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(DUALAC2-ing) Traction (DUALAC2

1. 20 _ m 191 g 6 X 665 Lag ES RI E iif N EN a W li A q TV NAY a E CO 2 IT AN s ai S lt Si E Z a A a 2 ry D Kl 4 w vE si A 4 et gt T gt i 35 Z Q g ES E AA SE O m O g Alal 1 El a a E 5 E E Se ls S a sl a S ENS Les s m AA z AJ s O Z m 3 o a SA Fi lt m RE lt Z S Els 5 g E z l en z De A W JAN s d STRI AS S NH RAN SF e we 4 L 98Z9LL N a IO Ve Page 38 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 7 1 2 Dimensions of Dualac2 Power A E L A a N i EA BERE a Wa A T ES q a 5 S 2 a ei e xe T l o mo O EL w Ti Mi H 8 A O 11 A T 7 Ss A ot i L y Fi D S l Bs lo C IF il lt SA e A IN YE VOZ Se WN A AE e wT f W
2. B Negative of the battery BT Positive of the battery if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection Page 36 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual BTF Um Vm Wm Us Vs Ws P BPF Positive of battery before power fuse must be connected to positive cable coming from LC contact Connection bars of the three right motors phases follow this sequence and the indication on the motor Connection bars of the three left motors phases follow this sequence and the indication on the motor Output of pump motor chopper Pump chopper positive if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection also the pump motor positive cable must be connected to this power connection Pump chopper positive before power fuse must be connected to positive cable coming from LC contact AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 37 89 7 DRAWINGS 7 1 Mechanical drawing 7 1 1 Dimensions of Dualac2 OH 27 118 No o 2 1145 RER 12925 OPTIONAL POWER FUSE 20
3. 300 A RMS for 2 per each motor Chopper maximum current 24 V cucuta 500 A for 2 Chopper maximum current 36 48 Mi 450 A for 2 Chopper maximum current 72 80 V sees eee 300 A for 2 Operating BE CINCY EE 8 kHz External temperature range eee eee eee eee eee 30 C 40 C Maximum inverter temperature at full power 75 C 2 2 1 Block diagram Page 8 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 2 2 2 Chopper block diagram 2 3 Technical specifications Dualac2 Power Inverter for pairs of AC asynchronous 3 phase motors Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chip Program Memory each microcontroller Digital control based upon a microcontroller one per each AC motor Voltage TE 24 36 48 72 80 V Maximum current 24 VI 500 A RMS for 3 per each motor Maximum current 36 48 V 450 A RMS for 3 per each motor Maximum current 72 80 V 400 A RMS for 2 per each motor Operating ieee Ee eee al e eee 8 kHz External temperature range sita 30 C 40 C Maximum inverter temperature at full power 75 CC 2 3 1 Block diagram See chapter 2 1 1 2 4 Technical specifications Dualac2 amp hp Power Inverter for pairs of AC asynchronous 3 phase motors plus choppe
4. 8 3 1 b Slave HEADING MAIN MENU PARAMETER CHANGE NOT AVAILABLE CONNECT TO 4 SET OPTIONS CNC 8 INPUT USE NONE OPTION 1 TESTER z AA Hz ADJUSTMENTS set BATTERY TYPE 24 36 48 72 80 96V ENCODER Hz ADJUST BATTERY LIN S BS AUX OUTPUT VOLT V CURRENT RMS A TEMPERATURE C VOLTAGE BOOS 7 VOLTAGE TER A ON OFF SAVE PARAME TER fa METER VACC SETTING MIN MAX STEER TABLEJ AVAILABLE NOT Page 46 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 8 3 2 Dualac28hp and Dualac2 amp hp Power menu configuration 8 3 2 a Master HEADING MAIN MENU L PARAMETER ACCELER DELAY 9 SET MODEL Bea CHANGE mt Kee EE NE be CONNECTED TO 3 RELEASE BRAKING 0 9 NVERS BRAKING 9 PEDAL BRAKING 9 SPEED LIMIT BRK 9 BRAKE CUTBAC 9 SET OPTIONSH HOUR COUNTER RUNNING KEY ON JAX SPEED FORW LJ BATTERY CHECK ON OFF MAX SPEED BACK Hz TRACTION CUTOUT ON OFF CUTBACK SPEED 1 Z HFT CUTOU ONZ OPF CURVE CUTBAC Ge FREQUENCY CREEP Hz E Se aa ees GE AUX INPUT 1 EXCLUSIVE HYDRO OPTION 1 2 ae A en zi PEDAL BRAKING ANALOG DIGITA SET TEMPERATURE ANALOG DIGITAL NONE BACKING
5. AMPSEAL P AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 40 89 f Dualac2 amp hp Power imensions o 7 1 4 D at 353 84MOd TVNOLLAD 97621 au OPTIONAL POWER FUSE M8 BOLT T human 4 H I FOL a EOL an 08 SS To L F A VA ae Wiel RQ y k IA Ne IONAL POWER FUSE M8 BOLT ZWS ffi CONNECTOR CO AMPSEAL Plug P N 776164 1 NSOLE MOLEX AMPSEAL Plug P N 776 P N 09 50 1081 286 1 AMPSEAL Plug P N 776273 1 Page 41 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 7 2 Connection drawing Dualac2 and Dualac2 Power standalone A B L D L G K 0 10A FUSE LI ACO L A A
6. 15 ACC SMOOTH It gives a different form to the acceleration curve in the frequency range O Hz to Stop smooth value see the figure below 16 INV SMOOTH It gives a different form to the acceleration curve after a direction inversion in the frequency range 0 Hz to Stop smooth value see the figure below AE9ZPOBC DUALAC2 amp HP POWER User Manual 17 STOP SMOOTH It sets the level of frequency where the smooth effect on the acceleration ramp ends standard f acceleration ramp k lt Stop Smooth 0 4 1 0 2 0 3 5 t 0 4 1 0 2 0 3 5 are some possible values of the Acc Smooth and Inv Smooth parameters see the table below 18 AUXILIARY TIME It determines the time that the truck is hold on the ramp if the stop on ramp option is ON AE9ZPOBC DUALAC2 8HP POWER User Manual Page 59 89 The following table shows the different values at which the parameters can be set PROGRAMMED LEVEL pot it2tsia ds e 7 PARAMETER UNIT ACCELERATION DELAY RELEASE BRAKING INVERSION BRAKING Sec PEDAL BRAKING Sec 0 0 eee goe ss 77 7a 66 60 l sela BRAKE CUTBACK 2 MAX SPEED RV Fo os Po Pes ao ss so 95 110 140 1 20 MAX SPEED BW S CUTBACK SPEED 1 09 Se E Nn oo inIiIZie i ai lu ATTN lnl elsa O N CURVE CUTBACK FREQUENCY CREEP 3 0 6 l MAXIMUM CURRENT BACKING SPEED ES BACKING TIME 8 3 l
7. Positive of left motor encoder power supply 5 V 12 V Negative of left motor encoder power supply Right motor encoder phase A Right motor encoder phase B Negative of steering potentiometer BATT Positive of steering potentiometer 5 V 12 V Steering potentiometer wiper signal Brake potentiometer wiper signal BATT Negative of traction accelerator potentiometer tested for wire disconnection diagnosis Traction potentiometer wiper signal Left motor encoder phase A Left motor encoder phase B Negative of right traction motor temperature sensor Right traction motor temperature signal Output of main contactor coil driver drives to BATT Positive of main contactor coil Output of electric brake coil drives the load to BATT maximum current 3 A Positive of the electromechanical brake coil Positive of auxiliary load Output of auxiliary load driver drives to BATT AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 29 89 C33 C34 C35 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 PPOT NTHERM_L PTHERM_L BATT 2ND 1ST ENABLE CMM 5TH 4TH 3RD CPOTLIFT BATT BATT BATT NPOTLIFT PPOTLIFT Traction potentiometer positive 5 10 V output use load gt 1 kohm Negative of left traction motor temperature sensor Left traction motor temperature signal Negative output Second hydraulic speed input active high First hydraulic speed input active high
8. Backing forward and reverse options are available with the tune and the speed of the function programmable with Zapi handset High efficiency of motor and battery due to high frequency commutations 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 Diagnostic function with Zapi handset for checking main parameters Built in BDI feature Flash memory sw downloadable via serial link and via CANBUS Canopen interface available 5 1 Diagnosis Page 24 89 The microcontrollers continually monitor the inverter and carry 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 charging phase s voltages contactor drivers can bus interface if the switch sequence for operation is correct and if the output of accelerator unit is correct correct synchronization of the two CS integrity of AE9ZPOBC DUALAC2 amp HP POWER User Manual safety related inputs hardware 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 Continuou
9. Input for proportional lifting enable active high Common output of microswitches BATT Fifth hydraulic speed input active high Fourth hydraulic speed input active high Third hydraulic speed input active high Input for proportional lift potentiometer Negative for proportional lift potentiometer Positive for proportional lift potentiometer 12 V 6 3 CANBUS connector description Dualac2 Controller has a canbus interface so it has been designed to work in a can network together with other electronic modules exchanging information over the canbus network Furthermore the exchange of information between master and slave microcontrollers is based on the canbus as well Dualac2 also provides built in can termination resistance which can be connected in different ways as described here following 6 3 1 Dualac2 Controller in stand alone configuration Bridge 2 4 and 5 7 connect both built in120 ohm can termination resistances Page 30 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 6 3 2 Dualac2 Controller is a termination module in the canbus net DUALAC2 oe a 7 AN H Bridge 2 4 connects one built in 120 ohm can termination resistance the second will be connected in another module of the canbus net 6 3 3 Dualac2 Controller is a repetition module in the canbus net DUALACe ONN ko FI 1 3 G X CT Lo 40 x f
10. The temperature measured on the aluminium heat sink holding the MOSFET devices AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 69 89 7 8 9 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 BATTERY VOLTAGE Level of battery voltage measured at the input of the key switch SEAT SWITCH The level of the Seat Microswitch digital input ON VB input active switch closed OFF GND input non active switch opened 10 FORWARD SWITCH The level of the Forward direction digital input FW ON VB input active switch closed OFF GND input non active switch opened 11 BACKWARD SWITCH The level of the Reverse direction digital input BW ON VB input active switch closed OFF GND input non active switch opened 12 ENABLE SWITCH The level of the Enable digital input ON VB input active switch closed OFF GND input non active switch open 8 9 3 Dualac28hp and Dualac2 amp hp Power Master See chapter 8 9 1 8 9 4 Dualac28hp and Dualac2 amp hp Power Slave 1 2 3 4 5 6 7 8 9 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 ENCOD
11. Traction potentiometer wiper signal Left motor encoder phase A Left motor encoder phase B Negative of right traction motor temperature sensor Right traction motor temperature signal Output of main contactor coil driver drives to BATT Positive of main contactor coil Output of electric brake coil drives the load to BATT maximum current 3 A Positive of the electromechanical brake coil Positive of auxiliary load Output of auxiliary load driver drives to BATT Traction potentiometer positive 5 10 V output use AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 27 89 load gt 1 kohm C34 NTHERM L Negative of left traction motor temperature sensor C35 PTHERM L Left traction motor temperature signal 6 2 Connectors of the logic Dualac2 amp hp and Dualac2 amp hp Power P H m A1 CAN_H High level CANBUS A2 CANT_H CANBUS termination output 120 ohm internally connected to CAN_H Connect to CAN_L_OUT to insert the termination A3 CAN_POS Positive of CAN circuit to be used in case of optoisolated CANBUS A4 CAN_L_OUT Low level CANBUS to be used as repetition for CAN L line or to be connected to CANT H to insert termination resistance A5 CANT L CANBUS termination output 120 ohm internally connected to CAN L Connect to CAN H OUT to insert the termination A6 CAN L Low level CANBUS A7 CAN_H_OUT High level CANBUS to be used as repetition for CAN H line or to be connected to CANT L
