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ZAPI AC3-AC4 Manual

1. ij e J C y V 1 B 352 26 eu ei 300 _ 150 965 X 6 2 R Paw W A Y J 0897 wy aa A _ D ANN D O Jt WY 2 D _ p SH S 3 D un 198 s 1 4 gt FA ooo al A EAS p E A X BN Oe we o y 7 Lm ey 6 85 A O b A Page 38 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 7 3 Connection drawing Traction configuration 7 3 1 Ampseal and Molex Spox connectors 12 2 E 3 L1 ss 5 M A E EM a T 2 d zi Pi T AS Og Li Ln t3 Oy 7 0 m 2 E y NG ai 5 lt ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Man
2. 17 4 2 7 Insulation of truck 18 4 3 Hardware protection and safety 18 4 3 1 Protection TSalures e 18 432 A A 19 A o 20 4 5 Various suggestions deti ees etic cun uestis tanen nsn 21 5 OPERATIONAL FEATURES 22 5 1 T HL 22 6 DESCRIPTION OF CONNEGTONBIB 24 6 1 Connectors of the logic Traction configuration 24 6 1 1 Ampseal and Molex Spox 24 6 1 2 Amp Saab 42 poles 26 6 1 3 Molex Minifit connectors 28 6 2 Connectors of the logic Pump configuration 30 6 2 1 Ampseal and Molex Spox 30 6 2 2 Saab 42 poles 31 6 2 3 Molex Minifit connectors 4 02 34 6 3 Description of power 36 T DRAWINGS 37 7 1 AC 3 FLASH mechanical drawing 0 24 4 1 0 11 1 37 7 2
3. Ampseal Amp Saab Minifit 1 29 1 45 V 12 V positive of encoder power supply A2 A30 E2 GND negative of encoder power supply A13 A31 E3 A phase A of encoder phase A inverted for A22 A18 E4 A encoders with differential output A14 A32 E5 B phase B of encoder phase B inverted for A23 A19 encoders with differential output Page 16 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Connection of encoder with differential outputs 5 V power supply Minifit 2 connectors Yd 3 Connection of encoder with open collector output 5 V power supply Minifit connectors 4 Connection of encoder with open collector output 12 V power supply Minifit connectors VERY IMPORTANT It is necessary to specify to Zapi when ordering the controller the type of encoder used power supply electronic output and n of pulses for revolution This is necessary because the logic unit must be set in the correct way by Zapi 4 2 6 Main contactor and key connection The connection of the main contactor can be carried out following the drawing in the figure ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 17 89 If a mechanical battery line switch is installed it is necessary that the key supply to the inverter is open together with power battery line if not the inverter may be damaged if the switch is opened during a regenerative braking An int
4. T Qu T T Toq HUS CHRUN PUMP ASY KEY 1 1 17 41198 LiVvd Page 42 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 7 4 2 Amp Saab 42 poles connector SENSOR d CONT COIL 5 gt E H E E E uw al a gt m mpi a Y 2 z z x No 2 4 lt T lt T lt lt 4 2 i 5 Iz 924 T 4 2 QA T AUX MC NMC NPHT AUX MC CHIL CANBUS ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 43 89 7 4 3 Molex Minifit connectors 44 89 ADWZPODF FLASH AC4 FLASH INVERTER User Manual 7 Connection drawing Combi configuration 7 5 1 Ampseal and Molex Spox connectors KEY TRACTION ASYNCHRONOUS LOGIC BOARD A NOE Sal 5 AUC 2M r 8 TEMP SENSOR RAMMINC MOT 1 2TH TEMP SENSOR S h BAT ADWZPODF AC3 FLASH AC4 FLASH INVERTE
5. 7 ADJUSTMENT 03 This parameter isn t used 8 ADJUSTMENT 02 It adjusts the lower level of the battery discharge table 9 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table A 10 LOAD HM FROM MDI For an explanation of this point see the MDI instrument handbook 11 PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the main contactor coil the PWM reduces the voltage at the loads on the main contactor coil down to 62 of the battery voltage 12 PWM ON AUX OUT OFF the inverter applies the battery voltage to the loads on the auxiliary output ON the PWM reduces the voltage at the loads on the auxiliary output down to 62 of the battery voltage ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 59 89 Flow chart showing how to make changes to OPTION 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 Desired OPTION appears 10 Press SET UP or SET DOWN button in order to modify the changes 11 New OPTION appears 12 Press OUT to exit the Menu 13 Confirmation request appears 14 Pre
6. 4 SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 5 CURRENT RMS Root Mean Square value of the motor current 6 TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices 7 MOTOR TEMPERAT This is the temperature of the motor if the option is programmed None see chapter 8 6 it shows 0 8 ACCELERATOR The voltage of the accelerator potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 FORWARD SWITCH The level of the Forward direction digital entry FW VB active entry of closed switch OFF GND non active entry of open switch 10 BACKWARD SWITCH The level of the Reverse direction digital entry BW VB active entry of closed switch OFF GND non active entry of open switch 11 ENABLE SWITCH Status of the accelerator enable input VB active entry of closed switch OFF GND non active entry of open switch 12 SEAT SWITCH The level of the Seat switch digital entry VB active entry of closed switch OFF GND non active entry of open switch 13 BACKING F Status of the inching function forward direction input VB active entry of closed switch OFF GND non active entry of open switch 14 BACKING B Status of
7. AC3 FLASH AC4 FLASH INVERTER User Manual 8 8 to assist 3 Perform the lift signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 4 4 Set the MAXIMUM CURRENT Current using the table in Chapter 8 7 5 Set the Acceleration and Deceleration Delay requirements for the pump 6 Setthe MIN SPEED level starting from 0 Hz The pump should just turn when the request microswitch is closed Increase the level accordingly 7 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 8 Set MAX SPEED UP max speed of pump motor 9 Set HYD SPEED FINE to adjust the hydraulic steering speed pump motor speed when HYDRO function is requested 10 Set AUXILIARY TIME time delay before pump stops when an hydraulic steering function request is switched off Depending the motor used it is necessary to set some parameters giving Zapi the motor curves it is possible to know the optimal setting in order to the motor runs efficiently 86 OPTION and ADJUSTMENTS configuration 8 6 1 Traction Using the CONFIG MENU of the programming console the user can configure the following functions see OPERATIONAL FEATURE chapter for an explanation of hydraulic steering function SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers tr
8. 4TH SAFETY PTHERM CM NAUX NHYDRO Analog input for lift potentiometer wiper Lift potentiometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 Negative of lift potentiometer This pin is tested for wire disconnection diagnosis Common of LIFT ENABLE 1 ST RD HYDRO SR microswitches Request input for potentiometer controlled lifting it must be connected to the lift enable microswitch It is active high First speed input it must be connected to the 1st speed microswitch It is active high Third speed input it must be connected to the 3rd speed microswitch It is active high Free analog input Auxiliary potentiometer positive It is the same voltage as A2 Keep load 1 kO It is a ground reference It is a ground reference Hydraulic steering request input It is active high Speed reduction input it must be connected to the speed reduction switch It is active low switch opened Free digital input input It is active high Connected to the power supply through a microswitch with a fuse in series Positive of the main contactor coil or of the auxiliary load It is equal to the key voltage Positive of the hydraulic steering contactor coil It is equal to the key voltage Fourth speed input it must be connected to the 4th speed microswitch It is active high If not connected to Batt the MC coil power
9. A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual DIG IN 4 TH 2 ND 12V 45V ENC GND ENC A ENC B CANT CANL CANH PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH Free digital input input It is active high Fourth speed input it must be connected to the 4th speed microswitch It is active high Second speed input it must be connected to the 2nd speed microswitch It is active high Positive of encoder power supply 5V or 12V output The output voltage must be configured by Zapi there is an internal jumper Negative of encoder power supply Phase A of encoder Phase B of encoder CAN termination connect to CANH A18 to insert 1200 CAN termination resistance Low level CAN BUS voltage I O High level CAN BUS voltage I O Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to A41 for the Flash memory programming Page 33 89 6 2 3 Molex Minifit connectors Page 34 89 A1 A2 A3 A4 5 A6 A7 A8 AQ A10 11 12 1 14 1 2 B3 5 B6 B7 B8 B9 CPOT PPOT NPOT CM LIFT ENABLE 1ST 3 RD CPOT AUX PPOT AUX NPOTB SR DIG IN KEY PAUX PHYDRO
10. ADJUSTMENTS appears on the display ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS Menu oo Og 7 The display will show the first OPTION E RORE 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears moo ADJUSTMENT BATTERY 9 ADJUST BATTERY appears 10 Press SET SET DOWN button order to increase or decrease respectively Set the value read by an external meter ADJUSTMENT BATTERY 11 Battery value appears on the display BA 5V 12 Press OUT to exit the Menu oo oo ARE YOU SURE 13 Confirmation request appears VEG C ATEB NI S 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 ADJUSTMENTS Menu appears jobs bm 16 Press OUT Display now show the Opening Zapi Menu ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 63 89 8 7 PARAMETER configuration In addition to the input configuration parameter modification is made directly by ZAPI on customer specifications or by the customer making the adjustments using the programming console 8 7 1 Traction Page 64 89 The following parameters can be modified 1 ACCELERATION DELAY It determines the acceleration ramp The parameter value in seconds sets the time needed to speed up the motor from 0 to 100 2 2 RELEASE BRAKING It controls the deceleration ramp when the travel request is released The p
11. AT start up the controller checks if the MC contact is already closed when the coil isn t driven yet The test is carried out by trying to discharge the capacitor bank If they don t discharge the failure condition is entered and any function is prevented It is suggested to check the contactor contacts in particular if they are mechanically stuck or pasted Notice that this test isn t carried out if at start up the capacitor are completely discharged 16 AUX OUTPUT KO The controller checks the driver inside the NEB pin If the status of the driver output does not correspond to the signal coming from the microcontroller this alarm is signalled MC opens and all function are stopped Possible causes are e Presence of external shorts or misconnections Check the EB coil wire e There is an internal failure Replace the controller 17 COIL SHORTED Inside the logic board there is a shunt in common with both the NMC and the NEB output drivers This shunt is used to detect overcurrent conditions in these outputs in case of an overcurrent event the NMC and ENB drivers are stopped and this alarm is raised Look for short circuit in parallel with the MC and EB coils or if these coils have the correct impedance If no short is present and the alarm persists the failure is internal to the controller which must be replaced The overcurrent detection circuit is checked at start up too If this test fails the alarm is raised In this case the fai
12. Analog SET POT BRK MAX It records the maximum value of braking pedal potentiometer when the braking pedal is fully pressed the procedure is similar to the Program Vacc function see chapter 9 4 This procedure must be carried out only if the Pedal braking option is programmed as Analog SET BATTERY TYPE It selects the nominal battery voltage ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve see also curve below THROTTLE X POINT This parameter changes the characteristic of the accelerator input curve THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve A Y VACC MIN and VACC MAX are values programmable by the Program Vacc function ADJUSTMENT 04 This parameter determines the motor temperature level at which the Motor temperature alarm is signalled The range is from 70 C to 160 C with 10 C steps This parameter must be adjusted only if the Set temperature menu Set option parameter is programmed Analog ADJUSTMENT 03 This parameter isn t used 10 ADJUSTMENT 02 It adjusts the lower level of the battery discharge table 11 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 55 89 gt 12 LOAD HM FROM MDI For an explanation of this point
13. logic board failure In both cases the controller must be replaced 17 DATA ACQUISITION This alarm is signalled in the current gain acquisition phase Wait the end of the acquisition activity The gain acquisition test can be carried out only by Zapi personnel or other trained technicians 18 MAIN CONTACTOR ALARMS The main contactor has many diagnoses related to it Here there is the complete list Notice that all of these alarm cause the opening of the MC and the stop of all functions of the controller DRIVER SHORTED When the key is switched ON the controller checks that the NMC pin is not at zero voltage If it is this alarm is signalled MC stay open and any function is prevented Possible causes are o Driver inside the NMC circuit is shorted The controller has to be replaced o external short is present between NMC and ground Check the cables CONTACTOR DRIVER When all initial diagnoses are finished the traction logic tries to closes the MC by activating the NMC driver NMC voltage is pulled towards Batt voltage If the voltage at the NMC pin does not become low this alarm is signalled and any function is prevented This alarm is caused by an internal failure the controller must be replaced ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual CONTACTOR OPEN The main contactor coil has been driven by the logic board NMC has become low but the contactor does not close Any function is prevented Tw
