Table of Contents
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1
Introduction .................................................................................................... 3
2
Specification .................................................................................................. 3
2.1
AC-3 Technical specifications ................................................................ 3
2.2
AC-4 Technical specifications ................................................................ 3
2.3
Block diagram ........................................................................................ 4
2.4
Control unit ............................................................................................. 4
2.4.a Microswitches ............................................................................... 4
2.4.b Accelerator unit ............................................................................. 4
2.4.c Other analog control unit ................................................................ 5
2.4.d Speed feedback............................................................................ 5
2.5
2.6
Operational features ............................................................................... 7
2.7
Diagnosis .............................................................................................. 8
2.8
Thermal consideration ............................................................................ 8
2.9
2.11 Main contactor and emergency switch .................................................... 9
3
Installation .................................................................................................... 10
3.1
Connection cables ............................................................................... 10
3.2
Contactors ........................................................................................... 10
3.3
Fuses ................................................................................................... 10
3.4
Description of connectors - Traction configuration ............................... 11
3.4.a Amp Saab connector ................................................................... 11
3.4.b Molex Minifit connectors .............................................................. 13
3.5
Description of connectors - Pump configuration .................................... 15
3.5.a Amp Saab connector ................................................................... 15
3.5.b Molex Minifit connectors .............................................................. 17
3.6
Encoder installation .............................................................................. 19
3.7
Description of power connections ......................................................... 20
3.8
AC-3 Mechanical drawing .................................................................... 21
3.9
AC-4 Mechanical drawing .................................................................... 22
3.10 Connection drawing - Traction configuration ......................................... 23
3.10.a Amp Saab connector ................................................................ 23
3.10.b Molex Minifit connectors ........................................................... 24
3.11 Connection drawing - Pump configuration ............................................ 25
3.11.a Amp Saab connector ................................................................ 25
3.11.b Molex Minifit connectors ........................................................... 26
3.12 Connection drawing - Combi configuration ........................................... 27
3.12.a Amp Saab connector ................................................................ 27
3.12.b Molex Minifit connectors ........................................................... 28
INDEX
.......................................................................... 6
. .............................................. 8
.................................. 9
Page
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Table of Contents
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Summary of Contents for Zapi ZAPIMOS Series
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Page 1: Table Of Contents
INDEX Page Introduction ....................3 Specification ....................3 AC-3 Technical specifications ..............3 AC-4 Technical specifications ..............3 Block diagram ..................4 Control unit ..................... 4 2.4.a Microswitches ................4 2.4.b Accelerator unit ................4 2.4.c Other analog control unit ..............5 2.4.d Speed feedback................ - Page 2 Programming & Adjustments using Digital Console ........ 29 Adjustments via Console ..............29 Description of Console & Connection ........... 29 Description of Standard Console Menu ..........30 4.3.a Traction configuration ..............30 4.3.b Pump configuration ..............31 Function configuration ................32 4.4.a Traction ..................
