J Z N Z Z Gan 7 V2 4 N The two graphs show the output voltage from non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close 0 represents the mechanical zero of the rotation The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer 3 3 Other analog control units 1 A21 Ampseal connector version A13 Amp Saab 29 poles connector version A17 Amp Saab 42 poles connector version A8 Molex Minifit version input is an analog input whose typical appl
76. re different in between 14 DATA ACQUISITION This alarm is signalled in the current gain acquisition phase Wait the end of the acquisition activity 15 MAIN CONTACTOR ALARMS In the combi system pump traction the main contactor is driven by the traction inverter So the following description concerns the pump inverter used independently from the traction inverter In this configuration the pump inverter manages its own main contactor SHORTED When the key is switched ON the uP checks the MC driver FF SR If it does not react in a correct way to the uP stimulus the alarm is signalled Replace the logic board The FF SR makes an hardware control of the current in the MC coil If this is too high it opens the MC and the alarm is signalled Check if there are external shortcircuit and if the ohmic value of the MC is correct otherwise replace the logic DRIVER SHORTED When the key is switched ON the uP checks that the MC coil driver is not shorted if it is this alarm is signalled replace the logic board CONTACTOR DRIVER When the initial diagnosis is finished the traction logic closes the MC and checks the voltage on the Drain of the driver If this is not low an alarm is signalled Replace the logic CONTACTOR OPEN The main contactor coil has been driven by the logic board but the contactor does not close Two possible reasons A the wires to the coil are interrupted or not well connected B the contact of the contact
77. rging resistance is opened if it is opened B The charging circuit has a failure C There is a problem on the power modules 12 VMN LOW VMN HIGH The test is carried out during initial diagnosis and in standby Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor towards ground B inverter failure replace it 13 VACC NOT OK The test is made in standby This alarm indicates that the accelerator voltage is 1 V greater than the minimum value programmed by the PROGRAM VACC function Possible causes A the potentiometer is not correctly calibrated B the potentiometer is defective 14 PEDAL WIRE KO This alarm is signalled if a fault is detected in the accelerator unit wiring NPOT or PPOT cable is interrupted 15 PEDAL FAILURE This alarm can be activated on request and it is signalled if the accelerator signal is out of the range Possible cause an hardware problem on the logic board or a potentiometer problem disconnected wire damaged cursor 16 STBY I HIGH Test carried out in standby Check if the current is O If not verified an alarm is signalled which inhibits machine operations Possible causes A current sensor failure B logic failure first replace the logic if the defect persists replace the power unit 17 DATA ACQUISITION This alarm is signalled in the current gain acquisitio
78. rmines the motor temperature level at which the Motor temperature alarm is signalled The range is from 70 C to 160 C with 10 C steps This parameter must be adjusted only if the Set temperature menu Set option parameter is programmed Analog 7 ADJUSTMENT 03 This parameter isn t used 8 ADJUSTMENT 02 It adjusts the lower level of the battery discharge table 9 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table 10 LOAD FROM For an explanation of this point see the MDI instrument handbook 11 PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the ADWZPODB AC 3 FLASH INVERTER User Manual Page 61 93 contactor coil ON the PWM reduces the voltage at the loads on the main contactor coil down to 62 of the battery voltage 12 PWM ON AUX OUT OFF the inverter applies the battery voltage to the loads on the auxiliary output ON the PWM reduces the voltage at the loads on the auxiliary output down to 62 of the battery voltage Page 62 93 ADWZPODB AC 3 FLASH INVERTER User Manual Flow chart showing how to changes to Menu E O E ood 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter SET Menu 3 The Display will show SET MODEL 4 Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears 5 SET OPTIONS appears on the display 6 Press ENTER to go into the SET M