14. maximum selectable speed This is the ideal ramp calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load The deceleration time shown in the table is the time from 100 Hz to 0 Hz This is the ideal ramp calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load Hz ec Page 66 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Adjustable with a 1 Hz resolution in the 0 to 200 Hz range After changing a parameter press ENTER to confirm data when requested by the message on the console Parameters modified and optimized on one unit can be stored by the console SAVE and then released RESTORE on another inverter thus allowing fast and standardized settings see console manual for details Flow Chart showing how to make Programme changes using Digital Console 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 Change 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 Parameter appears 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 S
15. 48 8 3 Description of Console amp 49 8 4 Description of Standard Console 49 84 1 Traction configuration m 50 8 4 2 Pump conii SUG 51 8 5 Sequence for setting up the parameters 52 e re ees 52 JR EE Uu PETER 52 8 6 OPTION and ADJUSTMENTS 20 53 53 57 8 7 64 E VION uM 64 e E 65 8 8 TESTER description of the uu saint 68 er ee ee 68 882 PUMP 69 OTHER FUNG TIONS 72 9 1 Description of Console SAVE 72 9 2 Description of Console RESTORE 73 9 3 Description of ALARMS MON 74 9 4 Description of Console PROGRAM 75 AC 3 4 FLASH DIAGNOSTIC ALARM 77 10 1 Analy
16. AC 4 FLASH mechanical drawing 38 7 3 Connection drawing Traction configuration 39 7 3 1 Ampseal and Molex Spox 39 7 3 2 Amp Saab 42 poles 40 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 3 89 10 11 12 7 3 3 Molex Minifit connectors 41 7 4 Connection drawing Pump 42 7 4 1 X Ampseal and Molex Spox 42 7 4 2 Saab 42 poles connector 43 7 4 8 Molex Minifit connectors 44 7 5 Connection drawing Combi 45 7 5 1 Ampseal and Molex Spox connectors 45 7 5 2 Amp Saab 42 poles connector 46 753 Molex Minifit connectors AR repa ERE 47 PROGRAMMING ADJUSTMENTS USING DIGITAL CONSOLE 48 8 1 Adjustments via Console DIM IAS rU RUN ES 48 8 2 Additional programming tO0ls cion rant
17. MAIN MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until Bod RESTORE PARAM appears on the Display goo 5 The Display will show 6 Press ENTER to go into the RESTORE PARAM Function 7 The Display shows the type of Model stored DO with a Code Number API V1 8 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display MOD 01 API V1 9 Press ENTER to commence the Restore operation 10 The Display will ask ARE YOU SURE pa YES ENTER NO 0UT 11 Press ENTER for YES or OUT for No ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 73 89 12 You can see the items that are being stored in the inverter memory whilst the RESTORE routine is happening STORINCG ACCELER DELAY MAIN MENU 13 When finished the Console displays RESTORE PARAM 14 Press OUT to return to the Opening Zapi Display 9 3 Description of ALARMS menu The microprocessor in the controller remembers the last five Alarms that have occurred ltems remembered relative to each Alarm are 1 the code of the alarm 2 the number of times the particular Alarm occurred 3 the Hour Meter count when the first alarm event has occurred 4 the controller temperature of the first alarm event This function permits a deeper diagnosis of problems as the recent history can now be accessed If an
18. SAVE function 7 If this facility has been used before the type of inverter data stored appears on the top Main with a 2 digit reference SELECT MOD 00 FREE 8 Keep pressing either ROLL UP or ROLL DOWN keys until the second Main indicates a FREE storage facility SELECT MOD 01 FREE 9 Press ENTER to commence SAVE routine o ue 10 You can see the items that are being stored READING whilst the SAVE routine is happening ACCEL DELAY ECC MAIN MENU 11 When finished the Console shows SAVE DARAN ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 12 Press OUT to return to the Opening Zapi Display nmn 9 2 Description of Console RESTORE function The RESTORE PARAM function allows transfer of the Console s stored data into the memory of the inverter This is achieved in a fast and easy way using the method previously used with the SAVE PARAM function The data that is available via the RESTORE PARAM function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The level of the Battery ADJUST BATTERY ATTENTION When the RESTORE operation is made all data in the inverter memory will be written over and replace with data being restored Flow Chart showing how to use the RESTORE function of the Digital Console ZAPI 0 1 Opening Zapi Display BOV 550A 00000 2 Press ENTER to go into the General menu E E
19. Saab 42 poles connector Page 26 89 A1 A2 A4 5 A6 A7 A8 AQ A10 11 12 1 14 15 16 17 18 19 20 21 22 23 NBRAKE PBRAKE CM KEY SAFETY BATT CPOT NPOT CPOTB ENC A ENC B MODE FORWARD BACKWARD PB Accelerator potentiometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 kQ It is a ground reference Brake potentiometer positive It is the same voltage as A1 Keep load gt 1 kQ Input for motor temperature sensor It is a ground reference It is a ground reference Output for driving the negative of main contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum current is 1 5A at 36 48V 0 5A at 80V and above Positive of main contactor coil It is equal to the key voltage Output for driving a brake or an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of the electromechanical brake coil It is equal to the key voltage Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches Connected to the power supply through a microswitch with a
20. THROTT THRO ADJ M FROM MDI ON MAIN CONT PWM ON AUX OUT ON OFF ON OFF ON OFF Page 51 89 8 5 Sequence for setting up the parameters 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 8 5 1 Traction 8 5 2 52 89 1 Select the Options required See Chapter 8 6 In particular Select and set the Battery voltage Select the type of motor temperature sensor 2 Confirm correct installation of all wires Use the Console s TESTER Chapter 8 8 to assist 3 Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 4 4 Set the MAXIMUM CURRENT Current using the table on Chapter 8 7 5 Set the Acceleration Delay requirements for the machine Test the parameters in both directions Set the FREQUENCY CREEP level starting from level 0 6 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly 7 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED parameter Check the performance with the accelerator pedal totally depressed If
21. alarm is continuously happening the controller does not use new memory of the logbook but it just updates the memory cell about that particular alarm Flow Chart showing how to use the ALARMS function via the Digital Console ZAPI VO O BOV 550A 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 PARAMETER CHANGE appears on the display a mH 5 The Display will show ALARMS 6 Press ENTER to go into the ALARMS function CODE 7 The Display will show the most recent Alarm 00005 02 20 C 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 Page 74 89 ADWZPODF FLASH AC4 FLASH INVERTER User Manual 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu 11 The Display will ask CLEAR LOGBOOK YES ENTER NO 0UT 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi Display 9 4 Description of Console PROGRAM VACC function This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal lt enables compensation for non symmetry of the mechan
22. are PC software which have to be installed in a computer Then in order to use them the computer must be connected to the Zapi inverter via serial line or CAN They access the internal settings in the same way as the handset does the names of the parameters alarm codes and all the other internal informations are the same as if an handset is being used In general the PC based tools provide larger flexibility than the standard Zapi handset especially if you have to review and modify many parameter settings If interested one of these solutions please contact for further information Page 48 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Description of Console amp Connection INN 19 Xu NO NS N DISPLAY 1 PARAM 2 IMAX SPEED 1 ACC SPEED II BRAKING SPEED 2 TESTER RBRAKE HIDRO SP Rm MAX SP HIDRO TIME 3 SAVE SP RED COMPENS 4 RESTORE I MOT V POT V BATT 5 ALARMS VMN MOT M SW TEST 6 PROGRAM PEDAL 7 MOTOR DATA 13 0 2 52 5 ROLL ENTER SET BUT TONS m ROLL OUT SET 121 21 8 4 Description of Standard Console Menu The following paragraph shows the structure of the parameter menu Special software versions may have additional parameters and setting In this case
23. brake pedal input are active or a movement of the truck is detected EX HYDRO the inverter manages an hydraulic steering function when the exclusive hydro input is active 7 PEDAL BRAKING ANALOG The mechanical brake pedal has a switch anda potentiometer installed When the accelerator is released and the pedal brake is pushed the inverter performs an electrical braking whose intensity is proportional to the brake pedal potentiometer The minimum intensity is established by the Release braking parameter when the brake pedal is slightly pressed brake switch close but brake potentiometer at the minimum The maximum intensity is established by the Pedal braking parameter when the brake pedal is fully pressed brake potentiometer at the maximum In the middle positions the electrical braking intensity is a linear function between minimum and maximum intensity DIGITAL The truck does not have a potentiometer installed on the mechanical brake pedal but only a microswitch when the accelerator pedal is released and the brake pedal is pushed brake switch closed the inverter performs an electrical braking following Pedal braking parameter 8 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected between B6 and B12 Minifit A4 and A5 Amp Saab A24 and A25 Ampseal ANALOG an analog motor thermal sensor like a KTY 84 is connected no motor thermal sensor switch is connected In the
24. carrying the positive of the battery see connection diagrams The fuse rating depends on the average current of a typical operating cycle of the application and not on the controller current Fuses in the range 355 5004 should cover the majority of applications The voltage rating must be the same or larger as the battery voltage Notice that the purpose of the power fuse is not to protect the power section of the inverter In case of an internal short circuit a damage in the inverter will occur too quickly and the fuse will not blow The purpose of the fuse is to protect the Page 12 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual A power cables in case the operating current rises too much For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles in the case the fuse blows a2 Installation of the hardware Before doing any operation ensure that the battery is disconnected and when all the installation is completed start the machine with the drive wheels raised from the floor to ensure that any installation error do not compromise safety After operation even with the Key Switch open the internal capacitors may remain charged for some time For safe operation we recommend that the battery is disconnected and a short circuit is made between Battery Positive and Battery Negative power terminals of the inverter using a Resistor between 10 ohm and 100
25. fuse in series If not connected to Batt the MC coil power output will be disabled It is a ground reference Analog input for accelerator potentiometer wiper Negative of accelerator unit This pin is tested for wire disconnection diagnosis Analog input for brake potentiometer wiper Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with A6 it is a pump inverter Forward direction request input it must be connected to the forward direction microswitch It is active high Backward direction request input it must be connected to the backward direction microswitch It is active high Brake request input it must be connected to the brake ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual A24 A25 A26 A27 A28 A29 A30 1 A32 A33 A34 A35 A36 A37 A38 A39 A40 41 42 pedal switch It is active high BACKING FORW Inching function forward direction input it must be connected to the inching forward switch It is active high BACKING BACK Inching function backward direction input it must be connected to the inching backward switch It is active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function SEAT SR
26. high frequency and generate RF energy but wires and cables have the key role to propagate the disturbs because they works as antennas so a good layout of the cables and their shielding can solve the majority of the emission problems 2 The study of the immunity can be divided in two main branches protection from electromagnetic fields and from electrostatic discharge The electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device There are well defined tests which the 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 3 The second type of immunity ESD concerns the prevention of the effects of electric current due to excessive electric charge stored in an object In fact when a charge is created on a material and it remains there it becomes an electrostatic charge ESD happens when there is a rapid transfer from a charged object to another This rapid transfer has in turn two important effects A this rapid charge transfer can determine by induction disturbs on the signal wiring and thus create malfunctions this effect is particularly critical in modern machines with serial communications canbus which are spread everywhere on the truck and which carry critical inform
27. input it must be connected to the 4th speed microswitch It is active high Request input for potentiometer controlled lifting it must be connected to the lift enable microswitch It is active high First speed input it must be connected to the 1st speed microswitch It is active high Free digital input input It is active high Third speed input it must be connected to the 3rd speed microswitch It is active high Second speed input it must be connected to the 2nd speed microswitch It is active high Hydraulic steering request input It is active high Speed reduction input it must be connected to the speed reduction switch It is active low switch opened If not connected to Batt the MC coil power output will be disabled Phase A of encoder Phase B of encoder Negative of lift unit This pin is tested for wire disconnection diagnosis Analog input for lift potentiometer wiper CAN termination connect to CAN H A18 to insert 1200 CAN termination resistance High level CAN BUS voltage I O Low level CAN BUS voltage I O It is a ground reference Free analog input Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual A24 A25 A26 A27 A28 A29 A30 1 A32 A33 A34 A35 B2 B3 B4 BS B6 B7 B8 NTHERM PTHERM NAUX PAUX NHYDRO PHYDR