12. User Manual Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 31 VMN HIGH X X X X Alarm wrong If the alarm is present voltage on motor in Init status remove power outputs the alarm condition failure in the If the alarm has power section or occurred in stby or in the mosfet running mode it is driver circuit orin necessary to remove the motor alarm condition and to activate a traction request 53 STBYIHIGH X X X X Alarm wrong If the alarm is present voltage in the in Init status remove current sensor the alarm condition feedback circuit If the alarm has occurred in stby or running mode it is necessary to remove alarm condition and to activate a traction request 60 CAP X X X Alarm power To remove alarm CHARGE capacitor voltage condition does not increase when the key is turned ON failure in the power section or in the Logic PCB or in the driver PCB or in the motor 74 DRIVER X X A A Alarm line If the alarm is present SHORTED contactor coil in Init status remove driver is shorted the alarm cause If the alarm has occurred in stby or running mode it is necessary to remove alarm cause and to activate traction request 75 CONTACTOR X A X Alarm line To remove alarm DRIVER contactor coil cause and to activate driver is open not traction request ab
13. 66 89 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 inverter s configuration 1 Select the Options required See Chapter 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 accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 3 5 Perform the steering potentiometer signal acquisition using the parameters in Adjustment menu see Chapter 8 4 Remember turning the wheel to right direction voltage has to increase 6 Set the maximum steering angles right and left direction use the parameters in Adjustments menu see Chapter 8 4 7 Set the MAXIMUM CURRENT Current using the table on Chapter 8 5 1 8 Set the Acceleration Delay requirements for the machine Test the parameter setting in both directions AE9ZPOBC DUALAC2 amp HP POWER User Manual 9 Set the FREQUENCY CREEP level starting from level 0 3 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly 10 Set the Speed Reductions as required Make adjustments to CUTBACK SPEE
14. ACC SMOOTH 15 1 aka INV SMOOTH 0 6 1 5 1 0 STOP SMOOTH AUXILIARY TINE sc Jo foafoafos s fas pa fa fal 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 IMAX S H H H H ec Z Z o o Z Z ec S o Rjoj i lajaju E LA aluoujpojojujuljii L S lad 1 Ss 00 Nop apo LA fann ta oo E o P W H 8 5 2 Dualac2 Slave The menu is not available 8 5 3 Dualac2 amp hp Master See chapter 8 5 1 8 5 4 Dualac28hp Slave Here following the list of parameters which can be set in this menu 1 SPEED LIMIT It determines the maximum lifting speed per cent of voltage applied to the motor with a potentiometer control when the potentiometer is at the maximum of the programmed range 2 PUMP IMAX The maximum current of pump chopper Page 60 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 3 4 5 6 7 8 9 PU ACCELER DELAY Acceleration ramp of pump
15. Check if there are external shortcircuit and if the ohmic value of the MC coil is correct otherwise replace the logic DRIVER SHORTED When the key is switched ON the uC checks that the LC coil driver is not shorted if it is this alarm is signalled Preliminary check if there is an external short or low impedance pull down between NLC C26 and BATT If no external causes can be found out replace the controller CONTACTOR DRIVER When the initial diagnosis is finished the traction logic closes the LC and checks the voltage on the Drain of the driver If this is not low the driver is not able to close 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 does not pull in CONTACTOR CLOSED Before driving the LC coil the controller checks if the LC contact is stuck The controller drives the bridge for a while 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 it is mechanically stuck 9 ENCODER ERROR This alarm is signalled in following condition the frequency supplied to the motor is higher than 20 Hz and the signal feedback from the encoder has a jump higher than 20 Hz in few tens millisecond This con
16. DUALAC2 amp HP POWER User Manual Page 79 89 Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 78 VACC NOT X X X Warning To remove Warning OK accelerator signal cause CPOT voltage higher than VACC MIN 1V while the traction enable switch is open 79 INCORRECT X X X X Warning wrong To remove Warning START traction request cause sequence 80 FORWARD X X X X Warning forward To remove Warning BACKWARD and reverse cause inputs are both active 249 THERMIC X X X X X Warning Master To remove Warning SENSOR KO or slave cause temperature sensor is out of range 251 WAITING X X X X Warning Master To remove Warning FOR NODE 4 UC signals that cause Slave uC is in alarm status 251 WAITING A A A A Warning Slave To remove Warning FOR NODE 3 UC signals that cause Master uC is in alarm status 247 NO CAN X X X X Alarm Master To remove Warning MESSAGE 4 has lost Can cause communication with the Slave 247 NO CAN A X A X Alarm Slave has To remove alarm MESSAGE 3 lost Can cause communication with the Master 244 SLAVE X X X X Warning Slave To remove Warning WARNING uC has a warning cause 250 HANDBRAKE X X X Warning the To remove Warning operator try to cause travel with the handbrake active Page 80 89 AE9ZPOBC DUALAC2 amp HP POWER
17. STEER RIGHT av MAX STEER LEF AV SET STEER 0 POS A SET STEER RIGH 9 SET STEER LEF E THROTTLE Q ZONE Z THROTTLE X POINT se HROTTLE Y POINT ee ADJUSTMENT 2 BD 1 9 ADJUSTMENT 1 BD 1 9 AIN CONT VOLT aa AUX OUTPUT VOLT aN LOAD HM FROM MDI ON OFF CHECK UP DONE ON OFF CHECK UP TYPE NONE OPTION 1 2 3 8 3 1 Dualac2 and Dualac2 Power menu configuration 8 3 1 a Master HEADING MAIN MENU PARAMETER ACCELER DELAY 0 9 SET MODEL CHA GI RELEASE BRAKING 0 9 NVERS BRAKING 0 9 PEDAL BRAKING 0 9 SPEED LIMIT BRK 0 9 BRAKE CUTBACK 0 9 SET OPTIONS AX SPEED FORW Hz AX SPEED BACK Hz CUTBACK SPEED 1 Z CURVE CUTBACK FREQUENCY CREEP Hz AXIMUM CURRENT 0 9 BACKING SPEED z BACKING TIME 0 9 ACC SMOO NV SMOOTH STOP SMOOTH Hz AUXILIARY TIME Sec ADJUSTMENTS TESTER MOTOR VOLTAGE FREQUENCY Hz ENCODER Hz SLIP VALUE Hz CURRENT RMS A TEMPERATURE C TEMPERATURE 1 de TEMPERATURE 2 sc AC RATOR V STEER ANGLE NT WHEEL CUTB FORWARD SWITCH ON OFF BACKWARD SWITCH ON OFF ENABLE SWITC ON OFF SEAT SWITCH ON OF BACKING SWITCH ON OFF CUTBACK SWITCH ON OFF BRAKE SWITCH ON OFF EXCLUSIVE HYDRO ON OFF BRAKEPEDAL POT HANDBRAKE ON OFF VOLTAGE BOOSTER BATTERY VOLTAGE V SAVI BATTERY CHARGE PARAMETER HOURS METER RESTORI PARAMETER A CODE ALARMS h N C alae KE VACC SETTING MIN MAX EE NOT STEER TABLE Roe en AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 45 89
18. The Display will show SET MODEL 4 Press ROLL UP button until ADJUSTMENTS moo Menu appears 000 5 ADJUSTMENTS appears on the display Menos 6 Press ENTER to go into the ADJUSTMENTS S 0 Menu ooo 7 The display will show the first OPTION Gi re O OV 8 Press ROLL UP or ROLL DOWN button until mon desired OPTION appears mon ADJUSTMENT BATTERY 9 ADJUST BATTERY appears 82 1V 10 Press SET UP or SET DOWN button in order to increase or decrease respectively Set the value read by an external voltmeter ADJUSTMENT BATTERY 11 Battery value appears on the display BA EN 12 Press OUT to exit the Menu oo D D D ARE YOU SURE 13 Confirmation request appears vee ein OT 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 ADJUSTMENTS Menu appears CONFIG MENU ADJUSTMENTS 16 Press OUT Display now show the Opening Zapi Menu AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 57 89 8 5 Parameter regulation 8 5 1 Dualac2 Master Page 58 89 The following parameters can be modified 1 ACCELER DELAY It determines the acceleration ramp 2 RELEASE BRAKING It controls the deceleration ramp when the travel request is released 3 INVERSION 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 th
19. User Manual Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 241 DATA X X X Warning To remove Warning ACQUISITION Maximum current cause and to activate adjustment traction request procedure is in progress NOTE this procedure has to be done only by Zapi test department 248 CHECK UP X X Warning To remove Warning NEEDED maintenance time cause is reached oz Analysis of traction related alarms displayed on console 1 2 3 4 5 6 WATCH DOG It is a self diagnosis test within the logic between Master and Slave ucontrollers This alarm could also be caused by a canbus malfunctioning which blinds Master Slave communication So before replacing the controller check the canbus LOGIC FAILURE 3 Fault in the hardware section of the logic board which manages the hardware current protection Replace the logic board LOGIC FAILURE 2 Fault in the hardware section of the logic board which manages the phase s voltage feedback Replace the logic board LOGIC FAILURE 1 This alarm signals that the undervoltage overvoltage protection interrupt has been triggered Two possible reasons B Areal undervoltage overvoltage situation happened C Fault in the hardware section of the logic board which manages the overvoltage protection Replace the logic card
20. between the two motors speed changes as a function of the steering angle and of the axle wheeltrack ratio While the steering angle is an information coming from the transducer AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 13 89 potentiometer the axle wheeltrack ratio is a constant characteristic of the truck that depends on his dimensions Actually two steering tables are provided Option 1 tables for 3 wheels trucks with driving wheels counter rotation the internal wheel inverts the direction Option 2 tables for 4 wheels trucks without driving wheels counter rotation the internal wheel does not inverts the direction The truck data have to be communicated to Zapi so that it is possible to put in the software the correct steering table The correct table selection is done in the SET OPTION menu see chapter 8 4 The relationship between the two motors speed is equal to the relationship between the two radius described during the curve Page 14 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours they mean E These are informations useful for anyone is working on the installation or a deeper examination of the content A 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
21. cable or a duplex cable not shielded Ina 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 A Wrong Layout Module 1 Module 2 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 This is apparently a good layout but can bring to errors in the can line The best solution depenas 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 17 89 A Correct Layout Module 4 Module 2 Note Module 1 power gt Module 2 power gt Module 3 power The chain starts from the DATT 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 a 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 A Correc