79. s on the display Bod Bod 5 The Display will show 6 Press ENTER to go into the SAVE function 7 If this facility has been used before the type of inverter data stored appears on the top Main with a 2 digit reference SELECT MOD OO FREE 8 Keep pressing either ROLL UP or ROLL DOWN keys until the second Main indicates a FREE storage facility 9 Press ENTER to commence SAVE routine 10 You can see the items that are being stored READING whilst the SAVE routine is happening AGCEL DELAY MAIN MENU 11 When finished the Console shows SAVE PARAN ADWZPO0DB 3 FLASH INVERTER User Manual Page 77 93 12 Press OUT to return to the Opening Zapi Display 78 93 ADWZPODB AC 3 FLASH INVERTER User Manual 9 2 Description of Console RESTORE function The RESTORE PARAM function allows transfer of the Console s stored data into the memory of the inverter This is achieved in a fast and easy way using the method previously used with the SAVE PARAM function The data that is available via the RESTORE PARAM function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The level of the Battery ADJUST BATTERY ATTENTION When the RESTORE operation is made all data in the inverter memory will be written over and replace with data being restored Flow Chart showing how to use the RESTORE function of the Digital Consol
80. scription of Console amp Connection aa 53 8 3 Description of Standard Console 54 8 3 1 Traction configuration 54 8 3 2 Pump CONG SU 3 55 8 4 Function configuration I n 56 56 842 uuu u u N 60 85 Parameter regulation I n 67 RERUMS 67 O 68 8 6 Programming console functions 70 8 7 Sequence for Ac Inverter Traction 71 8 8 Sequence for Ac Inverter Pump 72 8 9 Tester description of the functions r r 73 73 992 74 5 2 77 9 1 Description of Console SAVE function r 77 92 Description of Console RESTORE function 79 93 Description of ALARMS menu r Dei estan ade 81 94 Description of Console PROGRAM function 82 AC 3 FLASH DIAGNOSTIC TRACTION 84 10 1 Analysis of alarms disp
81. sed for auxiliary potentiometer Auxiliary potentiometer positive 10 V output keep load gt 1 Batt Batt Input for hydraulic steering request Active high Speed reduction input Active low switch opened This is a digital input free for customer request Connected to the power supply through a microswitch CH with a 10 A fuse in series Positive of the auxiliary output Positive for the hydraulic steering contactor Input for fourth speed request it is active HIGH If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Input for motor temperature sensor Common of 2nd SPEED 4th SPEED microswitches This output can be used for drive the main contactor coil single pump configuration or to drive an auxiliary load combi configuration Output for driving an hydraulic steering contactor it drives the load to Batt Maximum current 3 A Input for second speed request it is active HIGH Batt Batt Low level CAN BUS voltage I O Low level CAN BUS voltage I O High level CAN BUS voltage I O High level CAN BUS voltage I O ADWZPODB AC 3 FLASH INVERTER User Manual 01 Batt D2 MODE This input allows the customer to select the software for traction or lifting application Configuration MODE Open not connected Traction inverter MODE Close connected with A5 Pump inverter E1 E6 Incremental ENCODER connector see
82. ser Manual Page 43 93 F Connection drawing Pump configuration 7 3 1 Ampseal and Molex Spox connectors Gi E 5 L E3 z 24 E LA a gt NNN NNN N N lt ict LE x a L3 imo o lt lt A T T Y 7 lt N 1198 159 119 44 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 3 2 Amp Saab 29 poles connector 212277 ADWZPODB AC 3 FLASH INVERTER User Manual Page 45 93 7 3 3 Amp Saab 42 poles connector 5 NOU HRON ASYN UM 1 46 93 ADWZPODB AC 3 FLASH INVERTER User Manual 7 3 4 Molex Minifit connectors 1 L _ 1 E 5 s L 4 ul p 221 m x x oO I 2 2 Lr Y T y lt lt LE l a 77 ra 2 I b lt