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Page 3: Introduction
1 INTRODUCTION Within the ZAPIMOS family, the AC3 inverter is the model suitable for control of 7÷12 KW motors; the AC4 inverter is the model suitable for control of 12kW to 20kW motors. They have been expressly designed for battery electric traction. They are fit for electric truck, electric cars, tractors and buses. -
Page 4: Block Diagram
2.3 BLOCK DIAGRAM 2.4 CONTROL UNIT 2.4.a Microswitches - The microswitches must have a contact resistance lower than 0.1W and a leakage current lower than 100µA. - When full load connected, the voltage between the key switch contacts must be lower than 0.1V. -
Page 5: Other Analog Control Unit
The Procedure for automatic potentiometer signal acquisition is carried out using the Console. This enables adjustment of the minimum and maximum useful signal level (PROGRAM VACC function), in either direction. This function is unique when it is neces- sary to compensate for asymmetry with the mechanical elements associated with the potentiometer, especially relating to the minimum level. -
Page 6: Protection Features
2.5 PROTECTION FEATURES - Battery polarity inversion: It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery polarity and for safety reasons. - Connection Errors: All inputs are protected against connection errors. - Thermal protection If the chopper temperature exceeds 75°C, the maximum current is reduced in proportion to the thermal increase. -
Page 7: Operational Features
2.6 OPERATIONAL FEATURES - Speed control. - Optimum behavior 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 4.4) - Stable speed in every position of the accelerator. -
Page 8: Diagnosis
2.7 DIAGNOSIS The microprocessor continually monitors the inverter and carries out a diagnostic proce- dure on the main functions. The diagnosis is made in 4 points 1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capaci- tor charging, phase's voltages, contactor drives, can-bus interface, if the switch se- quence for operation is correct and if the output of accelerator unit is correct. -
Page 9: Susceptibility And Electromagnetic Emission
EN50081-2). 2.11 MAIN CONTACTOR AND EMERGENCY SWITCH - The connection of the battery line switches must be carried out following ZAPI instruc- tions. - 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;... -
Page 10: Installation
3 INSTALLATION Install the chopper with the base-plate on a flat metallic surface that is clean and unpainted. Apply a light layer of thermo-conductive grease between the two surfaces to permit better heat dissipation. Ensure that the wiring of the cable terminals and connectors is carried out correctly. Fit transient suppression devices to the horn, solenoid valves, and contactors not con- nected to the chopper such as those for activating the pump motor or steering motor. -
Page 11: Description Of Connectors - Traction Configuration
3.4 DESCRIPTION OF CONNECTORS - TRACTION CONFIGURATION The AC3 and AC4 have been designed to be produced with two different types of I/O connector: One AMP SAAB 29 poles connector or six Molex Minifit connectors. 3.4.a Amp Saab connector PPOT Potentiometer positive: 10V output;... - Page 12 A18 BACK. FORW Inching function, forward direction input. Must be connected to the inching forward switch. Active high. A19 BACK. BACK Inching function, backward direction input. Must be connected to the inching backward switch. Active high. A20 ENCODER Incremental ENCODER connector (see chapter 3.6). A21 ENCODER Incremental ENCODER connector (see chapter 3.6).
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Page 13: Molex Minifit Connectors
3.4.b Molex Minifit connectors CPOT Accelerator potentiometer wiper. PPOT Potentiometer positive: 10V output; keep load > 1KW. NPOT Negative of accelerator unit, tested for wire disconnection diagnosis. Common of FW / BW / SR / PB / SEAT / BACK. FW / BACK. BW / EXCLUSIVE HYDRO microswitches. - Page 14 SAFETY If not connected to -Batt the MC coil power output will be disabled. Can also be used as a general purpose input. PTHERM Input for motor temperature sensor. Common of FW / BW / SR / PB / SEAT / INCHING FW / INCHING BW / EXCLUSIVE HYDRO microswitches.
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Page 15: Description Of Connectors - Pump Configuration
3.5 DESCRIPTION OF CONNECTORS - PUMP CONFIGURATION The AC3 and AC4 have been designed to be produced with two different types of I/O connector: One AMP SAAB 29 poles connector or six Molex Minifit connectors. 3.5.a Amp Saab connector PPOT Potentiometer positive: 10V output;... - Page 16 A20 ENCODER Incremental ENCODER connector (see chapter 3.6). A21 ENCODER Incremental ENCODER connector (see chapter 3.6). A22 ENCODER Incremental ENCODER connector (see chapter 3.6). A23 ENCODER Incremental ENCODER connector (see chapter 3.6). A24 MODE This input allows the customer to select the software for traction or lifting application.
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Page 17: Molex Minifit Connectors
3.5.b Molex Minifit connectors CPOT Accelerator potentiometer wiper. PPOT Potentiometer positive: 10V output; keep load > 1KW. NPOT Negative of accelerator unit, tested for wire disconnection diagnosis. Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED / 4th SPEED / HYDRO / SR microswitches. - Page 18 NAUX This output can be used for drive the main contactor coil (single pump configuration) or to drive an auxiliary load (combi configura- tion) NHYDRO Output for driving an hydraulic steering contactor; drives the load to - Batt. Maximum current: 3A. B10 2nd SPEED Input for second speed request;...