22. edi ai ria 21 44 E 21 4 5 Various Suggestions E 23 5 OPERATIONAL FEATURES sssini tert aii ee eee aS ite Solano 24 5 1 RE e ie 24 6 DESCRIPTION OF THE GONNEGTOR Strikti kose toke sok ki do ked kask kako brin pasa bs eibkikstition 26 6 1 Connectors of the logic Dualac2 and Dualac2 Power 26 6 2 Connectors of the logic Dualac2 amp hp and Dualac2 amp hp Power 28 6 3 CANBUS connector description 30 6 3 1 Dualac2 Controller in stand alone configuration 30 6 3 2 Dualac2 Controller is a termination module in the canbus net 31 6 3 3 Dualac2 Controller is a repetition module in the canbus net 31 6 4 Description of power CONNECTIONS cc eee eee eee eee 32 GA De o E 32 642 Dualac2 EE 33 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 3 89 10 11 12 A Da REN WE 34 6 4 4 Dualac2 amp hp Ne 36 DRAWINGS usina 38 dal Mechanical drawing ske eee eee 38 7 1 1 Dimensions RTE EE 38 7 1 2 Dimensions of Dualac2 Power 39 7 1 3 Dimensions Of Dualacz2R hp sse 40 7 1 4 Dimensions of Dualac2 amp hp Power esse eee eee 41 7 2 Connection drawing Dualac2 and Dualac2 Power standalone 42 7 3 Connection drawing Dualac2 amp hp and Dualac2 amp hp Power standalone 43 PROGRAMMING 8 ADJUSTMENTS USING DIGITAL CONSOLE concccconocccccnnonccncnnnanannnos 44 8 1 Adjustments vi
23. 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 mm section For power connections to the motor and to the battery use cables having section of at least 70 mm 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 The main contactor must be installed The LC coil driver is voltage controlled by means of a 1 kHz PWM The voltage applied to the coil can be adjusted by Main Cont Voltage parameter in Config Adjustment menu It has to be adjusted to the LC coil nominal voltage 4 1 3 Fuses Use a 6 3 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 For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow 42 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 en
24. motor PU DECELER DELAY Deceleration ramp of pump motor CREEP SPEED It determines the minimum lifting speed per cent of voltage applied to the motor with a potentiometer control when the potentiometer is at the minimum of the programmed range COMPENSATION This parameter sets the voltage compensation DV applied to the motor when the proportional lifting function is active The value of this DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV will be increased 1ST SPEED FINE This parameter sets the pump motor speed voltage applied to the motor when the 1st speed request is active 1ST SPEED COMP This parameter sets the voltage compensation DV applied to the motor when the 1st speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 2ND SPEED FINE This parameter sets the voltage compensation DV applied to the motor when the 2nd speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 10 2ND SPEED COMP This paramet
25. of N gt N N L N N x N SS The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close O 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 unit 1 Input C18 is an analog input whose typical application 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 C18 signal range is from 0 to 5 V or from 0 V to 10 V 2 Connections C25 PTHERMR and C24 NTHERMR are used for the right motor thermal sensor Connections C35 PTHERML and C34 NTHERML are used for the left motor thermal sensor Sensors can be digital on off sensor normally closed or analog See also chapter 8 4 for more explanation 3 Inthe versions with integrated pump chopper DUALAC2 amp HP and DUALAC2 amp HP POWER it is possible to input to the controller an analog signal for proportional lifting This input will be the output of a potentiometer 3 wires resistance in the 1 to 10 kohm range or of a Hall Effect device the load must be below 10 mA CPOTLIFT D9 s
26. parameter changes the characteristic of the accelerator input curve 12 THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve AE9ZPOBC DUALAC2 amp HP POWER User Manual VACC MIN and VACC MAX are values programmable by the Program Vacc function 13 ADJUSTMENT 1 BDI It adjusts the upper level of the battery discharge table 14 ADJUSTMENT 2 BDI It adjusts the lower level of the battery discharge table 15 MAIN CONT VOLTAGE This parameters adjusts the Line contactor coil voltage PWM output C26 16 AUX OUTPUT VOLTAGE This parameters adjusts the Electric brake coil voltage PWM output C28 17 LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI connected on the Serial Link 18 CHECK UP DONE Turn it ON when the required Maintenance service has been executed to cancel the CHECK UP NEEDED warning 19 CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEEDED warning OPTION 1 CHECK UP NEENED warning shown on the hand set and MDI after 300 hours OPTION 2 Equal to OPTION 1 but speed reduction after 340 hours AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 51 89 OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 8 4 2 Dualac2 and Dualac2 Power Slave Using the config menu of the programming console the us
27. the Digital Console The Console is connected to the B connector of the inverter ez Description of Console amp Connection CONNECTOR DISPLAY 1 PARAM IMAX B REVERSE BRAKING COMPENS ACCEL R BRAKE e TESTER MAX SP SPEED I e S P I SPEED Il 3 SAVE S P I SPEED IlI BYPASS FIELD WEAK ik dit wer RON Z E Temp V BATT 5 ALARMS V MOT VMN MOT M SW TEST 6 ACCELERATOR 7 MOTOR DATA tij b 5 f 8 8 ROLL ENTER SET BUTTONS 4 i Se ROLL OUT SET il L oy um Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 02 Page 44 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 8 3 Description of Standard Console Menu CONNECTED TO 3 HOUR COUNTER BATTERY CHECK RACTION CUTOUT HYDRO KEY ON STOP ON RAMP AUX INPUT 1 PEDAL BRAKING SET TEMPERATURE RUNNING KEY ON ON OFF ON OFF ON OFF ON OFF EXCLUSIVE HYDRO OPTION 1 2 ANALOG DIGITA ANALOG DIGITAL NONE STEER TABLE OPTION 1 OPTION 2 CNC 8 INPUT USE NONE OPTION 1 2 SMART DISPLAY ON OFF SET POT BRK MIN uv SET POT BRK MAX LV SET BATTERY TYPE 24 36 48 72 80 96V ADJUST BATTERY ai AX
28. voltage frequency Hz encoder Hz slip value Hz Page 65 89 current rms A temperature C temperature 1 C temperature 2 C accelerator V steer angle int wheel cutback forward switch ON OFF backward switch ON OFF enable switch ON OFF seat switch ON OFF backing switch ON OFF cutback switch ON OFF brake switch ON OFF exclusive hydro ON OFF brakepedal pot handbrake ON OFF voltage booster current rms A temperature C voltage booster battery voltage V seat switch ON OFF forward switch ON OFF backward switch ON OFF enable switch ON OFF lifting control V lifting switch ON OFF 1st speed switch ON OFF 2nd speed switch ON OFF 3rd speed switch ON OFF 4th speed switch ON OFF 5th speed switch ON OFF pump current A pump voltage V pump temperature C wa battery voltage V battery charge hours meter Save function for storing data gt only with Pc console Restore function for downloading parameters to another controller gt only with Pc console 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 Traction Inverter setting Page
29. 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 40 more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected 4 2 7 Insulation of truck frame A 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 ALDO 4 3 1 Protection features Page 20 89 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 inverter temperature exceeds 75 C the maximum current is reduced in proportion to the thermal increase The temperature can never exceed 100 5 AE9ZPOBC DUALAC2 amp HP POWER User Manual External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP65 Protection against uncontrolled movements The main contactor will not close if The Power unit is not functioning The Logic is not functioning perfectly The o
30. C2 amp HP POWER User Manual 2 SPECIFICATION 2 1 Technical specifications Dualac2 Inverter for pairs of AC asynchronous 3 phase motors Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chip Program Memory each microcontroller Digital control based upon a microcontroller one per each motor o rpt NO ene 24 36 48 72 80 V Maximum current 24 VI 350 A RMS for 3 per each motor Maximum current 36 48 V 320 A RMS for 3 per each motor Maximum current 72 80 V 300 A RMS for 2 per each motor Operating helene 8 kHz External temperature range eee eee eee eee 30 C 40 C Maximum inverter temperature at full power 75 C 2 1 1 Block diagram AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 7 89 2 2 Technical specifications Dualac2 amp hp Inverter for pairs of AC asynchronous 3 phase motors plus chopper for DC series pump motor Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chip Program Memory each microcontroller Digital control based upon a microcontroller one per each AC motor Miell L 24 36 48 72 80 V Maximum current 24 V 350 A RMS for 3 per each motor Maximum current 36 48 V 300 A RMS for 3 per each motor Maximum current 72 80 V
31. C2 amp HP POWER User Manual DUALACZ2 ZAPI VO O 48V 350A 00000 Bod ood CONFIG ADJUSTMENTS MENU OMO S spe SET POT BRK MIN o ov Hon Hon TROTTLE O ZONE 3 oo oo CR TROTTLE O ZONE 7 oo BO oo DD OM oo Page 55 89 Flow chart showing how to use the SET BATTERY TYPE adjustment 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 Page 56 89 DUALAG2 ZAPI VO O 48V 350A 00000 NOM ood CONFIG MENU SET MODEL CONFIG MENU ADJUSTMENTS SET BATTERY TYPE BOV SET BATTERY TYPE 48V ARE YOU SURE YES ENTER NO OUT AE9ZPOBC DUALAC2 amp HP POWER User Manual Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console DUALACZ ZAPI VO O 1 Opening Zapi Menu 48V 350A ooooo NOM ood 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3
32. C4 C5 CD C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 FLASH FLASH DENG R NENG R KEY CM SEAT FORWARD REVERSE ENABLE BACK PB Positive of right motor encoder power supply 5 V 12 V Negative of right motor encoder power supply Connected to Batt trough a microswitch and a 10 A fuse in series Common of FW REV HB PB SEAT ENABLE SR EX HYDRO BACKING microswitches Seat presence signal active high Forward direction reguest signal active high Reverse direction reguest signal active high Traction or backing reguest signal active high Pedal brake reguest signal active high SR HB EX HYDRO Speed reduction signal or hand brake or exclusive PENC L NENC L PHA R PHB R NPOTST PPOTST CPOTST CPOTB NPOTB NPOT CPOT PHA L PHB L NTHERM R PTHERM R NLC PLC NBRAKE PBRAKE PAUX NAUX BATT PPOT hydro input active low microswitch open See also chapter 8 4 Positive of left motor encoder power supply 5 V 12 V Negative of left motor encoder power supply Right motor encoder phase A Right motor encoder phase B Negative of steering potentiometer BATT Positive of steering potentiometer 5 V 12 V Steering potentiometer wiper signal Brake potentiometer wiper signal BATT Negative of traction accelerator potentiometer tested for wire disconnection diagnosis
33. D 1 Check the performance with the accelerator pedal totally depressed If the machine is a forklift check the performance with and without load 11 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 12 INVERSION BRAKING Operate the machine at 25 full soeed 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 unladen full speed condition should be the most representative condition 13 PEDAL BRAKING If used Operate the machine at full Speed Release the accelerator pedal and press the Pedal Brake Set braking level to your requirements 14 Set MAX SPEED FORW 15 Set MAX SPEED BACK Reverse 16 Set BACKING SPEED and BACKING TIME if these options are used 17 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 18 Set SET TEMPERATURE setting the motor thermal sensor type used 19 Set MAIN CONT VOLTAGE setting the main contactor coil voltage 20 Set AUX OUTPUT VOLTAGE if used setting the auxiliary output voltage 8 8 Sequence for Dc Pump Cho