28. see the MDI instrument handbook 13 CHECK UP DONE Turn it On when the asked Maintenance service has been executed to cancel the CHECK UP NEEDED warning 14 CHECK UP TYPE This parameter set up a Maintenance hour counter It specifies the handling of the CHECK UP NEEDED warning No CHECK UP NEEDED warning OPTION 1 CHECK UP NEEDED warning appears on the hand set after 300 hours OPTION 2 Equal to OPTION 1 but performances are reduced down to 50 after 340 hours OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 15 PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the main contactor coil the PWM reduces the voltage at the loads on the main contactor coil down to 62 of the battery voltage 16 PWM ON AUX OUT OFF the inverter applies the battery voltage to the loads on the auxiliary output ON the PWM reduces the voltage at the loads on the auxiliary output down to 62 of the battery voltage Page 56 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual STOP ON RAMP STRATEGIES AUX STOP A9 Amp Saab OUTPUT ON B9 Minifit A28 Ampseal BEHAVIOUR ON A SLOPE RAMP OUTPUT The truck is electrically hold on a It drives the coil of a slope when the time set by electromagnetic brake auxiliary time parameter is BRAKE ON The hydraulic steering function elapsed the brake is applied and request is sent t
29. 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 FREQUENCY Hz 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 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 71 89 9 OTHER FUNCTIONS 9 1 Description of Console SAVE function Page 72 89 The SAVE function allows the operator to transmit the Parameter values and Configuration data of the controller into the Console memory It is possible to load 16 different programmes The information saved in the Console memory can then be reloaded into another inverter using the RESTORE function Chapter 9 2 The data that is available via the SAVE function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The Level of the Battery ADJUST BATTERY Flow Chart showing how to use the SAVE function of the Digital Console a ZAPI 0 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 SAVE PARAM appears the display 5 The Display will show 6 Press ENTER to go into the
30. standard configuration the controller is set to read a motor temperature sensor of the type KTY84 130 which is one of the most common sensors This setting cannot be modified by parameters Please inform Zapi if a different temperature sensor is going to be used 9 AUX FUNCTION ON OFF ifthis option is programmed ON the traction inverter applies maximum braking and traction torque 10 ENABLE FUNCTION PRESENT A14 Minifit A26 Amp Saab A7 Ampseal input is managed as accelerator enable input ABSENT 14 Minifit A26 Amp Saab A7 Ampseal input is managed as exclusive hydro input TO CHECK PUMP HYDRO ON OFF if ON it turns on the diagnosis of the CAN communication to a pump module In this case if the traction inverter doesn t receive any messages by the pump inverter from the CAN BUS line the CAN BUS KO warning appears on the traction and the maximum speed is reduced down to 1096 The traction also checks via CAN that there aren t alarms in the pump If pump is in alarm the maximum speed is reduced down to 1096 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual SUBMENU ADJUSTMENTS 1 2 3 4 5 6 7 8 9 SET POT BRK MIN It records the minimum value of braking pedal potentiometer when the braking pedal switch is closed the procedure is similar to the Program Vacc function see chapter 9 4 This procedure must be carried out only if the Pedal braking option is programmed as
31. 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 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 21 89 5 OPERATIONAL FEATURES Speed control Optimum behaviour an a slope due to the speed feedback the motor speed follows the accelerator starting a regenerative braking if the speed overtakes the speed set point the system can perform an electrical stop on a ramp the machine is electrically hold on a slope for a programmable time see also chapter 8 6 Stabl
32. the inching function backward direction input VB active entry of closed switch OFF GND non active entry of open switch Page 68 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 15 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 16 BRAKE SWITCH The level of the Pedal Brake Microswitch ON VB active entry of Brake pedal Microswitch OFF GND non active entry of microswitch 17 EXCLUSIVE HYDRO Status of the exclusive hydro input VB active entry of closed switch OFF GND non active entry of open switch 18 BRAKEPEDAL POT The percentage of the pressure on the brake pedal 100 if the pedal is totally pressed 0 if the pedal is released 19 HAND BRAKE The level of the Handbrake Microswitch ON GND active entry of Handbrake Switch open switch OFF VB non active entry of microswitch closed switch 20 VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition it is expressed in a percentage of the full voltage 21 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 22 BATTERY CHARGE The percentage Charge level of the battery 8 8 2 Pump 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
33. the power bridge Possible causes encoder failure has occurred e g one or two channels of the encoder are corrupted or disconnected Check both the electric and the mechanical encoder functionality the electromagnetic noise on the sensor bearing disturbs the encoder signal This event is quite common at low speed and very high motor currents when the bearing is not shielded CAPACITOR CHARGE When the key is switched ON the inverter tries to charge the internal capacitor bank through a power resistance and it checks if the capacitor are charged within a timeout The following image shows the circuit which charges the capacitors 6 34 pose o EE INVERTER If the charging procedure is incorrect an alarm is signalled and the main contactor is not closed Possible reasons e There is an external short circuit or low resistance path between Batt connector and ground This can prevent or slow down the charge Check the cables looking for wrong connections or cable dispersions to ground e The charging circuit has a failure for example the charging resistor is opened In this case the controller must be replaced e There is a failure on the power modules which interfere with the capacitor charging The controller must be replaced Notice that this test is not carried out if the capacitor are already charged when you switch on the controller VMN LOW VMN HIGH The test is carried out during initial diagnosis and
34. traction controller ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 19 89 a4 EMC A Page 20 89 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 manufacturer holds the responsibility 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 electromagnetic energy generated or received by an electrical device So the analysis works in two directions 1 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 and cables are involved radiated emissions issues when it is studied the propagation of electromagnetic energy through the open space In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at
35. will find some boxes of different colours they mean These are information useful for anyone is working on the installation deeper examination of the content AN These are Warning boxes they describe Operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator items which are important to guarantee system performance and safety 4 1 Wires and fuses Before starting 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 50 mm as a minimum The correct size depends on the average current of a typical operating cycle of the application 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 Fuse for I O circuits Use a fuse for protection of the auxiliary circuits normally this fuse is in series with the key switch see connection diagrams Typical fuse rating is 6 3 10A and the voltage must be the same or larger as the battery voltage 4 1 3 Fuse for power section We suggest to place a power fuse to protect the cables of the battery and of the motor phases Normally this fuse is placed in the cable
36. 2 poles A24 and A25 Ampseal ANALOG analog motor thermal sensor like 84 is connected between B6 and B12 Minifit A4 and A5 Amp Saab 42 poles A24 and A25 Ampseal NONE no motor thermal sensor switch is connected In the standard configuration the controller is set to read a motor temperature sensor of the type KTY84 130 which is one of the most common sensors This setting cannot be modified by parameters Please inform Zapi if a different temperature sensor is going to be 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 THROTTLE 0 ZONE It establishes a deadband the accelerator input curve see also curve below 4 THROTTLE X POINT This parameter changes the characteristic of the accelerator input curve 5 THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve A Y VACC MIN and VACC MAX are values programmable by the Program Page 58 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Vacc function 6 ADJUSTMENT 04 This parameter determines the motor temperature level at which the Motor temperature alarm is signalled The range is from 70 C to 160 C with 10 C steps This parameter must be adjusted only if the Set temperature menu Set option parameter is programmed Analog
37. ET 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 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual ZAPI VO O BOV 550A 00000 MAIN PARAMETE RELEASE LEVE MENU R GHANGE BRAKING RELEASE LEVE BRAKING L 6 ARE YOU SURE YES ENTE MAIN PARAMETE R NO OUT MENU R GHANGE Page 67 89 es TESTER description of the functions The most important input and output signals can be measured in real time using the TESTER function of the console The Console acts as a multimeter able to read voltage current and temperature The following list shows these measurements 8 8 1 Traction 1 MOTOR VOLTAGE This is the voltage supplied to the motor by the inverter it is expressed as a percentage of the full voltage which depends of the battery voltage 2 FREQUENCY This is the frequency of the voltage and current supplied to the motor 3 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor
38. HB 12V 5V ENC GND A ENC CANT CANL CANH PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH input it must be connected to the exclusive hydro microswitch or to the accelerator enable switch It is active high See also Chapter 8 6 SEAT input it must be connected to the SEAT microswitch It is active high Speed reduction handbrake input It is active low switch opened See also Chapter 8 6 Positive of encoder power supply 5V or 12V output The output voltage must be configured by Zapi there is an internal jumper Negative of encoder power supply Phase A of encoder Phase B of encoder CAN termination connect to CANH A18 to insert 1200 CAN termination resistance Low level CAN BUS voltage I O High level CAN BUS voltage I O Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to A41 for the Flash memory programming ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 27 89 6 1 3 Molex Minifit connectors Page 28 89 A1 A2 A4 5 A6 A7 A8 AQ A10 11 12 1 14 1 2 B3 B4 B5 B6 B7 B8 CPOT PPOT NPOT CM FORW BW PB CPOTB PPOTB NPOTB BACK FORW BACK BACK Analog input for accelerator potentiometer wiper Accelerator potentiome
39. LURE 3 Fault in the hardware section of the logic board which manages the hardware current protection This alarms stops the controller operation and opens the MC The controller must be replaced CHECK UP NEEDED This is a warning not a real alarm It is an information for the user that the programmed time for maintenance is elapsed INCORRECT START This alarm signals an incorrect starting sequence Possible causes microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check all external cables and devices controlling the starting sequence In case the failure persists replace the controller FORW BACK An alarm is signalled when a double running request is made simultaneously both forward and backward directions are selected Possible causes A microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check all external cables and devices controlling the selection of the travel direction In case the failure persists replace the controller HANDBRAKE The truck does not start because the handbrake switch is opened Possible Causes A microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check the handbrake cable and switches In case the failure persists replace the controller 10 ENCODER ERROR Two consecutive readings of the encoder speed are too much different because of the inertia of the system i
40. NANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors moving and fixed contacts Electrical Contacts should be checked every 3 months Check the Foot pedal or Tiller microswitch Using a suitable test meter confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals Switches should operate with a firm click sound Microswitches should be checked every 3 months Check the Battery cables cables to the inverter and cables to the motor Ensure the insulation is sound and the connections are tight Cables should be checked every 3 months Check the mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every 3 months Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 months Checks should be carried out by qualified personnel and any replacement parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special requirements should be made after consulting a Zapi Agent The supplier is 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 situat