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Page 19: Encoder Installation
3.6 ENCODER INSTALLATION 1) AC4 card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90°. The en- coder power supply can be +5 or +12V. It can have different electronic output. -
Page 20: Description Of Power Connections
3.7 DESCRIPTION OF POWER CONNECTIONS View of the power bars: -BATT Negative of the battery. +BATT Positive of the battery. U; V; W Connection bars of the three motor phases; follow this sequence and the indica- tion on the motor. Page 20... -
Page 21: Mechanical Drawing
3.8 AC3 MECHANICAL DRAWING Page 21... -
Page 22: Mechanical Drawing
3.9 AC4 MECHANICAL DRAWING Page 22... -
Page 23: Connection Drawing - Traction Configuration
3.10 CONNECTION DRAWING - TRACTION CONFIGURATION 3.10.a Amp Saab connector Page 23... -
Page 24: Molex Minifit Connectors
3.10.b Molex Minifit connectors Page 24... -
Page 25: Connection Drawing - Pump Configuration
3.11 CONNECTION DRAWING - PUMP CONFIGURATION 3.11.a Amp Saab connector Page 25... -
Page 26: Molex Minifit Connectors
3.11.b Molex Minifit connectors Page 26... -
Page 27: Connection Drawing - Combi Configuration
3.12 CONNECTION DRAWING - COMBI CONFIGURATION 3.12.a Amp Saab connector Page 27... -
Page 28: Molex Minifit Connectors
3.12.b Molex Minifit connectors Page 28... -
Page 29: Programming & Adjustments Using Digital Console
4 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 4.1 ADJUSTMENTS VIA CONSOLE Adjustment of Parameters and changes to the inverter’s configuration are made using the Digital Console. The Console is connected to the “F” connector of the inverter (Minifit connectors version). 4.2 DESCRIPTION OF CONSOLE &... -
Page 30: Description Of Standard Console Menu
4.3 DESCRIPTION OF STANDARD CONSOLE MENU 4.3.a Traction configuration Page 30... -
Page 31: Pump Configuration
4.3.b Pump configuration Page 31... -
Page 32: Function Configuration
4.4 FUNCTION CONFIGURATION 4.4.a Traction Using the CONFIG MENU of the programming console, the user can configure the follow- ing functions (see "OPERATIONAL FEATURE" chapter for an explanation of "hydraulic steering function") : SUBMENU "SET OPTIONS" 1 HOUR COUNTER - RUNNING: the counter registers travel time only. - Page 33 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).
- Page 34 VACC MIN and VACC MAX are values programmable by the "Program Vacc" function. 9 ADJUSTMENT #01: adjust the upper level of the battery discharge table. 10ADJUSTMENT #02: adjust the lower level of the battery discharge table. 11 LOAD HM FROM MDI: for an explanation of this point see the MDI instrument hand- book 12 CHECK UP DONE: for an explanation of this point see the MDI instrument hand-...
- Page 35 STOP A7 (Saab), B9 (Minifit) BEHAVIUR ON A SLOPE OUTPUT OUTPUT RAMP The truck is electrically hold on a -Drives the coil of a electromagnetic slope; when the time set by brake. "auxiliary time" parameter is elapsed BRAKE -The hydraulic steering function the brake is applied and the 3- request is sent to the pump inverter phase bridge is released.
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Page 36: Pump
4.4.b Pump Using the config menu of the programming console, the user can configure the follow- ing functions. SUBMENU "SET OPTIONS" 1 HOUR COUNTER - RUNNING: the counter registers travel time only. - KEY ON: the counter registers when the "key" switch is closed. 2 BATTERY CHECK - ON: the battery discharge level check is carried out;... - Page 37 input curve. 6 THROTTLE Y POINT: These parameter change the characteristic of the accelerator input curve. VACC MIN and VACC MAX are values programmable by the "Program Vacc" function. 7 ADJUSTMENT #02: adjust the upper level of the battery discharge table. 8 ADJUSTMENT #01: adjust the lower level of the battery discharge table.