34. ER 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 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 BATTERY VOLTAGE Level of battery voltage measured at the input of the key switch SEAT SWITCH The level of the Seat Microswitch digital input ON VB input active switch closed OFF GND input non active switch open 10 FORWARD SWITCH Page 70 89 The level of the Forward direction digital input FW ON VB input active switch closed OFF GND input non active switch open AE9ZPOBC DUALAC2 amp HP POWER User Manual 11 BACKWARD SWITCH The level of the Reverse direction digital input BW ON VB input active switch closed OFF GND input non active switch open 12 ENABLE SWITCH The level of the Enable digital input ON VB input active switch closed OFF GND input non active switch open 13 LIFTING CONTROL Voltage of the lifting potentiometer CPOT LIFT 14 LIFTING SWITCH Status of the lifting switch ON
35. I OPTIONAL E P 13 POTI 14 Le BATT s ATT H i 10 so 1 BATT 1 WAN PUMP D H BATT H MOTOR 12 R H CANH s CANT l CAN POS C 0U ae 4 GE OUT ENA o CANT L 6 CANL 3 CANH QUT CAN NEG 8 3 ong 4 5 6 El FLASH 8 PROGRAMMING 3 o 5 Z 6 Ao FW 10 enn SR HB EXAYDRO a Py EN ACC BACK 7 AIN 4 9 A PB CMM enc 4 Topor 33 a 5 CPOT BRAKE 2 907 ap Lineal CPOTBR 18 OTB 19 BATI a _ NAUX 4 m A DA 39 LIPALX UX CHAN EB 28 LIN PEB E EB ETT S EB CHIL 27 HPLC AAA ki NLC LE GOL 26 16 PPOTST ER r3 NPOTST A 5 py LEPUTST PENC_R 32 Pat NENC_R Cal DUALAC2 CONTROLLER PHB_R PANNECTARS 14 CONNECTORS See la CONNECTORS N R AIR k s i NTHERM RH o CONN A AMPSEAL 8 POLES CONN B MOLEX SPOX 8 POLES CONN C AMPSEAL ao PLIES CONN D AMPSEAL 14 PULES THIS DRAWING IS A ZAPI s p a PROPERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS Ti TO THE REPAIRS OF ZAPI PRODUCTS STANDALONE File File AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 43 89 8 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 8 1 Adjustments via Console Adjustment of Parameters and changes to the inverter s configuration are made using
36. LE m CANH a L CANT 83 gt CAN POS a CANL QUT E BEA ENAL L CANT I 5 sK CANL aon HHT o E PCLRXD l NCLRXD a NEAR mm o n PCLTXD ZAP LEFT AC 3 pr Sg L MOTOR NcLTXD ge HANDSET J CNB GND a Vs 5 Sy 3 VS 12 ff 6 H 7 7 FLASH aT 8 PROGRAMMING WO d S SwITU 3 5 6 4 HB EX HYDRO 10 8 Y ACC BACK 7 T PENC 3 J ENCE E CMM NENC L ja CNG 4 PHAI 33 Seege EES ki BRAKE E Ni PHB_L SNE al a PTHERM_L 35 20 NTHERM LI A 19 30 RIGHT AC 28 MOTOR 28 6 fi 29 A a o a 26 Sep LI cl deentrar STEER PU in l J NPOTST a CPOTST 5 N PENC_R go BATT pa NENC_R E PHA_R 7 Ph w CNC PTHERM RI 2M NTHERM_R 8 UAI a A B THIS DRAWING IS A ZAPI s p o PROPERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THAT RELATIVE TO THE REPAIRS OF ZAPI PRODUCTS ROLLER FUNCTIONAL DRA STANDALONE CONFIGURATION CP File File Pagina Page 1 1 Page 42 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual Connection drawing Dualac2 amp hp and Dualac2 amp hp Power standalone A B C E F G I 10A FUS D 1 emm ce i a 2 7 3 4 6 a CN CPOT LIFT s ND 9 JEPOT L
37. ONS Gianni kajaka ke tacts ekle k kaki kak ki 73 9 1 Save and Restore function EE 73 9 2 Description of Alarms menu sica 73 9 3 Description of Console Program Vacc function 74 DUALAC2 AND DUALAC28HP INVERTER DIAGNOSTIC nana 76 10 1 Traction related Ke 76 10 2 Analysis of traction related alarms displayed on console 81 10 3 Pump related fault GOUS occu esse kaa kek bi ak kl a n kk ak ia kk ik aaa 85 10 4 Analysis of pump related alarms displayed on console 86 RECOMMENDED SPARE PARTS FOR INVERTER nena nana nana 87 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 87 Page 4 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual APPROVAL SIGNS COMPANY FUNCTION INITIALS SIGN GRAPHIC AND LAYOUT CP PROJECT MANAGER FG TECHNICAL ELECTRONIC pp MANAGER VISA SALES MANAGER VISA PN Publication N AE9ZPOBC Edition July 2006 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 5 89 1 INTRODUCTION Within the ZAPIMOS family the DUALAC2 inverter is the model suitable for control of pairs of 3 0kW to 7 0kW motors The DUALAC2 amp HP can also control a DC Series pump motor up to 15kW These controllers have been expressly designed for battery powered applications traction and hydraulic functions They are fit for electric trucks utility cars tractors Page 6 89 AE9ZPOBC DUALA
38. TIME 0 9 STEER TABLE OPTION 1 OPTION 2 ACC SMOOTH CNC 8 INPUT USE NONE OPTION 1 2 NV SMOOTH SMART DISPLAY ON OFF STOP SMOOTH z AUXILIARY TIME Sec ADJUSTMENTS SET POT BRK MIN MN TESTER OTOR VOLTAGE SET POT BRK MAX AN FREQUENCY Hz SET BATTERY TYPE 24 36 48 72 80 96V ENCODER Hz ADJUST BATTERY a P VALUE Hz MAX STEER RIGHT V URRENT RMS A MAX STEER LEFT A PERATURE ze SET STEER 0 POS A PERATURE SET STEER RIGHT u MPERATURE 2 Se SET STEER LEF SCELERATOR V THROTTLE O ZONE 21 STEER ANGLE THROTTLE X POINT WR NT WHEEL CUTB HROTTLE Y POINT es FORWARD SI ON OFF ADJUSTMENT 2 BDI 129 BACKWARD SWITCH ON OFF ADJUSTMENT 1 BDI 129 ENABLE SWITCH ON OFF MAIN CONT VOLT AN SEAT SWITC ON OFF AUX OUTPUT VOLT aM BACKING SWITCH ON OFF LOAD HM FROM MDI ON OFF CUTBACK SWITCH ON OFF CHECK UP DONE ON OFF BRAKE SWITCH ON OFF CHECK UP TYPE NONE OPTION 41 12 43 EXCLUSIVE HYDRO ON OFF BRAKEPEDAL POT ANDBRAKE ON OFF VOLTAGE BOOSTER Z BATTERY VOLTAGE V SAVE BATTERY CHARGE PARAMETER HOURS METER RESTORE PARAMETER ALARMS Mi n PROGRAM mwe VACC VACC SETTING MIN MAX STEER TABLE A AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 47 89 8 3 2 b Slave HEADING MAIN MENU lt Re K SPEED LIMIT SET MODEL e CHANGE PUMP IMAX 0 9 ik mal PU ACCELER DEL Se
39. UALAC2 amp HP POWER User Manual Page 61 89 Page 62 89 when the 4th speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 15 5TH SPEED FINE This parameter sets the voltage compensation DV applied to the motor when the 5th speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 16 5TH SPEED COMP This parameter sets the voltage compensation DV applied to the motor when the 5th speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 17 HYDRO SPEED FINE This parameter sets the pump motor speed voltage applied to the motor when the hydraulic steering function request is active 18 HYDRO COMPENS This parameter sets the voltage compensation DV applied to the motor when the hydro speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loa
40. V Azam 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 EN User Manual DUALAC2 amp HP POWER INVERTER Copyright 1975 2006 Zapi S p A All 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 IZ AMI 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 A The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security Pay special attention to the annotations pointed out with this symbol Page 2 89 AE9ZPOBC DUALAC2 a
41. VB input active switch closed OFF GND input non active switch open 15 1ST SPEED SWITCH Status of the first speed switch of the hydraulic system ON VB input active switch closed OFF GND input non active switch open 16 2ND SPEED SWITCH Status of the second speed switch of the hydraulic system ON VB input active switch closed OFF GND input non active switch open 17 3RD SPEED SWITCH Status of the third speed switch of the hydraulic system ON VB input active switch closed OFF GND input non active switch open 18 4TH SPEED SWITCH Status of the fourth speed switch of the hydraulic system ON VB input active switch closed OFF GND input non active switch open 19 5TH SPEED SWITCH Status of the fifth speed switch of the hydraulic system ON VB input active switch closed OFF GND input non active switch open 20 PUMP CURRENT Current of the pump motor 21 PUMP VOLTAGE Voltage between pump chopper output and BATT 22 PUMP TEMPERATURE Temperature of pump chopper power section AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 71 89 Flow Chart showing how to use the TESTER function of the Digital Console ina Zani Disol DUALAC2 ZAPI VO O 1 Opening Zapi Display 48V 350A ooooo 2 Press ENTER to go into the General menu MAIN MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until mon TESTER MENU appea
42. VMN LOW VMN HIGH The test is carried out during initial diagnosis and in standby Possible causes D 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 to truck frame E fault in the inverter power section replace the controller STBY HIGH The pCs verify if the feedback of current sensors device output is within the zero current window Possible causes of the alarm A current sensor failure B failure in the logic card first replace the logic card if the defect persists replace the power unit AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 81 89 7 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 they do not charge an alarm is signalled the main contactor is not closed Possible reasons A the charging resistance is opened B The charging circuit has a failure C There is a problem in the power section 8 MAIN CONTACTOR ALARMS COIL SHORTED When the key is switched ON the uController checks the LC coil driver shortcircuit protection hardware If it does not react in a correct way to the uC stimulus the alarm is signalled Replace the logic board When the fault occurs while the LC is closed the alarm signals a shortcircuit across LC coil
43. a Console sees 44 8 2 Description of Console 8 Connection 44 8 3 Description of Standard Console Menu 45 8 3 1 Dualac2 and Dualac2 Power menu configuration 45 8 3 2 Dualac28hp and Dualac28hp Power menu confguraton 47 8 4 Function configuration REN 49 8 4 1 Dualac2 and Dualac2 Power Master 49 8 4 2 Dualac2 and Dualac2 Power Glave 52 8 4 3 Dualac28hp and Dualac2 amp hp Power Master 52 8 4 4 Dualac28hp and Dualac2 amp hp Power Slave 52 8 5 Parameter TEQUIALON T 58 8 5 1 NAGS SME EE 58 CR Se e TEE 60 8 5 3 le KEE WEE 60 8 54 Dualac2 amp hp Slave E 60 8 6 Programming console functions AE 65 8 6 1 Dualac2 and Dualac2 POWBI sse eee seer 65 8 6 2 Dualac28hp and Dualac28hp Power 65 8 7 Sequence for Ac Traction Inverter setting 66 8 8 Sequence for Dc Pump Chopper setting DUALAC amp HP only 67 8 9 Tester description of the function EE 68 8 9 1 Dualac2 and Dualac2 Power Master 68 8 9 2 Dualac2 and Dualac2 Power Glave 69 8 9 3 Dualac28hp and Dualac28hp Power Master 70 8 9 4 Dualac28hp and Dualac2 amp hp Power Slave 70 OTHER FUNG TI
44. ack is not occurred in stby or coherent with running mode it is applied PWM necessary to remove the fault cause and to activate a function request 56 PUMP STBY X X X Alarm in stby If the alarm is present HIGH condition no in Init status remove PWM applied to the alarm cause pump chopper If the alarm has the pump current occurred in stby or sensor feedback running mode it is is out of the zero necessary to remove current window the fault cause and to activate a function request 242 PUMP X X X X Warning the To remove warning Sla TEMPERAT pump chopper cause ve temperature is higher than 75 C AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 85 89 Cod ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to e STRING ster STATUS occur to come out from alarm status Init Stby Motor running 242 PUMP X X X X Warning Master To remove warning Ma WARNING controller signals cause ster that Slave uC has detected a fault in the pump chopper 243 PUMP INC X X X Warning pump To remove warning START chopper incorrect cause start sequence 244 PUMP VACC X X X Warning pump To remove warning NOT OK chopper cause accelerator voltage is 1V greater than the minimum value programmed 245 PUMP TH X X X X Warning pump To remove Warning SENS KO chopper cause temperature sensor is out of range 10 4 Analysis of pump rela