83. software for traction or lifting application Configuration MODE Open not connected Traction inverter MODE Close connected with A6 Pump inverter Forward direction request input It must be connected to the forward direction microswitch active high Backward direction request input It must be connected to the backward direction microswitch active high Brake request input It must be connected to the brake pedal switch active high BACKING FORW Inching function forward direction input It must be connected to the inching forward switch Active high BACKING BACK Inching function backward direction input It must be ADWZPODB AC 3 FLASH INVERTER User Manual Page 27 93 connected to the inching backward switch Active high A26 EX HYDRO ENABLE Exclusive hydro or accelerator enable function input It must be connected to the exclusive hydro microswitch or to the accelerator enable switch Active high see also OPTION chapter A27 SEAT SEAT input it must be connected to the SEAT microswitch it is active high A28 5 Speed reduction handbrake input Active low switch opened See also OPTION chapter A29 412V 5V Positive of encoder power supply A30 ENC GND Negative of encoder power supply A31 ENCA Phase A of encoder A32 ENCB Phase B of encoder A33 CANT CAN termination connect to CANH A18 to insert can termination resistance A34 Low level CAN BUS voltage I O A35
84. ssed in the same unit of the frequency this information comes from the speed sensor 4 SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 5 CURRENT RMS Root Mean Square value of the motor current 6 TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices 7 MOTOR TEMPERAT This is the temperature of the motor if the option is programmed None see chapter 8 4 1 it shows 0 8 ACCELERATOR The voltage of the accelerator potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 FORWARD SWITCH The level of the Forward direction digital entry FW ON VB active entry of closed switch OFF GND non active entry of open switch 10 BACKWARD SWITCH The level of the Reverse direction digital entry BW ON VB active entry of closed switch OFF GND non active entry of open switch 11 ENABLE SWITCH Status of the accelerator enable input ON VB active entry of closed switch OFF GND non active entry of open switch 12 SEAT SWITCH The level of the Seat Microswitch digital entry ON VB active entry of closed switch OFF GND non active entry of open switch ADWZPODB AC 3 FLASH INVERTER User Manual Page 73 93 8 9 2 74 93 13 BACK
85. steering contactor The truck is not electrically hold CONT The hydraulic steering function on a slope but comes down request is also sent to the pump very slowly till the flat is inverter by the can bus link reached It drives the coil of a hydraulic The truck is electrically hold on a EXCL ON steering contactor slope when the time set by HYDRO The hydraulic steering function auxiliary time parameter is request is also sent to the pump elapsed the truck comes down inverter by the can bus link very slowly till the flat is reached It drives the coil of a hydraulic EXCL OFF steering contactor The truck is not electrically hold HYDRO The hydraulic steering function on a slope but comes down request is also sent to the pump very slowly till the flat is inverter by the can bus link reached Page 59 93 8 4 2 60 93 Using the config menu the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers travel time only KEYON the counter registers when the key switch is closed 2 BATTERY CHECK ON the battery discharge level check is carried out when the battery level reaches 10 an alarm is signalled and the maximum current is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled Very important In the combi system pump traction
86. t is open the SAFETY circuit becomes active and within a timeout it is able to open the drivers of LC coil and EB coil The safety circuit is also periodically checked by the AC 3 FLASH microcontroller if the microcontroller detects a failure in the SAFETY circuit the microcontroller itself will bring the machine in a safe status Suggested connection of SAFETY circuit STANDALONE CONFIGURATION it must be used only if there are other controllers that can stop the system in case of failure for example EPS COMBI CONFIGURATION in this case the pump controller acts as supervisor checking the traction controller functionality by the CANBUS So it is suggested to connect the SAFETY input of traction controller to a dedicated output of pump controller so that the pump controller can drive the traction safety input and open the power line in case of malfunctioning of traction controller EMC 18 93 and ESD performances of an electronic system are strongly influenced by the installation Special attention must be given to the lengths and the paths of the electric connections and the shields This situation is beyond ZAPI s control Zapi can offer assistance and suggestions based on its years experience on EMC related items However declines any responsibility for non compliance malfunctions and failures if correct testing is not made The machine manufacturer holds the responsibility to carry