41. NVERTER User Manual Page 7 89 23 Block diagram KEY CJ POTENTIOMETER 1 4 MICROSWITCHES PROGRAMMING X CONSOLE KEY C 8 89 ADWZPODF FLASH 4 FLASH INVERTER User Manual 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC 3 AC 4 FLASH inverters need some external parts in order to work The following devices complete the kit for the installation in a typical application The use of special devices to be connected to the inverter has to discussed with Zapi Technicians 3 1 Main contactor The main contactor is a component of extreme importance for electrical safety It must be installed See connection diagram for more details The coil of the main contactor has to be connected between the pins PMC A27 Ampseal A8 Ampsaab B2 Minifit and NMC A26 Ampseal A7 Amp Saab B8 can be driven in two ways on off control the coil is driven with the full battery voltage the coil is switched on and off at high frequency 1 kHz with a duty cycle around 60 this feature is useful to decrease the power dissipation of the contactor coil Each coil has a preferred way which has to be used to drive it The AC3 FLASH AC4 FLASH support both driving methods a software parameter can switch between on off control and switching control 3 2 Microswitches The micr
42. O CM MODE PPOT AUX KEY PCLRXD NCLRXD PCLTXD NCLTXD GND 112 FLASH FLASH output It is a ground reference Input for motor temperature sensor Output for driving the negative of main contactor coil single pump configuration or the negative of an auxiliary load It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of the main contactor coil or of the auxiliary load It is equal to the key voltage Output for driving an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of the hydraulic steering contactor coil It is equal to the key voltage Common of LIFT ENABLE 1 ST 2 ND 3RD 4 TH HYDRO SR microswitches This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with A35 it is a pump inverter Auxiliary potentiometer positive It is the same voltage as A3 Keep load 1 kO Connected to the power supply through a microswitch with a fuse in series It is a ground reference It is a ground reference Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive cons
43. R User Manual Page 45 89 7 5 2 Amp Saab 42 poles connector A K iA roe 902 P Y 748 a Z 29 Tec P peo E A 7 A A A A Y N ae Page 46 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 7 5 3 Molex Minifit connectors F BACKIN Y FORWA Y Ko 2 v Y A 3 Y 2 SR A A ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 47 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 the Digital Console In the Ampseal connector version the Console is connected to the B Molex Spox connector of the inverter In the Minifit connectors version the Console is connected to the F connector of the inverter In the Amp Saab 42 poles connector version the Console can be connected to inverter cabling the pins of the console connector to the pins of the inverter connector 8 2 Additional programming tools Other tools are available to access the internal parameters and the other settings They are console it uses the same serial connection as the standard handset console similar to the previous software but it requires CAN connection Both of them
44. SH AC4 FLASH INVERTER User Manual Contents 13 csc ae S ec 6 2 OPEGIFIGATION sociale 7 2 1 FLASH technical specifications 7 2 2 AC 4 FLASH technical specifications 7 922 OS E EST 8 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 9 3 1 Main MP 9 3 2 Microswitches er E 9 222 PP tems SR HUI eg cece 9 3 4 Other analog control 5 10 3 5 Speed TSS DAI AAA 11 4A INSTALLATION HINTS 12 41 Wires and TUS dessen 12 4 1 1 Connection cables pec 12 AP MEE Uode m 12 4 1 3 Fuse for power 5 12 4 2 Installation of the 13 4 2 1 Positioning and cooling of the controller 13 4 2 2 Connection of power 5 13 4 2 3 connections and possible interferences 14 4 2 4 VO connections mm 16 4 2 5 Connection of the 204444000 16 4 2 6 Main contactor and key connection
45. TYPE 48v 0 ZONE 3 oo oo TROTTLE O ZONE 7 oo oo oo Page 61 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 62 89 ZAPI 0 550A 00000 Bo CONFIG MENU SET MODEL CONFIG MENU ADJUSTMENTS SET BATTERY TYPE 48v SET BATTERY TYPE ARE YOU BOV SURE YES ENTER NO 0UT ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console ZAPI 0 1 Opening Zapi Menu 550A 20000 E O ood 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
46. V ELECTRONIC OLEODYNAMIC INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma 59 42028 POVIGLIO RE ITALY Tel 39 0522 960050 Fax 39 0522 960259 e mail zapi zapispa it web www zapispa it END User Manual AC 3 FLASH AC 4 FLASH INVERTER Copyright 1975 2011 Zapi S p A All rights reserved The contents of this publication is a S p A property all related authorizations are covered by Copyright Any partial or total reproduction is prohibited Under no circumstances will Zapi S p A be held responsible to third parties for damage caused by the improper use of the present publication and of the device devices described in it Zapi spa reserves the right to make changes or improvements to its products at any time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication therefore does not reflect any changes in the characteristics of the product as a result of updating VA MAP I 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 DA 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 ADWZPODF AC3 FLA
47. Y POINT MENT 04 0 ADJUSTMENT 01 LOAD HM FROM MD CHECK UP DONE CHECK UP TYPE PWM ON MAIN CONT PWM ON AUX OUT UNNING KEYON ON OFF PRESENT ABSENT ON OFF ON OFF ANALOG DIGITAL ANALOG DIGITAL NONE ON OFF PRESENT ABSENT ON O 24 36 48 72 80 m N 0 9 0 9 ON OFF ON OI NONE OPTION 1 2 ON OFF ON OFF IYDRO CONTACTOR EXCLUSIVE HYDRO BRAKE 3 8 4 2 Pump configuration HEADING PARAMETER CHANGE MAIN MENU jJ CCELER DELAY JECELER DELAY MAX SPEED UP MIN SPEED UP 2 K SPEED 1ST SPEED FINE Hz 2ND EED FINE Hz SRD SPEED FINE Hz 4TH SPEED FINE Hz HYD SPEED FINE Hz MAXIMUM CURRENT AUXILIARY TIME E SET MODE HA CONNECTED SET OPTIONS HA HOUR COUNTER BATTERY CHECK SE EMPERATURE NNING KEYON N OFF gt ITAL ANALOG NONE Hz Hz SLIP VALUE Hz CURRENT RMS A TEMPERATURE G MOTOR TEMPERAT LERATOR V ON ON ON ON OFF ON OFF ON OFF VOLTAGE BOC BATTERY VOLTA BATTERY CHARGE SAVE PARAMETER RESTORE PARAMETER CODE SETTING MIN MAX STEER TABLE NOT AVAILABLE ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual ADJUSTMENTS I SET BATTERY TYPE ADJUST BATTERY THROTTLE 0 ZON
48. additional documentation will be provided ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 49 89 8 4 1 Traction configuration HEADING CONNECTED TO 0 50 89 MAIN MENU PARAMETER ACCELER DELAY SET MODEL CHANGE E BRAKING BRAKING BRAKING LIMIT BRK CUTBACK c SPEED FORW 2 SPEED BACK Hz CUTBACK SPEED Z SEE MESE CURVE CUTBACK A Vd d FREQUENCY CREEP Hz MAXIMUM CURRENT 0 9 BACKING SPEED BACKING TIME AUXILIARY TIME TESTER MOTOR VOLTAGE FREQUENCY Hz ENCODER 2 5 VALUE Hz CURRENT RMS A ADJUSTMENTS TEMPERATURE 6 MOTOR TEMPERAT CCELERATOR V ON OFF ON OFF ON OFF ON OFF ON OFF BACKING ON OFF CUTBACK ON OI BRAKE ON OF EXCLUSIVE HYDRO ON OFF BRAKEPEDAL POT HANDBRAKE ON OFF VOLTAGE BOOSTER BATTERY VOLTAGE V BATTERY CHARGE x SAVE PARAMETER CODE ALARMS h C PROGRAM VACC VACC SETTING MIN MAX STEER TABLE NOT AVAILABLE ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual HOUR COUNTER BATTERY CHECK CUTBACK MODE HYDRO KEY ON STOP ON RAMP AUX OUTPUT 1 PEDAL BRAKING SET TEMPERATURE AUX FUNCTION ENABLE FUNCTION CHECK PUMP HYDRO RK MIN RK MAX TYPE BATTERY THROTTLE O ZONE THROTTLE X POINT THROTTLE
49. al ENCODER connector see chapter 4 2 5 Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to F8 for the Flash memory programming It must be connected to F7 for the Flash memory programming ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 29 89 6 2 Connectors of the logic Pump configuration The AC 3 AC 4 FLASH has been designed to be produced with three different types of I O connector an AMPSEAL 35 poles connector together a MOLEX SPOX 8 poles connector used to connect the Console one AMP SAAB 42 poles connector or six Molex Minifit connectors 6 2 1 Ampseal and Molex Spox connectors Page 30 89 Al A2 A3 4 5 A6 A7 A8 AQ A10 11 12 1 14 15 16 17 18 19 20 21 22 23 12V 5V ENC GND PPOT 4 TH LIFT ENABLE 1ST DIG IN RD 2ND HYDRO SR SAFETY A ENC B NPOT CPOT CAN T CAN H CAN L NPOT AUX CPOT AUX ENC A ENC B Positive of encoder power supply 5V or 12V output The output voltage must be configured by Zapi there is an internal jumper Negative of encoder power supply Lift potentiometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 Fourth speed
50. ance If no short is present and the alarm persists the failure is internal to the controller which must be replaced The overcurrent detection circuit is checked at start up too If this test fails the alarm is raised In this case the failure is only internal to the logic board and the controller must be replaced 21 HIGH TEMPERATURE This is a warning and not an alarm It indicates that the controller temperature is greater than 75 C The maximum current is reduced proportionally to the temperature increase The controller current drops to zero at 100 C If the alarm is signalled when the controller is cold there is an internal failure and the controller must be replaced 22 MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal overtakes the cut off level defined by ADJUSTMENT 4 parameter The motor current is reduced to avoid any damage to the motor If it happens when the motor is cold check the wiring If the wires are ok replace the controller 23 THERMIC SENSOR KO The range of internal temperature sensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to half its max value This is an internal failure replace the controller 24 MOT TH SENSOR KO ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 81 89 This test is performed if the thermal sensor is analog the range of the s
51. andbrake input It is active low switch opened See also Chapter 8 6 BACKING FORW Inching function forward direction input it must be connected to the inching forward switch It is active high BACKING BACK Inching function backward direction input it must be SAFETY A ENC B NPOT CPOT CAN T CAN H connected to the inching backward switch It is active high If not connected to Batt the MC coil power output will be disabled Phase A of encoder Phase B of encoder Negative of accelerator unit This pin is tested for wire disconnection diagnosis Analog input for accelerator potentiometer wiper CAN termination connect to CAN A18 to insert 1200 CAN termination resistance High level CAN BUS voltage I O ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 19 20 21 22 23 24 25 26 27 28 29 1 A32 A33 A34 A35 B1 B2 B3 B4 B5 B6 B7 B8 CANL NPOTB CPOTB ENC A ENC B NTHERM PTHERM NMC PMC NBRAKE PBRAKE CM MODE PPOTB KEY PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH Low level CAN BUS voltage I O It is a ground reference Analog input for brake potentiometer wiper Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output It is a ground reference Input for motor tempe
52. arameter value in seconds sets the time needed to slow down the motor from 100 to OHZ 3 INVERS BRAKING It controls the deceleration ramp when the direction switch is inverted during travel The parameter value in seconds sets the time needed to slow down the motor from 100 to OHz 4 PEDAL BRAKING It determines the deceleration ramp when the travel request is released and the brake pedal switch is closed The parameter value in seconds sets the time needed to slow down the motor from 100 to OHz 5 SPEED LIMIT BRK Deceleration ramp when the pedal position is changed but not completely released The parameter value in seconds sets the time needed to slow down the motor from 100 to 2 6 BRAKE CUTBACK It determines the deceleration ramp when the speed reduction input becomes active and the motor slow down The parameter value in seconds sets the time needed to slow down the motor from 100 to OHz 7 MAX SPEED FORW It determines the maximum speed in forward direction 8 MAX SPEED BACK It determines the maximum speed in backward direction 9 CUTBACK SPEED Speed reduction percentage of the max speed when the cutback switch is active 10 CURVE CUTBACK Determines the speed reduction percentage of the max speed during a steering movement and only if an electric steering control like a Zapi EPS is present in the truck 11 FREQUENCY CREEP Minimum speed in Hz when the forward or reverse switch is closed but the accel
53. 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 After changing a parameter press ENTER to confirm data when requested by the message on the console Parameters modified and optimized on one unit can be stored by the console SAVE and then released RESTORE on another inverter thus allowing fast and standardized settings see console manual for details 8 7 2 Pump The following parameters can be modified 1 ACCELER DELAY It determines the acceleration ramp The parameter value in seconds sets the time needed to speed up the motor from 0 to 100 2 2 DECELER DELAY It controls the deceleration ramp when the pump request is released The parameter value in seconds sets the time needed to slow down the motor from 100 to OHZ ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 65 89 3 MAX SPEED UP It determines the maximum lifting speed with a potentiometer control 4 MIN SPEED UP It determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed nut the lift potentiometer is at its minimum 5 CUTBACK SPEED Speed red
54. ation B inthe worst case and when the amount of charge is very high the ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 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 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 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