45. 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 the operator who is most of the time the source of ESD 4 5 Various suggestions 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 23 89 5 OPERATIONAL FEATURES Speed control Optimum behaviour an a slope due to the speed feedback the motors speed f
46. c PU DECELER DELAY Sec CREEP SPEED COMPENSATIO ST SPEED FINE z SPEED AE E SET OPTIONS cNc 8 INPUT USE NONE OPTION 1 2 2ND SPEED FINE 2ND SPEED COMP 3RD SPEED FINE 3RD SPEED COMP 4TH SPEED FINE 4TH SPEED COMP 5TH SPEED FINE 5TH SPEED COMP HYD SPEED FINE HYDRO COMPENS HYDRO TIME Sec TESTER MOTOR VOLTAGE E SET BATTERY TYPE FREQUENCY Hz ADJUST BATTERY ENCODER Hz SET ACCELER MIN V SLIP VALUE Hz SET ACCELER MAX V CURRENT RMS A AUX OUTPUT VOLT V TEMPERATURE C THROTTLE O ZONE VOLTAGE BOOSTER 2 THROTTLE X POINT RAJE Res 2 THROTTLE Y POINT 5 SEAT SWITCH ON OFF WARD SWITCH ON OFF BACKWARD SWITC ON OFF ENABLE SWITCH ON OFF LIFTING CONTROL aM LIFTING SWITCH ON OFF ST s ON OFF N ON OFF ON OFF SAVE ON OFF PARAMETER ON OFF PUMP CURRENT A PUMP VOLTAGE V RESTORE PUMP TEMPERATURE C PARAMETER ALARMS haa IR OCR EEN VACC SETTING MIN MAX STEER TABLE Mame Page 48 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 8 4 Function configuration 8 4 1 Dualac2 and Dualac2 Power Master 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 2 3 4 5 6 7 HOUR COUNTER RUNNING the counter registers travel time only KEY ON the counter registers when the key switch is clo
47. d the inverter 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 DUALACZ ZAPI VO O 48V 350A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu ae MAIN MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display 5 The Display will show 6 Press ENTER to go into the ALARMS function 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 73 89 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu CLEAR LOGBOOK 11 The Display will ask CLEAR LOGBOOK YES ENTER NO OUT 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi ooo Display omo 9 3 Description of Console Program Vacc function Page 74 89 This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal It enables compensation for non symmetry of the mechanical system between directions The operation is performed by o
48. d to SET BATTERY programming 246 SLAVE KO A X A X Alarm Master uC To recycle the key detects a Slave uC malfunctioning Page 78 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 246 MASTER KO X X X X Alarm Slave uC To recycle the key detects a Master uC malfunctioning or a mismatch between inputs status and Master commands via Canbus 250 INPUT X X X X Alarm Slave uC To recycle the key MISMATCH has detected a mismatch between inputs status and the input status transmitted via Canbus by Master uC 253 AUX OUTPUT X X A A Alarm EB coil If the alarm is present KO driver shorted or in Init status remove open the alarm cause If the alarm has occurred in stby or running mode it is necessary to remove alarm cause and to activate traction request 13 EEPROMKO X X X X X Warning Eeprom To remove Warning fault controller cause will use default parameters 61 HIGH X X X X X Warning Master To remove Warning TEMPERA or Slave or both cause TURE temperature higher than 75 C 65 MOTOR X X X X X Warning Master To remove Warning TEMPERA or Slave or both cause TURE motors temperature high 66 BATTERY X X X X Warning battery To remove Warning LOW charge level cause below 20 AE9ZPOBC
49. ded Increasing the parameter the DV is increased 19 HYDRO TIME Hydraulic steering function delay AE9ZPOBC DUALAC2 amp HP POWER User Manual The following table shows all the values of parameters ESESESESERESEZESESES SPEEDLIMIT OO CS on 0 100 Puveimax o o e efe on pe EE ER Pmr canana se oo GH G os 1 us 2 slo ss PUMPDECHLERDELAY ON se o2foafosfos 1 sle esp gt as CREEP SPEED 0 100 E ac a n HYDROCOMPENS TE mom AE A The acceleration time shown is the iheoreticalt time to change from OV to full voltage applied to the motor This is an ideal ramp the real ramp can change as a function of the load ES The deceleration feature is based upon deceleration ramps The value shown in the table is the time to decrease the voltage applied to the motor from 100 down to 0 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 63 89 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 Zapi Pc console SAVE and then downloaded RESTORE to another controller thus allowing fast and standardized settings see Pc console manual for details Flow Chart showing how to make Parameter changes using Digital Console fitted with Eprom CK ULTRA 1 Opening Zapi Display 2 Press ENTER to go into the General Menu 3 The Display will show 4 Press ENTER to go into the Parameter Chan
50. dition clearly shows a malfunctioning of the encoder signal It is suggested to preliminary check the encoder wiring if no fault is found in the wiring it is necessary to replace the encoder 10 STEER SENSOR KO This is an alarm which signals an out of range of the steering potentiometer signal The fault condition is entered in these two following conditions Page 82 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual A the Set steer 0 pos straight wheels programming parameter is wrong lower than Set steer min or higher than Set steer max B the feedback signal of the steering potentiometer is outside the window defined by Set steer min and Set steer max parameters In the first case repeat the steering potentiometer acquisition In the second case check the steering poti and its wiring Eventually repeat again the steering potentiometer acquisition 11 PEDAL WIRE KO This alarm is signalled if a fault is detected in the accelerator unit wiring NPOT or PPOT cable is interrupted 12 WRONG SET BATTERY When the key is turned ON the controller check the battery voltage and compares it with the SET BATTERY parameter setting If the actual value is 20 higher or lower than nominal value the fault condition is entered Replace the battery with a correct battery 13 SLAVE KO Slave and Master uCs perform a cross check in order to verify their functionality If the MASTER detects SLAVE uC malfunctioning it brings the controll
51. e N 7 No j LA Y pa U 23 2 A NI LC r En A 2 m SZ a a 2g KA F l e AN LW T N An y AT Y S lt gt f mo ES d LS Ow K i se LI B PI m a HB eS KE W y Tu O z S FE i Le kel x x e CO ZU U La m S H i 4 2 l E WS pe w S ka a JU gt a a N Ju NOSNI fa E A og NA i NY No AFF am IL 1 SL La FS ZIP Y AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 39 89 f Dualac2ahp imensions o 7 1 3 D OPTIONAL POWER FUSE M8 BOLT i 1007 Se A 3 ES ESL OL N Z gt f f Ly Se 7 RS AN jan YO i HAY NE Nani a AS AA T d 7 OPTIONAL POWER FUSE M8 BOLT d j 191 SS L 23 Jr A A ann SZ WHIM VUS VVS 13 X M8 MALE SCREW N A En SA e Ju SMI HAME NNOUaD 9 62 1 w BLL 9 00 m OZ CU Fon LET io J L N lo SI 8 X 06 SS A ae pr JD LU Wi NECTOR CONSOLE MOLEX P N 09 50 1081
52. e level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 10 STEER ANGLE This is the indication of the angular position of the steered wheel 11 INTERNAL WHEEL CUTBACK This is the indication of the speed reduction applied to the internal wheel in other words it shows the ratio of the two speeds 12 FORWARD SWITCH The level of the Forward direction digital input FW ON VB input active switch closed OFF GND input non active switch open 13 BACKWARD SWITCH The level of the Reverse direction digital input BW ON VB input active switch closed OFF GND input non active switch open 14 ENABLE SWITCH The level of the Enable digital input ON VB input active switch closed OFF GND input non active switch open AE9ZPOBC DUALAC2 amp HP POWER User Manual 15 SEAT SWITCH The level of the Seat Microswitch digital input ON VB input active switch closed OFF GND input non active switch open 16 BACKING SWITCH The level of the Backing Microswitch ON VB input active switch closed OFF GND input non active switch open 17 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND input active switch opened OFF VB input non active switch closed 18 BRAKE SWITCH The level of the Pedal Brake Microswitch ON VB input active switch closed OFF GND input non active switch ope
53. e EZ Lo MAN X CANH The canbus built in termination resistances are not inserted AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 31 89 6 Description of power connections 6 4 1 Dualac2 View of the power bars BT BTF Um Vm Wm Us Vs Ws Page 32 89 AR ON Ar J SS Negative of the battery Positive of the battery if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection Positive of battery before power fuse must be connected to positive cable coming from LC contact Connection bars of the three right motors phases follow this sequence and the indication on the motor Connection bars of the three left motors phases follow this sequence and the indication on the motor AE9ZPOBC DUALAC2 amp HP POWER User Manual 6 4 2 Dualac2 Power View of the power bars BT BTF Um Vm Wm Us Vs Ws Negative of the battery Positive of the battery if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection Positive of battery before power fuse must be connected to positive cable coming from LC contact Connection bars of the three right motors phases follow this sequence and the indication on the motor Connection bars of the three left motors phases follow this sequence and the indication on the motor AE9ZPOBC DUALAC2 amp HP POWER User Ma
54. e brake pedal switch is closed 5 SPEED LIMIT BRAKING 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 FORWARD It determines the maximum speed in forward direction 8 MAX SPEED BACKWARD It determines the maximum speed in backward direction 9 CUTBACK SPEED 1 Typically from 10 to 100 It determines the percentage of the max speed applied when the cutback switch is active When set to 100 the speed reduction is ineffective 10 CURVE CUTBACK Speed reduction when the truck is doing a curve The parameter sets the speed setpoint when the truck driving wheels are running in opposite direction 3 wheels truck steering angle greater than roughly 67 or when the maximum steering angle is reached 4 wheels truck the internal wheel is stopped In intermediate steering angles the speed setpoint will be within a range between the straight wheel speed and the CURVE CUTBACK SPEED 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 changes the maximum current of the inverter 13 BACKING SPEED Drive Motor Speed during the Backing function when the backing switch is closed 14 BACKING TIME Operation time of the Backing Function during which the backing switch is closed
55. ed 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 DUALAG2 ZAPI VO O 48V 350A 00000 Bo ood CONFIG Of MENU SET MODEL CONFIG OM od SET OPTIONS MENU DO DO HOUR COUNTER RUNNING B O B O BATTERY DO DO CHECK OFF oo oo ARE YOU BATTERY CHECK SURE YES ENTER NO OUT CONFIG SET OPTIONS MENU AE9ZPOBC DUALAC2 amp HP POWER User Manual Flow chart showing how to make changes to ADJUSTMENTS Menu NOM 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 or ROLL DOWN button until ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will shows SET POT BRK MIN 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 to confirm 13 Repeat the same from 5 to 12 points for the other adjustments AE9ZPOBC DUALA