87. the maximum speed is reduced down to 1096 The traction also checks via CAN that there aren t alarms on pump If pump is in alarm the maximum speed is reduced down to 10 but in this case any alarm or warning appears SUBMENU ADJUSTMENTS 1 SET POT BRK MIN It records the minimum value of braking pedal potentiometer when the braking pedal switch is closed the procedure is similar to the Program Vacc function see chapter 9 4 This procedure must be carried out only if the Pedal braking option is programmed as Analog 2 SET POT BRK MAX It records the maximum value of braking pedal potentiometer when the braking pedal is fully pressed the procedure is similar to the Program Vacc function see chapter 9 4 This procedure must be carried out only if the Pedal braking option is programmed as Analog 3 SET BATTERY TYPE It selects the nominal battery voltage 4 ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller 5 THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve see also curve below 6 THROTTLE X POINT This parameter changes the characteristic of the accelerator input curve 7 THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve ADWZPODB AC 3 FLASH INVERTER User Manual Page 57 93 gt gt phn VACC MIN and VACC MAX are values programmable by the Program Vacc function 8 ADJUSTMENT 04
88. the operator who is most of the time the source of ESD 4 5 Various suggestions Page 20 93 Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR choppers work If it is necessary to use two or more control units traction lift for ex they must belong to the ZAPIMOS family During battery charge disconnect ASYNCHRONOUS from the battery ADWZPODB AC 3 FLASH INVERTER User Manual 5 OPERATIONAL FEATURES Speed control Optimum behaviour a slope due to the speed feedback the motor speed follows the accelerator starting a regenerative braking if the speed overtakes the speed set point the system can perform an electrical stop on a ramp the machine is electrically hold on a slope for a programmable time see also chapter 8 4 Stable speed in every position of the accelerator Regenerative release braking based upon deceleration ramps Regenerative braking when the accelerator pedal is partially released deceleration Direction inversion with regenerative braking based upon deceleration ramp Regenerative braking and direction inversion without contactors only the main contactor is present release braking ramp can be modulated by an analog input so that a proportional brake feature is obtained Optimum sensitivity at low speeds gt Voltage boost at the start and with overload to obtain more torque w
89. the request microswitch is closed Increase the level accordingly 8 Set the Speed Reductions as required Make adjustments to SPEED Check the performance with the full request Check the performance with and without load 9 Set MAX SPEED UP max speed of pump motor 10 Set HYD SPEED FINE to adjust the hydraulic steering speed pump motor speed when HYDRO function is requested 11 Set AUXILIARY TIME time delay before pump stops when an hydraulic steering function request is switched off 12 Set SET TEMPERATURE setting the motor thermal sensor type used ADWZPODB AC 3 FLASH INVERTER User Manual Depending the motor used it is necessary to set some parameters giving Zapi the motor curves it is possible to know the optimal setting in order to the motor runs efficiently 8 9 Tester description of the functions The most important input or output signals can be measured in real time using the TESTER function of the console The Console acts as a multimeter able to read voltage current and temperature The following definition listing shows the relative measurements 8 9 1 Traction 1 MOTOR VOLTAGE This is the voltage supplied to the motor by the inverter it is expressed as a percentage of the full voltage which depends of the battery voltage 2 FREQUENCY This is the frequency of the voltage and current supplied to the motor 3 ENCODER This is the speed of the motor expre