55. avel time only KEYON the counter registers when the key switch is closed 2 BATTERY CHECK the battery discharge level check is carried out when the battery level reaches 10 an alarm is signalled and the maximum current is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled 3 CUTBACK MODE PRESENT B10 Minifit A28 Amp Saab A9 Ampseal input is managed as a cutback speed input ABSENT B10 Minifit A28 Amp Saab A9 Ampseal input is managed as an handbrake input 4 HYDRO KEY ON ON OFF if this option is programmed ON the traction inverter manages an hydraulic steering function when the key is switched ON only if the aux output 1 option is programmed as hydro contactor or as exclusive hydro 5 STOP ON RAMP ON the stop on ramp feature truck electrically hold on a ramp is managed for a time established by auxiliary time parameter After this time the behaviour depends on the AUX OUTPUT 1 option setting ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 53 89 Page 54 89 see also the table at the end of this paragraph OFF the stop on ramp feature is not performed 6 AUX OUTPUT 1 BRAKE B9 Minifit A9 Amp Saab A28 Ampseal output drives an electromagnetic brake coil see also the table below HYDRO CONT the inverter manages an hydraulic steering function when the direction input or
56. by internal voltage thresholds which depend on the nominal battery voltage The list of these thresholds is the following 36V 48V undervoltage 15V overvoltage 65V e 80V undervoltage overvoltage 115V 96V undervoltage 34V overvoltage 125V e 120V undervoltage 40V overvoltage 152V LOGIC FAILURE 2 Fault in the hardware section of the logic board which reads the feedback signals of the phase s voltages This alarms stops the controller operation and opens the MC The controller must be replaced LOGIC FAILURE 3 Fault in the hardware section of the logic board which manages the hardware current protection This alarms stops the controller operation and opens the MC The controller must be replaced INCORRECT START This alarm signals an incorrect starting sequence Possible causes microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check all external cables and devices controlling the starting sequence In case the failure persists replace the controller ENCODER ERROR Two consecutive readings of the encoder speed are too much different because of the inertia of the system it is not possible the encoder changes its speed a lot in a short period The alarm is set to appear if the read speed changes of more than 40 Hz in few milliseconds ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 83 89 Page 84 89 8 9 This alarm stops
57. ched It drives the coil of a hydraulic EXCL OFF steering contactor The truck is not electrically hold HYDRO The hydraulic steering function on a slope but comes down request is also sent to the pump very slowly till the flat is inverter by the can bus link reached 8 6 2 Pump ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Using the CONFIG MENU of the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers travel time only KEY 2 the counter registers when the key switch is closed 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 Page 57 89 Very important In the combi system pump traction the battery discharge calculation for the complete system is carried out by the traction inverter the information about the pump inverter consumption is sent on the can bus line from the pump inverter to the traction inverter So the correct programming for the Battery check option is traction inverter ON pump inverter OFF 3 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected between B6 and B12 Minifit A4 and A5 Amp Saab 4
58. 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 MOTOR TEMPERATURE This is the temperature of the motor if the option is programmed None see chapter 8 6 it shows 0 8 ACCELERATOR The voltage of the lift potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 LIFTING SWITCH Status of the lifting switch ON VB active entry of closed switch OFF GND non active entry of open switch ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 69 89 10 1ST SPEED SWITCH Status of the first speed switch of the pump VB active entry of closed switch OFF GND non active entry of open switch 11 2ND SPEED SWITCH Status of the second speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 12 3RD SPEED SWITCH Status of the th
59. dle state showing this Page 82 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual warning Verify the other modules to determinate in which of them there is the problem 10 2 Analysis of alarms for Pump controller 1 2 3 4 5 6 7 WATCH DOG The test is made in both running operation and in stand by It is a self diagnosing test within the electronic board If an alarm should occur the controller must be replaced EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ON again replace the logic If the alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values LOGIC FAILURE 1 This alarm signals that an undervoltage overvoltage protection operation has occurred This alarms stops the controller operation and opens the MC Two possible reasons A Areal undervoltage overvoltage situation happened The alarm should disappear by simply switching off and on again the key The cause of the undervoltage overvoltage event has to be found on the application For example a very strong regenerative braking has increased too much the battery voltage B Fault in the hardware section of the logic board which manages the hardware protection The controller must be replaced The activation of this alarm is regulated
60. e Opening Zapi ooo Menu oma Page 76 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 10 AC 3 AC 4 FLASH DIAGNOSTIC ALARM DESCRIPTION The controller carries out a continuous diagnosis activity in order to detect any kind of failure In this chapter the types of alarm are listed for each alarm possible failure causes are described and a solution if available is suggested Notice that special software versions may have additional alarm codes Please ask Zapi for further information Be careful while to trying to repair a controller under alarm condition even if the alarm is quite simple Possible malfunctions and unexpected behaviour may arise gt In case of an alarm regarding the power section use all precautions to avoid electric hazards before accessing the live parts of the controller Always remember to discharge the capacitors and disconnect the battery before reparation maintenance DM Do not hesitate to contact Zapi technicians for help 10 1 Analysis of alarms for Traction controller 1 WATCH DOG The test is made in both running operation and in stand by It is a self diagnosing test within the electronic board If an alarm should occur the controller must be replaced 2 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ON again the controller must be replac
61. e speed in every position of the accelerator Regenerative release braking based upon deceleration ramps Regenerative braking when the accelerator pedal is partially released deceleration Direction inversion with regenerative braking based upon deceleration ramp Regenerative braking and direction inversion without contactors only the main contactor is present 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 1 traction inverter the traction inverter sends a hydraulic steering function request to the pump inverter on the can bus line see also Chapter 8 6 moreover if the pump inverter is not present for ex tractor application the traction inverter can manage an hydraulic steering function by driving a hydro contactor which drive a hydraulic steering motor A28 Ampseal A9 Amp Saab 42 poles B9 Minifit output see also Chapter 8 6 2 pump inverter the pump inverter manage an hydraulic steering function That is it drives the pump motor at the programmed speed for the programmed time High efficiency of motor and battery due to high frequency commutations Self diagnosis Modification of parameters through the programming console Inte
62. ed DA If the EEPROM KO alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values 3 LOGIC FAILURE 1 This alarm signals that an undervoltage overvoltage protection operation has occurred This alarms stops the controller operation and opens the MC Two possible reasons A Areal undervoltage overvoltage situation happened The alarm should disappear by simply switching off and on again the key The cause of the undervoltage overvoltage event has to be found on the application For example a very strong regenerative braking has increased too much the ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 77 89 Page 78 89 4 5 6 7 8 9 battery voltage B Fault in the hardware section of the logic board which manages the hardware protection The controller must be replaced The activation of this alarm is regulated by internal voltage thresholds which depend on the nominal battery voltage The list of these thresholds is the following 36V 48V undervoltage 15V overvoltage 65V 80V undervoltage overvoltage 115V 96V undervoltage 34V overvoltage 125V e 120V undervoltage 40V overvoltage 152V LOGIC FAILURE 2 Fault in the hardware section of the logic board which reads the feedback signals of the phase s voltages This alarms stops the controller operation and opens the MC The controller must be replaced LOGIC FAI
63. ensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to half its max value Check the integrity of the sensor and of its connections If the sensor is ok and the alarm persists the controller must be replaced 25 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this link it depends on the software version It is signalled when the inverter does not receive any message from the CAN BUS line Possible causes are o wiring disconnected or damaged check them o Failure inside the external module which has to send the messages that the inverter is waiting Check any module connected via CANbus o There is a problem inside the logic board replace the controller 26 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circuit gets active and opens via hardware control the drivers of MC and EB Moreover any function of the controller is stopped This could happen because o This pin is not connected to ground level single controller configuration Check the wires o The slave module has deactivated the output which holds the SAFETY input at low level master slave configuration Check the slave controller and the connection between master and slave o The SAFETY input circuit has an internal failure Replace the controller 27 SAFETY KO This alarm is present on some software version when a slave controll
64. er the pump in combi configuration uses one of its outputs to drive the SAFETY pin at low level At start up the master controller tests if the SAFETY input is not active while the slave controller has not yet activated its driver in this way the master can detect the presence of a short circuit between SAFETY pin and ground This alarm arises if a short is detected the MC does not close and any function is prevented Possible causes o The SAFETY pin has an external short check the wires o output driver of the slave module is shorted check the slave controller and replace it if necessary o Theinternal SAFETY circuit has a failure replace the master controller 28 BATTERY LOW If the BATTERY CHECK parameter is set ON a battery discharge algorithm is executed When the estimated charge level is 10 this alarm is signalled and the current is reduced to the half of the programmed level 29 WRONG SET BATT When the key is turned ON the controller check the battery voltage and verifies it is within a window around the nominal value If not the MC does not close and any operation is prevented Replace the battery with a correct battery 30 WAITING FOR NODE This warning is present on some software version The controller via CANbus waits some synchronization signal from an external module before performing a particular action for example closing the MC If this signal is not received in time the controller stays stuck in an i
65. er detects the diode turn off the alarm is signalled because either PPOT or NPOT are not connected anymore Controller operation is prevented while this alarm is active Check the potentiometer cables if this alarm arises If the alarm persists there is an internal failure and the controller must be replaced 12 STBY HIGH Test carried out in stand by The controller checks if the current in stand by is zero If it is non zero this alarm is activated The controller opens the MC and it inhibits machine operations Possible causes A current sensor failure B logic board failure In both cases the controller must be replaced 13 SEAT KO This alarm may be present in combi systems traction pump The pump can use of its digital input to read the status of the SEAT switch together with the traction controller Then master and slaves compare the two read status via CAN messages The alarm is signalled if a mismatch is found Check the connection of the SEAT switch to both master and slave If no failure is found the problem is internal to the controller 14 DATA ACQUISITION This alarm is signalled in the current gain acquisition phase Wait the end of the acquisition activity The acquisition test can be carried out only Zapi personnel or other trained technicians 15 MAIN CONTACTOR ALARMS In the combi system pump traction the main contactor is driven by the traction inverter So the following descriptio
66. erator is at its minimum position 12 MAXIMUM CURRENT This parameter changes the maximum current of the inverter It is a percentage of the current defined by factory settings 13 BACKING SPEED It determines the speed while the inching function is active 14 BACKING TIME It determines the time duration of the inching function 15 AUXILIARY TIME During the time defined by this option the truck is hold on the ramp if the ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual stop on ramp option is ON The following table shows the different values at which the parameters can be set ORE PROGRAMMED LEVEL 112 9 ACCELERATION DELAY 25 55 35 5 70 seco rar o 72 68 60 55 ss s o m Max peep ack 85 se s 155 o 200 seed 20 curve cursace ps FREQUENCY 12 50 m Eo 20 25 35 40 45 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