56. er can configure the following functions SUBMENU SET OPTIONS 1 CNC 8 INPUT USE OPTION 1 input C8 is used as enable input for the traction request active high closed switch OPTION 2 input C8 activates backing function active high closed switch NONE input C8 isn t used 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 AUX OUTPUT VOLTAGE This parameter adjusts the voltage of the auxiliary output coil hydraulic steering contactor coil PWM output C31 8 4 3 Dualac28hp and Dualac2 amp hp Power Master There are the same functions described in chapter 8 4 1 but in the SET OPTIONS SUBMENU there is also the following parameter 1 LIFT CUTOUT ON OFF when the Battery low alarm appears if this option is programmed ON the lifting is stopped 8 4 4 Dualac28hp and Dualac2 amp hp Power Slave Page 52 89 Using the config menu of the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 CNC 8 INPUT USE OPTION 1 input C8 is used as enable input for the traction request active high closed switch OPTION 2 input C8 activates backing function active high closed switch NONE input C8 isn t used SUBMENU ADJUSTMENTS 1 SET BATTERY TYPE It selects the nominal battery voltage 2 ADJUST BATTERY Fine adj
57. er in a safe status opening the power bridge and the Line Contactor 14 MASTER KO Slave and Master uCs perform a cross check in order to verify their functionality There are two conditions under which slave enters this fault condition A the SLAVE uC receives incoherent can message from the MASTER UC B the SLAVE uC compares the inputs status and the related MASTER operations and find they are not coherent In both cases the SLAVE brings the controller to a safe status opening the power bridge and the Line contactor 15 INPUT MISMATCH Safety related inputs Fw direction Rev direction accelerator ENABLE SEAT switch are input to both microcontrollers by independent hw circuit The two uCs read these inputs and compare by exchanging related status on the canbus If the SLAVE uC finds a mismatch between its inputs and MASTER inputs it brings the controller to a safe status opening the power bridge and the Line contactor 16 AUX OUTPUT KO The uP checks the driver of the electromechanical brake coil If the status of the driver output does not correspond to the signal coming from the uP the alarm is signalled It is suggested to preliminary check if there is an external short or low impedance pull down between NAUX C31 and BATT If no external cause can be found replace the logic card 17 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm does not inhibits truck operation but the controller wil
58. er sets the voltage compensation DV applied to the motor when the 2nd speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 11 3RD SPEED FINE This parameter sets the voltage compensation DV applied to the motor when the 3rd speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 12 3RD SPEED COMP This parameter sets the voltage compensation DV applied to the motor when the 3rd speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 13 4TH SPEED FINE This parameter sets the voltage compensation DV applied to the motor when the 4th speed request is active The value of DV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed change when the motor is loaded Increasing the parameter the DV is increased 14 4TH SPEED COMP This parameter sets the voltage compensation DV applied to the motor AE9ZPOBC D
59. ge facility 5 The Display will show the first parameter 6 Press either ROLL UP and ROLL DOWN to display the next parameter 7 The names of the Parameters appear on the Display 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 9 The Display will show the New Level 10 When you are satisfied with the results of the changes you have made press 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 13 The Display will show DUALACZ 48V 350 ZAPI VO O A 00000 D O MAIN PARAMETE H L ka fe MENU R CHANGE O O E D D D ACCELER DELAY LEVE RELEASE LEVE oo oo L 4 BRAKING LSS oo oo CR RELEASE LEVE DL ER EI D We BRAKING L 6 ARE YOU SURE YES ENTE MAIN PARAMETE R NO OUT MENU R GHANGE AE9ZPOBC DUALAC2 amp HP POWER User Manual 8 6 Programming console functions 8 6 1 Dualac2 and Dualac2 Power Functional configuration see 8 4 Parameter programming see 8 5 Tester user can verify the state of the following parameters MASTER motor voltage frequency Hz encoder Hz slip value Hz current rms A temperat
60. he current drawn and the duty cycle 4 2 2 Wirings power cables A 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 DUALAC2 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 4 2 3 Wirings CAN connections and possible interferences EY Page 16 89 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual CAN Controller MO Transceiver 12042 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
61. he motor thermal sensor type used 8 9 Tester description of the function 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 In the following chapter a list of relative measurements for different configurations 8 9 1 Dualac2 and Dualac2 Power Master Page 68 89 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 expressed 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 TEMPERATURE 1 This is the temperature of the right motor if the option is programmed None see chapter 8 4 a it shows 0 8 TEMPERATURE 2 This is the temperature of the left motor if the option is programmed None see chapter 8 4 a it shows 0 9 ACCELERATOR The voltage of the accelerator potentiometer s wiper CPOT The voltag
62. hes send a voltage signal to the microprocessor when a function request for ex running request is made 3 2 Accelerator unit The accelerator unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration CPOT C21 signal ranges from 0 to 10 V 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 Faults can occur if it is outside this range MU vo 2 Da A A PPOT is the accelerator unit positive supply It can be either a 5 V output or a 10 V output The selection of the output voltage is made in the logic card by moving a jumper factory set NPOT is the accelerator unit negative supply This output is feedback to the uC A D converter to test the continuity of the accelerator unit circuit test of poti wire disconnection 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 11 89 gt gt gt gt gt gt gt gt N SY SSN pr KW G
63. id 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 informations B inthe 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 EMISSIONS Three ways can be followed to reduce the emissions AE9ZPOBC DUALAC2 amp HP POWER User Manual 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 ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid
64. ignal has to be within the 0 to 10 V range 3 4 Speed feedback The traction motors 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 Vor 12V electric output open collector NPN or PNP push pull For more details about encoder installation see also chapter 4 2 5 3 5 Steering angle transducer Angular position of steered wheels is transduced to an electric information voltage by means of a potentiometer with following characteristics resistance in the 2 kohm to 20 kohm range suggested rotation electric angle at least 300 Page 12 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual positive supply 5 V or 10 V potentiometer has to be installed in a way that in the zero position straight wheels poti output voltage is in the middle of the electric range corresponding to a full left to right transition of the steered wheels install the potentiometer in a way that when truck turns right poti output voltage increases use SET STEER MIN and SET STEER MAX functions to record the extremes minimum and maximum of the potentiometer range see chapter 8 4 use SET STEER 0 POS function to record the poti output when the steered wheels are straight see chapter 8 4 MOTOR MANAGEMENT TABLE Potentiometer connections 9 Ya 4 Steering table The relationship
65. ignalled if it is out of range When this warning is signalled the maximum current of the pump chopper is reduced to half AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 87 89 INVERTER 11 RECOMMENDED SPARE PARTS FOR Part Number Description C16507 Protected 500 A strip Fuse C16505 Protected 355 A strip Fuse C16520 6 3 A 20 mm Control Circuit Fuse C29523 SW 180 80 V Single Pole Contactor C29522 SW 180 48 V Single Pole Contactor C29508 SW 180 24 V Single Pole Contactor C12529 Ampseal Connector 8 pins Female C12532 Ampseal Connector 35 pins Female C12530 Ampseal Connector 14 pins Female C12796 Female pin harness side Page 88 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 12 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 t
66. iller 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 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 89 89
67. l use default parameters 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 18 HIGH TEMPERATURE Master or Slave or both temperatures are greater than 75 C The maximum current is reduced proportionally to the temperature increase At 100 C the max current of both inverter is reduced to zero If the alarm is signalled when the controller is cold A thermal sensor failure B failure in the logic card AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 83 89 Page 84 89 19 MOTOR TEMPERATURE This warning is signalled if right or left or both motors temperature switches open digital sensor or if the analog signals overtakes the cut off level If it happens when the motor is cold check the wiring If all is ok replace the logic board 20 BATTERY LOW If the battery check option is ON a battery discharge algorithm is carried out When the charge level is 20 this alarm is signalled and the current is reduced to the half of the programmed level 21 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 22 INCORRECT START This alarm signals an incorrec
68. le to drive the coil to the correct voltage AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 77 89 Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 76 COIL X X X X Alarm If the alarm is present SHORTED Init the LC and in Init status remove EB coil driver the alarm cause protection circuit If the alarm has is damaged occurred in stby or Stby or running running mode it is short on LC coil necessary to remove or EB coil alarm cause and to activate traction request 37 CONTACTOR X X Alarm line To remove alarm CLOSED contactor power cause within a contact is stuck timeout if the timeout is elapsed it is necessary to re cycle the key 38 CONTACTOR X X Alarm line To remove alarm OPEN contactor power cause within a contact does not timeout if the timeout pull in is elapsed it is necessary to re cycle the key 82 ENCODER A A X Alarm motor To recycle the key ERROR speed sensor encoder does not work properly 84 STEER X A A A Alarm steering To remove alarm SENSOR KO poti signal out of cause range 86 PEDAL WIRE X X X A Alarm fault in To remove alarm KO accelerator cause and activate a negative NPOT traction request input circuit 245 WRONG SET X X Alarm the battery To remove alarm BATTERY voltage does not cause correspon
69. lose 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 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 49 89 Page 50 89 8 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected to C25 C35 input ANALOG an analog motor thermal sensor is connected to C25 C35 the curve can be customized on a customer request NONE no motor thermal sensor switch is connected 9 STEER TABLE This parameter is used to set the correct steering table 10 CNC 8 INPUT USE OPTION 1 input C8 is used as enable input for the traction request active high closed switch OPTION 2 input C8 activates backing function active high closed switch NONE input C8 isn t used 11 SMART DISPLAY ON OFF if this option is programmed ON the communication with the Smart display is active SUBMENU ADJUSTMENTS 1 SET POT BRK MIN It records the minimum value of braking pedal p