90. tive of encoder power supply Lift potentiometer positive 10 V output keep load gt 1 Input fourth speed request it is active HIGH Input for potentiometer lifting enable input it is active HIGH Input for first speed request it is active HIGH This is a digital input free for customer request Input for third speed request it is active HIGH Input for second speed request it is active HIGH Input for hydraulic steering request Active high Speed reduction input Active low switch opened If not connected to Batt the MC coil power output will be disabled It can also be used as a general purpose input Phase A of encoder Phase B of encoder Negative of lift potentiometer tested for wire disconnection diagnosis Lift potentiometer wiper CAN termination connect to CAN H A18 to insert can termination resistance High level CAN BUS voltage I O Low level CAN BUS voltage I O Batt Free analog input used for auxiliary potentiometer Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output Batt Input for motor temperature sensor This output can be used to drive the main contactor coil single pump configuration or to drive an auxiliary load combi configuration Page 31 93 32 93 A27 A28 A29 A30 A31 A32 A33 A34 A35 B1 B2 B3 B4 B5 B6 B7 B8 PAUX NHYDRO PHYD
91. to confirm 13 Repeat the same from 5 to 12 points for the other adjustments Page 64 93 CONFIG ZAPI VD D BOV 550A 00000 MENU SET MODEL CONFIG ADJUSTMENTS MENU BATTERY TYPE 48V TROTTLE D ZONE 7 oo ADWZPODB AC 3 FLASH INVERTER User Manual Flow chart showing how to use the SET BATTERY adjustment E O E ood 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The Display will show SET MODEL 4 Press ROLL UP button until ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will show SET BATTERY TYPE 8 Press SET UP to choose nominal value of the battery 9 New battery value appears 10 Press OUT 11 Confirmation request appears 12 Press ENTER to accept the changes or press OUT if you do not accept the changes 13 Press OUT Display now shows the Opening Zapi Menu ADWZPODB AC 3 FLASH INVERTER User Manual ZAPI VD D BOV 550A 00000 CONFIG MENU SET MODEL Bod ood CONFIG MENU ADJUSTMENTS E El El SET BATTERY TYPE 48V SET BATTERY ood ARE YOU SURE YES ENTER Page 65 93 66 93 Flow chart showing how to carry out ADJUSTMENT BATTE
92. uit gets active and opens the drivers of LC and EB and stops the machine Verify the SAFETY input connection 22 BATTERY LOW If the battery check option is ON a battery discharge algorithm is carried out When the charge level is 1095 this alarm is signalled and the current is reduced to the half of the programmed level 23 WRONG SET BATT When the key is turned ON the controller check the battery voltage and verifies it is within a window around the nominal value Replace the battery with a correct battery 24 WAITING FOR NODE The controller receives from a remote module via CAN Bus the information that it isn t possible to close the LC the module isn t ready locked in an alarm state Verify the other modules to determinate in which of them there is the problem ADWZPODB AC 3 FLASH INVERTER User Manual Page 91 93 12 RECOMMENDED SPARE PARTS FOR INVERTER Part number Description C16507 Protected 500 A strip Fuse C16505 Protected 355 A strip Fuse C16520 10 A 20 mm Control Circuit Fuse C29509 SW 200 80 V Single Pole Contactor C29532 SW 200 48 V Single Pole Contactor C12532 Ampseal Connector 35 pins Female C12442 Molex Minifit Connector 2 pins Female C12358 Molex Minifit Connector 4 pins Female C12359 Molex Minifit Connector 6 pins Female C12414 Molex Minifit Connector 8 pins Female C12407 Molex Minifit Connector 12 pins Female C12403 Molex Minifit Connector 14 p
93. urred the Hour Meter count and the controller temperature This function permits a deeper diagnosis of problems as the recent history can now be accessed Flow Chart showing how to use the ALARMS function via the Digital Console ZAPI VD D BOV 550A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu MAIN PARAMETER 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until mun PARAMETER CHANGE appears on the display un MAIN 5 The Display will show ALARMS 6 Press ENTER to go into the ALARMS function 00005 02 20 C 7 The Display will show the most recent Alarm 8 Each press of the ROLL UP button brings up following Alarms Pressing ROLL DOWN returns to the most recent 9 If an Alarm has not occurred the Display will CODE show ALARM NULL 00007 03 18 C 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu 11 The Display will ask CLEAR LOGBOOK 22242 YES ENTER 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi Display ADWZPODB AC 3 FLASH INVERTER User Manual Page 81 93 9 4 Description of Console PROGRAM VACC function Page 82 93 This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal

AC-3 FLASH INVERTER - User Manual

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