67. f these operations are not carried out correctly Any requests for drive must be made after closing the key switch ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Low battery charge When the battery charge is low the maximum current is reduced to the half of the maximum current programmed Wrong battery The controller checks if the battery has a wrong nominal voltage for example if a 48V battery is connected to a 80V inverter In case a wrong battery is detected the main contactor is not closed to prevent damage to the power section Transient overvoltage and undervoltage During operation the battery voltage can vary a lot If a lot of current is absorbed the battery voltage will drop while during regenerative braking it will increase An hardware protection deactivates the power section and opens the main contactor in case of large overvoltage and undervoltage See the description of the alarm LOGIC FAILURE 1 in Chapter 10 4 3 2 Safety Features A ZAPI controllers are designed according to the prEN954 1 specifications for safety related parts of control system and to UNI EN1175 1 norm The safety of the machine is strongly related to installation length layout and screening of electrical connections have to be carefully designed ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions Furthermore ZAPI is available to develop new SW or HW solutions
68. ical system between directions The operation is performed by operating the pedal after entering the PROGRAM VACC function Flow Chart showing how to use the PROGRAM VACC function of the Digital Console ZAPI VO O 550A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General Menu 5 MAIN MENU PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display EO Bod 5 The Display will show 6 Press ENTER to go into the PROGRAM VACC routine oo oo 7 The Display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown SETTING 4 8 4 8 8 Press ENTER to clear these values Display will show 0 0 9 Select Forward Direction close any interlock switches that may be in the system ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 75 89 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 part MIN 10 0 6 4 4 12 When finished press OUT mE 13 The Display will ask ARE YOU SURE 22 14 Press ENTER for yes or OUT for NO 15 When finished the Console shows 16 Press OUT again to return to th
69. in stand by when the phase voltages has to be about half the voltage on the power capacitors with MC closed each phase voltage is about half of the battery voltage An alarm condition is detected if a phase voltage is too close to ground VMN LOW or to battery voltage VMN HIGH The MC is opened and the controller is stopped if this alarm arises Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor towards ground or towards battery B failure inside the inverter power stage replace it 10 VACC NOT OK The test is made in stand by when pump is not enabled yet This alarm says that the voltage of the lift potentiometer is 1 V greater than the minimum value programmed by the PROGRAM VACC function Unless this alarm is removed any pump request will be ignored Possible causes A the potentiometer is not correctly calibrated Do the PROGRAM VACC procedure ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual B the potentiometer is not correctly connected Check the cables C the potentiometer itself is defective Check the potentiometer 11 PEDAL WIRE KO The inverter continuously checks the NPOT pin to find out if the potentiometer has been disconnected Inside the NPOT circuit there is a sense diode which is on only if the potentiometer is correctly connected between PPOT and NPOT If the controll
70. ion The AC 3 AC 4 FLASH has been designed to be produced with three different types of I O connector an AMPSEAL 35 poles connector plus a MOLEX SPOX 8 poles connector used to connect the Console one AMP SAAB 42 poles connector or six Molex Minifit connectors 6 1 4 Ampseal and Molex Spox connectors Page 24 89 1 2 A4 5 A7 8 9 10 11 12 1 14 15 16 17 18 12V 5V ENC GND PPOT SEAT FORWARD BACKWARD Positive of encoder power supply 5V or 12V output The output voltage must be configured by Zapi there is an internal jumper Negative of encoder power supply Accelerator potentiometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 SEAT input it must be connected to the SEAT microswitch It is active high Forward direction request input it must be connected to the forward direction microswitch It is active high Backward direction request input it must be connected to the backward direction microswitch It is active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function PB SR HB input it must be connected to the exclusive hydro microswitch or to the accelerator enable switch It is active high See also Chapter 8 6 Brake request input it must be connected to the brake pedal switch It is active high Speed reduction h
71. ion 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 DA IMPORTANT NOTE ABOUT WASTE MANAGEMENT This controller has both mechanical parts and high density electronic parts printed circuit boards and integrated circuits If not properly handled during waste processing this material may become a relevant source of pollution The disposal and recycling of this controller has to follow the local laws for these types of waste materials Zapi commits itself to update its technology in order to reduce the presence of polluting substances in its product ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 89 89
72. ird speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 13 4TH SPEED SWITCH Status of the fourth speed switch of the pump VB active entry of closed switch OFF GND non active entry of open switch 14 HYDRO SPEED REQ Status of the hydro speed request of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 15 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 16 VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition it is expressed in a percentage of the full voltage 17 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 18 BATTERY CHARGE The percentage Charge level of the battery Page 70 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Flow Chart showing how to use the TESTER function of the Digital Console EN ZAPI 1 Opening Zapi Display 80V 550A 00000 oo oo 2 Press ENTER to go into the General menu MAIN MENU PARAMETER GHANGE 4 Press ROLL UP or ROLL DOWN button until TESTER MENU appear on the display 3 The Display will show 5 The Display shows 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is
73. ists the controller must be replaced 22 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this link it depends on the software version It is signalled when the inverter does not receive any message from the CAN BUS line Possible causes are e CAN wiring disconnected or damaged check them e Failure inside the external module which has to send the messages that the inverter is waiting Check any module connected via CANbus There is a problem inside the logic board replace the controller 23 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circuit gets active and opens via hardware control the drivers of MC and EB Moreover any function of the controller is stopped This could happen because e This pin is not connected to ground level single controller configuration Check the wires e Another module has deactivated the output which holds the SAFETY input at low level master slave configuration Check the module and the connection between controllers e The SAFETY input circuit has an internal failure Replace the controller 24 BATTERY LOW If the BATTERY CHECK parameter is set ON a battery discharge algorithm is executed When the estimated charge level is 10 this alarm is signalled and the current is reduced to the half of the programmed level 25 WRONG SET BATT When the key is turned ON the controller check the battery voltage and verifies it is within a
74. lectromechanical brake coil It is equal to the key voltage SEAT input it must be connected to the SEAT microswitch It is active high If not connected to Batt the MC coil power output will be disabled Input for motor temperature sensor Common of SR PB SEAT microswitches Output for driving the negative of main contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual B9 NBRAKE B10 SR HB GND B12 NTHERM C1 CAN L C2 CAN L OUT C3 CAN H C4 CAN H OUT D1 BATT D2 MODE E1 E6 F1 PCLRXD F2 NCLRXD F3 PCLTXD F4 NCLTXD F5 GND F6 412 F7 FLASH F8 FLASH Output for driving a brake or an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Speed reduction handbrake input It is active low switch opened See also Chapter 8 6 It is a ground reference is a ground reference Low level CAN BUS voltage I O Low level CAN BUS voltage I O High level CAN BUS voltage I O High level CAN BUS voltage I O It is a ground reference This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with D1 it is a pump inverter Increment
75. lure is only internal to the logic board and the controller must be replaced 18 HIGH TEMPERATURE This is a warning and not an alarm It indicates that the controller temperature is greater than 75 C The maximum current is reduced proportionally to the temperature increase The controller current drops to zero at 100 If the alarm is signalled when the controller is cold there is an internal failure and the controller must be replaced 19 MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal overtakes the cut off level defined by ADJUSTMENT 4 parameter The motor current is reduced to avoid any damage to the motor If it happens when the motor is cold check the wiring If the wires are ok replace the controller 20 THERMIC SENSOR KO The range of internal temperature sensor is always checked and a warning is Page 86 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual signalled if it is out of range When this happens the motor current is reduced to half its max value This is an internal failure replace the controller 21 MOT TH SENSOR KO This test is performed if the thermal sensor is analog the range of the sensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to half its max value Check the integrity of the sensor and of its connections If the sensor is ok and the alarm pers
76. ly connected Check the cables C the potentiometer itself is defective Check the potentiometer 14 PEDAL WIRE KO The inverter continuously checks the NPOT pin to find out if the ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 79 89 Page 80 89 potentiometer has been disconnected Inside the NPOT circuit there is a sense diode which is on only if the potentiometer is correctly connected between PPOT and NPOT If the controller detects the diode turn off the alarm is signalled because either PPOT or NPOT are not connected anymore Controller operation is prevented while this alarm is active Check the potentiometer cables if this alarm arises If the alarm persists there is an internal failure and the controller must be replaced 15 PEDAL FAILURE This alarm is activated if the accelerator analog signal voltage on CPOT pin is out of range too high or too small Controller operation is prevented while this alarm is active Possible causes the potentiometer has a failure for example the wiper is mechanically broken Check the potentiometer here is some problem in the connections Check the wires There is an internal failure in the controller Replace it 16 STBY HIGH Test carried out in stand by The controller checks if the current in stand by is zero If itis non zero this alarm is activated The controller opens the MC and it inhibits machine operations Possible causes A current sensor failure B
77. n concerns the pump inverter when used independently from the traction inverter In this configuration the pump inverter manages its own main contactor Notice that all of these alarm cause the opening of the MC and the stop of all functions of the controller DRIVER SHORTED When the key is switched ON the controller checks that the NMC pin is not at zero voltage If it is this alarm is signalled MC stay open and any function is prevented Possible causes are e Driver inside the NMC circuit is shorted The controller has to be replaced e An external short is present between NMC and ground Check the cables CONTACTOR DRIVER When all initial diagnoses are finished the traction logic tries to closes the MC by activating the NMC driver NMC voltage is pulled towards ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 85 89 Batt voltage If the voltage at the NMC pin does not become low this alarm is signalled and any function is prevented This alarm is caused by an internal failure the controller must be replaced OPEN The main contactor coil has been driven by the logic board NMC has become low but the contactor does not close Any function is prevented Two possible reasons A the MC coil is damaged or it is rated to a voltage larger than the voltage applied Check the coil B the two contacts of the contactor are not properly working and they cannot close Check them CONTACTOR CLOSED
78. ng console manual A A A 4 p AN j 72 1 d 7 N 7 N N 2 gt 2 N 7 Z Y 2 7 7 ES ES pa 5 Yj N A 2 Wi N 3 The two graphs show the output voltage from non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close 0 represents the mechanical zero of the rotation The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer 3 4 Other analog control devices Page 10 89 Other devices whose output is an analog signal can be connected to the inverter 1 Input CPOTB A21 Ampseal connector A17 Amp Saab connector A8 Molex Minifit is another analog input whose typical application is to read a signal from a braking pedal proportional braking The external device should be in a 3 wire configuration like CPOT Potentiometer value should be in the 0 5 10 kohm range Generally the ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual load should be in the 1 5 mA to 30 mA range The CPOTB signal range is from 0 to 10 V 2 Electric motors very often have a thermal sensor which can be digital on off sensor normally closed or analog The