- Page 38 Flow chart showing how to make changes to OPTION Menu. 1) Opening Zapi Menu 2) Press Top Left & 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.
- Page 39 Flow chart showing how to make changes to ADJUSTMENT Menu 1) Opening Zapi Menu 2) Press Top Left & 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.
- Page 40 Flow chart showing how to use the SET BATTERY TYPE adjustment 1) Opening Zapi Menu 2) Press Top Left & Right Buttons to enter CONFIG Menu. 3) The Display will show: SET MODEL 4) Press ROLL UP button until ADJUSTMENTS. menu appears.
- Page 41 12) Press OUT to exit the Menu. 13) Confirmation request appears. 14) Press ENTER to accept the changes, or press OUT if you do not accept the changes. 15) ADJUSTMENTS Menu appears. 16) Press OUT. Display now show the Opening Zapi Menu. Page 41...
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Page 42: Parameter Regulation: Traction Configuration
4.5 PARAMETER REGULATION: TRACTION 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 program- ming console. The following parameters can be modified: ACC DELAY: determines the acceleration ramp. - Page 43 The following table shows the different values at which the parameters can be set. PARAMETER PROGRAMMED LEVEL UNIT ACCELERATION DELAY (*) Sec. RELEASE BRAKING (**) Sec. INVERS BRAKING (**) Sec. PEDAL BRAKING (**) Sec. SPEED LIMIT BRAKING (**) Sec. BRAKE CUTBACK (**) Sec.
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Page 44: Parameter Regulation: Pump Configuration
4.6 PARAMETER REGULATION: PUMP CONFIGURATION The following parameters can be modified: PU. ACCELER DEL: acceleration ramp. PU. DECELERATION DEL: deceleration ramp. MAX SPEED UP determines the maximum lifting speed with a potentiometer control. MIN SPEED UP determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed. - Page 45 (see console manual for details). Flow Chart showing how to make Program changes using Digital Console fitted with Eprom CK ULTRA. 1) Opening Zapi Display. 2) Press ENTER to go into the General Menu. 3) The Display will show : 4) Press ENTER to go into the Parameter Change facility.
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Page 46: Programming Console Functions
4.7 PROGRAMMING CONSOLE FUNCTIONS - Functional configuration (see 4.1 , 4.2 , 4.3 , 4.4) - Parameter programming (see 4.5 , 4.6) - Tester: the user can verify the state of the following parameters: TRACTION PUMP motor voltage (%) motor voltage (%) frequency (Hz) frequency (Hz) encoder (Hz) -
Page 47: Sequence For Ac Inverter Traction Setting
4.8 SEQUENCE FOR AC INVERTER TRACTION SETTING When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the chopper is not configured to your requirements, follow the sequence detailed on Chapter 5.2 . -
Page 48: Tester: Description Of The Function; Traction Configuration
4.9 TESTER: DESCRIPTION OF THE FUNCTION; TRACTION CONFIGURATION The most important input or output signals can be measured in real time using the TE- STER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. The following definition listing shows the relative measurements : 1) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter;... - Page 49 15) SEAT SWITCH: the level of the Seat Microswitch digital entry. ON / +VB = active entry of closed seat switch. OFF / GND = non active entry of open seat switch. 16) EXCLUSIVE HYDRO: status of the exclusive hydro switch. ON / +VB = active entry of closed switch.
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Page 50: Tester: Description Of The Function; Pump Configuration
4.10 TESTER: DESCRIPTION OF THE FUNCTION; PUMP CONFIGURATION The most important input or output signals can be measured in real time using the TE- STER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. The following definition listing shows the relative measurements : 1) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter;... - Page 51 9) When you have finished, Press OUT. 10) The Display shows : 11) Press OUT again and return to Opening Zapi Display. 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.