70. mp HP POWER User Manual Contents 1 INTRODUCTION eege di 6 2 OPEGIFIGATION Sotano EE 7 2 1 Technical specifications Dualac2 aaa 7 2 1 1 Block A A 7 2 2 Technical specifications Duaiac2A bp 8 2 2 1 Block diagram E 8 22 2 Chopper block diagram sss sees 9 2 3 Technical specifications Dualac2 Power 9 2 3 1 Blo k digra APP o ki da ccs dp De AREA 9 2 4 Technical specifications Dualac2 amp hp Power 9 2 4 1 019 do LOIN EE 10 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 11 3 1 Wee 11 3 2 Arccleralo EE 11 3 3 Other analog control E 12 3 4 Speed TAUB ACI ceca sese 12 3 5 Steering angle transducer ana 12 a INSTALLATION NIM oni ok ii bie 15 4 1 Material OVervieW add kase kibik a ea a oo ks e n kk kel ea ai e ob op rido oken 15 4 1 1 Connection cables AAA 15 E ere 15 Ge EC E E 15 4 2 Installation of the hardware 15 4 2 1 Positioning and cooling of the controller 16 422 Wirings power ADIOS mesitas 16 4 2 3 Wirings CAN connections and possible interferences 16 4 2 4 Wirings WO connections EEN 19 d 2 5 Encoder MS LA ON E 19 4 2 6 Main contactor and key connection serere eee eee eee eee 20 4 2 7 Insulation Of truck frame nn 20 4 3 Protection and safety features EEN 20 4 3 1 Protection features EEN 20 4 3 2 Safety FOAlIOS escasos dro
71. n 19 EXCLUSIVE HYDRO Status of the exclusive hydro switch ON VB input active switch closed OFF GND input non active switch open 20 BRAKEPEDAL POT Voltage of the brake potentiometer s wiper CPOTB The parameter is active only if the PEDAL BRAKING parameter is set ANALOG see chapter 8 4 21 HANDBRAKE The level of the Handbrake Microswitch ON GND input active switch opened OFF VB input non active switch closed 22 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 23 BATTERY VOLTAGE Level of battery voltage measured at the input of the key switch 24 BATTERY CHARGE The percentage Charge level of the battery 25 HOURS METER This is the machine hour meter value 8 9 2 Dualac2 and Dualac2 Power Slave 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 expressed 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
72. n to the Opening Zapi ooo Menu OMO AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 75 89 10 DUALAC2 AND DUALAC2 amp HP INVERTER DIAGNOSTIC 10 1 Traction related fault codes Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 8 WATCHDOG X A A A A Alarm the If the alarm is present Watchdog circuit in Init status remove has been the alarm condition triggered If the alarm has occurred in stby or running mode it is necessary to remove alarm condition and to activate a traction request 17 LOGIC A A X Alarm failure in To remove alarm FAILURE 3 over load condition activation protection hw of traction request circuit 18 LOGIC X X X Alarm failure in To remove alarm FAILURE 2 U V W voltage condition activation feedback circuit of traction request 19 LOGIC X X X X X Alarm an To recycle the key FAILURE 1 overvoltage or switch undervolt condition has been detected 30 VMN LOW X X A A X Alarm wrong If the alarm is present voltage on motor in Init status remove power outputs the alarm condition failure in the If the alarm has power section or occurred in stby or in the mosfet running mode it is driver circuit orin necessary to remove the motor alarm condition and to activate a traction request Page 76 89 AE9ZPOBC DUALAC2 amp HP POWER
73. nd 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 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 machine 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 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 rap
74. ntroller logic card It is suggested to preliminary check canbus connection 28 NO CAN MESSAGE 3 Slave node 4 signals that it has lost can communication with the Master node 3 This fault could be determined by a problem in the truck canbus line or by an internal problem in the controller logic card It is suggested to preliminary check canbus connection AE9ZPOBC DUALAC2 amp HP POWER User Manual 29 SLAVE WARNING The slave has a warning Connect to the slave with the hand set console and check the warning 30 HANDBRAKE This warning occurs when the operator try to travel with the handbrake active Possible causes A handbrake microswitch failure B incorrect wiring C if the defect persists replace the logic 31 DATA ACQUISITION This warning signals that the inverter is in the acquisition of the current gains phase it ends when the acquisition is done 32 CHECK UP NEEDED This is just a warning to call for the time programmed maintenance It is just enough to turn the CHECK UP DONE option to level ON after the maintenance is executed 10 3 Pump related fault codes Co ALARM Ma Slave CONTROLLER DESCRIPTION Condition that has to de STRING ster STATUS occur to come out from alarm status Init Stby Motor running 28 PUMP VMN X X X X Alarm wrong If the alarm is present LOW voltage output of in Init status remove pump chopper the alarm cause the motor voltage If the alarm has feedb
75. nual Page 33 89 6 4 3 Dualac28hp View of the power bars B Negative of the battery BT Positive of the battery if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection Page 34 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual BTF Positive of battery before power fuse must be connected to positive cable coming from LC contact Um Vm Wm Connection bars of the three right motors phases follow this sequence and the indication on the motor Us Vs Ws Connection bars of the three left motors phases follow this sequence and the indication on the motor P Output of pump motor chopper P Pump chopper positive if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection also the pump motor positive cable must be connected to this power connection BPF Pump chopper positive before power fuse must be connected to positive cable coming from LC contact AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 35 89 6 4 4 Dualac2 amp hp Power View of the power bars
76. ollows 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 Electronic differential feature with torque balance between external and internal wheel 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 The release braking ramp can be modulated by an analog input so that a proportional brake feature is obtained Optimum sensitivity at low speeds Voltage boost at the start and with overload to obtain more torque with current control The inverter can drive an electromechanical brake Hydraulic steering function the traction inverter sends a hydraulic steering function request to the pump inverter on the can bus line moreover if the pump inverter does not manage the steery function because it is managed by a motor other than the main hydraulic motor the traction inverter can manage an hydraulic steering function by driving a hydro contactor which drive a hydraulic steering motor output C31
77. otentiometer when the braking pedal switch is closed the procedure is similar to the Program Vacc function see chapter 9 3 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 3 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 MAX STEER RIGHT This is the function to record in the controller EEPROM the steering poti output voltage when the wheels are fully turned right maximum of the steering poti range 6 MAX STEER LEFT This is the function to record in the controller EEPROM the steering poti output voltage when the wheels are fully turned left minimum of the steering poti range 7 SET STEER 0 POS This is the function to record in the controller EEPROM the steering poti output voltage when the wheels are straight 8 SET STEER RIGHT This parameter sets the max steering angle in right direction 9 SET STEER LEFT This parameter sets the max steering angle in left direction 10 THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve see also curve below 11 THROTTLE X POINT This
78. perating the pedal after entering the PROGRAM VACC function Flow Chart showing how to use the PROGRAM VACC function of the Digital Console DUALACZ ZAPI VO O 48V 350A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General Menu a ea MAIN MENU PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until NOG PROGRAM VACC appears on the display 18 MAIN MENU 5 The Display will show PROGRAM VACGC 6 Press ENTER to go into the PROGRAM VACC S fe routine ooo 7 The Display will show the minimum and i A A VAGG SETTING maximum values of potentiometer wiper output a o 4 8 4 8 Both directions can be shown 8 Press ENTER to clear these values S fe Display will show 0 0 Dou 9 Select Forward Direction close any interlock MIN VACC MAX switches that may be in the system 0 0 s a o AE9ZPOBC DUALAC2 amp HP POWER User Manual 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 MIN VACC MAX 10 0 6 4 4 12 When finished press OUT an ARE YOU SURE YES ENTER NO OUT 13 The Display will ask ARE YOU SURE 14 Press ENTER for yes or OUT for NO D m O MAIN MENU 15 When finished the Console shows PROGRAM VAGE 16 Press OUT again to retur
79. pper setting DUALAC amp HP only 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 reguired 2 Select and set the Battery Voltage 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the lift signal acguisition procedure using the Console PROGRAM VACC 5 Set the MAXIMUM CURRENT Current 6 Set the Acceleration and Deceleration Delay requirements for the pump 7 Set the MIN SPEED LIFT level starting from 0 Hz The pump should just turn when the request microswitch is closed Increase the level accordingly 8 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED Check the performance with the full request Check the performance with and without load 9 Set MAX SPEED LIFT 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 67 89 steering function request is switched off 12 Set SET TEMPERATURE setting t
80. r for DC series pump motor Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chip Program Memory each microcontroller Digital control based upon a microcontroller one per each AC motor Uis e EE 24 36 48 72 80 V Maximum current 24 VI 500 A RMS for 3 per each motor Maximum current 36 48 V 450 A RMS for 3 per each motor Maximum current 72 80 V 400 A RMS for 2 per each motor Chopper maximum current 24 Visionado peas 500 A for 2 Chopper maximum current 36 48 MI 450 A for 2 Chopper maximum current 72 80 MI 300 A for 2 Operating TOQUE EE 8 kHz AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 9 89 External temperature range eee eee eee eee eee eee 30 C 40 C Maximum inverter temperature at full power 75 C 2 4 1 Block diagram See chapters 2 2 1 and 2 2 2 Page 10 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The DUALAC2 inverter needs some external parts in order to work The following devices complete the kit for the DUALAC2 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 between the key switch contacts must be lower than 0 1 V The microswitc
81. r on the display goa 5 The Display shows 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 72 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 9 OTHER FUNCTIONS 9 1 Save and Restore function SAVE function allows to transfer controller parameters to the Pc console memory With this function a copy of the controller set of parameters can be retained in a Pc and downloaded to another controller see RESTORE RESTORE function allows to download controller parameters from the Pc console memory to the controller Eeprom Thus a copy of the parameters stored in a Pc can be downloaded in a controller avoiding the parameter setting operation For more details please refer to Pc console manual 9 2 Description of Alarms menu The microprocessor in the controller records 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 occurred the Hour Meter count an