79. o possible reasons A the MC coil is damaged or it is rated to a voltage larger than the voltage applied Check the coil B the two contacts of the contactor are not properly working and they cannot close Check them CLOSED AT start up the controller checks if the MC contact is already closed when the coil isn t driven yet The test is carried out by trying to discharge the capacitor bank If they don t discharge the failure condition is entered and any function is prevented It is suggested to check the contactor contacts in particular if they are mechanically stuck or pasted Notice that this test isn t carried out if at start up the capacitor are completely discharged 19 AUX OUTPUT KO The controller checks the driver inside the NEB pin If the status of the driver output does not correspond to the signal coming from the microcontroller this alarm is signalled MC opens and all function are stopped Possible causes are o Presence of external shorts or misconnections Check the EB coil wire o Thereis an internal failure Replace the controller 20 COIL SHORTED Inside the logic board there is a shunt in common with both the NMC and the NEB output drivers This shunt is used to detect overcurrent conditions in these outputs in case of an overcurrent event the NMC and ENB drivers are stopped and this alarm is raised Look for short circuit in parallel with the MC and EB coils or if these coils have the correct imped
80. o the pump the 3 phase bridge is released inverter by the can bus link Do not use this combination if the negative brake is not installed The truck is not electrically hold on a slope but comes down It drives the coil of a very slowly when the time set electromagnetic brake by auxiliary time parameter is BRAKE OFF The hydraulic steering function elapsed the brake is applied request is sent to the pump and the 3 phase bridge is inverter by the can bus link opened Do not use this combination if the negative brake is not installed It drives the coil of a hydraulic The truck is electrically hold on a HYDRO steering contactor slope when the time set by CONT ON The hydraulic steering function auxiliary time parameter is request is also sent to the pump elapsed the truck comes down inverter by the can bus link very slowly till the flat is reached It drives the coil of a hydraulic HYDRO OFF steering contactor The truck is not electrically hold CONT The hydraulic steering function on a slope but comes down request is also sent to the pump very slowly till the flat is inverter by the can bus link reached It drives the coil of a hydraulic The truck is electrically hold on a EXCL ON steering contactor slope when the time set by HYDRO The hydraulic steering function auxiliary time parameter is request is also sent to the pump elapsed the truck comes down inverter by the can bus link very slowly till the flat is rea
81. 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 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 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 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 cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify with a multimeter the continuity between the starting point and the end of a signal wire For information about the mating connector pin assignment see the chapter description of the connectors 4 2 5 Connection of the encoder 1 AC 3 AC 4 FLASH support 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 12 V it depends on the position of an internal jumper
82. 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 A Fit transient suppression devices to the horn solenoid valves and contactors not connected to the controller The heat generated by the power block must be dissipated For this to be possible the compartment must be ventilated and the heat sink materials ample The heat sink material and system should be sized on the performance requirement of the machine Abnormal ambient air temperatures should be considered In situations where either ventilation is poor or heat exchange is difficult forced air ventilation should be used The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle 4 2 2 Connection of 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 AC 3 AC 4 FLASH module should only be connected to a traction battery Do not use converters outputs or power supplies For special applications please contact the nearest Zapi Service Centre Do not connect the controller to a batte
83. ole power supply It must be connected to B8 for the Flash memory programming It must be connected to B7 for the Flash memory programming 6 2 2 Amp Saab 42 poles connector A1 A2 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual PPOT NPOT AUX PPOT AUX Lift potentiometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 kQ It is a ground reference Auxiliary potentiometer positive It is the same voltage Page 31 89 Page 32 89 A4 5 A6 A7 A8 AQ A10 11 12 1 14 15 16 17 18 19 20 21 22 23 24 25 NAUX PAUX NHYDRO PHYDRO CM KEY SAFETY MODE LIFT ENABLE 1ST 3 RD HYDRO SR as 1 Keep load gt 1 Input for motor temperature sensor It is a ground reference It is a ground reference Output for driving the negative of main contactor coil single pump configuration or the negative of an auxiliary load It drives to Batt It can be on off controlled or PWM controlled Maximum current is 1 5A at 36 48V 0 5A at 80V and above Positive of the main contactor coil or of the auxiliary load It is equal to the key voltage Output for driving an hydraulic steering contactor coil It drive
84. oswitches must have a contact resistance lower than 0 1 ohm and a leakage current lower than 100 When full load connected the voltage drop between the key switch contacts must be lower than 0 1 V The microswitches send a voltage signal to the microprocessor when a function request for ex forward request is made Microswitches are used to send digital signals and thus are typically connected to digital inputs 3 3 Accelerator unit The accelerator unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration typically positive supply negative supply and signal The main analog input CPOT A16 Ampseal version A15 Amp Saab version A1 Molex Minifit version can read signals ranging from 0 to 10 V ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 9 89 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 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 see Chapter 9 4 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 programmi
85. output will be disabled Input for motor temperature sensor Common of 2 4 microswitches Output for driving the negative of main contactor coil single pump configuration or the negative of an auxiliary load It drives to Batt It can be on off controlled or PWM controlled Maximum current is 1 5A at 36 48V 0 5A at 80V and above Output for driving an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual at 80V and above B10 2ND Second speed input it must be connected to the 2nd speed microswitch It is active high B11 GND It is a ground reference 12 It is a ground reference C1 CAN L Low level CAN BUS voltage I O C2 CAN L OUT Low level CAN BUS voltage I O C3 CAN H High level CAN BUS voltage I O C4 CAN H OUT High level CAN BUS voltage I O D1 BATT It is a ground reference D2 MODE This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with D1 it is a pump inverter E1 E6 Incremental ENCODER connector see chapter 4 2 5 1 PCLRXD Positive serial reception F2 NCLRXD Negative serial reception F3 PCLTXD Positive serial transmission F4 NCLTXD Negative serial transmission F5 GND Negative console power sup
86. p Program Memory Digital control based upon a microcontroller Voltage c 36 48 V 72 80 V 96 V 120 V Maximum current 36 48 600 A RMS for 3 Maximum current 72 80 Visca a cien EH ROG 600 A RMS for 3 Maximum current 96 3 usi pete E va pen Ela cess 450 A RMS for Maximum Current 120 3 lt lt pese li 500 RMS for 3 Operating frequency c 8 kHz External temperature range 30 C 40 Maximum inverter temperature at full power 75 2 2 AC 4 FLASH technical specifications Inverter for AC asynchronous 3 phase motors Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chip Program Memory Digital control based upon a microcontroller porco T 36 48 V 72 80 V 96 V Maximum current 36 48 750 A RMS for 3 Maximum current 72 80 V tee reete ensi 550 A RMS for 3 Maximum current 96 V sees 550 A RMS for 3 Operating TEQUGNCY T 8 kHz External temperature range 30 C 40 Maximum inverter temperature at full power 75 ADWZPODF FLASH 4 FLASH I
87. ply F6 12 Positive console power supply F7 FLASH It must be connected to F8 for the Flash memory programming F8 FLASH It must be connected to F7 for the Flash memory programming ADWZPODF FLASH AC4 FLASH INVERTER User Manual Page 35 89 63 Description of power connections View of the power bars J O e lO BATT 9 t 1 Negative of the battery BATT Positive of the battery U V W Connection bars of the three motor phases follow this sequence and the indication on the motor Page 36 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 7 DRAWINGS 3 FLASH mechanical drawing Optional Power Fuse 6 x 8 Male Screw in co pes ex J _ ERN 7 Rd E Ory ery 9 i VA ZN L4 ox Ld A a pS N c AS _ O Y 17 1 1 140 140 D 300 ADWZPODF FLASH AC4 FLASH INVERTER User Manual Page 37 89 2 4 FLASH mechanical drawing
88. rature sensor Output for driving the negative of main contactor coil It drives to It can be on off controlled or PWM controlled Maximum current is 1 5A at 36 48V 0 5A at 80V and above Positive of main contactor coil It is equal to the key voltage Output for driving a brake or an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of the electromechanical brake coil It is equal to the key voltage Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with A35 it is a pump inverter Brake potentiometer positive It is the same voltage as A3 Keep load 1 kO Connected to the power supply through a microswitch with a fuse in series It is a ground reference It is a ground reference Positive serial reception Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to B8 for the Flash memory programming It must be connected to B7 for the Flash memory programming ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 25 89 6 1 2 Amp
89. rging circuit has a failure for example the charging resistor is opened In this case the controller must be replaced There is a failure on the power modules which interfere with the capacitor charging The controller must be replaced Notice that this test is not carried out if the capacitor are already charged when you switch on the controller 12 VMN LOW VMN HIGH The test is carried out during initial diagnosis and in stand by when the phase voltages has to be about half the voltage on the power capacitors with MC closed each phase voltage is about half of the battery voltage An alarm condition is detected if a phase voltage is too close to ground VMN LOW or to battery voltage VMN HIGH The MC is opened and the controller is stopped if this alarm arises Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor towards ground or towards battery B failure inside the inverter power stage replace it 13 VACC NOT OK The test is made in stand by when traction is not enabled yet This alarm says that the accelerator voltage is 1 V greater than the minimum value programmed by the PROGRAM VACC function Unless this alarm is removed any traction request will be ignored Possible causes A the potentiometer is not correctly calibrated Do the PROGRAM VACC procedure B the potentiometer is not correct
90. rinsic protection is present inside the logic when the voltage on the battery power connection is much higher 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 Page 18 89 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 43 Hardware protection and safety features 4 3 4 Protection features The 3 AC 4 FLASH is protected against some controller injuries and malfunctions Battery polarity inversion It is necessary to fit MAIN CONTACTOR to protect the inverter against reverse battery polarity and for safety reasons Connection Errors All inputs are protected against connection errors Thermal protection If the controller temperature exceeds 75 C the maximum current is reduced in proportion to the increase of temperature At 100 C the motor current is reduced to zero The temperature can never exceed 100 C External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP54 Molex Minifit connectors IP65 Ampseal and Amp Saab connectors Protection against accidental Start up A precise sequence of operations are necessary before the machine will start Operation cannot begin i
91. rnal hour meter with values that can be displayed on the console Memory of the last five alarms with relative hour meter and temperature displayed on the console Test function within console for checking main parameters 5 1 Diagnosis Page 22 89 The microcontroller continually monitors the inverter and carries out a diagnostic procedure on the main functions The diagnosis is different in the four main operational modes 1 Diagnosis at start up watchdog circuit current sensor capacitor charging phase s voltages contactor drives can bus interface It also checks if the switch sequence for operation is correct and if the output of accelerator unit is correct ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 2 Standby diagnosis watchdog circuit phase s voltages contactor driver current sensor can bus interface 3 During traction watchdog circuits contactor driver current sensors can bus interface 4 Continuous diagnosis temperature of the inverter motor temperature The status of the internal diagnosis is provided in two ways 1 the digital console can be used which gives a detailed information about any failure which can be present 2 any failure code is also sent on the Can Bus to other modules for example human interface modules like displays ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 23 89 6 DESCRIPTION OF CONNECTORS 6 1 Connectors of the logic Traction configurat
92. ry with a nominal voltage different than the value indicated on the controller label A higher battery voltage ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 13 89 may cause power section failure A lower voltage may prevent the logic operating 4 2 3 CAN connections and possible interferences CAN stands for Controller Area Network It is communication protocol for real time control applications CAN operates at data rate of up to 1 Megabits per second It was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic modules of a vehicle connected as illustrated in this image CAN Controller Transceiver 12002 The best cable for can connections is the twisted pair if it is necessary to increase the immunity of the system to disturbances a good choice would be to use a cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded dna system like an industrial truck where power cables carry hundreds of Ampere there are voltage drops due to the impedance of the cables and that could cause errors on the data transmitted through the can wires In the following figures there is an overview of wrong and right layouts of the cables routing Wrong Layout Module Page 14 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual The red line