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Page 52: Other Functions
9) Press ENTER to commence SAVE routine. 10) You can see the items that are being stored whilst the SAVE routine is happening. 11) When finished, the Console shows : 13) Press OUT to return to the Opening Zapi Display. Page 52... -
Page 53: Description Of Console Restore Function
11) You can see the items that are being stored in the chopper memory whilst the RESTORE routine is happening. 12) When finished the Console displays : 13) Press OUT to return to the Opening Zapi Display . Page 53... -
Page 54: Description Of Alarms Menu
10) When you have finished looking at the Alarms, press OUT to exit the ALARMS menu. 11) The Display will ask CLEAR LOGBOOK ? 12) Press ENTER for yes, or OUT for NO. 13) Press OUT to return to the Opening Zapi Display. Page 54... -
Page 55: Description Of Console Program Vacc Function
11) Select the Reverse Direction and repeat Item 10. 12) When finished , press OUT. 13) The Display will ask : ARE YOU SURE ?. 14) Press ENTER for yes, or OUT for NO. 15) Press OUT again to return to the Opening Zapi Menu. Page 55... -
Page 56: Ac Inverter Diagnostic - Traction Configuration
6 AC INVERTER DIAGNOSTIC - TRACTION CONFIGURATION The alarms are signalled by a diagnostic LED. 1 blink: logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3", "CHECK UP NEEDED"). 2 blinks: running request on start-up or error in seat sequence or double direction request ("INCORRECT START", "HANDBRAKE", "FORW + BACK"). - Page 57 protection. Replace the logic board. 6. CHECK UP NEEDED This is a warning. It is an information for the user that the programmed time for mainte- nance is elapsed. 7. INCORRECT START This alarm signals an incorrect starting sequence. Possible causes: a.
- Page 58 11. VMN LOW, VMN HIGH The test is carried out during initial diagnosis and in standby. Possible causes: a. problem with the motor connections or the motor power circuit; check if the 3 phases are correctly connected; check if there's a dispersion of the motor towards ground; b.
- Page 59 16. AUX OUTPUT KO The µP checks the driver of the electromechanical brake. If the status of the driver output does not correspond to the signal coming from the µP, the alarm is signalled. Replace the logic. 17. HIGH TEMPERATURE Chopper temperature is greater than 75°C.
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Page 60: Ac Inverter Diagnostic - Pump Configuration
7 AC INVERTER DIAGNOSTIC - PUMP CONFIGURATION The alarms are signalled by a diagnostic LED. 1 blink: logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3"). 2 blinks: running request on start-up or error in seat sequence ("INCORRECT START"). - Page 61 5. LOGIC FAILURE #3 Fault in the hardware section of the logic board which manages the hardware current protection. Replace the logic board. 6. INCORRECT START This alarm signals an incorrect starting sequence. Possible causes: a. running microswitch failure; b. error in sequence made by the operator; c.
- Page 62 11. STBY I HIGH Test carried out in standby. Check if the current is 0. If not verified, an alarm is signalled which inhibits machine operations. Possible causes: a. current sensor failure; b. logic failure: first replace the logic; if the defect persists, replace the power unit. 12.
- Page 63 16. WAITING TRACTION This alarm is present in combi systems (traction+pump). The traction has detected a failure has informed the pump inverter through the can-bus line. The pump is waiting for the traction ok. The failure must be looked for in the traction inverter. 17.
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Page 64: Recommended Spare Parts For Inverter
8 RECOMMENDED SPARE PARTS FOR INVERTER Part Number Description C16507 Protected 500A strip Fuse. C16505 Protected 355A strip Fuse. C16520 6.3A 20mm Control Circuit Fuse C29509 SW 200 80V Single Pole Contactor C29532 SW 200 48V Single Pole Contactor Page 64... -
Page 65: Periodic Maintenance To Be Repeated At Times Indicated
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. - Page 66 ELECTRONIC INDUSTRIAL DEVICES 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: zapi@zapispa.it AC3/AC4 INVERTER OPERATING HANDBOOK AND FUNCTION DESCRIPTION...
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