82. s diagnosis that checks 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 AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 25 89 6 DESCRIPTION OF THE CONNECTORS Z Connectors of the logic Dualac2 and Dualac2 Power A1 CAN H High level CANBUS A2 CANT H CANBUS termination output 120 ohm internally connected to CAN H Connect to CAN L OUT to insert the termination A3 CAN POS Positive of CAN circuit to be used in case of optoisolated CANBUS A4 CAN L OUT Low level CANBUS to be used as repetition for CAN L line or to be connected to CANT H to insert termination resistance A5 CANT L CANBUS termination output 120 ohm internally connected to CAN L Connect to CAN H OUT to insert the termination A6 CAN L Low level CANBUS A7 CAN H OUT High level CANBUS to be used as repetition for CAN H line or to be connected to CANT L to insert termination resistance A8 CAN NEG Negative of CAN circuit to be used in case of optoisolated CANBUS B1 PCLRXD Positive serial reception B2 NCLRXD Negative serial reception B3 PCLTXD Positive serial transmission B4 NCLTXD Negative serial transmission B5 GND Negative console power supply B6 12 Positive console power supply Page 26 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual B7 B8 C1 C2 C3
83. sed 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 TRACTION CUTOUT ON OFF when the Battery low alarm appears if this option is programmed ON the traction speed is reduced to 60 Hz 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 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 OFF the stop on ramp feature is not performed AUX INPUT 1 EXCLUSIVE HYDRO input C10 activates hydraulic steering function output C31 is activated OPTION 1 input C10 is the input for an handbrake device active low open switch OPTION 2 input C10 is the input for a speed reduction device active low open switch 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 c
84. sure that any installation error do not compromise safety AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 15 89 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 better heat dissipation Ensure that the wiring of the cable terminals and connectors is carried out correctly Fit transient suppression devices to the horn solenoid valves and contactors not connected to the controller such as those for activating the pump motor 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 t
85. t Layout Module 1 Module 2 Center of the Ground connection 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 E Can advantages The complexity of today systems needs more and more data signal and information must flow 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 Page 18 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual 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 I O 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 A A cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify wi
86. t starting sequence Possible causes A Fwor Rev or Enable microswitch failure B error in sequence made by the operator C incorrect wiring D if the default persists after checking the harness replace the logic 23 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 if the defect persists replace the logic 24 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 the maximum current of the controller is reduced to half 25 WAITING FOR NODE 4 The Slave has detected a failure the Master cannot close the main contactor because of the alarm status of the Slave which the Master knows by the CAN BUS line The failure must be looked for in the Slave controller use the remote console to get connection to the Slave uC 26 WAITING FOR NODE 3 The Master uC has detected a fault condition the Slave is aware of this thanks to canbus communication it cannot drive the motor until the Master has resolved its problem The fault has to be looked for in the Master 27 NO CAN MESSAGE 4 Master node 3 signals that it has lost can communication with the Slave node 4 This fault could be determined by a problem in the truck canbus line or by an internal problem in the co
87. ted alarms displayed on console 1 2 3 4 5 Page 86 89 PUMP VMN LOW The pump chopper power output is feedback to the uC If this feedback voltage is not coherent with the applied PWM this fault condition is signalled There could be many causes failure in the pump chopper power section failure in the pump chopper driving section failure in the pump chopper voltage feedback circuit dispersion in the pump motor to truck frame PUMP STBY I HIGH The pump chopper current sensor feedback is out of the zero current window while no PWM is applied to the pump chopper The most likely cause is a failure in the current sensor PUMP TEMPERATURE Pump chopper temperature is higher than 75 C maximum current is proportionally reduced If the alarm is present when the controller is cold there is a failure in the temperature sensor or in the feedback circuit PUMP WARNING This is a warning in the MASTER controller which inform that the SLAVE is in a pump chopper related fault condition PUMP INC START This is a warning in the pump chopper which inform that an incorrect start sequence happened on the pump AE9ZPOBC DUALAC2 amp HP POWER User Manual 6 PUMP VACC NOT OK This is a warning in the pump chopper which inform that accelerator voltage is 1 V grater than the minimum value programmed 7 PUMP TH SENS KO The range of pump chopper temperature sensor is always checked and a warning is s
88. th 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 paragraph description of the connectors 4 2 5 Encoder installation 1 Dualac2 and Dualac2 amp hp card 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 or 12V It can have different electronic output C11 C1 5V 12V positive of encoder power supply C12 C2 GND negative of encoder power supply C22 C13 A phase A of encoder C23 C14 B phase B of encoder 2 Connection of encoder with open collector output 5V power supply 3 Connection of encoder with open collector output 12V power supply Ja A VERY IMPORTANT It is necessary to specify in the order the type of encoder used in terms of power supply electronic output and n of pulses for revolution because AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 19 89 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 The 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
89. to both microcontrollers which implement a cross check of the inputs status thus preventing an abnormal behaviour due to a failure in the input hardware It is strongly suggested to connect the machine safety related devices to these five inputs in order to increase machine safety sa EMC A EMC 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 ZAPI declines any responsibility for non compliance malfunctions and failures if correct testing is not made The machine AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 21 89 Page 22 89 manufacturer holds the responsability to carry 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 electromagnetical energy generated or received by an electrical device So the analysis works in two directions 1 2 3 The study of 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 a
90. to insert termination resistance A8 CAN NEG Negative of CAN circuit to be used in case of optoisolated CANBUS B1 PCLRXD Positive serial reception B2 NCLRXD Negative serial reception B3 PCLTXD Positive serial transmission B4 NCLTXD Negative serial transmission B5 GND Negative console power supply Page 28 89 AE9ZPOBC DUALAC2 amp HP POWER User Manual B6 B7 B8 C1 C2 C3 C4 C5 CD C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 12 FLASH FLASH PENC_R NENC_R KEY CM SEAT FORWARD REVERSE ENABLE BACK PB Positive console power supply Positive of right motor encoder power supply 5 V 12 V Negative of right motor encoder power supply Connected to Batt trough a microswitch and a 10 A fuse in series Common of FW REV HB PB SEAT ENABLE SR EX HYDRO BACKING microswitches Seat presence signal active high Forward direction reguest signal active high Reverse direction reguest signal active high Traction or backing reguest signal active high Pedal brake reguest signal active high SR HB EX HYDRO Speed reduction signal or hand brake or exclusive PENC L NENC L PHA R PHB R NPOTST PPOTST CPOTST CPOTB NPOTB NPOT CPOT PHA L PHB L NTHERM R PTHERM R NLC PLC NBRAKE PBRAKE PAUX NAUX BATT hydro input active low microswitch open See also chapter 8 4
91. ure C temperature 1 C temperature 2 C accelerator V steer angle int wheel cutback forward switch ON OFF backward switch ON OFF enable switch ON OFF seat switch ON OFF backing switch ON OFF cutback switch ON OFF brake switch ON OFF exclusive hydro ON OFF brakepedal pot handbrake ON OFF voltage booster battery voltage V battery charge hours meter SLAVE motor voltage frequency Hz encoder Hz slip value Hz current rms A temperature C voltage booster battery voltage V seat switch ON OFF forward switch ON OFF backward switch ON OFF enable switch ON OFF Save function for storing data gt only with Pc console Restore function for downloading parameters to another controller gt only with Pc console 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 6 2 Dualac2 amp hp and Dualac2 amp hp Power Functional configuration see 8 4 Parameter programming see 8 5 Tester user can verify the state of the following parameters MASTER motor voltage frequency Hz encoder Hz slip value Hz AE9ZPOBC DUALAC2 amp HP POWER User Manual SLAVE motor
92. ustment of the battery voltage measured by the controller 3 SET ACCELER MIN This parameter is used to adjust minimum value of the lift potentiometer Press ENTER pull the lever till the lift switch closes then record the value OUT gt ENTER 4 SET ACCELER MAX This parameter is used to adjust maximum value of the lift potentiometer Press ENTER pull the lever to the maximum then record the value OUT gt AE9ZPOBC DUALAC2 amp HP POWER User Manual ENTER 5 AUX OUTPUT VOLTAGE This parameter adjusts the voltage of the auxiliary output coil hydraulic steering contactor coil PWM output C31 6 THROTTLE 0 ZONE It establishes a deadband in the lifting accelerator input curve see also curve below 7 THROTTLE X POINT This parameter changes the characteristic of the lifting accelerator input curve 8 THROTTLE Y POINT This parameter changes the characteristic of the lifting accelerator input curve AE9ZPOBC DUALAC2 amp HP POWER User Manual Page 53 89 Flow chart showing how to make changes to OPTIONS Menu 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 MODEL Menu 7 The display will shows the first OPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 Desir
93. utput 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 maximum 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 4 3 2 Safety Features A 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 Dualac2 controller electronic implements double hardware circuit for four Digital inputs Seat C5 Forward C6 Reverse C7 Accelerator Enable C8 and one Analog input CPOT C21 These signals are input through two independent hardware circuits

(DUALAC2-ing) Traction (DUALAC2

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