93. s 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 depends on the type of nodes modules connected in the network If the modules are very different in terms of power then the preferable connection is the daisy chain AN Correct Layout Module 3 Note Module 1 power gt Module 2 power gt Module 3 power The chain starts from the 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 DA Correct Layout Module 2 Center of the Ground connection Module 3 Note Module 1 power Module 2 power gt Module 3 power In this case the power cables starting from the two similar controllers must be as short as possible Of course also the diameter of the cable concurs in the voltage ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 15 89 EY 4 2 4 1 0 drops described before higher diameter means lower impedance so in this last example the cable between the minus
94. s to It can be on off controlled or PWM controlled Maximum current is 1 5A at 36 48V 0 5A at 80V and above Positive of the hydraulic steering contactor coil It is equal to the key voltage Common of LIFT ENABLE 1 51 2 ND RD 4 TH HYDRO SR microswitches Connected to the power supply through a microswitch with a fuse in series If not connected to Batt the MC coil power output will be disabled It is a ground reference Lift potentiometer wiper Negative of lift potentiometer This pin is tested for wire disconnection diagnosis Free analog input Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with A6 it is a pump inverter Request input for potentiometer controlled lifting it must be connected to the lift enable microswitch It is active high First speed input it must be connected to the 1st speed microswitch It is active high Third speed input it must be connected to the 3rd speed microswitch It is active high Hydraulic steering request input It is active high Speed reduction input it must be connected to the speed reduction switch It is active low switch opened ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual
95. se sensor are 2 wire components in the majority of cases In case the sensor is present it can be connected between the signal input PTHERM A25 Ampseal A4 Amp Saab B6 Minifit and NTHERM A24 Ampseal A5 Amp Saab B12 Minifit See also chapter 8 4 for more explanation Analog motor temperature sensors must be configured via software Please contact Zapi technicians for more details p Speed feedback The motor control is based upon the motor speed feedback The speed transducer is an incremental encoder with two phases shifted at 90 The encoder can be of different types power supply 5 Vor 12V electric output open collector NPN or PNP push pull line driver standard A and B or differential output For more details about encoder installation see also chapter 4 2 5 Note The encoder resolution and the motor poles pair the controller can handle is specified in the home page display of the handset showing following headline AC3T2D F ZP1 13 That means AC3T AC 3 traction controller AC3P AC 3 pump controller 2 motor s poles pair number D 128 pulses rev encoder F flash The encoder resolution is given by the last letter in the following list A 32 pulses rev B 64 pulses rev C 80 pulses rev D 128 pulses rev ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 11 89 4 INSTALLATION HINTS In the description of these installation suggestions you
96. sis of alarms for Traction controller 77 10 2 Analysis of alarms for Pump 83 RECOMMENDED SPARE PARTS FOR INVERTER 88 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 89 Page 4 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual APPROVAL SIGNS COMPANY FUNCTION INITIALS SIGN PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication ADWZPODF Edition May 2011 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 5 89 1 INTRODUCTION Page 6 89 Within the ZAPIMOS family the AC 3 FLASH and the AC 4 FLASH inverters are the model suitable for control of 9 22 kW motors they have been expressly designed for battery electric traction Their typical applications are e electric truck e electric cars e tractors e buses The are available for battery voltages from 24V to 120V Both AC3 FLASH and AC4 FLASH can be purchased with three different I O connectors e Ampseal 35 poles plus a Molex Spox connector for the Zapi console e Amp Saab 42 poles e Molex Minifit ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 2 SPECIFICATION 2 1 AC 3 FLASH technical specifications Inverter for AC asynchronous 3 phase motors Regenerative braking functions Can bus interface Flash memory 256 Kbytes On Chi
97. ss 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 ZAPI VO O BOV 550A 00000 Bo CONFIG MENU SET MODEL CONFIG SET OPTIONS MENU HOUR COUNTER RUNNING Bo BATTERY OFF oo oo ARE YOU BATTERY GHEGK SURE YES ENTER NO 0UT CONFIG SET OPTIONS MENU ADWZPODF FLASH AC4 FLASH INVERTER User Manual Flow chart showing how to make changes to ADJUSTMENT Menu E O E ood 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The display will show SET MODEL 4 Press ROLL UP 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 BATTERY TYPE 8 Press ROLL UP or ROLL DOWN button until the desired parameter is reached 9 The desired parameter appears 10 Press SET UP or SET DOWN button to modify the adjustment 11 Press OUT 12 Press ENTER to confirm 13 Repeat the same from 5 to 12 points for the other adjustments ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual ZAPI 0 BOV 550A 00000 O oo CONFIG ADJUSTMENTS MENU 0E O BATTERY
98. t is not possible the encoder changes its speed a lot in a short period The alarm is set to appear if the read speed changes of more than 40 Hz in few milliseconds This alarm stops the power bridge Possible causes encoder failure has occurred e g one or two channels of the encoder are corrupted or disconnected Check both the electric and the mechanical encoder functionality the electromagnetic noise on the sensor bearing disturbs the encoder ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual signal This event is quite common at low speed and very high motor currents when the bearing is not shielded the truck has encountered high step or a wide hole on the road The abnormal movement of the wheel may trigger this alarm 11 CAPACITOR CHARGE When the key is switched ON the inverter tries to charge the internal capacitor bank through a power resistance and it checks if the capacitor are charged within a timeout The following image shows the circuit which charges the capacitors RS A NAAA z RES 6 34 DX 521 INVERTER AA A EET y If the charging procedure is incorrect an alarm is signalled and the main contactor is not closed Possible reasons There is an external short circuit low resistance path between Batt connector and ground This can prevent or slow down the charge Check the cables looking for wrong connections or cable dispersions to ground cha
99. ter positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 kQ Negative of accelerator unit This pin is tested for wire disconnection diagnosis Common of FW BW BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches Forward direction request input it must be connected to the forward direction microswitch It is active high Backward direction request input it must be connected to the backward direction microswitch It is active high Brake request input it must be connected to the brake pedal switch It is active high Analog input for brake potentiometer wiper Brake potentiometer positive It is the same voltage as A2 Keep load gt 1 It is a ground reference It is a ground reference Inching function forward direction input it must be connected to the inching forward switch It is active high Inching function backward direction input it must be connected to the inching backward switch It is active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function KEY PMC PBRAKE SEAT SAFETY PTHERM CM NMC input it must be connected to the exclusive hydro microswitch or to the accelerator enable switch It is active high See also Chapter 8 6 Connected to the power supply through a microswitch with a fuse in series Positive of main contactor coil It is equal to the key voltage Positive of the e
100. the machine is a forklift check the performance with and without load 8 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 9 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 unloaded full speed condition should be the most representative condition 10 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 11 Set MAX SPEED FORW 12 Set MAX SPEED BACK Reverse 13 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 Depending on the motor used it is necessary to set some parameters giving Zapi the motor curves it is possible to know the optimal setting in order to the motor runs efficiently 1 Select the Options required See Chapter 8 6 In particular Select and set the Battery voltage Select the type of motor temperature sensor 2 Confirm correct installation of all wires Use the Console s TESTER Chapter ADWZPODF
101. to improve the safety of the machine according to customer requirements Machine manufacturer holds the responsibility for the truck safety features and related approval AC 3 AC 4 FLASH inverter electronic implements an hardware safety circuit which is able to open the Main Contactor MC and the Electric Brake EB and therefore to cut the power line stopping the machine via HARDWARE that is bypassing the software control of the MC and EB This safety circuit is driven by SAFETY input If safety input is connected to Batt the SAFETY circuit is inactive if the input is open the SAFETY circuit becomes active and within a timeout it is able to open the drivers of MC coil and EB coil The safety circuit is also periodically checked by the AC 3 AC 4 FLASH microcontroller if the microcontroller detects a failure in the SAFETY circuit the microcontroller itself will bring the machine in a safe status Suggested connection of SAFETY circuit STAND ALONE CONFIGURATION it must be used only if there are other controllers that can stop the system in case of failure COMBI CONFIGURATION in this case the pump controller acts as supervisor checking the traction controller functionality by the CANBUS So it is suggested to connect the SAFETY input of traction controller to a dedicated output of pump controller so that the pump controller can drive the traction safety input and open the power line in case of malfunctioning of
102. ual Page 39 89 7 3 2 Amp Saab 42 poles connector 7039 9NIdanisl qvaad DNIA v 2 gt e Lu 5 3 Z mE 1 5 is Y rs El o C E SEN da 2 Cu Cx x LO m m ES e x m ei Ela KE r T HE EN oju oj a lt Lad a min Oo tr m Z a a gt gt d O 0 D d Te EE lt 44 lt EE V TINO 9 ONG FRACTION ASYNCHRONOUS 1199 Ae 11 1 44 11v8 Page 40 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 7 3 3 Molex Minifit connectors ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual Page 41 89 g Connection drawing Pump configuration 7 4 1 Ampseal and Molex Spox connectors TERNI 2 p Ll a Yin 5 L E3 H 3 5 E tj H 5 sh of a ma C C C tz VAN INNA gt gt lt gt a c aa o CO gt gt E qu T 2E NE E Pi am aj i wu D
103. uction percentage of the max speed when the cutback switch is active 6 1ST SPEED FINE Speed in Hz which is set when the First speed request is activated It is can be regulated with a 1Hz precision 7 2ND SPEED FINE Speed in Hz which is set when the Second speed request is activated It is can be regulated with a 1Hz precision 8 3RD SPEED FINE Speed in Hz which is set when the Third speed request is activated It is can be regulated with a 1Hz precision 9 4TH SPEED FINE Speed in Hz which is set when the Fourth speed request is activated It is can be regulated with a 1Hz precision 10 HYD SPEED FINE Speed in Hz which is set when the hydraulic steering request is activated It is can be regulated with a 1Hz precision 11 MAXIMUM CURRENT This parameter changes the maximum current of the inverter It is a percentage of the current defined by factory settings 12 AUXILIARY TIME Time delay before switching off the hydraulic steering function after the hydraulic steering request has been deativated The following table shows the different values at which the parameters can be set EE PROGRAMMED LEVEL 0 MIN SPEED UP 13 5 15 0 22 5 24 0 CUTBACK SPEED 5 1 MAXIMUM CURRENT 100 AUXILIARY TIME sec 02 0 8 10 1 5 2 0 40 50 The acceleration time shown is the time from 0 Hz to 100 Hz
104. window around the nominal value If not the MC does not close and any operation is prevented Replace the battery with a correct battery 26 WAITING FOR NODE This warning is present on some software version The controller via CANbus waits some synchronization signal from an external module before performing a particular action for example closing the MC If this signal is not received in time the controller stays stuck in an idle state showing this warning Verify the other modules to determinate in which of them there is the problem ADWZPODF FLASH AC4 FLASH INVERTER User Manual Page 87 89 11 RECOMMENDED SPARE PARTS FOR INVERTER Part number Description C16507 Protected 500 A strip Fuse C16505 Protected 355 A strip Fuse C16500 10 A 20 mm Control Circuit Fuse C16520 6 3 A 20 mm Control Circuit Fuse C29509 SW 200 80 V Single Pole Contactor C29532 SW 200 48 V Single Pole Contactor C12532 Ampseal Connector 35 pins Female C12442 Molex Minifit Connector 2 pins Female C12358 Molex Minifit Connector 4 pins Female C12359 Molex Minifit Connector 6 pins Female C12414 Molex Minifit Connector 8 pins Female C12407 Molex Minifit Connector 12 pins Female C12403 Molex Minifit Connector 14 pins Female C12796 Female Ampseal pin harness side C12777 Female Molex Minifit pin harness side Page 88 89 ADWZPODF AC3 FLASH AC4 FLASH INVERTER User Manual 12 PERIODIC MAINTE

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